TECHNICAL FIELD
[0001] The present invention relates to arrangement of electrical devices of saddle-ride
type vehicles.
BACKGROUND ART
[0002] Some saddle-ride type vehicles such as motorcycles adopt a structure that electric
power generated by an AC generator built in a crankcase of an engine is stored in
a battery through a regulator for voltage regulation. It is known that the regulator
is mounted on an air cleaner in order to shorten the cable between the AC generator
and the regulator (see Patent JP-A No.247181/1988).
[0003] In addition, a batteryless power supply circuit which directly uses electric power
from the AC generator for various types of electrical devices such as an ignition
device without using a battery is also publicly known. In this case, the use of a
capacitor for stable power supply to various types of electrical devices is also known
(see Patent JP-Y No.15833/1995).
[0004] In many motorcycles in which the above regulator is mounted on the air cleaner, the
AC generator is built in the engine crankcase and the distance to the air cleaner
located above and behind the crankcase is slightly long and, because the regulator
is located in a higher position of the vehicle, the vehicle's center of gravity is
high. Therefore, there has been demand for an arrangement that the regulator is located
in a lower position than the air cleaner and its distance to the AC generator is minimized.
[0005] When the batteryless structure is adopted, there is a tendency to increase the size
of a capacitor as a substitute for a battery in order to obtain a larger capacitor
capacity. As a consequence, it is difficult to ensure sufficient space for the large
capacitor and there is a need for an optimum layout for the capacitor. The present
invention has an object to meet this demand.
DISCLOSURE OF THE INVENTION
[0006] In order to solve the above problem, the invention of Claim 1 concerning the arrangement
of electrical devices in a saddle-ride type vehicle with an engine having a crankcase
extending in the longitudinal direction of a vehicle body, a cylinder located before
the crankcase and extending almost upward, a cylinder head located above the cylinder,
and an AC generator built in the crankcase, is characterized in that a regulator for
regulating output voltage of the AC generator is located behind the cylinder and on
the top surface of the crankcase.
[0007] The invention of Claim 2 is as described in Claim 1, a capacitor for stabilizing
the voltage regulated by the regulator and supplying power to various electrical devices
being located near the regulator.
[0008] The invention of Claim 3 is as described in Claim 1, a mounting stay for holding
the regulator being fitted through a heat-insulating member on the top surface of
the crankcase.
[0009] The invention of Claim 4 is as described in Claim 3, a mounting stay for holding
the regulator being fitted through a heat-insulating member on the top surface of
the crankcase and a capacitor for stabilizing the voltage regulated by the regulator
and supplying power to various electrical devices being fitted through a heat-insulating
member to the mounting stay.
[0010] The invention of Claim 5 is as described in Claim 2 or 4, a fuel injection system
being fitted to an engine air intake system extending behind the cylinder head and
this fuel injection system being electromagnetically driven using power supplied from
the capacitor for fuel injection.
[0011] The invention of Claim 6 is as described in Claim 5, the engine air intake system
at least comprising a throttle body connected upstream of an air intake duct of the
cylinder head and incorporating a throttle valve, and a connecting tube connected
upstream of it, and the regulator being inclined down backward and the capacitor being
located above the regulator and behind and below the throttle body.
[0012] The invention of Claim 7 is as described in Claim 5 or 6, the capacitor being divided
into a second capacitor for supplying power to the fuel injection system and a first
capacitor for supplying power to various electrical devices other than the fuel injection
system and the second capacitor beingg located nearer to the vehicle front than the
first capacitor.
[0013] According to Claim 1, since the regulator is held on the top surface of the crankcase
behind the cylinder, the cable from the AC generator, often built in the front part
of the crankcase, to the regulator is shortened and power loss is reduced. In addition,
since the regulator is located on the back of the crankcase, the vehicle's center
of gravity is low and mass concentration is achieved. Moreover, the front of the regulator
in the traveling direction is covered by the cylinder and the crankcase and its bottom
is covered by the crankcase, so the regulator is effectively protected from scattering
stones or the like.
[0014] According to Claim 2, since the capacitor is located near the regulator, the cable
from the regulator to the capacitor is shortened and power loss is reduced.
[0015] According to Claim 3, since the electrical device mounting stay for holding the regulator
is fitted onto the top surface of the crankcase through the heat-insulating member,
heating of the regulator due to thermal conduction from the engine can be prevented.
[0016] According to Claim 4, since the electrical device mounting stay for holding the regulator
is fitted onto the top surface of the crankcase through the heat-insulating member
and the capacitor for stabilizing the voltage regulated by the regulator and supplying
power to various electrical devices is also fitted through a heat-insulating member
to the mounting stay, heating of the regulator due to thermal conduction from the
engine can be prevented and at the same time heating of the capacitor due to thermal
conduction from the engine and regulator can be prevented.
[0017] According to Claim 5, since a fuel injection system is fitted to an engine air intake
system which extends behind the cylinder head and fuel is injected by electromagnetic
drive of this fuel injection system using power supplied from the capacitor, the cable
from the capacitor to the fuel injection system is shortened and power loss is reduced.
Therefore, the fuel injection system is driven stably and startability of the engine
and drivability of the vehicle can be improved.
[0018] According to Claim 6, since the capacitor is located above the regulator inclined
backward and behind and below the throttle body which is relatively large in the air
intake system, it can be easily mounted even when it is a large-size capacitor with
a large capacity. Therefore, even when the batteryless type is adopted, layout for
the capacitor is easy. Also, because the regulator is inclined backward, latitude
is wide in the arrangement of a connecting tube connected upstream of the throttle
body.
[0019] According to Claim 7, since an exclusive capacitor for the fuel injection system
is provided, the fuel injection system is driven more stably and the engine's startability
and the vehicle's drivability are improved. Also, since the capacitor is divided into
two capacitors, a capacitor for supplying power to the fuel injection system and a
capacitor for supplying power to other electrical devices, the size of each capacitor
can be decreased. Besides, since one capacitor is on the front side and the other
is on the back side, latitude in the layout for the engine air intake system is wide.
Moreover, since the exclusive capacitor for the fuel injection system is on the front
side, the cable between the fuel injection system and the exclusive capacitor can
be shortened.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] Next, an embodiment of the present invention which is applied to an off-road racing
motorcycle will be described referring to drawings. A motorcycle is an example of
a saddle-ride type vehicle.
Figure 1 is a side view of a motorcycle to which the present invention is applied;
Figure 2 is a side view of the key part in an enlarged form;
Figure 3 is a plan view of the key part; Figure 4 is a side view of the regulator,
etc in a further enlarged form;
Figure 5 is a plan view of the regulator, etc in a further enlarged form;
Figure 6 is an enlarged view of a capacitor;
Figure 7 is a side view of the electrical device mounting stay;
Figure 8 is a plan view of the electrical device mounting stay;
Figures 9 are graphs which illustrate the functions of the regulator and capacitors;
Figure 10 is a power supply circuit diagram.
[0021] Figure 1 is a side view of this motorcycle. 1 represents a front wheel; 2 a front
fork; 3 a head pipe; 4 a handlebar; 5 a body frame; 6 a fuel tank; 7 a seat; 8 a rear
frame; 9 a rear wheel; and 10 an engine.
[0022] The body frame 5 includes: a pair of main frames 11 (left and right) located above
the engine 10 and sloping down backward; a down frame 12 sloping down from the head
pipe 3 to the front of the engine 10; a pair of pivot frames 13 (left and right) sloping
down from the rear ends of the main frames 11, where the pivot frames 13 swingably
support the front end of the rear frame 8 through their pivot shafts.
[0023] The engine 10 is a water-cooled 4-cycle engine which is cooled by a radiator 14 supported
by the down frame. It has a crankcase 15, a cylinder 16 protruding upward on it front
side and a cylinder 17 located above it and is supported by the body frame 5.
[0024] Figure 2 is an enlarged view of the key part of Figure 1. A cooling fan 14a for the
radiator 14 is located in front of the cylinder head 17. An exhaust pipe 18 once extends
forward from the front face of the cylinder head 17 and then bends and extends backward
and connects to a muffler 19 at its rear end.
[0025] An air intake duct which opens on the back side of the cylinder head 17 is connected
with a throttle body 20 and an electronic fuel injection system 21. The throttle body
20 incorporates a throttle valve and is supplied with clean air through a connecting
tube 23 from an air cleaner 22 located behind it. The air cleaner 22 takes in ambient
air downward through an intake 22a which lies under the seat 7 with its opening inclined
facing upward. The throttle body 20 and air cleaner 22 constitute an engine air intake
system. The electronic fuel injection system 21 is supplied with fuel from the fuel
tank 6 where fuel is supplied to the air intake duct through electromagnetic drive.
[0026] When viewed sideways, the crankcase 15, cylinder 16, cylinder head 17 and main frame
11 constitute a virtually triangular space S and this space is used for arrangement
of a regulator 24, a first capacitor 25a and a second capacitor 25b. These are held
on the top surface of the crankcase 15 behind the cylinder 16 by an electrical device
mounting stay 26. The electrical device mounting stay 26 is detachably fitted to bosses
27 and 28 from above with bolts. 29a and 29b represent relays which are held on the
front of the electrical device mounting stay 26 in front of the regulator 24.
[0027] The electrical device mounting stay 26 is supported in a way that it is inclined
down backward in the front-back (longitudinal) direction where the regulator 24 lies
longitudinally when viewed sideways. For power supply to these electrical devices,
alternate current from an AC generator 30 built in the front part of the crankcase
15 is used and the power circuit is of the batteryless type which uses no battery.
[0028] The AC generator 30 is connected through an electric cable 31a to the regulator 24
and alternate current from the AC generator is rectified into direct current by the
regulator 24; and after its voltage is regulated, it is sent to the first capacitor
25a and the second capacitor 25b through cables 31b and 31c. It is smoothed by these
capacitors. The first capacitor 25a supplies power for various electrical devices
such as ignition power for a spark plug 32 in the cylinder head 17.
[0029] 33a represents a cable which connects the first capacitor 25a and an ignition coil
42; 33b represents a cable which connects the ignition coil 42 and the spark plug
32. The ignition coil 42 is supported at its top and bottom by a stay 12a provided
on the bottom of the down frame 12.
[0030] In addition, the first capacitor 25a supplies power through the relays 29a and 29b
to other electrical devices. The second capacitor 25b exclusively supplies power through
a cable 34 to the fuel injection system 21.
[0031] In the figure 2, numeral 35 represents a rear cushion, mounted vertically, which
connects the upper end of a pivot frame 13 and a cushion ring 8a located before and
below a rear frame 8. 36 represents a front mount; 37 an engine hanger; 38 an upper
mount located between the lower part of the engine hanger and the cylinder head; and
39 a rear mount located between the rear lower part of the crankcase 15 and the bottom
of the pivot frame 13. The engine is held on the body frame 5 at these three points.
[0032] On the top surface of the crankcase 15, there is no supporting point between the
back face of the cylinder 16 and the pivot shaft 13a, generating a large space S between
the top surface of the crankcase 15 and the main frame 11. This contributes to facilitation
of layout for electrical devices.
[0033] Numeral 40 represents a secondary air valve for exhaust emission purification. It
is supported by a gusset 41 connecting the front of the main frame 11 and the top
of the down frame 12 and located before and obliquely above an exhaust port which
is connected with the exhaust pipe 18 of the cylinder head 17, or near the exhaust
port.
[0034] Figure 3 is a plan view of the key part of the vehicle body above the engine and
the paired left and right main frames 11 are pipes made of a light alloy whose cross
section is a vertically long rectangle. Their rear portions expand to the left and
right and the throttle body 20 lies between them. The connecting tube 23, extending
backward, is curved to the left of the vehicle body in order to escape from the rear
cushion 35 behind the throttle body 20 and, beside the rear cushion 35, connected
with the front of the air cleaner 22 extended from behind. C represents the centerline
of the vehicle body.
[0035] Figure 4 is an enlarged side view which shows an area where electrical devices are
mounted. The electrical device mounting stay 26 is fitted onto the bosses 27 and 28
integral with the top surface of the crankcase 15, through heat-insulating rubber
43 which also serves as a known vibration-isolating mount, using bolts 44, so that
it is mounted on the top surface of the crankcase 15 in a vibration-isolating and
heat-insulating manner. The stay is inclined down backward, where the angle with respect
to a horizontal line H parallel to the ground is expressed by θ. The regulator 24
has many fins 24a so that it can be efficiently air-cooled.
[0036] Above the regulator 24, the first and second capacitors 25a and 25b arranged back
and front are rubber-mounted on the capacitor holders 46 for the electrical device
mounting stay 26 through heat-insulating rubbers 45 respectively. Each heat-insulating
rubber 45 is a band portion integral with the periphery of the case for the first
capacitor 25a or second capacitor 25b and the capacitor holder 46 is inserted into
it to support the electrical device mounting stay 26 in a vibration-insolating manner.
[0037] The first and second capacitors 25a and 25b are each cylindrical and arranged back
and front independently from each other with their axes along the vehicle body transverse
direction. The front one is the second capacitor 25b, dedicated to injection, which
supplies power to the fuel injection system 21. The rear one is the first capacitor
25b which is used for other electrical devices and supplies power to electrical devices
other than the fuel injection system 21. The second capacitor 25b, intended for injection
only, is exposed above the regulator 24 and below the main frame 11 when viewed sideways
while the first capacitor 25a, intended for the other electrical devices, partially
overlaps the main frame 11 and lies inside the main frame 11 when viewed sideways.
[0038] Figure 5 is an enlarged plan view which shows an area where electrical devices are
mounted. These electrical devices lie between the left and right main frames 11. The
relays 29a and 29b are supported by support pieces 48a and 48b of relay holders 48
which deviate toward the right side of the vehicle body and extend forward from the
electrical device mounting stay 26.
[0039] Similarly, the rear end of the electrical device mounting stay 26 is fitted onto
the two (left and right) bosses 28 through holes 54a in the two (left and right) bosses
54 using bolts. Numeral 24b represents a connector provided on the front face of the
regulator 24. 51 represents a reservoir tank stay for supporting a reservoir tank
for a rear brake fluid which protrudes upward from a main body 50 integrally with
it. The reservoir tank 52 is held on the electrical device mounting stay 26 by bolting
the bottom of the reservoir tank 52 to a weld nut 51a at the upper end.
[0040] Figure 6 shows the structure of the first capacitor 25a where the heat-insulating
rubber 45 extends sideways on the side face of the case integrally and this heat-insulating
rubber 45 has a slit 45a penetrating the first capacitor 25a along its axial direction.
A cord tube 49 extends from the center of a circular end face of the first capacitor
25a, and wires 49a lie inside the tube. The wires 49a are connected with other wires
such as cable 33a by a coupler 49b provided at an end of the cord tube 49.
[0041] Since the first capacitor 25a is used for power supply as a substitute for a battery,
its capacity is large: for example, approximately 10000 µF. Therefore, its size is
relatively large. The second capacitor 25b has a similar structure and its heat-insulating
rubber 45 has the same structure.
[0042] Figure 7 is a side view of the electrical device mounting stay 26. The electrical
device mounting stay 26 is made by press-forming an iron plate or the like or a similar
method. It comprises the following components continuously and integrally molded from
one plate: a main body 50, a reservoir tank stay 51, a capacitor holder 47, a relay
holder 48 and so on. The reservoir tank stay 51 and the capacitor holder 47 are made
by bending the left and right sides of the main body 50 upward.
[0043] The upper part of the capacitor holder 50 has an insert 46 in a curved form which
extends above the main body 50 from right to left. These inserts 46 are provided at
two points (a front point and a rear point) which correspond to the first capacitor
25a and the second capacitor 25b. Each insert 46 is designed to engage with the slit
45a (Figure 6) provided in the heat-insulating rubber 45 of the corresponding capacitor.
[0044] Tongue-shaped inserts 48a and 48b are standing upward, with an angle difference of
90 degrees between them, before and on the right of the relay holder 48 and respectively
inserted into the slit of the holder 29c integral with the relay 29a and relay 29b
(Figure 4) from below and engaged to support the relay 29a and relay 29b. These slits
are formed in the same way as the slits 45a of the capacitors. The inserts 48a and
48b are integrated with the relay holder 48 by welding their bottoms onto it.
[0045] The tongue-shaped insert 48b has engaging projections 48c and 48d which are vertically
spaced. This spacing coincides with the insertion (vertical) width of the slit of
the band-shaped holder 29c integral with the corresponding relay. The engaging projections
48c and 48d protrude beyond the slit width.
[0046] The structure of the insert 48b is the same as that of the insert 48a. Hence, when
the insert 48a is inserted into the slit of the holder 29c for the relay 29a from
below in a way to protrude upward as shown in Figure 4, the holder 29c fits in the
space between the upper and lower engaging projections (48c and 48d) with the engaging
projections 48c and 48d engaged with the upper and lower ends of the holder 29c, so
that the relay 29a is latched together with the insert 48a. The same is true of the
insert 48b.
[0047] Figure 8 is a plan view of the electrical device mounting stay 26. A front extension
53, which protrudes from the front right side of the main body 50 and connects to
the relay holder 48, has an insertion hole 53a which is used for bolting to the boss
27 of the crankcase 15.
[0048] The paired front and rear inserts 46 of the capacitor holder 47 are structurally
the same as the inserts 48a and 48b, where they each have engaging projections 46a
and 46c on the left and right sides and are inserted into the corresponding slits
45a of the heat-insulating rubbers 45 of the first and second capacitors 25a and 25b
for engagement.
[0049] Figure 9 explains the functions of the regulator 24, the capacitor 25a and so on.
The regulator 24 is used to rectify the alternate current generated by the AC generator
30 and, at the same time, regulate the voltage to prevent a voltage rise above a specific
level.
[0050] In other words, alternate current as shown in A is full-wave rectified as shown in
B and further cut to a specific voltage level (for example, 14.5 V) as shown in C.
In this condition, it becomes pulsating incomplete direct current. In these graphs,
the vertical axis represents voltage V and the horizontal axis represents time t.
[0051] The first capacitor 25a is intended to smooth pulsating output of the regulator 24
as shown in C and the voltage is smoothed by smoothing charges and discharges in response
to waveform change as shown in C so that virtually complete direct current is obtained.
[0052] Figure 10 is a circuit diagram of the power supply circuit for electrical devices.
The regulator 24 is connected between the AC generator 30 and the ground. This regulator
24 rectifies the alternate current from the AC generator 30 into direct current and
adjusts its voltage to a specific level and outputs it to an output line 60. The first
capacitor 25a is connected between this output line 60 and the ground to smooth the
voltage of the output line 60 and make it virtually complete alternate current.
[0053] Downstream from the point of connection of the first capacitor 25a in the output
line 60, an ECU 61 is connected between it and the ground. Between the output line
60 and the ECU 61, the fuel injection system 21, ignition coil 42 and relays 29a and
29b are connected and their operations are controlled by the ECU 61.
[0054] The second capacitor 25b is connected between a point between the fuel injection
system 21 and output line 60, and the ground. The second capacitor 25b is charged
through the output line 60 when the fuel injection system 21 is off; and when it is
turned on by the EDU 61, the second capacitor 25b is discharged to supply driving
power to the fuel injection system 21 and the fuel injection system 21, electromagnetically
driven, injects a measured volume of fuel into the air intake duct.
[0055] The ignition coil 42 energizes a primary coil 42a through the ECU 61. High voltage
is generated in a secondary coil 42b and this is applied to the ignition plug 32 to
induce spark ignition.
[0056] When the relay 29a is turned on by the ECU 61, the output line 60 energizes a fuel
pump 62 to drive it so that fuel is pressure-fed from the fuel tank 6 to the fuel
injection system 21.
[0057] When the relay 29b is turned on by the ECU 61, the output line 60 energizes a cooling
fan 14a of a radiator 14 to drive it to raise the cooling efficiency of the radiator
14.
[0058] Next, an explanation will be given about how this embodiment functions. The alternate
current generated by the AC generator 30 is sent through the cable 31 to the regulator
24 where it becomes a direct current with a given voltage in the form of a pulsating
flow. This incomplete pulsating direct current is smoothed by the first and second
capacitors 25a and 25b and becomes an almost complete direct current. The first capacitor
25a supplies power to electrical devices other than the fuel injection system 21 while
the second capacitor 25b supplies power only to the fuel injection system 21. Therefore,
a batteryless power supply circuit is constituted in which the power generated by
the AC generator 30 is directly used for power supply without a battery.
[0059] Since the regulator 24 is held behind the cylinder 16 and on the top surface of the
crankcase 15, the cable 31a from the AC generator 30 (incorporated in the front part
of the crankcase 15) to the regulator 24 is shortened and power loss is reduced. In
addition, since the regulator 24 lies on the top surface of the crankcase 15, the
vehicle's center of gravity is low and mass concentration is achieved. Moreover, the
front of the regulator 24 in the traveling direction is covered by the cylinder 16
and the crankcase 15 and its lower part is covered by the crankcase 15, so the regulator
is effectively protected from scattering stones.
[0060] Furthermore, since the first and second capacitors 25a and 25b are located near the
regulator 24, the cables 31b and 31c from the regulator 24 to the first and second
capacitors 25a and 25b are shortened and power loss is reduced.
[0061] Besides, since the electrical device mounting stay 26 for holding the regulator 24
is fitted onto the bosses 27 and 28 on the top surface of the crankcase through the
heat-insulating rubber 43, heating of the regulator 24 due to thermal conduction from
the engine 10 is prevented. It is known that as ambient temperature rises, the permissible
short-circuit current lowers and stability declines in the regulator 24, so output
is maintained stably by interrupting thermal conduction to the regulator 24 and suppressing
temperature rise.
[0062] Furthermore, since the first and second capacitors are mounted on the capacitor holder
47 of the electrical device mounting stay 26 held in a heat-insulating manner through
the heat-insulating rubber 45, heating of these first and second capacitors 25a and
25b due to thermal conduction from the engine 10 and regulator 24 is prevented.
[0063] In addition, since the first and second capacitors 25a and 25b are mounted simply
by inserting the tongue-shaped inserts 46 into the slits 45a of the heat-insulating
rubbers 45, their installation is easy and quick. Also, since the engaging projections
46a and 46b are provided, their engagement with the heat-insulating rubbers 45 permits
reliable installation.
[0064] In addition, since the fuel injection system 21 is fitted to the throttle body 20
which extends behind the cylinder head 17 and constitutes an engine air intake system
and fuel is injected by electromagnetic drive of this fuel injection system 21 using
power supplied exclusively from the second capacitor 25b, the cable 34 from the second
capacitor 25b to the fuel injection system 21 is shortened, and power loss is reduced.
Therefore, the fuel injection system 21 is driven stably and startability of the engine
10 and drivability of the vehicle can be improved.
[0065] Furthermore, since the first and second capacitors 25a and 25b are located above
the regulator 24 inclined downward toward the rear of the vehicle body and behind
and below the throttle body 20 which is relatively large in the air intake system,
they can be easily mounted even if they are large-capacity large-size capacitors.
Therefore, even when the batteryless type is adopted, layout for the first and second
capacitors 25a and 25b is easy. Also, because the regulator 24 is inclined backward,
latitude is wide in the arrangement of the connecting tube 23 connected through a
space above the regulator 24 to the upstream of the throttle body 20.
[0066] Since the second capacitor 25b is provided as an exclusive capacitor for the fuel
injection system 21, the fuel injection system 21 is driven more stably and the engine's
startability and the vehicle's drivability can be improved. Also, since the capacitor
is divided into the second capacitor 25b for the fuel injection system and the first
capacitor 25a for other electrical devices, the size of each capacitor can be decreased.
Besides, since one capacitor is on the front side and the other is on the back side,
latitude in the layout for the engine air intake system is wide. In addition, since
the second capacitor 25b for the fuel injection system is on the front side, the cable
34 for connection with the fuel injection system 21 can be shortened as far as possible.
[0067] The present invention is not limited to the above embodiment but can be modified
or applied in various forms within the scope of the invention's principles. For example,
the second capacitor 25b, exclusively intended for the fuel injection system, can
be omitted. If that is the case, the first capacitor 25a, now intended for other devices,
can be used for power supply to both the fuel injection system 21 and the other electrical
devices. The heat-insulating members are not limited to heat-insulating rubbers but
other known heat-insulating materials may be used instead. Vehicles to which the present
invention can be applied are not limited to motorcycles but it may be applied to other
saddle-ride type vehicles such as buggies.