ELECTRIC BICYCLE DRIVE UNIT
20220332389 · 2022-10-20
Assignee
Inventors
Cpc classification
B62M6/55
PERFORMING OPERATIONS; TRANSPORTING
B62J43/13
PERFORMING OPERATIONS; TRANSPORTING
International classification
Abstract
The disclosure relates to an electric Bicycle Drive Unit for arrangement in a Bottom Bracket Area of a Bicycle Frame. The Drive Unit has an Electric Motor Device and a Bottom Bracket Assembly having a Bottom Bracket Shaft. The disclosure also relates to a Bicycle Frame or Frame Interface Unit, and an Energy Storage Device for the Electric Bicycle Drive Unit. The Drive Unit includes s an Integrative Energy Storage Device for supplying energy to the motor device. The Integrative Energy Storage Device can be arranged adjacent to the motor device in such a way that the center of gravity position of the Energy Storage Device and the center of gravity position of the Drive Unit lie within the Bottom Bracket Area.
Claims
1. An Electric Bicycle Drive Unit comprising: an Electric Motor Device having a Bottom Bracket Assembly and a Bottom Bracket Shaft; and an Integrative Energy Storage Device for supplying energy to the electric motor device, wherein the Integrative Energy Storage Device is arranged adjacent to the electric motor device so that a center of gravity position of the Energy Storage Device and a center of gravity position of the Electric Bicycle Drive Unit lie within the Bottom Bracket Area of a bicycle frame.
2. The Electric Bicycle Drive Unit of claim 1, wherein in an operational state of the Drive Unit, the Integrative Energy Storage Device is not attached to the Bicycle Frame and the Integrative Energy Storage Device is attached to any one of the Motor Device, a housing of the Motor Device, or a common drive housing.
3. The Electric Bicycle Drive Unit of claim 1, wherein the Integrative Energy Storage Device is arranged, at least in part, in a Down Tube of the Bicycle Frame.
4. The Electric Bicycle Drive Unit of claim 1, wherein an Auxiliary Energy Storage Device is associated with the Electric Bicycle Drive Unit and the Auxiliary Energy Storage Device is arranged, at least in part, in a Down Tube of the Bicycle Frame.
5. The Electric Bicycle Drive Unit of claim 4, wherein the Auxiliary Energy Storage Device is mechanically fixed to any one of the Electric Bicycle Drive Unit or to the Integrative Energy Storage Device.
6. The Electric Bicycle Drive Unit of claim 1, wherein the Integrative Energy Storage Device is located at least partially below an axis of rotation of the Bottom Bracket Shaft.
7. The Electric Bicycle Drive Unit of claim 1, wherein a center of mass of the Integrative Energy Storage Device and a center of mass of the Electric Bicycle Drive Unit is within a circumference with the radius less than or equal to 175 mm around the axis of rotation of the Bottom Bracket Shaft.
8. The Electric Bicycle Drive Unit of claim 1, wherein a center of mass of the Integrative Energy Storage Device and a Center of Mass of the Electric Bicycle Drive Unit is located at a height of less than or equal to 50 mm above the axis of rotation of the Bottom Bracket Shaft.
9. The Electric Bicycle Drive Unit of claim 1, further comprising a drive protection shield fastened to any one of a housing of the motor device or to a common drive housing of the Electric Bicycle Drive Unit, wherein the drive protection shield forms a movable closure flap for covering, holding, or both covering and holding the Integrative Energy Storage Device.
10. The Electric Bicycle Drive Unit of claim 1, further comprising two Rear Frame Interface Arrangements that define a Front mounting axis and a Rear mounting axis.
11. The Electric Bicycle Drive Unit of claim 10, wherein the front mounting axis and the rear mounting axis are arranged in a vertical region above a horizontal plane that contains the axis of rotation of the Bottom Bracket Shaft, and below a horizontal plane that contains a point of application of the Chain Pull Force.
12. The Electric Bicycle Drive Unit of claim 10, wherein the front mounting axis and the rear mounting axis are arranged in front of a vertical plane that contains the axis of rotation of the Bottom Bracket Shaft.
13. The Electric Bicycle Drive Unit of claim 10, wherein the front mounting axis and the rear mounting axis are arranged within an angle of 30° to 80° located in a top right Bottom Bracket Quadrant, the vertex of the angle coinciding with the axis of rotation of the Bottom Bracket Shaft.
14. The Electric Bicycle Drive Unit of claim 1, wherein a Support Width is selected as the distance between a left-hand and a right-hand Interface Planes of a Rear Frame Interface Arrangement such that a Support Factor, defined as a quotient of the Support Width and a Pedal Force Effective Width, is greater than 0.5.
15. The Electric Bicycle Drive Unit of claim 1, wherein all degrees of freedom of movement of the Drive Unit relative to the Bicycle Frame or relative to a Frame Interface Unit is fixed via a Rear Frame Interface Arrangement, with the exception of a degree of freedom of rotation about an axis of rotation parallel to the axis of rotation of the Bottom Bracket Shaft.
16. The Electric Bicycle Drive Unit of claim 15, wherein a degree of rotational freedom can be fixed by a Front Frame Interface Arrangement relative to the Bicycle Frame or relative to a Frame Interface Unit by means of a frictional connection.
17. The Electric Bicycle Drive Unit of claim 15, wherein the Rear Frame Interface Arrangement has a Frame Offset Adapter configured to: compensate for width tolerances of the Bicycle Frame or of a Frame Interface Unit, radially fix the Rear Frame Interface Arrangement relative to the Bicycle Frame or to the Frame Interface Unit, and provide play-free adjustable axial tolerance compensation between the Rear Frame Interface Arrangement and the Bicycle Frame or Frame Interface Unit.
18. The Electric Bicycle Drive Unit according to claim 1 further comprising a Controller Enclosure including a plugless Current Interface for connecting the Controller Device to the Energy Storage Device with one or more Interface Planes arranged parallel to a Removal Direction of the Energy Storage Device in such a way that the Current Interface is opened by removing the battery and connected by inserting the battery.
19. The Electric Bicycle Drive Unit of claim 1 further comprising an output shaft of the motor device arranged coaxially with the Bottom Bracket Shaft.
20. The Electric Bicycle Drive Unit of claim 1 further comprising bearing mounts for a swing arm of a sprung rear frame.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The following is an exemplary description of embodiments based on the figures.
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DETAILED DESCRIPTION
[0051] Location or direction references used and not further specified in the following description, such as “left”, “right”, “front”, “back”, “top”, “bottom”, “side view”, etc., correspond to a rider's perspective on a bicycle.
[0052] Based on the prior art described above, it is the task of the present disclosure to provide a solution for the arrangement or integration of the energy storage unit or battery and the Drive Unit for an e-mountain bike, with which the disadvantages described above can be overcome.
[0053] According to an embodiment, the Drive Unit D.sub.u includes an Electric Motor device ME as well as a Bottom Bracket Assembly A.sub.B with a Bottom Bracket Shaft S.sub.B for receiving the pedal cranks C.sub.P of the bicycle. Depending on the design of the motor, a drive unit of the generic type usually also includes a reduction gearbox, usually arranged together with the motor in a common Motor Housing, for transmitting the supporting motor torque to the Bottom Bracket Shaft, although gearless drive units for directly driving the Bottom Bracket Shaft are also known.
[0054] The Drive Unit D.sub.u has an Integrative Energy Storage Device S.sub.i for supplying energy to the Motor device M.sub.E. In this case, the Integrative Energy Storage Device S.sub.i is arranged adjacent to the Motor device M.sub.E, and the center of mass of the Integrative Energy Storage Device S.sub.i is located in the Bottom Bracket Area after the Drive Unit D.sub.u has been mounted on the Bicycle Frame 1.
[0055] This means that the energy storage unit is spatially combined with the Motor device M.sub.E and with the Bottom Bracket Assembly A.sub.B, and possibly together with the reduction gear between the Motor device M.sub.E and the Bottom Bracket Shaft S.sub.B, and is formed as a thus integrated Drive Unit D.sub.u, which is positioned in the Bottom Bracket Area of the bicycle after the assembly of the Drive Unit D.sub.u.
[0056] For the purposes of the present disclosure, “Bottom Bracket Area” means the immediate spatial environment of the bicycle bottom bracket, including the immediate end regions of the saddle and Down Tubes T.sub.L adjacent to the bottom bracket, as distinguished from the spatial region of the entire bicycle Down Tube T.sub.L up to the bicycle control head, which in the prior art typically contains the Energy Storage Device for the Electric Motor device M.sub.E.
[0057] For the purposes of the present disclosure, the term “Integrative Energy Storage Device” means an Energy Storage Device which is either integrated into the housing of the Electric Motor device M.sub.E, or is arranged together with the Electric Motor device M.sub.E in a common housing, or which can be arranged in an independent housing directly on a housing of the Electric Motor device M.sub.E.
[0058] The Energy Storage Device according to the present disclosure is positioned in the immediate vicinity of the Drive Unit D.sub.u and approximately at the horizontal height of the Bottom Bracket Assembly A.sub.B. This results in a vertically very low center of gravity position of the integrated Drive Unit D.sub.u, which is limited only by maintaining the respective desired ground clearance in the area of the bottom bracket.
[0059] Furthermore, the distance of the center of gravity of the Drive Unit D.sub.u or the entire bicycle from the rear wheel axle is also advantageously reduced in this way.
[0060] Since the widest area of a Bicycle Frame, apart from the rear end, is usually the bottom bracket receptacle, the Drive Unit D.sub.u according to the disclosure allows the space available in the axial direction (relative to the Bottom Bracket Shaft) in this area to be used much more effectively than is usual in the prior art.
[0061] In other words, this means that the cross-sectional dimensions of the integrative energy storage unit in particular (in relation to a section plane parallel to the Bottom Bracket Shaft) can be significantly larger than with conventional energy storage units arranged in the area of the Down Tube T.sub.L or in the Down Tube T.sub.L.
[0062] Due to the integrated Drive Unit D.sub.u, the Bicycle Frame can be realized with an intact, i.e. closed, Down Tube T.sub.L cross-section, in contrast to the typical configuration where the Down Tube T.sub.L is open for battery removal resulting in the Down Tube T.sub.L often having a U-shaped cross-section, whereby the bending and torsional stiffnesses of the Down Tube T.sub.L is adversely affected. With the Drive Unit D.sub.u integration the stiffness Bicycle Frame can be increased, or the mass of the Bicycle Frame can be reduced accordingly.
[0063] The integration of the Motor device ME and Energy Storage Device also reduces or eliminates the cables and, in particular, separable, complex connector devices otherwise required for the electrical connection of these assemblies, resulting in further cost and weight savings.
[0064] According to an embodiment, the Integrative Energy Storage Device S.sub.i can be arranged directly on a housing of the Motor device M.sub.E. In this embodiment, the Integrative Energy Storage Device S.sub.i can have its own housing or at least partial housing, which is connected or connectable to a housing or partial housing of the Motor device M.sub.E.
[0065] In particular, this connection between the Integrative Energy Storage Device S.sub.i and the Motor device M.sub.E may be designed to be separable, for example with a quick release fastener, allowing the user to remove the Integrative Energy Storage Device S.sub.i independently of the Motor device M.sub.E, for example for the purpose of charging regardless of the location of the bicycle.
[0066] This removal of the Integrative Energy Storage Device S.sub.i also allows an opening to the interior of the Down Tube to be revealed, so that this installation space can be used, by way of example, for storing tools, smaller items of luggage or also for an additional battery, without affecting the closed tube cross section of the Down Tube T.sub.L.
[0067] According to a further embodiment, the Integrative Energy Storage Device S.sub.i is at least partially enclosed or enclosable by a housing of the Motor device M.sub.E. A housing of the motor device M.sub.E need not be a closed housing, in particular not in that region of the housing which is designed to enclose the Energy Storage Device. Rather, at least this housing area can also be designed to enclose the Energy Storage Device in a substantially skeleton-like manner. In this way, weight is saved and the accessibility of the battery is improved, in particular for the purpose of battery replacement.
[0068] Another embodiment provides for the Integrative Energy Storage Device S.sub.i to be arranged together with the Motor device M.sub.E in the form of a fully integrated design in a Common Drive Housing. In this embodiment, mass and costs can be saved in particular by eliminating the need for connecting and separate housing elements. In this embodiment, any necessary replacement of the Integrative Energy Storage Device S.sub.i is carried out by skilled personnel after the joint housing of the Motor device M.sub.E and Integrative Energy Storage Device S.sub.i has been opened accordingly.
[0069] In another embodiment, the Integrative Energy Storage Device S.sub.i, when ready for operation, is attached exclusively to the Motor device M.sub.E, or to a housing of the Motor device M.sub.E, or to the Common Drive Housing, but not to the Bicycle Frame. This improves the handling or the removal and reinsertion of the Energy Storage Device. Moreover, costs for procuring parts and assembling a bicycle equipped with the Drive Unit D.sub.u according to the present disclosure can be significantly reduced, since the additional fastening devices for the battery to the Bicycle Frame, which are common in the prior art, are not required.
[0070] Another embodiment provides that the Integrative Energy Storage Device Si, after mounting the Drive Unit D.sub.u to a Bicycle Frame 1, is at least partially arranged in a Down Tube T.sub.L of the Bicycle Frame 1. In this way, the Integrative Energy Storage Device S.sub.i can be further enlarged, and in particular a part of the Integrative Energy Storage Device S.sub.i can extend, substantially along a longitudinal axis of the Down Tube T.sub.L, from below into the Down Tube T.sub.L. The Down Tube T.sub.L can thus further have a closed tube cross-section and still contain at least part of the Integrative Energy Storage Device Si. In another embodiment the entire Integrative Energy Storage Device S.sub.i can be arranged in a Down Tube T.sub.L of the Bicycle Frame.
[0071] According to another embodiment, an Auxiliary Energy Storage Device is also assigned to the Drive Unit D.sub.u in addition to the Integrative Energy Storage Device S.sub.i. After assembly of the Drive Unit D.sub.u with the Auxiliary Energy Storage Device, the Auxiliary Energy Storage Device is arranged at least partially, and in another embodiment, in a Down Tube T.sub.L of the Bicycle Frame. By means of the Auxiliary Energy Storage Device, the energy supply of the Drive Unit D.sub.u can be increased accordingly, for which purpose installation space in the Down Tube T.sub.L of the Bicycle Frame can again be used without impairing its closed tube cross-section.
[0072] According to a further embodiment, the Auxiliary Energy Storage Device is mechanically connectable or connected directly to the Drive Unit D.sub.u or to the Integrative Energy Storage Device S.sub.i. In the case of direct mechanical connection of the Auxiliary Energy Storage Device to the Integrative Energy Storage Device S.sub.i, the mechanical connection also includes an electrical connection between the two Energy Storage Devices, which is designed, for example, as an electrical plug-in connection.
[0073] If the Auxiliary Energy Storage Device is directly mechanically connected to the Integrative Energy Storage Device S.sub.i, or if it is a one-piece design, the two Energy Storage Devices are thus combined to form an Energy Storage Assembly or Energy Storage Device, which is then fixed to a housing of the motor device M.sub.E. This connection of the Auxiliary Energy Storage Device to the Integrative Energy Storage Device S.sub.i to form a possibly one-piece Integrative Energy Storage Device Si allows the installation space in the Down Tube to be used for additional energy storage capacity without the need for additional fixation devices or mechanical interfaces for fixing or securing the Auxiliary Energy Storage Device or the Integrative Energy Storage Device S.sub.i in the Down Tube T.sub.L.
[0074] In another embodiment, in a mounted state of the Drive Unit D.sub.u on the Bicycle Frame, the Integrative Energy Storage Device S.sub.i is arranged to a major extent outside a Down Tube T.sub.L of the Bicycle Frame. Also, the Integrative Energy Storage Device S.sub.i is located at least partially below the axis of rotation of the Bottom Bracket Shaft S.sub.B in a position of the Drive Unit D.sub.u corresponding to the mounted state of the Drive Unit D.sub.u on the Bicycle Frame. This accommodates for the desired low center of gravity of the Bicycle, and facilitates both the structural integration of the Drive Unit D.sub.u into the Bicycle Frame 1 and the handling of the Energy Storage Device during removal and reinsertion.
[0075] With regard to the desired lowest possible center of gravity, a further embodiment provides that the Center Of Gravity of the Integrative Energy Storage Device S.sub.i, or the common center of gravity of the Integrative Energy Storage Device S.sub.i and Auxiliary Energy Storage Device, or the center of gravity of the Drive Unit D.sub.u including the Integrative Energy Storage Device S.sub.i, is located within a radius of 350 mm, in another embodiment 250 mm, and in yet another embodiment 200 mm, around the Bottom Bracket Shaft S.sub.B in a side view of the bicycle. For this purpose, the integrative energy storage unit S.sub.i is arranged in such a way that it is located at least partially below the Bottom Bracket Shaft S.sub.B when the Drive Unit D.sub.u is mounted on the bicycle.
[0076] In this way, a low center of mass of the bicycle is achieved which is advantageous for handling. At the same time, this also ensures that the center of mass of the bicycle is shifted as far back as possible in relation to the direction of travel, which also benefits handling.
[0077] According to an embodiment of the Drive Unit D.sub.u, a Center of Mass of the Energy Storage Device and/or a Center of Mass of the Drive Unit D.sub.u is located, in a side view from the right and with respect to the axis of rotation of the Bottom Bracket Shaft S.sub.B, within an upper right Bottom Bracket Quadrant having a side length of 175 mm, in another embodiment within a Bottom Bracket Quadrant having a side length of 125 mm, and in yet another embodiment within a Bottom Bracket Quadrant having a side length of 100 mm.
[0078] Also in an embodiment, the battery center of mass and/or the Drive Unit D.sub.u center of mass, relative to the axis of rotation of the Bottom Bracket Shaft S.sub.B, is located at a height of 50 mm, in an embodiment 30 mm, and in another embodiment 20 mm above the axis of rotation of the Bottom Bracket Shaft S.sub.B.
[0079] This position of the battery and/or Drive Unit's D.sub.u center of gravity addresses many of the issues common to typical e-mountain bikes, particularly with regard to handling and riding safety.
[0080] Another embodiment of the Drive Unit D.sub.u includes a Drive Shield S.sub.D attached solely to the Motor device Housing or to the common Energy Storage Device Housing, wherein the Drive Shield S.sub.D simultaneously forms a movable closure flap for covering and/or supporting the Integrative Energy Storage Device S.sub.i.
[0081] This is advantageous because the considerable forces that can occur, for example, when the bicycle hits an obstacle in the Bottom Bracket Area, can be transmitted directly from the drive shield to the Drive Unit D.sub.u and, if necessary, from the latter to the Bicycle Frame 1.
[0082] The Bicycle Frame 1 is also significantly relieved by the fact that the rider often stands in the pedals when the bicycle hits an obstacle in the Bottom Bracket Area. In this case, the impact forces can be transmitted directly to the Bottom Bracket Shaft S.sub.B of the Drive Unit D.sub.u and from there to the damping and cushioning legs of the rider without significantly stressing the frame 1, thanks to an attachment of the Drive Shield S.sub.D exclusively to the Drive Unit D.sub.u.
[0083] Typically, however, drive shields are usually not connected to the drive housing but directly to the Bicycle Frame. For this reason, there is a considerable risk with the prior art of damaging the Bicycle Frame 1, for example, when the bicycle hits obstacles.
[0084] According to a another embodiment, the Drive Unit D.sub.u includes exactly two frame interface arrangements. These in turn define a front and a rear mounting axis.
[0085] Example positions of the Frame Interface Assemblies, Drive Unit Interface Assemblies, or mounting axes relative to the Drive Unit D.sub.u or relative to the Frame Interface Unit are briefly described below.
[0086] In one embodiment, the frame interfaces and the two attachment axes as interfaces between the Drive Unit D.sub.u and the Main Frame are located in a vertical region above an imaginary horizontal plane containing the axis of rotation of the Bottom Bracket Shaft S.sub.B and below a horizontal plane containing the point of application of the Chain Pull Force to the chainring.
[0087] To minimize torques generated by the Chain Traction Force and corresponding loads or deformations of the Drive Unit D.sub.u or Main Frame, the vertical distance between the rear mounting axis and the point of application of the Chain Traction Force is as small as possible, in an embodiment less than 30 mm, and in another embodiment less than 21 mm.
[0088] Also, the two mounting axes are further forward than an imaginary vertical plane containing the axis of rotation of the Bottom Bracket Shaft S.sub.B, and in another embodiment more than 15 mm further forward than the imaginary vertical plane.
[0089] Here, the two mounting axes are located in front of an imaginary Inclined Plane containing the axis of rotation of the Bottom Bracket Shaft S.sub.B, the Inclined Plane being tilted forward relative to a horizontal plane by an angle β of 50°, in other words tilted clockwise with respect to a view from the right-hand side of a bicycle.
[0090] Viewed from the right, the two mounting axes lie within an angle α of 30° to 80° located in the top right Bottom Bracket Quadrant, particularly within an angle α of 50° to 60°, the apex of the angle coinciding with the axis of rotation of the Bottom Bracket Shaft S.sub.B.
[0091] Such a positioning of the two fastening axes is only made possible by the interaction of the features of the Drive Unit D.sub.u according to the present disclosure, including in particular the allocation of almost all forces, torque and tolerances to the rear frame interface and the short tolerance chains and force transmission paths as well as high stiffnesses of the Drive Unit D.sub.u thus achieved, which in turn makes it possible to dispense with the third fastening axis far behind, and in some cases even below, the Bottom Bracket Shaft S.sub.B, which is common in the prior art.
[0092] Positioning the two fastening axes in this way as interfaces between the Drive Unit D.sub.u and the Main Frame offers numerous advantages over the state of the art.
[0093] Firstly, this provides considerably more space for assemblies such as swing arm bearings and shock linkage, since the Main Frame 1 no longer has to extend relatively far behind the bottom bracket, as in the state of the art, and in some cases even below the bottom bracket height, in order to support the electric drive unit there. This also reduces complexity, weight and costs, and gives the frame manufacturer considerably more design freedom in the functionally very important area directly behind the bottom bracket.
[0094] Furthermore, compared with the prior art, in which the frame often largely encloses the Drive Unit D.sub.u, the above-described embodiments also improve the possibilities for cooling the electrical and electronic components of the Drive Unit D.sub.u. This is playing an increasingly important role in view of the current trend toward ever smaller sizes for these components, coupled with a simultaneous upward trend in engine output.
[0095] With regard to the lateral positioning of the frame interfaces on the Drive Unit D.sub.u, it is provided that interface planes between the Rear Frame Interface Arrangement of the Drive Unit D.sub.u and an associated frame-side Rear Interface Arrangement are positioned on the left and right frame sides outside of the Main Frame 1, respectively, with a regard to optimum torque and force transmission from the Drive Unit D.sub.u to the Main Frame, and with a view to high rigidity of the Drive Unit D.sub.u, resulting in a correspondingly advantageously large Support Width W.sub.S.
[0096] In this context, a Support Factor can be formed as a quotient of this Support Width W.sub.S and a Pedal Force Effective Width, which corresponds to the horizontal distance between the effective pedal force application points on the connecting surfaces between the pedal crank C.sub.P and Bottom Bracket Shaft S.sub.B. The Support Factor is greater than 0.5, in another embodiment greater than 0.55 and in yet another embodiment greater than 0.6.
[0097] Alternatively or in addition to the values of the Support Factor, the Support Width W.sub.S is selected such that a Chain Pull Factor formed as a quotient of the Support Width W.sub.S and a Chain Pull Horizontal Distance between the Chain Pull Attack Point to the chain ring and the right-hand Interface Plane is greater than 5, in another embodiment greater than 5.5, and in yet another embodiment greater than 6.
[0098] This ensures optimum transmission of the lateral forces acting on the Drive Unit D.sub.u, in particular the pedal forces, and also the Chain Traction Forces, by the shortest possible route into the Bicycle Frame. This also gives the structures of the Drive Unit D.sub.u and Main Frame 1 involved in this power transmission a particularly high rigidity with low weight, which counteracts undesirable twisting and associated power losses during operation of the Drive Unit D.sub.u.
[0099] In the case of prior-art Drive Units values for the Support Factor are typically below 0.4, and values for the Chain Pull Factor are typically below 3.
[0100] The values for the Support Factor or for the Chain Pull Factor are made possible in particular by the fact that the Drive Unit Du according to the present disclosure grips around the outside of the Bicycle Frame 1 in the Bottom Bracket Area, or the Frame Interface Unit arranged there. In the prior art, it is usually the other way around, in other words, the Bicycle Frame (often relatively narrow in itself) surrounds the Drive Unit D.sub.u at least in the areas of the frame interfaces or mounting axes, whereby in particular the Support Widths W.sub.S are considerably narrower than can be achieved according to the present disclosure.
[0101] In the prior art, this results in high bending moments due to the effect of the pedal forces and the Chain Traction Forces, which either lead to correspondingly large deformations of the Drive Unit D.sub.u or the Bicycle Frame 1 in the Bottom Bracket Area, or have to be absorbed and compensated for with large wall thicknesses in these areas, which leads to correspondingly high weights of the Drive Unit D.sub.u and/or frame 1.
[0102] Furthermore, all degrees of freedom of movement of the Drive Unit D.sub.u relative to the Bicycle Frame 1 or relative to a Frame Interface Unit, except a degree of freedom of rotation about an axis of rotation parallel to the axis of rotation of the Bottom Bracket Shaft S.sub.B, are fixed or fixable via the Rear Frame Interface Arrangement. In terms of the present disclosure, this is also intended to include that all forces and torques are transmittable between the Drive Unit D.sub.u and the Bicycle Frame 1 or Frame Interface Unit via the Rear Frame Interface Arrangement, with the exception of torques acting about an axis of rotation or attachment of the Rear Frame Interface Unit. The remaining degree of rotational freedom with respect to the Bicycle Frame or Frame Interface Unit is thereby fixed or fixable by means of the Front Frame Interface Arrangement.
[0103] The Rear Frame Interface Arrangement of the Drive Unit also includes a Frame Offset Adapter for compensating for width tolerances of the Bicycle Frame or Frame Interface Unit. For radial fixing of the Rear Frame Interface Arrangement relative to the Bicycle Frame or relative to the Frame Interface Unit, and for infinitely play-free adjustable axial tolerance compensation between the Rear Frame Interface Arrangement and the Bicycle Frame or Frame Interface Unit, the Frame Offset Adapter includes a stepped sleeve which can be screwed into a receiving bore of the drive housing in an axially adjustable manner, or a radial clamping device which can be received in a receiving bore of the drive housing in an axially displaceable manner.
[0104] This tolerance compensation is of considerable importance, since in practice in the bicycle market the Drive Unit can be combined with a wide variety of Bicycle Frames or different Frame Interface Units, whereby the Bicycle Frames, or the Frame Interface Units, can be supplied by a wide variety of manufacturers.
[0105] Experience has shown that, depending on the origin or manufacturer of the Bicycle Frame or the Frame Interface Unit, respectively, this results in a wide variety of tolerance situations with regard to the Support Width. Such different tolerance situations can be compensated easily and steplessly with the compensation adapter.
[0106] Furthermore, the Drive Unit D.sub.u includes a hermetically sealable Controller Enclosure disposed in a space region between the Motor device M.sub.E and the Energy Storage Device for housing a Controller Device for controlling the Motor device M.sub.E and/or the Energy Storage Device.
[0107] The Controller Enclosure may have a plugging device in itself known in the prior art for connecting the Controller Enclosure and the Energy Storage Device.
[0108] In another embodiment, the Controller Enclosure includes a plugless Current Interface for connecting the Controller Device and the Energy Storage Device. The plugless Current Interface has Interface Planes arranged parallel to a Removal Direction of the Energy Storage Device. In this way, the Current Interface can be automatically opened by removing the battery and automatically connected by inserting and/or attaching the battery.
[0109] In order to provide sufficient installation space for the largest possible energy storage, a motor device M.sub.E with a compact design is used for the Drive Unit D.sub.u. So-called or concentric coaxial Motor devices are particularly advantageous in this respect, in which the Motor device and the usually required reduction gear, or their respective output shafts, are arranged coaxially or concentrically to the Bottom Bracket Shaft S.sub.B.
[0110] Alternatively, the Motor device M.sub.E of the Drive Unit D.sub.u can also have an output shaft which is aligned axially parallel or also at an angle or right angle to the Bottom Bracket Shaft S.sub.B. In particular, motor device M.sub.Es with output shafts aligned axially parallel to the Bottom Bracket Shaft S.sub.B are widely used and inexpensive. In this case, it is advantageous to arrange the Motor device M.sub.E so that the installation space provided for the integrative Energy Storage Unit or for the integrative Energy Storage Assembly does not overlap with the installation space of the Drive Unit D.sub.u provided for the Motor device M.sub.E.
[0111] For this purpose, the Motor device M.sub.E is arranged in such a way that the area of maximum radial extension of the motor device M.sub.E is vertically above the Bottom Bracket Assembly A.sub.B or Bottom Bracket Shaft S.sub.B, and thus outside the installation space area according to the disclosure for the integrative energy storage system. With such a substantially vertical orientation of the motor device M.sub.E, the housing of the Motor device M.sub.E extends into an area in which a main pivot bearing for the rear suspension is usually arranged in the case of sprung Bicycle Frames.
[0112] With this in mind, another embodiment of the disclosure provides that the housing of the Motor device M.sub.E or the Common Drive Housing of the Motor device M.sub.E and Integrative Energy Storage Device S.sub.i simultaneously has or forms an interface or bearing receptacle for a main pivot bearing or for a swing arm of the rear suspension of a suspended rear frame.
[0113] This results in further functional integration with simultaneous weight reduction and savings in installation space and costs. In addition, the desirably high lateral stiffness of the rear suspension is improved in this way.
[0114] According to a further embodiment, the Energy Storage Device and/or the Auxiliary Energy Storage Device contains substantially prismatically shaped Energy Storage Cells, wherein the definition of “prismatic” also includes cylindrical shapes in particular. The Energy Storage Cells are thereby arranged such that the longitudinal axes of a predominant portion of the Energy Storage Cells extend substantially axially parallel to the rotation axis of the Bottom Bracket Shaft S.sub.B, with the longitudinal axes of the remaining portion of the Energy Storage Cells extending substantially parallel to a direction perpendicular to the rotation axis of the Bottom Bracket Shaft S.sub.B.
[0115] In an embodiment, the ratio of the number of Energy Storage Cells arranged essentially parallel to the axis of the Bottom Bracket Shaft SB to the number of Energy Storage Cells arranged essentially parallel to a direction perpendicular to the Bottom Bracket Shaft S.sub.B is between 3 and 5 to 1.
[0116] With the Energy Storage Cells positioned predominantly parallel to the Bottom Bracket Shaft S.sub.B, a cell packing configuration is achieved which allows optimum utilization of the volume available in the Bottom Bracket Area.
[0117] Alternatively, all Energy Storage Cells of the Integrative Energy Storage Device Si and/or the Auxiliary Energy Storage Device can be arranged essentially parallel to one or more directions perpendicular to the rotation axis of the Bottom Bracket Shaft S.sub.B, which usually results in a correspondingly lower packing density of the Energy Storage Cells.
[0118] The orientation of the polarity of the Energy Storage Cells can be selected as required in that the positive or negative pole sides of the Energy Storage Cells point alternately to the left/right or front/rear or top/bottom.
[0119] The present disclosure further relates to a Bicycle Frame or Frame Interface Unit. The Bicycle Frame or Frame Interface Unit includes a Drive Unit Rear Interface Assembly and a Drive Unit Front Interface Assembly for connection to a Drive Unit D.sub.u as described above.
[0120] The Bicycle Frame 1 or Frame Interface Unit thus has exactly two Drive Unit Interface arrangements defining a front and a rear mounting axis for mounting the Drive Unit. The Rear Frame Interface Arrangement is configured to fixate all degrees of freedom of movement of the Drive Unit relative to the Bicycle Frame or Frame Interface Unit, except for the remaining degree of freedom of rotation about the rear mounting axis. The Front Frame Interface Arrangement is configured as a torque arm to fixate the remaining degree of freedom of rotation.
[0121] In other words, this means that the Rear Frame Interface Arrangement transmits all forces and torques to and from the Drive Unit D.sub.u, except torques about the rear mounting axis as the axis of rotation. In contrast to the prior art, this enables in particular a clear definition of all load paths, and a clear assignment of all essential tolerances to the rear frame interface, while the front frame interface as torque arm only has to transmit comparatively small forces and is subject to very low requirements in terms of accuracy and tolerances.
[0122] The mounting axes of the Bicycle Frame 1 or the Frame Interface Unit, respectively, are arranged analogously to the arrangement of the mounting axes at the Drive Unit D.sub.u as described above with respect to the Drive Unit D.sub.u. Likewise, Support Factor and Chain Pull Factor are of the same values as described above with regard to the Drive Unit.
[0123] In an embodiment, the Bicycle Frame 1 or the Frame Interface Unit, respectively, includes bearing mounts for a swing arm of a suspended rear frame. Particularly in the case of the Frame Interface Unit, this enables a particularly compact and weight-saving design of a sprung rear frame while at the same time reducing costs compared to the state of the art.
[0124] The present disclosure further relates to an Energy Storage Device for a Drive Unit D.sub.u as described above. The Energy Storage Device, in an embodiment, has those features which have already been mentioned above in the description of the Drive Unit D.sub.u, and which are shown in detail in the following figure description.
[0125]
[0126] The Energy Storage Device S.sub.E is arranged inside the Down Tube T.sub.L of the Main Frame 1 and can be removed from the Down Tube T.sub.L essentially radially in the Removal Direction D.sub.R with reference to the Down Tube T.sub.L and reinserted in the opposite direction. For this purpose, it is necessary for the Down Tube T.sub.L to have a downwardly open, in particular U-shaped tube cross section, with the disadvantages described in the introduction to the description, in particular with regard to reduced rigidity or increased weight.
[0127] A comparatively complex sealing of the Down Tube T.sub.L against penetrating dirt or water is also required, as well as a similarly complex electrical connection with cabling and detachable plug-in devices, and a mechanical locking device for the Energy Storage Device S.sub.E.
[0128] In relation to the bicycle, the Auxiliary Energy Storage Device S.sub.A is arranged on top of the Down Tube T.sub.L and has a Removal Direction D.sub.R also running essentially radially to the Down Tube T.sub.L. The Auxiliary Energy Storage Device S.sub.A also requires a further plug connection with corresponding cabling as well as a mechanical locking device to the Down Tube T.sub.L of the Main Frame 1.
[0129] Due to the positioning of the Motor Device M.sub.E and the Energy Storage Devices S.sub.E, S.sub.A in front of or far in front of the bottom bracket A.sub.B, which entails the center of gravity position C.sub.GEA of Energy Storage Device S.sub.E+S.sub.A, or the common center of gravity position CGCA of Drive Unit D.sub.U and Energy Storage Device S.sub.E, S.sub.A, as shown in
[0130]
[0131] For the sake of simplicity and better clarity, in
[0132] It can be seen that the Motor Device M.sub.E is arranged above the Bottom Bracket Assembly A.sub.B or Bottom Bracket Shaft S.sub.B to save space. This frees up space in front of and diagonally above the Bottom Bracket Assembly A.sub.B, which is used here for the Integrative Energy Storage Device S.sub.i in accordance with the disclosure. In this embodiment, the Integrative Energy Storage Device S.sub.i has its own housing H.sub.B. In the embodiment shown, the housing H.sub.B of the Integrative Energy Storage Device S.sub.i is suspended by means of a hook device F.sub.B1 on the housing H.sub.M containing the Motor Device M.sub.E with Motor Controller C.sub.M, gearbox and Bottom Bracket Assembly A.sub.B and is additionally connected, for example screwed, to the Motor Housing H.sub.M by means of a detachable connection F.sub.B2. The Motor Housing H.sub.M, and thus also the Battery Housing H.sub.B attached to the Motor Housing H.sub.M, can be connected to the Main Frame 1 at two frame interfaces or attachment axes F.sub.M1 and F.sub.M2. The Motor Controller C.sub.M can also be a combined Controller C.sub.MB for motor and/or battery. In another embodiment, however, the motor and battery have separate controllers C.sub.M and C.sub.B, with the Battery Controller C.sub.B in particular taking over control and monitoring of the battery charging processes.
[0133] The Integrative Energy Storage Device or integrated battery S.sub.i is made up of essentially prismatic, in this case cylindrical Energy Storage Cells C, at least a large part of which C.sub.C is arranged axially parallel to the Bottom Bracket Shaft S.sub.B.
[0134]
[0135] In addition to the assemblies described above with reference to
[0136] Furthermore, it can be seen from
[0137] The e-mountain bike shown in
[0138] However, due to the Motor Device M.sub.E arranged vertically above the Bottom Bracket Assembly A.sub.B in the Drive Unit D.sub.U according to
[0139] In this way, the closed tube cross-section of the Down Tube T.sub.L can be maintained, which benefits the rigidity and desirably low weight of the frame 1.
[0140] The e-mountain bike and the Drive Unit D.sub.U according to
[0141] The interfaces between a Drive Unit D.sub.U and a bicycle main frame 1, which are partially referred to as “attachment axes” in the present disclosure, do not necessarily have to be axis-shaped attachments or interfaces. Rather, the term “attachment axes” in the present disclosure is intended to imply generally spaced-apart connecting structures or attachment regions of a Drive Unit D.sub.U, a Bicycle Frame or a Frame Interface Unit I.sub.U along a longitudinal axis and/or along a vertical axis of the bicycle. In this regard, each mounting axis may in turn include a plurality of connecting structures spaced along a transverse axis of the Bicycle Frame. These connecting structures, for example bolted connections, also need not necessarily extend or be arranged in the transverse direction of the bicycle. Rather, the longitudinal axes of such bolted connections may also extend, for example, within longitudinal planes, relative to a bicycle.
[0142] The arrangement of all components or assemblies of the electric Drive Unit D.sub.U in a Common Drive Housing H.sub.C results in considerable integration advantages, including in particular weight and cost advantages as well as advantages with regard to maintenance and service life.
[0143] The e-mountain bike and the Drive Unit D.sub.U according to
[0144] In this embodiment, the Integrative Energy Storage Device S.sub.i is connected to the Motor Housing H.sub.M by means of two attachment points or attachment axes F.sub.B1 and F.sub.B2. The energy storage device S.sub.i is mounted on the frame 1. This eliminates the need for a separate mounting interface between the Energy Storage Device S.sub.i and the frame 1, which in turn reduces complexity, weight and costs.
[0145] As an alternative to the illustration in
[0146] The e-mountain bike and the Drive Unit D.sub.U according to
[0147] Similar to the embodiments according to
[0148] The use of a coaxial motor-gear unit M.sub.E in this embodiment results in a compact Drive Unit so that additional free space can be used for other components. Examples of other components include, but are not limited to, the pivot bearing P.sub.S, the connection of the Rear Swing Arm A.sub.S, or also for further enlargements of the Integrative Energy Storage Device S.sub.i. In another embodiment, the pivot bearing P.sub.S of the Rear Swing Arm A.sub.S is arranged coaxially with the shaft S.sub.B of the coaxial motor gearbox device M.sub.E so that the Rear Swing Arm A.sub.S is thus mounted on an output shaft S.sub.M of the coaxial motor gearbox device M.sub.E or on the Bottom Bracket Shaft SB coaxial therewith.
[0149]
[0150] In comparison with the prior art according to
[0151] The centers of mass C.sub.GE, C.sub.GC according to the present disclosure provide for improved handling as compared to the prior art.
[0152] In
[0153] It can be seen that the center of gravity C.sub.GC of the Drive Unit D.sub.U in the embodiment according to
[0154] In addition, the alternating orientation of the polarity of the Energy Storage Cells C.sub.C1 or C.sub.C2 to the right or to the left in relation to the direction of travel can be seen in
[0155]
[0156] It can also be seen that the Drive Unit D.sub.U according to the embodiment shown in
[0157] By looking at
[0158]
[0159] The illustrated embodiment of the Drive Unit D.sub.U has a motor device M.sub.E arranged above the Bottom Bracket Assembly A.sub.B, which acts on the Bottom Bracket Shaft S.sub.B via a gear device, for example via a spur gear and/or via a belt drive. Due in particular to this space-saving arrangement and functional integration, it is possible to position the energy storage unit S.sub.i directly in the Bottom Bracket Area and in the immediate vicinity of the motor M.sub.E.
[0160] The illustration in
[0161] The same applies to the embodiment shown in
[0162]
[0163] It can be seen in
[0164] The Drive Unit D.sub.U according to the embodiment example shown in
[0165] First,
[0166] The Rear Frame Interface Arrangement I.sub.R, and accordingly also the Rear Drive Unit Interface Arrangement I.sub.DR of the Frame Interface Unit I.sub.U, is located on a straight mounting axis F.sub.M1 (cf.
[0167] Similarly, the horizontal distance D.sub.M1 between the mounting axis F.sub.M1 and the axis of rotation of the Bottom Bracket Shaft S.sub.B (point of application of the rider weight force and rider drive force, i.e. the Effective Pedal Force F.sub.PE, which runs approximately in the Bottom Bracket Axis Vertical Plane P.sub.VB according to
[0168] In this way, the torques generated by these two possibly very high forces, which have to be transmitted from the Drive Unit to the frame, are minimized. In particular, the Chain Traction Force F.sub.TC can easily reach and exceed orders of magnitude of 5000 N in dynamic load cases. Due to the minimization of the torques generated by Chain Traction Force F.sub.TC and Rider Weight Force/Drive Force F.sub.PE achieved with this design, and due to the large effective length D.sub.M2 of the Drive Housing Cantilevers C.sub.D, the reaction forces required to support these torques at the Front Frame Interface Arrangement I.sub.F are small and can be easily introduced into the frame there by means of a frictional connection between Drive Unit D.sub.U and Frame Interface Unit I.sub.U, which is also subject to only minor requirements regarding compliance with dimensional tolerances.
[0169] Conversely, this means that of the two Frame Interface Arrangements I.sub.F and I.sub.R, only the Rear Frame Interface Arrangement I.sub.R is subject to high requirements in terms of force transmission, rigidity and compliance with tolerances, while the Front Frame Interface Arrangement I.sub.F is only subject to low forces and is only subject to low tolerance or accuracy requirements.
[0170] This specific distribution of tasks between the two Frame Interface Arrangements I.sub.F (torque support) and I.sub.R (shortest-path support of all forces as well as dimensional referencing) also means that the connection between the Drive Unit D.sub.U and Rear Frame Interface Arrangement I.sub.R offers particularly high rigidity as well as direct force flow.
[0171] Furthermore, all degrees of freedom of movement of the Drive Unit D.sub.U (except for the degree of freedom of rotation F.sub.R about the rear mounting axis F.sub.M1, cf.
[0172] In the first embodiment example, the screw connection C.sub.R (cf. in particular
[0173] The connection between Motor Housing H.sub.M or Common Drive Housing H.sub.C and rear Drive Unit Interface I.sub.DR of Frame Interface Unit I.sub.U by means of Frame Offset Adapter A.sub.O is not only free of play in the axial direction, relative to the longitudinal axis of Offset Adapter A.sub.O. By selecting the appropriate fits between the outer diameter of Frame Offset Adapter A.sub.O and the bores O.sub.R1, O.sub.R2 in Motor Housing H.sub.M or Drive Unit D.sub.U receiving it, it is possible to ensure that the connection between Motor Housing H.sub.M or Common Drive Housing H.sub.C and rear Drive Unit Interface I.sub.DR is free of play in the axial direction. Common Drive Housing H.sub.C and in the Drive Unit Interface I.sub.DR of the Frame Interface Unit I.sub.U, it can be ensured that the connection between the Motor Housing H.sub.M or Common Drive Housing H.sub.C and the rear Drive Unit Interface I.sub.DR is also free of play in the radial direction, relative to the longitudinal axis of the Compensating Adaptor A.sub.O.
[0174] In this context, the Frame Offset Adapter A.sub.O serves in particular to compensate for any tolerances existing on the Bicycle Frame 1 or on the Drive Unit Interface I.sub.DR, in particular with regard to the Support Width W.sub.S (cf.
[0175] This tolerance compensation is of considerable importance, since the Drive Unit D.sub.U can be combined in practice on the bicycle market with a wide variety of Bicycle Frames or with possibly different Frame Interface Units I.sub.U, whereby the Bicycle Frames, or possibly the Frame Interface Units I.sub.U, can come from or be supplied by a wide variety of manufacturers.
[0176] Experience has shown that, depending on the origin or manufacturer of the Bicycle Frame or the Frame Interface Unit I.sub.U, respectively, this results in a wide variety of tolerance situations with regard to the Support Width W.sub.S. Such different tolerance situations can be easily and continuously compensated for with the compensation adapter A.sub.O.
[0177] As previously discussed, the Front Frame Interface Arrangement I.sub.F of the Drive Unit D.sub.U serves to provide torque support via the Drive Housing Cantilevers C.sub.D (and thus to fixate the sixth degree of freedom F.sub.R of six degrees of freedom of movement of the Drive Unit D.sub.U relative to the Main Frame 1). Due to the large horizontal distance D.sub.M2 between Front Frame Interface Arrangement I.sub.F or Front Mounting Axis F.sub.M2 and the axis of rotation of Bottom Bracket Shaft S.sub.B, this results in only small reaction forces to be supported at Front Frame Interface Arrangement I.sub.F.
[0178] In the prior art, three mounting axes are commonly used to connect the Drive Unit to the Bicycle Frame, however, unlike the present disclosure, there is no specific division of duties among the various mounting axes with respect to power transmission, torque transmission, and fixation of the degrees of freedom of movement of the Drive Unit relative to the Bicycle Frame. In particular, no clear load path exists for the introduction of forces and moments from the Drive Unit into the Bicycle Frame. Rather, in the prior art, the actual load path as well as the question of which suspension point or which mounting axis transmits which portion of the forces and moments is essentially dependent on random tolerance ratios and distributions between the multiple equal mounting axes on the Drive Unit and the Bicycle Frame.
[0179] In the state of the art, this often results in considerable difficulties with regard to tolerance compensation when mounting the Drive Unit in the Bicycle Frame, as well as with regard to a permanently firm and backlash-free connection between the Drive Unit and the Bicycle Frame.
[0180] In addition, in the prior art, one of the usually three mounting axes for connecting the Drive Unit and Bicycle Frame is located in an area behind or even considerably far behind the vertical plane P.sub.VB, which contains the axis of rotation of the Bottom Bracket Shaft S.sub.B, typically more than about 40 mm behind this vertical plane P.sub.VB, and thereby often even below the horizontal plane P.sub.HB, which contains the axis of rotation of the Bottom Bracket Shaft S.sub.B. This means that the Bicycle Frame, or a Frame Interface Unit of the Bicycle Frame, must be built around the bottom bracket until far behind the bottom bracket and often even below the bottom bracket height in order to provide the required mounting axis or mounting receptacle there for connection to the Drive Unit.
[0181] However, such an extension or protrusion of the frame behind the bottom bracket, also known in the industry as a “frame flap”, in order to be able to attach the Drive Unit there, is complex to manufacture, especially if it is to meet the aforementioned high requirements regarding compliance with tolerances and the absorption of forces at the same time. In addition, such an extension or protrusion of the frame behind the bottom bracket conflicts with the mount for the Rear Swing Arm Pivot Mount M.sub.P (cf.
[0182] The Drive Unit D.sub.U according to the present disclosure provides two Frame Interface Arrangements I.sub.R, I.sub.F or two Fastening Axes F.sub.M1, F.sub.M2, of which the Rear Frame Interface Arrangement I.sub.R or mounting axis F.sub.M1 is positioned very close to the essential force application lines of both the Chain Traction Force F.sub.TC and the rider weight force/drive force F.sub.PE and takes over all tolerance compensation and force transmission tasks as well as the fixation of all degrees of freedom of movement of the Drive Unit D.sub.U (except for a rotational degree of freedom F.sub.R about a rotational axis parallel to the Bottom Bracket Shaft S.sub.B, cf.
[0183] Accordingly, the Drive Unit D.sub.U particularly has two Frame Interface Units I.sub.R, I.sub.F, which are designed for connection to the respective associated Drive Unit Interfaces I.sub.DR, I.sub.DF of the Frame Interface Unit I.sub.U.
[0184] In an embodiment, the Front Frame Interface Arrangement I.sub.F of the Drive Unit D.sub.U is thereby formed in functional combination with a swivel bearing P.sub.D for the Drive Shield S.sub.D, which is shown in particular in
[0185] In this case, the Drive Protection Shield S.sub.D is pivotably mounted on the Motor Housing H.sub.M and/or on the Frame Interface Unit I.sub.U. This mounting of the Drive Shield S.sub.D is carried out on the axis F.sub.M2 coaxially with the screw connection C.sub.F of the Front Frame Interface Arrangement I.sub.F of the Drive Unit D.sub.U with the Drive Unit Interface Arrangement I.sub.DF of the Frame Interface Unit I.sub.U (cf.
[0186] The Drive Shield S.sub.D protects the Drive Unit D.sub.U and in particular its removable battery S.sub.i, and simultaneously forms a movable flap for the purpose of battery retention and battery removal. In the first embodiment, the battery S.sub.i is held by clamping between Drive Shield S.sub.D and Motor Housing H.sub.M.
[0187] As can be seen in particular from
[0188] This is particularly advantageous, since in this way the considerable forces which occur in particular when the bicycle touches down in the Bottom Bracket Area, for example on obstacles (which can occur quite frequently1 in sporting use) can be introduced directly from the Drive Guard S.sub.D via the fastening interfaces P.sub.D, L.sub.D of the Drive Guard S.sub.D on the Common Drive Housing H.sub.C into the Common Drive Housing H.sub.C, and from this via the Frame Interfaces I.sub.R, I.sub.F of the Drive Unit D.sub.U and via the Drive Unit Interface arrangements I.sub.DR, I.sub.DF into the Main Frame 1. Since both the Common Drive Housing H.sub.C with the frame interfaces I.sub.R, I.sub.F and the Drive Unit Interface arrangements I.sub.DR, I.sub.DF are designed to absorb high forces, such forces occurring, for example, when the bicycle is set down can be absorbed without difficulty and introduced safely into the Bicycle Frame.
[0189] The Bicycle Frame is also significantly relieved by the fact that the rider often stands on the pedals when the bicycle hits an obstacle in the Bottom Bracket Area. Here, thanks to the attachment of the Drive Shield S.sub.D to the Motor Housing H.sub.M, the impact forces can be transmitted directly via the bearing B.sub.R, B.sub.L of the Bottom Bracket Shaft S.sub.B from the Motor Housing H.sub.M into the Bottom Bracket Shaft S.sub.B and from there into the damping and cushioning legs of the rider.
[0190] In the prior art, on the other hand, drive shields are usually not connected to the drive housing but directly to the Main Frame 1. For this reason, there is a considerable risk in the prior art of damaging the Bicycle Frame, for example, when it hits obstacles.
[0191] In order to further improve the ability of the drive protection shield S.sub.D to absorb force impacts, the rear attachment L.sub.D of the drive protection shield S.sub.D in the direction of travel in particular can also be arranged further forward (not shown) so that the unsupported length of the drive protection shield S.sub.D is shortened accordingly.
[0192] In an embodiment, there is an air gap between the drive end shield S.sub.D and the battery S.sub.i, at least over the unsupported length of the drive end shield S.sub.D, so that the unsupported length of the drive end shield S.sub.D can yield in the event of force impacts occurring and absorb the force impacts accordingly without the drive end shield S.sub.D colliding with the battery S.sub.i and causing impermissibly high mechanical loads on the battery S.sub.i.
[0193] Alternatively, it is also possible to at least partially dissipate force impacts via the cantilevered area of the drive end shield S.sub.D onto the battery S.sub.i. For this purpose, the Battery Housing H.sub.B is designed to be suitably robust and an elastomer intermediate layer is provided to dampen and distribute the force, at least between the cantilevered area of the drive end shield S.sub.D and the front lower area of the battery S.sub.i.
[0194] With the drive protection shield S.sub.D according to the present disclosure, it is also possible to dispense with the further mechanical interfaces between Main Frame 1 and battery S.sub.i which further reduces effort, costs and possible sources of error.
[0195] In another embodiment the Drive Shield S.sub.D is provided with retaining projections R.sub.P (cf.
[0196] As can be seen from
[0197] This fastening and locking of the battery S.sub.i by means of an elastic flexible Locking Protrusion P.sub.L has the further advantage that twisting of the Bicycle Frame and/or the Drive Unit D.sub.U occurring during operation in the area between the bottom bracket and the Down Tube T.sub.L has no detrimental effect on the firm enclosure of the battery S.sub.i in the Drive Unit D.sub.U, since the elastic flexible Locking Protrusion P.sub.L compensates for such twisting.
[0198]
[0199] For comparison,
[0200] This brings advantages with regard to the center-of-gravity problem with known e-mountain bikes, as explained in the introduction to the description, in particular significant improvements in terms of handling and riding safety.
[0201] Furthermore,
[0202]
[0203] This arrangement of the mounting axes F.sub.M1, F.sub.M2 is made possible by the interaction of a plurality of features of the Drive Unit according to the present disclosure, including the allocation of almost all forces, moments and tolerances to the rear frame interface, and the short force transmission paths and high stiffnesses of the Drive Unit thus achieved. This allows for dispensing with the third mounting axis that is typically far behind and often below the Bottom Bracket Shaft in the prior art.
[0204]
[0205] At the same time, the hexagonal packing together with the arrangement of most or all of the battery cells C.sub.C axially parallel to the Bottom Bracket Shaft makes it possible to give the battery S.sub.i a shape optimally adapted to the irregularly shaped spatial boundary conditions between Motor Housing H.sub.M/T.sub.H, Controller C.sub.MB, Down Tube T.sub.L or Down Tube Lug L.sub.L (cf. synopsis of
[0206] This allows the energy content of the battery S.sub.i to be maximized, ensures easy removal of the battery S.sub.i by swinging it out of the Drive Unit D.sub.U (cf.
[0207] Furthermore,
[0208] According to
[0209] The Drive Shield S.sub.D has a Drive Shield Latch L.sub.D, which is designed as a bolt that can be easily removed with a conventional Allen key for easy opening of the Drive Shield S.sub.D (cf.
[0210] In contrast to the embodiments shown in
[0211]
[0212] The Rear Swing Arm Pivot Mount M.sub.P can also be arranged or attached to the Bicycle Frame 1 similar to the prior art as shown in
[0213] The bearing axis P.sub.S of the Rear Swing Arm A.sub.S (cf.
[0214] In
[0215] The Saddle Tube T.sub.S (cf.
[0216] In another embodiment, Saddle Tube L.sub.S, Down Tube Lug T.sub.L, Rear Swing Arm Pivot Mount M.sub.P, Rear Shock Support Pivot Mount S.sub.R, together with the Drive Unit Interface Units I.sub.DR and I.sub.DF form in one piece the Frame Interface Unit I.sub.U, which is thus set up in particular to connect the Drive Unit D.sub.U to the Main Frame 1 and, if necessary, to the sprung Rear Swing Arm 2 (cf.
[0217] As already explained above, the Drive Housing Cantilevers C.sub.D serve to define the sixth (Rotatory) Freedom of Movement F.sub.R (cf.
[0218] Since the connection of the Drive Housing Cantilever C.sub.D to the Front Drive Unit Interface Arrangement I.sub.DF of the Frame Interface Unit I.sub.U, as also explained above in the discussion of the distribution of tasks of the two Frame Interface Arrangements I.sub.F and I.sub.R, only has to transmit comparatively low forces and does not have to meet high accuracy requirements or tolerance requirements, it is sufficient that the connection between the Drive Housing Cantilever C.sub.D and the Front Drive Unit Interface Arrangement I.sub.DF is made by friction locking.
[0219] Friction Washers W.sub.F (cf.
[0220] As already explained, the connection between the Drive Housing Cantilever C.sub.D and the front Drive Unit Interface Unit I.sub.DF of the Frame Interface Unit I.sub.U serves to rotationally fix the Drive Unit D.sub.U and to introduce torque starting from the Drive Unit D.sub.U into the Frame Interface Unit I.sub.U or into the Bicycle Frame.
[0221] In an embodiment, the connection between the Drive Housing Cantilever C.sub.D and the Front Frame Interface Arrangement I.sub.DF by means of frictional locking, (for example by means of bolting C.sub.F and Friction Washers W.sub.F), does not place any high demands on the accuracy of the frame-side Front Frame Interface Arrangement I.sub.DF and the drive-side Frame Interface Arrangement I.sub.F, i.e. in this case on the accuracy of the bores, shoulders and threads of the bolting C.sub.F in the radial direction, relative to the front mounting axis F.sub.M2.
[0222] Also in the axial direction, relative to the front mounting axis F.sub.M2, the connection between the Drive Housing Cantilevers C.sub.D and the front Drive Unit Interface Unit I.sub.DF of the Frame Interface Unit I.sub.U, which is used as a torque arm to fixate the rotational degree of freedom F.sub.R, places very few demands.
[0223] In particular, the Drive Housing Cantilevers C.sub.D can be designed so that, in the force-free, non-assembled state of the Drive Unit D.sub.U, they have a distance that is slightly too large compared to the Interface Surfaces or Interface Planes P.sub.iF of the front Drive Unit Interface I.sub.DF. When the Drive Unit D.sub.U is mounted, the Drive Housing Cantilevers C.sub.D are then elastically deformed slightly inwards by the force of the screw connection C.sub.F, allowing any spacing tolerances of the Interface Planes P.sub.iF of the front Drive Unit Interface arrangement I.sub.DF to be generously and easily compensated.
[0224] In contrast, the Drive Unit D.sub.U is dimensionally fixed relative to the Frame Interface Unit I.sub.U or relative to the Main Frame 1 in all three spatial directions and the forces corresponding to these spatial directions are transmitted practically exclusively by the connection between the rear Drive Unit Interface I.sub.DR and Drive Unit D.sub.U, which is positive in all three spatial directions (cf.
[0225] In contrast, the connection between the Drive Housing Cantilever C.sub.D and the Front Drive Unit Interface Arrangement I.sub.DF is subject to only minor requirements in terms of accuracy and tolerances, which also reduces the manufacturing effort and costs for the Frame Interface Unit I.sub.U.
[0226]
[0227] As shown in particular in
[0228] In the sectional view of
[0229] The Crank Adapter A.sub.C is advantageous in two respects. On the one hand, it enables a simpler assembly concept for the Motor Device M.sub.E, in particular an assembly concept for a reduction gearbox (not shown in the figures) of the Motor Device M.sub.E arranged on the right-hand side for an electric motor arranged on the left-hand side (also not shown). In the assembly concept, the Bottom Bracket Shaft S.sub.B in particular can be assembled more easily with other components of the Motor Device M.sub.E, in particular with components of the reduction gear, without the attached Crank Adapter A.sub.C, since the Bottom Bracket Shaft S.sub.B has a smaller diameter without the attached Crank Adapter A.sub.C.
[0230] Another advantage of the Crank Adapter A.sub.C is the positive connection between the pedal cranks C.sub.C and the Bottom Bracket Shaft S.sub.B, which is free of play in both directions of rotation.
[0231] In other applications in transmission technology, serrations S.sub.W usually only have to transmit a nominal torque backlash-free in one direction. On bicycles, on the other hand, it is necessary to transmit high torques between the pedal cranks C.sub.P and the Bottom Bracket Shaft S.sub.B without backlash in both directions of rotation. For example, the rider of a bicycle can stand with his entire body weight on the pedals, as a result of which high torques with opposite directions of rotation act in each case from the pedal cranks C.sub.P on the Bottom Bracket Shaft S.sub.B. If the torques were not transmitted backlash-free from the splines S.sub.W of the pedal cranks C.sub.P to the Bottom Bracket Shaft S.sub.B, this would lead to undesirable jerky rotational movements between the pedal cranks C.sub.P and the Bottom Bracket Shaft S.sub.B and to corresponding clicking noises. In addition, the connection between the pedal cranks C.sub.P and the Bottom Bracket Shaft S.sub.B would become damaged or loose over time, which would also lead to the risk of accidents.
[0232] For this reason, serrations S.sub.W between pedal cranks C.sub.P and Bottom Bracket Shaft S.sub.B on the bicycle must be tapered in addition to the torque-transmitting gearing in order to be able to press the pedal cranks C.sub.P axially onto the Bottom Bracket Shaft S.sub.B and thereby create a backlash-free connection between the pedal cranks C.sub.P and the Bottom Bracket Shaft S.sub.B. Only in this way can the torque applied by the rider in both directions be transmitted backlash-free in both directions of rotation.
[0233] In particular, if the Pedal Crank Adapter A.sub.C is made of a ductile material and/or is thin-walled, pressing the Pedal Crank C.sub.P axially onto the Bottom Bracket Shaft S.sub.B results in radial compression of the Crank Adapter A.sub.C onto the Shaft Toothing S.sub.T (cf.
[0234] The Frame Interfaces I.sub.R, I.sub.F arranged on the Drive Unit D.sub.U as shape-corresponding counterparts to the Drive Unit Interface arrangements I.sub.DR, I.sub.DF of the Frame Interface Unit I.sub.U are located on the housing covers C.sub.H of the Drive Unit D.sub.U, as shown in particular in
[0235] In this way, among other things, a desirably maximum Support Width W.sub.S of the connection between the Frame Interfaces I.sub.R, I.sub.F of the Drive Unit D.sub.U and the Main Frame 1 or the Frame Interface Unit I.sub.U is achieved (cf.
[0236] The Drive Unit D.sub.U can also be designed asymmetrically (not shown) with respect to its essential dimensions in the transverse direction (along the axis of the Bottom Bracket Shaft S.sub.B) with respect to a Frame Center Plane P.sub.FC (cf.
[0237] Due to the one-piece arrangement of the Frame Interface Units I.sub.R, I.sub.F in the Housing Covers C.sub.H, weight or Drive Forces F.sub.PE on the Bottom Bracket Shaft S.sub.B as well as Chain Traction Forces F.sub.TC are transmitted directly via the Bearings B.sub.L, B.sub.R arranged in the Housing Covers C.sub.H into the Housing Covers C.sub.H, and from there via the Frame Interface Units I.sub.R, I.sub.F and the Drive Unit Interface Arrangements I.sub.DR, I.sub.DF into the Frame Interface Unit I.sub.U and thus into the Bicycle Frame.
[0238] As a result, the central Housing Tube T.sub.H hardly has to transmit any load and can be optimized with regard to other aspects, for example in terms of material selection and manufacturing options. Due to the completely prismatic shape of the Housing Tube T.sub.H, it is also easy and inexpensive to manufacture, for example by turning or extruding an aluminum tube.
[0239] The Housing Tube T.sub.H can also be optimized in terms of maximum thermal conductivity combined with low weight by selecting an aluminum alloy such as AL6060 for the Housing Tube T.sub.H, which has far better thermal conductivity than the magnesium frequently used in the prior art.
[0240] Alternatively, the housing covers C.sub.H can also be arranged on the Bicycle Frame 1, in particular formed integrally with the Bicycle Frame 1. An embodiment is also provided in which one of the housing covers (e.g., the housing cover C.sub.HR arranged on the drive side, i.e. on the right-hand side in relation to the rider) is arranged on the Bicycle Frame and is formed in one piece with the Bicycle Frame, while the other housing cover C.sub.HL on the left-hand side is formed as a separate component that can be separated from the Housing Tube T.sub.H. This provides easy access to the Motor Housing H.sub.M, which is thus at least partially integral with the Main Frame 1, for example for maintenance purposes.
[0241] The Motor Output Hollow Shaft S.sub.HM (not shown in the figures of the first embodiment according to
[0242] The Internal Toothing T.sub.i can also be arranged directly in a Chainring R.sub.C (omitting the Chainring Spider S.sub.C). In another embodiment there is a Chainring Spider S.sub.C on which optionally sprockets R.sub.C with, for example, different numbers of teeth or different Chain Line L.sub.C can be mounted (cf.
[0243] In another embodiment, positions of the Frame Interface Units I.sub.R, I.sub.F and Drive Unit Interface Units I.sub.DR, I.sub.DF relative to the Drive Unit D.sub.U and relative to the Frame Interface Unit I.sub.U, respectively, are described below (see
[0244] As can be seen in particular from
[0245] To minimize torques generated by the Chain Traction Force F.sub.TC and corresponding loads or deformations of Drive Unit D.sub.U, Frame Interface Unit I.sub.U or Main Frame 1, the vertical distance D.sub.PV between the rear attachment axis F.sub.M1 and the point of application P.sub.C of the Chain Traction Force F.sub.TC is as small as possible, in an embodiment less than 30 mm, an in yet another embodiment less than 21 mm.
[0246] Also in another embodiment, the two mounting axes F.sub.M1, F.sub.M2 lie further forward than an imaginary vertical plane P.sub.VB, which contains the axis of rotation of the Bottom Bracket Shaft S.sub.B, more than 15 mm further forward than the imaginary vertical plane P.sub.VB.
[0247] In another embodiment, the two mounting axes F.sub.M1, F.sub.M2 lie in front of an imaginary Inclined Plane I.sub.P, which contains the axis of rotation of the Bottom Bracket Shaft SB, wherein the Inclined Plane I.sub.P is tilted forward by an angle β of 50° relative to a horizontal plane, in other words tilted clockwise, with respect to a view from the right as depicted, for example, in
[0248] In a in another embodiment, a combination of the three aforementioned embodiments, the two fastening axes F.sub.M1, F.sub.M2 are located in a vertical region between the two horizontal planes P.sub.HB and PH.sub.C, in front of the vertical plane P.sub.VB, and in front of the inclined plane I.sub.P.
[0249] In another embodiment, the two mounting axes F.sub.M1, F.sub.M2 lie within an angle α of 30° to 80° located in the top right Bottom Bracket Quadrant Q.sub.B1, in yet another embodiment within an angle α of 50° to 60°, the vertex of the angle coinciding with the axis of rotation of the Bottom Bracket Shaft S.sub.B (cf.
[0250] Furthermore, a combination of the above-mentioned embodiments in which the two fastening axes F.sub.M1, F.sub.M2 lie in a vertical region between the two horizontal planes P.sub.HB and P.sub.HC and in front of the vertical plane P.sub.VB, furthermore in front of the inclined plane I.sub.P, and within an angle α of 30° to 80°, an in another embodiment within an angle α of 50° to 60°.
[0251] This provides more space for rear suspension assemblies such as swingarm bearings and shock linkage, since the Main Frame 1 no longer has to extend relatively far behind the bottom bracket, as in the state of the art, and in some cases even below the bottom bracket height. This also reduces complexity, weight and costs, and gives the frame manufacturer considerably more design freedom in the functionally very important area directly behind the bottom bracket.
[0252] Furthermore, at least in the area of the mounting axes, the above-described designs also improve the possibilities for cooling the electrical and electronic components of the Drive Unit since the Drive Unit is not enclosed by the frame. This is playing an increasingly important role in view of the current trend toward ever smaller sizes for these components, coupled with a simultaneous upward trend in engine output.
[0253] With regard to the lateral positioning of the Frame Interfaces, the Interface Planes P.sub.iR between the Rear Frame Interface Arrangements I.sub.R of the Drive Unit D.sub.U and the associated, Rear Drive Unit Interface Arrangements I.sub.DR of the frame and/or of the Frame Interface Unit I.sub.U are positioned on the left and right outboard side of the Main Frame 1 with a view to optimum torque and force transmission from the Drive Unit D.sub.U to the Main Frame 1 and with a view to high rigidity of the Drive Unit D.sub.U, resulting in a correspondingly advantageously large Support Width W.sub.S (cf.
[0254] In this context, a Support Factor F.sub.S can be formed as a quotient of the Support Width W.sub.S and a Pedal Force Effective Width W.sub.PE, which corresponds to the horizontal distance between the effective pedal force application points on the connection surfaces between the pedal crank and Bottom Bracket Shaft (cf.
[0255] Alternatively or in addition to the values of the Support Factor F.sub.S, the Support Width W.sub.S is selected such that a Chain Pull Factor F.sub.PC formed as a quotient of the Support Width W.sub.S and a Chain Pull Horizontal Distance D.sub.PH between the Chain Pull Attack Point F.sub.TC and the right-hand Interface Plane P.sub.iR is greater than 5, in another embodiment greater than 5.5 and in yet another embodiment greater than 6.
[0256] This ensures optimum transmission of the lateral forces acting on the Drive Unit D.sub.U, in particular the pedal forces F.sub.PE, and also the Chain Traction Forces F.sub.TC, by the shortest possible route into the Bicycle Frame. This also gives the structures of the Drive Unit D.sub.U and the Main Frame 1 or the Frame Interface Unit I.sub.U involved in this power transmission a particularly high rigidity with low weight, which counteracts undesirable twisting and associated power losses during operation of the Drive Unit D.sub.U.
[0257] In prior art Drive Units, however, values for the Support Factor F.sub.S are usually well below 0.4, and values for the Chain Pull Factor F.sub.PC are usually well below 3.
[0258] In the prior art, this results in high bending moments due to the effect of the pedal forces F.sub.PE and the Chain Traction Forces F.sub.TC, which either lead to correspondingly large deformations of the Drive Unit D.sub.U or the Bicycle Frame 1 in the Bottom Bracket Area, or must be absorbed and compensated for with large wall thicknesses in these areas, which leads to correspondingly high weights of the Drive Unit D.sub.U and frame.
[0259] If the Drive Unit D.sub.U is formed asymmetrically with respect to its essential dimensions in the transverse direction (along the axis of the Bottom Bracket Shaft S.sub.B) with respect to a Frame Center Plane P.sub.FC, as described above with reference to
[0260]
[0261] Firstly, it can be seen there in particular that the Motor and/or Battery Controller C.sub.MB, which in the first embodiment example according to
[0262] Thus, the Motor Controller C.sub.M of the second embodiment provides, among other things, a number of Auxiliary Connections C.sub.A to which further power consumers can be connected. Examples of power consumers include, but are not limited to, bicycle lighting, an electric Rear Derailleur 4 according to
[0263] One or more of the Auxiliary Connections C.sub.A can also be used, for example, to provide the power supply for a Man-Machine Interface or Operating Interface H.sub.Mi, which is set up to control the various electrical or electronic systems of the bicycle. Charging sockets for operating or charging auxiliary devices such as smartphones can also be arranged at the Operating Interface H.sub.Mi or elsewhere on the bicycle, for example in the area of an Upper Tube T.sub.U of the Bicycle Frame, the power supply for which can also be implemented via one of the Auxiliary Connections C.sub.A.
[0264] In an embodiment, the Auxiliary Connections C.sub.A only serve to supply power to additional devices, such as those mentioned above, while data exchange between the Motor Controller C.sub.M and the additional devices, or data exchange between different additional devices, in particular for the purpose of controlling additional devices or the Motor Controller C.sub.M, takes place by means of a wireless communication protocol, for example via Bluetooth.
[0265] In
[0266] As a further significant difference between the first embodiment example according to
[0267] The Current Interface I.sub.C can be set up for additional mechanical fixing of the battery S.sub.i in its ready-to-operate swiveled-in position similar to
[0268] In the prior art, for which
[0269] Such known plug connections are electrically and mechanically complex and therefore cause relatively high costs in production and assembly on the one hand. Futhermore, such plug connections are often the cause of malfunctions or failures, for example due to contamination or improper handling when removing or reinserting the battery S.sub.i.
[0270] As explained above and in the description of
[0271] With this in mind, the Current Interface I.sub.C is of two-pole design and, in another embodiment, does not include a plug connection.
[0272] The operation of such an embodiment of the Current Interface I.sub.C can be seen in a synopsis of
[0273] To establish this electrical contact connection, Metal Contact Washers W.sub.CB are arranged on the battery S.sub.i both on the left side (according to
[0274] Corresponding Metal Contact Washers W.sub.CC are arranged on the right side (according to
[0275] When the battery S.sub.i is inserted counter to the Removal Direction D.sub.R in
[0276] If the Threaded bolt B.sub.T is then guided through the battery through the associated Clamp Openings O.sub.C and, in the case of B.sub.P, through the battery as shown in
[0277] The structure of the Current Interface I.sub.C can be seen particularly clearly in
[0278] In the illustrated embodiment of the Current Interface I.sub.C, the Contact Washers W.sub.CB assigned to the battery S.sub.i are formed by outer end faces of Metal Contact Sleeves C.sub.S, while the Contact Washers W.sub.CC assigned to the controller C.sub.MB each have an integrally formed Contact Flap F.sub.CC. Thus the Contact Flaps W.sub.CC together with the Contact Flaps F.sub.CC form a two-pole electrical current connection from the disc-shaped elements W.sub.CC into the housing of the controller C.sub.MB.
[0279] In the illustrated embodiment of the Current Interface I.sub.C, the contact washers W.sub.CB associated with the battery S.sub.i are formed by End Faces of conductive Contact Sleeves C.sub.S, which are pressed onto Contact Flaps F.sub.CB, also by the contact pressure of the Threaded bolt B.sub.T. The Contact Flaps F.sub.CB form a two-pole electrical connection from the conductive Contact Sleeves C.sub.S into the housing of the battery S.sub.i, see also
[0280]
[0281] Firstly, the Common Drive Housing H.sub.C with its Drive Housing Cantilevers C.sub.D, which are only shown in sections or partially cut away, and the controller C.sub.MB and battery S.sub.i with Battery Housing H.sub.B, which are also only shown in sections and partially cut away, can be seen.
[0282] The Current Interface I.sub.C includes Threaded bolts B.sub.T, Battery-side Contact Flaps F.sub.CB, Contact Sleeves C.sub.S and Contact Washers W.sub.CB as well as Controller-side Contact Washers W.sub.CC and Contact Flaps F.sub.CC. In the illustration of
[0283] When the Threaded bolt B.sub.T is tightened, the Drive Housing Cantilevers C.sub.D together with the projections C.sub.E of the Controller C.sub.MB resting against them on the inside are bent slightly inward by the screw force of the Threaded bolt B.sub.T, pressing the battery-side contact washers W.sub.CB and the controller-side contact washers W.sub.CC firmly against each other.
[0284] At the same time, the Contact Sleeves C.sub.S on the battery side and the Contact Flaps F.sub.CB (cf.
[0285] In this way, a reliable, two-pole electrical connection with high current-carrying capacity is established between battery S.sub.i and controller C.sub.MB via the contact path F.sub.CB.fwdarw.C.sub.S.fwdarw.W.sub.CB.fwdarw.W.sub.CC.fwdarw.F.sub.CC without the need for technically complex, expensive and also damage-prone plug connections according to the state of the art. For example, the left-hand contact elements F.sub.CB, C.sub.S, W.sub.CB, W.sub.CC and F.sub.CC are assigned to the positive pole of the power supply by the battery S.sub.i, and the right-hand contact elements F.sub.CB, C.sub.S, W.sub.CB, W.sub.CC and F.sub.CC to the negative pole. Reverse assignment of positive pole and negative pole is also possible without further ado.
[0286] In order to electrically insulate the left-hand and right-hand contact elements F.sub.CB, C.sub.S, W.sub.CB, W.sub.CC and F.sub.CC associated with the two electrical poles from one another, the embodiment of the Current Interface I.sub.C according to
[0287] The Insulating Tube I.sub.T is used to electrically insulate the left-hand contact elements, i.e. the electrically conductive Contact Sleeves C.sub.S with the Contact Washers W.sub.CB arranged thereon (here in one piece), as well as the Contact Flaps F.sub.CB with respect to the Threaded bolt B.sub.T, from the corresponding right-hand contact elements C.sub.S, W.sub.CB and F.sub.CB.
[0288] In another embodiment, a charging port (not shown in the figures) is also arranged on the housing E.sub.C of the controller C.sub.MB for connecting an external or internal charger with respect to the Drive Unit D.sub.U to the power supply. A further function of the housing E.sub.C of the controller C.sub.MB can be to connect electrical or electronic assemblies of the Drive Unit D.sub.U, which are arranged in the area of different sides of the Drive Unit D.sub.U, to one another without requiring power lines for this purpose, in particular within or across the Motor Device M.sub.E.
[0289] For example, a torque sensor device of the Drive Unit D.sub.U can be arranged in a right-hand area of the Drive Unit D.sub.U in the vicinity of the torque connection to the Chainring R.sub.C, while at least parts of the Motor Controller C.sub.MB, in particular parts of the power electronics, can be arranged in a left-hand area of the Drive Unit in the vicinity of the electric motor. In such cases, the housing E.sub.C of the controller C.sub.MB offers the possibility of connecting, for example, the torque sensor device to the power electronics or to their drive circuitry through the housing E.sub.C without having to route lines either through the motor device or, largely unprotected, outside the motor device. In particular, the latter is common in the prior art.
[0290] It is also possible and intended to arrange only certain parts of the power electronics for operating the electric motor, in particular the relatively voluminous capacitors of an electronic motor commutation in the housing E.sub.C of the controller C.sub.MB, while other parts of the power electronics, in particular the power transistors, are arranged in the Motor Housing H.sub.M, for example on an inner side in particular of the left-hand housing cover C.sub.HL. The latter enables optimum cooling of the power transistors in particular if the corresponding housing cover C.sub.HL is provided with cooling fins on the outside (cf.
[0291]
[0292] In the first embodiment example according to
[0293] In contrast, the Compensation Adapter A.sub.O of the second embodiment example according to
[0294] When mounting the Drive Unit D.sub.U on the Main Frame 1 or on the Frame Interface Unit I.sub.U, the Connecting Bolt B.sub.C is screwed into the Screw Bushing B.sub.S, (cf.
[0295] When the Connecting Bolt B.sub.C is tightened, the Compensation Adapter A.sub.O including Thrust Rings R.sub.T1, R.sub.T2, Expansion Ring R.sub.E and Alignment Bushing B.sub.A is then pulled inward in the locating hole O.sub.R of the Rear Frame Interface Arrangement I.sub.R (in
[0296] When the Connecting Bolt B.sub.C was further tightened, the compensating adapter A.sub.O was axially compressed in such a way that the Thrust Rings R.sub.T1 and R.sub.T2 were pressed axially into the Expansion Ring R.sub.E, increasing the outside diameter of the Expansion Ring R.sub.E until the Expansion Ring R.sub.E was firmly pressed into the location hole O.sub.R by friction.
[0297] Thus, merely by tightening the Connecting Bolt B.sub.C, a backlash-free, fixed connection is automatically produced both axially and radially (in relation to the Connecting Bolt B.sub.C) between the Drive Unit D.sub.U and the Main Frame 1 or the Frame Interface Unit I.sub.U.
[0298] This accelerates and facilitates the assembly of the Drive Unit D.sub.U, in particular with regard to the fact that in practice on the bicycle market it will be combined with a wide variety of Bicycle Frames or with possibly different Frame Interface Units I.sub.U, whereby the Bicycle Frame, or possibly the Frame Interface Unit I.sub.U, can come from or be supplied by a wide variety of manufacturers.
[0299] Experience shows that this can result in a wide variety of tolerance situations with regard to the Support Width W.sub.S of the rear Drive Unit Interface I.sub.DR. Such different tolerance situations, depending on the origin of the Bicycle Frame or the Frame Interface Unit I.sub.U, respectively, can thus be handled and compensated for in the simplest way, in particular with the compensation adapter A.sub.O of the second embodiment example according to
[0300] Precise adaptation to any tolerances of the Main Frame 1 or the Frame Interface Unit I.sub.U and a tight, backlash-free connection between the Drive Unit D.sub.U and the Main Frame 1 or the Frame Interface Unit I.sub.U in all three spatial directions is not only important with regard to the safe and reliable transmission of the considerable drive and Chain Traction Forces, as described further above in
[0301] Since in the prior art at least two or more fastening axes are usually used to connect the Drive Unit and the Bicycle Frame, but in which, unlike in the present disclosure, no specific division of tasks is made among the various fastening axes with respect to power transmission, torque transmission and fixation of the degrees of freedom of movement of the Drive Unit relative to the Bicycle Frame, considerable difficulties frequently arise there with respect to tolerance compensation when mounting the Drive Unit in the Bicycle Frame, as well as with respect to a permanently fixed and play-free connection between the Drive Unit and the Bicycle Frame.
[0302] As already explained in detail above in the description of
[0303]
[0304] Since in particular the properties and assemblies of the Drive Unit D.sub.U that are essential for the center of gravity positions C.sub.GE, C.sub.GC according to the second embodiment according to
[0305] Also, all other features and advantages as described above with respect to the first embodiment example according to
[0306] The following clauses are offered as further description of the examples. Any one or more of the following clauses may be combinable with any another one or more of the following clauses. Any one of the following clauses may stand on its own merit without having to be combined with another other of the above-identified clauses. Clause 1: the Electric Bicycle Drive Unit of any clause mentioned in this paragraph, further including an Electric Motor Device having a Bottom Bracket Assembly and a Bottom Bracket Shaft; and an Integrative Energy Storage Device for supplying energy to the electric motor device, wherein the Integrative Energy Storage Device is arranged adjacent to the electric motor device so that a center of gravity position of the Energy Storage Device and a center of gravity position of the Electric Bicycle Drive Unit lie within the Bottom Bracket Area of a bicycle frame. Clause 2: the Electric Bicycle Drive Unit of any clause mentioned in this paragraph, wherein the Integrative Energy Storage Device is attached directly on a housing of the electric motor device. Clause 3: the Electric Bicycle Drive Unit of any clause mentioned in this paragraph, wherein the Integrative Energy Storage Device is at least partially enclosed by a housing of the electric motor device. Clause 4. the Electric Bicycle Drive Unit of any clause mentioned in this paragraph, wherein the Integrative Energy Storage Device is at least partially arranged with the electric motor device in a common drive housing. Clause 5: the Electric Bicycle Drive Unit of any clause mentioned in this paragraph, wherein in an operational state of the Drive Unit, the Integrative Energy Storage Device is not attached to the Bicycle Frame and the Integrative Energy Storage Device is attached to any one of the Motor Device, a housing of the Motor Device, or a common drive housing. Clause 6: the Electric Bicycle Drive Unit of any clause mentioned in this paragraph, wherein the Integrative Energy Storage Device is arranged, at least in part, in a Down Tube of the Bicycle Frame. Clause 7: the Electric Bicycle Drive Unit of any clause mentioned in this paragraph, wherein an Auxiliary Energy Storage Device is associated with the Electric Bicycle Drive Unit and the Auxiliary Energy Storage Device is arranged, at least in part, in a Down Tube of the Bicycle Frame. Clause 8: the Electric Bicycle Drive Unit of any clause mentioned in this paragraph, wherein the Auxiliary Energy Storage Device is mechanically fixed to any one of the Electric Bicycle Drive Unit or to the Integrative Energy Storage Device. Clause 9: the Electric Bicycle Drive Unit of any clause mentioned in this paragraph, wherein the Auxiliary Energy Storage Device is integrated into the Integrative Energy Storage Device. Clause 10: the Electric Bicycle Drive Unit of any clause mentioned in this paragraph, wherein, in a mounted state of the Electric Bicycle Drive Unit on the Bicycle Frame, the Integrative Energy Storage Device is arranged outside a Down Tube of the Bicycle Frame. Clause 11: the Electric Bicycle Drive Unit of any clause mentioned in this paragraph, wherein the Integrative Energy Storage Device is located at least partially below an axis of rotation of the Bottom Bracket Shaft. Clause 12: the Electric Bicycle Drive Unit of any clause mentioned in this paragraph, wherein a center of mass of the Integrative Energy Storage Device and a center of mass of the Electric Bicycle Drive Unit is within a circumference with the radius less than or equal to 175 mm around the axis of rotation of the Bottom Bracket Shaft. Clause 13: the Electric Bicycle Drive Unit of any clause mentioned in this paragraph, wherein a Center of Mass of the Integrative Energy Storage Device and a Center of Mass of the Electric Bicycle Drive Unit is within an upper right Bottom Bracket Quadrant having a side length less than or equal to 175 mm. Clause 14: the Electric Bicycle Drive Unit of any clause mentioned in this paragraph, wherein a center of mass of the Integrative Energy Storage Device and a Center of Mass of the Electric Bicycle Drive Unit is located at a height of less than or equal to 50 mm above the axis of rotation of the Bottom Bracket Shaft. Clause 15: the Electric Bicycle Drive Unit of any clause mentioned in this paragraph, further including a drive protection shield fastened to any one of a housing of the motor device or to a common drive housing of the Electric Bicycle Drive Unit, wherein the drive protection shield forms a movable closure flap for covering, holding, or both covering and holding the Integrative Energy Storage Device. Clause 16: the Electric Bicycle Drive Unit of any clause mentioned in this paragraph, further including two Rear Frame Interface Arrangements that define a Front mounting axis and a Rear mounting axis. Clause 17: the Electric Bicycle Drive Unit of any clause mentioned in this paragraph, wherein the front mounting axis and the rear mounting axis are arranged in a vertical region above a horizontal plane that contains the axis of rotation of the Bottom Bracket Shaft, and below a horizontal plane that contains a point of application of the Chain Pull Force. Clause 18: the Electric Bicycle Drive Unit of any clause mentioned in this paragraph, wherein the front mounting axis and the rear mounting axis are arranged in front of a vertical plane that contains the axis of rotation of the Bottom Bracket Shaft. Clause 19: the Electric Bicycle Drive Unit of any clause mentioned in this paragraph, wherein the front mounting axis and the rear mounting axis are arranged in front of an Inclined Plane that contains the axis of rotation of the Bottom Bracket Shaft, the Inclined Plane being tilted forwards by an angle of 50° relative to a horizontal plane. Clause 20: the Electric Bicycle Drive Unit of any clause mentioned in this paragraph, wherein the front mounting axis and the rear mounting axis are arranged within an angle α of 30° to 80° located in a top right Bottom Bracket Quadrant, the vertex of the angle coinciding with the axis of rotation of the Bottom Bracket Shaft. Clause 21: the Electric Bicycle Drive Unit of any clause mentioned in this paragraph, wherein a Support Width is selected as the distance between a left-hand and a right-hand Interface Planes of a Rear Frame Interface Arrangement such that a Support Factor, defined as a quotient of the Support Width and a Pedal Force Effective Width, is greater than 0.5. Clause 22: the Electric Bicycle Drive Unit of any clause mentioned in this paragraph, wherein a Support Width is selected as a distance between a left-hand and a right-hand Interface Planes of a Rear Frame Interface Arrangements such that a Chain Pull Factor, defined as a quotient of the Support Width and a Chain Pull Horizontal Distance, is greater than 5. Clause 23: the Electric Bicycle Drive Unit of any clause mentioned in this paragraph, wherein all degrees of freedom of movement of the Drive Unit relative to the Bicycle Frame or relative to a Frame Interface Unit is fixed via a Rear Frame Interface Arrangement, with the exception of a degree of freedom of rotation about an axis of rotation parallel to the axis of rotation of the Bottom Bracket Shaft. Clause 24: the Electric Bicycle Drive Unit of any clause mentioned in this paragraph, wherein a degree of rotational freedom can be fixed by a Front Frame Interface Arrangement relative to the Bicycle Frame or relative to a Frame Interface Unit by means of a frictional connection. Clause 25: the Electric Bicycle Drive Unit of any clause mentioned in this paragraph, wherein the Rear Frame Interface Arrangement has a Frame Offset Adapter configured to: compensate for width tolerances of the Bicycle Frame or of a Frame Interface Unit, radially fix the Rear Frame Interface Arrangement relative to the Bicycle Frame or to the Frame Interface Unit, and provide play-free adjustable axial tolerance compensation between the Rear Frame Interface Arrangement and the Bicycle Frame or Frame Interface Unit. Clause 26: the Electric Bicycle Drive Unit of any clause mentioned in this paragraph, wherein the Frame Offset Adapter is a stepped sleeve that can be screwed axially adjustably into a receiving bore of the drive housing. Clause 27: the Electric Bicycle Drive Unit of any clause mentioned in this paragraph, wherein the Frame Offset Adapter is a radial clamping device that can be received axially displaceably in a receiving bore of the drive housing. Clause 28: the Electric Bicycle Drive Unit of any clause mentioned in this paragraph, further including a hermetically sealed Controller Enclosure arranged in a space region between the Motor Device and the Energy Storage Device for receiving a Controller Device for controlling any one or a combination of the Motor Device and the Energy Storage Device. Clause 29: the Electric Bicycle Drive Unit of any clause mentioned in this paragraph, wherein the Controller Enclosure further includes a plugless Current Interface for connecting the Controller Device to the Energy Storage Device with one or more Interface Planes arranged parallel to a Removal Direction of the Energy Storage Device in such a way that the Current Interface is opened by removing the battery and connected by inserting the battery. Clause 30: the Electric Bicycle Drive Unit of any clause mentioned in this paragraph, further including an output shaft of the motor device arranged coaxially with the Bottom Bracket Shaft. Clause 31: the Electric Bicycle Drive Unit of any clause mentioned in this paragraph, further including bearing mounts for a swing arm of a sprung rear frame. Clause 32: A Bicycle Frame of any clause mentioned in this paragraph, including a Frame Interface Rear Connection and a Frame Interface Front Connection for connection to an Electric Bicycle Drive Unit having a rear mounting axis and a front mounting axis, wherein the frame interface rear connection fixes degrees of freedom of movement of the Electric Bicycle Drive Unit with respect to the Bicycle Frame except for a degree of rotational freedom about the rear mounting axis, and the Frame Interface Front Connection fixes the degree of rotational freedom of the Drive Unit about the rear mounting axis. Clause 33: the Bicycle Frame of any clause mentioned in this paragraph, further including a Support Factor, defined as a quotient of a Support Width and a Pedal Force Effective Width, wherein the Support Factor is greater than 0.5. Clause 34. the Bicycle Frame of any clause mentioned in this paragraph, further including a Chain Pull Factor, defined as a quotient of a Support Width and a Chain Pull Horizontal Distance, wherein the Chain Pull Factor is greater than 5. Clause 35: an Energy Storage Device of any clause mentioned in this paragraph, including a wireless transceiver for wirelessly communicating with a battery controller; and a connector for electrically connecting to an electric motor device so that the Energy Storage Device supplies energy to the electric motor device, wherein the center of gravity position of the Integrative Energy Storage Device lies within the Bottom Bracket Area of a bicycle frame. Clause 36: the Energy Storage Device of any clause mentioned in this paragraph, further including a connector for electrically connecting to an auxiliary energy storage device.
[0307] The illustrations of the embodiments described herein are intended to provide a general understanding of the structure of the various embodiments. The illustrations are not intended to serve as a complete description of all of the elements and features of apparatus and systems that utilize the structures or methods described herein. Many other embodiments may be apparent to those of skill in the art upon reviewing the disclosure. Other embodiments may be utilized and derived from the disclosure, such that structural and logical substitutions and changes may be made without departing from the scope of the disclosure. Additionally, the illustrations are merely representational and may not be drawn to scale. Certain proportions within the illustrations may be exaggerated, while other proportions may be minimized. Accordingly, the disclosure and the figures are to be regarded as illustrative rather than restrictive.
[0308] While this specification contains many specifics, these should not be construed as limitations on the scope of the invention or of what may be claimed, but rather as descriptions of features specific to particular embodiments of the invention. Certain features that are described in this specification in the context of separate embodiments may also be implemented in combination in a single embodiment. Conversely, various features that are described in the context of a single embodiment may also be implemented in multiple embodiments separately or in any suitable sub-combination. Moreover, although features may be described above as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination may in some cases be excised from the combination, and the claimed combination may be directed to a sub-combination or variation of a sub-combination.
[0309] Similarly, while operations and/or acts are depicted in the drawings and described herein in a particular order, this should not be understood as requiring that such operations be performed in the particular order shown or in sequential order, or that all illustrated operations be performed, to achieve desirable results. In certain circumstances, multitasking and parallel processing may be advantageous. Moreover, the separation of various system components in the embodiments described above should not be understood as requiring such separation in all embodiments, and it should be understood that any described program components and systems may generally be integrated together in a single software product or packaged into multiple software products.
[0310] One or more embodiments of the disclosure may be referred to herein, individually and/or collectively, by the term “invention” merely for convenience and without intending to voluntarily limit the scope of this application to any particular invention or inventive concept. Moreover, although specific embodiments have been illustrated and described herein, it should be appreciated that any subsequent arrangement designed to achieve the same or similar purpose may be substituted for the specific embodiments shown. This disclosure is intended to cover any and all subsequent adaptations or variations of various embodiments. Combinations of the above embodiments, and other embodiments not specifically described herein, are apparent to those of skill in the art upon reviewing the description.
[0311] The Abstract of the Disclosure is provided to comply with 37 C.F.R. § 1.72(b) and is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. In addition, in the foregoing Detailed Description, various features may be grouped together or described in a single embodiment for the purpose of streamlining the disclosure. This disclosure is not to be interpreted as reflecting an intention that the claimed embodiments require more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive subject matter may be directed to less than all of the features of any of the disclosed embodiments. Thus, the following claims are incorporated into the Detailed Description, with each claim standing on its own as defining separately claimed subject matter.
[0312] It is intended that the foregoing detailed description be regarded as illustrative rather than limiting and that it is understood that the following claims including all equivalents are intended to define the scope of the invention. The claims should not be read as limited to the described order or elements unless stated to that effect. Therefore, all embodiments that come within the scope and spirit of the following claims and equivalents thereto are claimed as the invention.