E-clutch for pedelec bicycle

Patent metadata

Field	Value
Publication number	US-10850801-B2
Application number	US-201816165079-A
Country	US
Kind code	B2
Filing date	Oct 19, 2018
Priority date	Dec 7, 2017
Publication date	Dec 1, 2020
Grant date	Dec 1, 2020

Abstract

A pedal-electric bicycle utilizes an e-clutch to prevent a motor of the pedal-electric bicycle that is fixedly engaged to a drivetrain of the pedal-electric bicycle from resisting movement of the drivetrain when the motor is not transferring power to the drivetrain. The e-clutch causes the motor to operate at a minimum torque level to overcome the internal resistance thereof. The use of an e-clutch beneficially permits the elimination of a mechanical motor clutch, thus reducing complexity, cost, and weight of the pedal-electric bicycle.

First claim

What is claimed is:

1. A pedal-electric bicycle, comprising:
a set of pedals;
a drive wheel;
a drivetrain configured to transfer power from the set of pedals to the drive wheel;
a pedal clutch for disengaging the set of pedals from the drivetrain;
a motor, the motor in fixed engagement with the drivetrain and configured to selectively transfer power to the drivetrain; and
a motor controller configured to selectively operate the motor at a minimum torque level when the drivetrain is transferring power from the set of pedals to the drive wheel and the motor is not transferring power to the drivetrain.

2. The pedal-electric bicycle of claim 1 , wherein the minimum torque level is a torque level sufficient to overcome an internal resistance of the motor.

3. The pedal-electric bicycle of claim 2 , wherein the motor controller comprises a memory that stores a look-up table containing information about the minimum torque level.

4. The pedal-electric bicycle of claim 1 , further comprising a battery for providing electricity to the motor.

5. The pedal-electric bicycle of claim 4 , wherein the motor controller is configured to operate the motor at the minimum torque level if a charge level of the battery reaches a predetermined minimum charge level.

6. The pedal-electric bicycle of claim 5 , wherein the predetermined minimum charge level is higher than a lowest safe charge level of the battery.

7. The pedal-electric bicycle of claim 1 , further comprising a speed sensor configured to transmit speed information to the motor controller.

8. The pedal-electric bicycle of claim 1 , further comprising a cadence sensor configured to transmit cadence information to the motor controller.

9. The pedal-electric bicycle of claim 1 , further comprising a motor support level sensor configured to transmit motor support level information to the motor controller.

10. The pedal-electric bicycle of claim 1 , further comprising a brake sensor configured to transmit braking information to the motor controller.

11. The pedal-electric bicycle of claim 1 , further comprising a motor sensor configured to transmit motor information to the motor controller.

12. The pedal-electric bicycle of claim 1 , further comprising a battery management unit configured to transmit battery information to the motor controller.

13. A method of operating a motor of a pedal-electric bicycle, comprising:
receiving, at a motor controller, information about a change in context of the pedal-electric bicycle;
determining, with a processor of the motor controller and based on the received information, that the motor of the pedal-electric bicycle is to be depowered;
determining, based on information stored in a memory of the motor controller and with the processor of the motor controller, a minimum torque level required to overcome an internal resistance of the motor; and
causing the motor to operate at the minimum torque level.

14. The method of claim 13 , wherein the pedal-electric bicycle comprises a drivetrain configured to transfer power from a set of pedals and the motor to a drive wheel, the set of pedals selectively disengageable from the drivetrain, the motor fixedly engaged to the drivetrain.

15. The method of claim 13 , wherein the information about a change in context of the pedal-electric bicycle comprises information about braking of the pedal-electric bicycle, a position of a motor support level selector of the pedal-electric bicycle, a cadence of a set of pedals of the pedal-electric bicycle, a motor winding temperature within the motor of the pedal-electric bicycle, a speed of the pedal-electric bicycle, a charge state of a battery of the pedal electric bicycle, or the motor of the pedal-electric bicycle.

16. The method of claim 13 , wherein the information about a change in context of the pedal-electric bicycle corresponds to information sensed by a brake sensor, a motor support level sensor, a cadence sensor, a temperature sensor, a speed sensor, a motor sensor, or a battery management unit.

17. The method of claim 16 , wherein the information about a change in context of the pedal-electric bicycle corresponds to information sensed by the motor sensor, and the information sensed by the motor sensor comprises a motor RPM.

18. The method of claim 13 , wherein the motor comprises a direct current, brushless, slotless motor.

19. The method of claim 13 , wherein the information stored in the memory of the motor controller is a look-up table that correlates motor RPM with minimum torque levels.

20. A pedal-electric bicycle e-clutch, comprising:
a processor; and
a memory storing instructions for execution by the processor that, when executed, cause the processor to:
receive context information from a braking sensor, a motor support level sensor, a cadence sensor, a speed sensor, or a battery management unit of the pedal-electric bicycle;
determine, based on the context information, that a context of the pedal-electric bicycle has changed;
cause a motor of the pedal-electric bicycle to stop transferring power to a drivetrain of the pedal-electric bicycle, the motor fixedly engaged to the drivetrain;
identify, using a look-up table stored in the memory, a minimum torque level necessary to overcome an internal resistance of the motor; and
cause the motor to operate at the minimum torque level.

Assignees

• Flex Ltd

Inventors

• Wiegel Christopher D
• DEVA Shaily
• Saiki Neal

Classifications

• B62M6/45

  Control or actuating devices therefor · CPC title

• F16D41/24

  specially adapted for cycles · CPC title

• B60L58/12

  responding to state of charge [SoC] · CPC title

• B60L2220/16

  DC brushless machines · CPC title

• B60L50/20

  using propulsion power generated by humans or animals · CPC title