Electric motor device for pedal assist bicycles

Patent metadata

Field	Value
Publication number	US-11396346-B2
Application number	US-201816640396-A
Country	US
Kind code	B2
Filing date	Aug 23, 2018
Priority date	Aug 24, 2017
Publication date	Jul 26, 2022
Grant date	Jul 26, 2022

Abstract

An electric motor device for pedal assist bicycles may include an electric motor connectable to a rear wheel rim of a bicycle, a pedaling sensor connectable to a hanger of a frame of the bicycle, a charging outlet, a control unit, and a block insertable into an oblique main tube of the frame. The electric motor may include at least one free wheel rigidly connectable to transmission gear wheels of the bicycle. The block may include a battery configured to actuate the electric motor, a motor controller configured to control a plurality of operating parameters of the electric motor, a battery manager configured to manage the battery connected in parallel to the battery and to the motor controller, a plurality of first cables connecting the block to the electric motor, the charging outlet, and the pedaling sensor, and a plurality of second cables connecting the block to the control unit.

First claim

The invention claimed is:

1. An electric motor device for pedal assist bicycles, comprising:
an electric motor having a hub shape, the electric motor connectable to a rim of a rear wheel of a bicycle, the electric motor including at least one free wheel rigidly connectable to at least one transmission gear wheel of the bicycle;
a pedaling sensor connectable to a hanger of a frame of the bicycle, the hanger disposed in an anchoring zone of a rear hub of the frame of the bicycle;
a charging outlet;
a control unit connectable to the frame of the bicycle and operable via a user for actuation and control;
a block insertable into an oblique main tube of the frame of the bicycle;
wherein the block includes:
a battery operatively connected to the charging outlet such that the battery is rechargeable via the charging outlet, the battery configured to actuate the electric motor;
a motor controller connected in parallel to the battery, the motor controller configured to control a plurality of operating parameters of the electric motor;
a battery manager connected in parallel to the battery and to the motor controller, the battery manager configured to manage the battery;
a plurality of first cables connecting the block to the electric motor, the charging outlet, and the pedaling sensor;
a plurality of second cables connecting the block to the control unit;
a first cover closing a first axial end of the block, the plurality of first cables extending out of the block through the first cover; and
a second cover closing a second axial end of the block, the plurality of second cables extending out of the block through the second cover;

wherein the battery manager and the motor controller are directly connected to one another in parallel.

2. The electric motor device as claimed in claim 1 , wherein the pedaling sensor includes:
a disk rigidly connectable to the at least one free wheel of the electric motor; and
a plurality of magnets arranged on the disk configured to activate the pedaling sensor.

3. The electric motor device as claimed in claim 1 , wherein the control unit includes:
a pushbutton with at least one button actuatable via the user;
a lighting mechanism configured to transmit information via emitting light; and
a vibration motor connected to the pushbutton configured to transmit information via providing vibrations.

4. The electric motor device as claimed in claim 3 , wherein the vibration motor includes a variable-frequency drive configured to transmit information via providing a plurality of different vibrations.

5. The electric motor device as claimed in claim 1 , wherein:
the battery includes a block of cells; and
the block of cells includes a group of ten cells and an auxiliary cell structured and arranged in an 11S2P layout.

6. The electric motor device as claimed in claim 1 , wherein:
the battery includes a block of cells; and
the block of cells includes a group of thirteen cells and an auxiliary cell structured and arranged in a 14S2P layout.

7. The electric motor device as claimed in claim 1 , wherein:
the battery includes a block of cells;
the block of cells includes eleven cells connected to one another in series; and
the eleven cells includes two groups of cells connected in parallel such that the eleven cells are arranged in an 11S2P layout.

8. The electric motor device as claimed in claim 1 , wherein:
the battery includes a block of cells;
the block of cells includes fourteen cells connected to one another in series; and
the fourteen cells includes two groups of cells connected in parallel such that the fourteen cells are arranged in an 14S2P layout.

9. The electric motor device as claimed in claim 1 , wherein:
the battery includes a block of cells;
the block of cells includes a plurality of groups of cells;
each of the plurality of groups of cells includes at least one of ten cells and thirteen cells; and
the block of cells further includes one auxiliary cell for each group of the plurality of groups of cells.

10. The electric motor device as claimed in claim 1 , wherein:
the battery, the battery manager, and the motor controller are directly connected to one another in parallel; and
a circuit board of the battery manager is connected directly to a circuit board of the motor controller.

11. The electric motor device as claimed in claim 1 , wherein a direct connection between the battery manager and the motor controller is free of cables.

12. The electric motor device as claimed in claim 1 , further comprising an auxiliary battery that is operatively connectable to the battery and is releasably connectable to the bicycle.

13. The electric motor device as claimed in claim 1 , wherein the battery manager and the motor controller are directly connected to one another physically and electrically such that the battery manager and the motor controller are configured as a single unit.

14. An electric motor device for pedal assist bicycles, comprising:
an electric motor having a hub shape, the electric motor connectable to a rim of a rear wheel of a bicycle, the electric motor including at least one free wheel rigidly connectable to at least one transmission gear wheel of the bicycle;
a pedaling sensor connectable to a hanger of a frame of the bicycle, the hanger disposed in an anchoring zone of a rear hub of the frame of the bicycle;
a charging outlet;
a control unit connectable to the frame of the bicycle and operable via a user for actuation and control;
a block insertable into an oblique main tube of the frame of the bicycle;
wherein the block includes:
a battery operatively connected to the charging outlet such that the battery is rechargeable via the charging outlet, the battery configured to actuate the electric motor;
a motor controller configured to control a plurality of operating parameters of the electric motor;
a battery manager configured to manage the battery;
the battery manager, the battery, and the motor controller connected directly together in parallel;
a plurality of first cables connecting the block to the electric motor, the charging outlet, and the pedaling sensor;
a plurality of second cables connecting the block to the control unit;
a first cover closing a first axial end of the block, the plurality of first cables extending out of the block through the first cover; and
a second cover closing a second axial end of the block, the plurality of second cables extending out of the block through the second cover.

15. The electric motor device as claimed in claim 14 , wherein:
the block further includes a rubber insulator and a rubber O-ring seal; and
the O-ring seal and the insulator are coupled to the block via the first cover and seal the block.

16. The electric motor device as claimed in claim 15 , wherein the insulator is overmolded onto the plurality of first cables sealingly connecting the plurality of first cables together.

17. An electric motor device for pedal assist bicycles, comprising:
an electric motor having a hub shape, the electric motor connectable to a rim of a rear wheel of a bicycle, the electric motor including at least one free wheel rigidly connectable to at least one transmission gear wheel of the bicycle;
a pedaling sensor connectable to a hanger of a frame of the bicycle, the hanger disposed in an anchoring zone of a rear hub of the frame of the bicycle;
a charging outlet;
a control unit connectable to the frame of the bicycle and operable via a user for actuation and control;
a block insertable into an oblique main tube of the frame of t

Assignees

• Mahle Int Gmbh

Inventors

• De La Serna Gonzalez Marco Antonio
• Franco Revilla Jose Vicente
• Cortes Lopez Jose Joaquin

Classifications

• A01K1/0064 Primary

  Construction of air inlets or outlets in walls · CPC title

• B62K19/40

  for attaching accessories, e.g. article carriers, lamps · CPC title

• B62M6/60

  power-driven at axle parts · CPC title

• B62M6/90 Primary

  Batteries · CPC title

• B62K3/04

  having a substantially horizontal top bar · CPC title