阅读说明：本技术 电动自行车马达系统 (Motor system of electric bicycle ) 是由 尼尔·齐木 于 2019-08-14 设计创作，主要内容包括：一种具有电动马达驱动齿轮的电动马达自行车系统,所述电动马达驱动齿轮适于驱动联接到自行车轮毂的车轮齿轮。所述马达驱动齿轮通过链条联接到车轮齿轮。链条可以用一个或多个张紧器张紧,这允许更紧密的系统几何结构。马达可以用适合于安装到工业标准盘制动器安装接口的支架支撑。在一些方面,马达驱动齿轮联接到车轮轮毂的盘安装接口。在一些方面,电动马达自行车系统还可以具有集成在其中的盘制动器系统。(An electric motor bicycle system has an electric motor drive gear adapted to drive a wheel gear coupled to a bicycle hub. The motor drive gear is coupled to the wheel gear by a chain. The chain may be tensioned with one or more tensioners, which allows for a tighter system geometry. The motor may be supported by a bracket adapted to mount to an industry standard disc brake mounting interface. In some aspects, the motor-driven gear is coupled to a disk mounting interface of the wheel hub. In some aspects, the electric motor bicycle system can also have a disc brake system integrated therein.)

1. An electric bicycle system, comprising:

a bicycle frame having a longitudinal axis;

a rear wheel coupled to the bicycle frame, the rear wheel comprising:

a rotating shaft;

a first pedal drive side of the rear wheel coupled to a first side of the bicycle frame; and

a second side of the rear wheel coupled to a second side of the bicycle frame;

a motor unit coupled to the bicycle frame, the motor unit including a low aspect ratio electric motor having a rotational shaft, wherein the motor unit is coupled to the second side of the bicycle frame such that the rotational shaft of the motor is longitudinally forward of the rotational shaft of the rear wheel and within an outer diameter of the rear wheel;

an output gear coupled to the motor; and

a drive gear coupled to the second side of the rear wheel, the drive gear mechanically coupled to the output gear of the motor.

2. The electric bicycle system of claim 1, wherein the low aspect ratio electric motor is a BLDC external rotor electric motor, wherein the motor includes a motor stator, and wherein the stator diameter of the motor stator is greater than 2 times the laminate stack thickness.

3. The electric bicycle system of claim 1, wherein the low aspect ratio electric motor is a BLDC external rotor electric motor, wherein the motor includes a motor stator, and wherein the stator diameter of the motor stator is greater than 4 times the laminate stack thickness.

4. The electric bicycle system of claim 1, wherein the bicycle frame includes a rear disc brake caliper mounting interface, and the motor unit is coupled to the bicycle frame at the rear brake caliper mounting interface.

5. The electric bicycle system of claim 4, wherein the rear wheel includes a brake disc mounting interface along the second side of the rear wheel, and the drive gear is mounted to the brake disc mounting interface.

6. The electric bicycle system of claim 1, further comprising a chain, wherein the drive gear is mechanically coupled to the output gear of the motor through the chain.

7. The electric bicycle system of claim 1, further comprising a belt, wherein the drive gear is mechanically coupled to the output gear of the motor by the belt.

8. The electric bicycle system of claim 1, wherein the motor unit is adapted to function as a drive motor and an electric regenerative brake.

9. The electric bicycle system of claim 6, wherein the motor unit is adapted to function as a drive motor and an electric regenerative brake.

10. The electric bicycle system of claim 1, wherein the rear wheel includes a central hub having a disc brake disc mounting interface, and the drive gear is mounted to the disc brake mounting interface.

11. The electric bicycle system of claim 6, wherein the rear wheel includes a central hub having a disc brake disc mounting interface, and the drive gear is mounted to the disc brake mounting interface.

12. An electric bicycle system according to claim 1, wherein the motor unit has an outer surface that is remote from a center plane of the bicycle, and the bicycle further comprises a pedal crank having an outermost surface that is remote from the center plane of the bicycle, wherein the outer surface of the motor unit is substantially in line with or inboard of the outermost surface of the pedal crank.

13. An electric bicycle system according to claim 6, wherein the motor unit has an outer surface that is remote from a center plane of the bicycle, and the bicycle further comprises a pedal crank having an outermost surface that is remote from the center plane of the bicycle, wherein the outer surface of the motor unit is substantially in line with or inboard of the outermost surface of the pedal crank.

14. The electric bicycle system of claim 13, wherein the motor comprises a motor stator and the stator diameter of the motor stator is greater than 4 times the laminate stack thickness.

15. The electric bicycle system of claim 1, further comprising a motor controller coupled to the power source and the motor unit, the motor controller adapted to power the motor as a drive motor in a first mode of operation, the motor controller adapted to use the motor for regenerative braking in a second mode of operation.

16. The electric bicycle system of claim 13, further comprising a motor controller coupled to the power source and the motor unit, the motor controller adapted to power the motor as a drive motor in a first mode of operation, the motor controller adapted to use the motor for regenerative braking in a second mode of operation.

17. The electric bicycle system of claim 14, further comprising a motor controller coupled to the power source and the motor unit, the motor controller adapted to power the motor as a drive motor in a first operating mode, the motor controller adapted to use the motor for regenerative braking in a second operating mode.

18. The electric bicycle system according to claim 6, wherein the distance between the rotation axis of the motor and the rotation axis of the driving gear is in the range of 150 and 230 mm.

19. The electric bicycle system according to claim 13, wherein a distance between the rotation axis of the motor and the rotation axis of the driving gear is in the range of 150 and 230 mm.

20. The electric bicycle system according to claim 14, wherein a distance between the rotation axis of the motor and the rotation axis of the driving gear is in the range of 150 and 230 mm.

21. The electric bicycle system of claim 6, further comprising a first chain idler sprocket along a first chain portion on a first side of the output gear of the motor.

22. The electric bicycle system according to claim 21, wherein the first chain idler sprocket is mounted on a spring-loaded arm adapted to maintain tension on the chain.

23. The electric bicycle system of claim 22, further comprising a second chain idler sprocket that applies tension to the chain along a second chain portion on a second side of the output gear of the motor.

24. The electric bicycle system of claim 15, further comprising:

a first chain tensioner that applies tension to the chain along a first chain portion on a first side of the motor gear; and

a second chain tensioner that applies tension to the chain along a second chain portion of the second side of the chain.

25. An electric bicycle motor system, comprising:

an electric motor;

a motor mount for the electric motor, wherein the motor mount is adapted to attach to a rear disc brake caliper mounting interface;

a motor output gear coupled to the electric motor;

a drive gear adapted to attach to a disc brake disc mounting interface of a bicycle wheel hub; and

a chain coupling the motor output gear to the drive gear.

26. The electric bicycle motor system of claim 25, further comprising:

a first chain tensioner that applies tension to the chain along a first chain portion on a first side of the motor gear; and

a second chain tensioner that applies tension to the chain along a second chain portion of the second side of the chain.

27. The electric bicycle motor system of claim 25, wherein the motor is a BLDC external rotor electric motor, and wherein the motor comprises a motor stator having a stator diameter greater than 4 times a laminate stack thickness.

28. The electric bicycle motor system of claim 25, wherein the motor is a BLDC external rotor electric motor, and wherein the motor comprises a motor stator having a stator diameter greater than 6 times a laminate stack thickness.

29. The electric bicycle motor system according to claim 27, wherein the laminated stack thickness is less than 30 mm.

30. The electric bicycle motor system according to claim 28, wherein the laminated stack thickness is less than 30 mm.

31. The electric bicycle motor system according to claim 27, wherein the laminated stack thickness is less than 20 mm.

32. The electric bicycle motor system according to claim 28, wherein the laminated stack thickness is less than 20 mm.

33. An electric bicycle system, comprising:

a bicycle frame having a longitudinal axis;

a rear wheel coupled to the bicycle frame, the rear wheel comprising:

a rotating shaft;

a first pedal drive side coupled to a pedal drive side of the bicycle frame; and

a second side coupled to a second side of the bicycle frame;

a motor unit coupled to the bicycle frame, the motor unit including a low aspect ratio electric motor having a rotational shaft, wherein the motor unit is coupled to the second side of the bicycle frame such that the rotational shaft of the motor is longitudinally forward of the rotational shaft of the rear wheel and within an outer diameter of the rear wheel;

a disc brake caliper unit coupled to the frame;

an output gear coupled to the motor;

a drive gear coupled to the second side of the rear wheel, the drive gear mechanically coupled to the output gear of the motor; and

a brake disc coupled to the second side of the rear wheel.

34. The electric bicycle system of claim 33, wherein the disc brake caliper unit is coupled to the frame by the motor unit.

35. The electric bicycle system of claim 33, wherein the drive gear and the brake disc are coupled to a brake disc mounting interface of the rear wheel.

36. The electric bicycle system of claim 33, further comprising a chain, wherein the drive gear is mechanically coupled to the output gear of the motor through the chain.

37. The electric bicycle system of claim 33, wherein the low aspect ratio electric motor is a BLDC external rotor electric motor, wherein the motor includes a motor stator, and wherein the stator diameter of the motor stator is greater than 4 times the laminate stack thickness.

38. The electric bicycle system of claim 33, wherein the motor unit further comprises a directional clutch.

39. The electric bicycle system of claim 33, wherein the electric bicycle system further comprises a directional clutch.

40. The electric bicycle system of claim 33, further comprising a motor controller coupled to the power source and the motor unit, the motor controller adapted to power the motor as a drive motor in a first operating mode, the motor controller adapted to use the motor for regenerative braking in a second operating mode.

41. An electric bicycle system, comprising:

a bicycle frame having a longitudinal axis;

the bicycle comprises a frame rear wheel mounting shaft;

a motor unit coupled to the bicycle frame, the motor unit including a low aspect ratio electric motor having a rotational shaft, wherein the motor unit is coupled to the second side of the bicycle frame such that the rotational shaft of the motor is longitudinally forward of the rotational shaft of the rear frame rear wheel mounting axle and within an outer diameter of a rear wheel used with the bicycle frame;

an output gear coupled to the motor; and

a drive gear mechanically coupled to the output gear of the motor.

42. The electric bicycle system of claim 41, wherein the low aspect ratio electric motor is a BLDC external rotor electric motor, wherein the motor includes a motor stator, and wherein the stator diameter of the motor stator is greater than 2 times the laminate stack thickness.

43. The electric bicycle system of claim 41, wherein the low aspect ratio electric motor is a BLDC external rotor electric motor, wherein the motor includes a motor stator, and wherein the stator diameter of the motor stator is greater than 4 times the laminate stack thickness.

44. The electric bicycle system according to claim 41, wherein the bicycle frame includes a rear disc brake caliper mounting interface and the motor unit is coupled to the bicycle frame at the rear brake caliper mounting interface.

45. The electric bicycle system of claim 41, further comprising a chain, wherein the drive gear is mechanically coupled to the output gear of the motor through the chain.

Technical Field

The present invention relates to electric transportation, and more particularly to electric bicycle motor systems.

Description of the Related Art

Motivated by the environmental, public health, ecological, and carbon footprint issues associated with gasoline powered vehicles, researchers, governments, and the entire society are constantly seeking viable alternatives. Electric bicycles (electric bicycles) propelled by a combination of a pedal and a battery-driven electric motor are a promising alternative to automotive transportation. Their main advantages include: lower purchase and operation costs compared to automobiles; compared with the traditional bicycle, the bicycle has longer running distance and less physical consumption; and zero emission during operation.

Regenerative braking is a unique technique used in electric vehicles to capture the energy generated by the vehicle as it moves, or in other words, the kinetic energy of the vehicle is wasted as it decelerates during braking. By measuring the initial vehicle speed and the final vehicle speed, the amount of kinetic energy lost to braking can be calculated.

City driving cycles have considerable periods of acceleration and deceleration due to the presence of traffic control systems around towns, and therefore, a large amount of energy is lost in deceleration. However, through regenerative braking, such energy may be captured and "wasted" energy may be utilized and used for vehicle propulsion. Likewise, off-road bicycles also have considerable acceleration and deceleration requirements due to climbing and descending slopes.

Background

Disclosure of Invention

An electric motor bicycle system has an electric motor drive gear adapted to drive a wheel gear coupled to a bicycle hub. The motor drive gear is coupled to the wheel gear by a chain. The chain may be tensioned with one or more tensioners, which allows for closely spaced system geometries. The motor may be supported by a bracket adapted to mount to an industry standard disc brake mounting interface. In some aspects, the motor-driven gear is coupled to a disk mounting interface of the wheel hub. In some aspects, the electric motor bicycle system can also have a disc brake system integrated therein. The electric motor bicycle system may include a regenerative braking system, which may be a fully proportional regenerative braking system.

Drawings

FIG. 1 is an isometric view of an electric bicycle motor system according to some embodiments of the present invention.

FIG. 2A is a left side view of a bicycle having an electric bicycle motor system mounted thereon in accordance with some embodiments of the present invention.

FIG. 2B is a top plan view of a bicycle having an electric bicycle motor system mounted thereon in accordance with some embodiments of the present invention.

FIG. 3 is a right side view of an electric bicycle motor system according to some embodiments of the present invention.

Fig. 4 is a left side view of an electric bicycle motor system according to some embodiments of the present invention.

FIG. 5 is a side cross-sectional view of an electric bicycle motor system according to some embodiments of the present invention.

FIG. 6A is an isometric view of a bicycle having an electric bicycle motor system mounted thereon in accordance with some embodiments of the present invention.

FIG. 6B is an isometric view of a bicycle having an electric bicycle motor system mounted thereon in accordance with some embodiments of the present invention.

FIG. 7 is an isometric view of a mounting bracket for an electric bicycle motor according to some embodiments of the present invention.

Fig. 8A is an exploded isometric view of an electric bicycle motor system according to some embodiments of the present invention.

Fig. 8B is an internal view of a motor housing according to some embodiments of the invention.

FIG. 9 is a left side elevational view of a bicycle having an electric bicycle motor system mounted thereto in accordance with some embodiments of the present invention.

FIG. 10 is an isometric view of an electric bicycle motor system according to some embodiments of the present invention.

FIG. 11 is a side cross-sectional view of an electric bicycle motor system according to some embodiments of the present invention.

FIG. 12 is an isometric view of an electric bicycle motor system with a disc brake according to some embodiments of the present invention.

FIG. 13 is a cross-sectional view of an electric bicycle motor system with a disc brake according to some embodiments of the present invention.

FIG. 14 is an exploded isometric view of an electric bicycle motor system according to some embodiments of the present invention.

FIG. 15 is an isometric view of a mounting bracket for an electric bicycle motor according to some embodiments of the present invention.

FIG. 16 is an isometric view of a mounting bracket for an electric bicycle motor according to some embodiments of the present invention.

Fig. 17A illustrates a stent according to some embodiments of the inventions.

FIG. 17B illustrates a mounting interface according to some embodiments of the inventions.

Fig. 18 is a flow chart of a motor and battery system according to some embodiments of the invention.

Detailed Description

In some embodiments of the present invention, as shown in fig. 1, 3, 4 and 5, the electric bicycle motor system 100 couples the motor unit 101 to the drive gear 102 through the drive chain 103. The motor unit 101 is coupled to a mounting bracket 110, the mounting bracket 110 being adapted to mount the motor unit 101 to a bicycle. In some aspects, the mounting bracket 110 is adapted to mount the rear disc brake mounting interface 107 of the bicycle. In some aspects, the mounting bracket 110 is adapted to mount to an industry standard brake mounting interface. With such a system, a non-electric bicycle can be converted into an electric bicycle. In some aspects, the electric bicycle system is adapted to be mounted to a customized mounting interface.

In an exemplary application, as shown in fig. 2A and 2B, the electric bicycle system 100 can be mounted to an existing bicycle designed to accommodate a rear disc brake system. The rear wheel assembly on a bicycle may include a rim 106 with a tire 105 mounted on the rim 106. The rim 106 may be coupled to a hub that includes a disk mounting interface 109. The rear disc brake mounting interface 107 may be located on a rear portion of the frame 104. Instead of mounting the rear disc and rear disc brake mechanism, the mounting interface 119 of the gear 102 may be mounted to the disc interface 109 of the rear hub. A bracket 110 adapted to support the motor unit 101 is mounted to the disk mounting interface 109, and the motor unit 101 is coupled to the bracket 110. In this manner, the electric bicycle system 100 can be easily incorporated into an industry standard bicycle without the need for any rework or additional installation changes or brackets. The use of an electric bicycle system as a rear brake braking system avoids the need for a rear disc brake, allowing the use of a disc and disc brake mechanism mounting interface for the drive gear 102 and motor unit 101 and motor bracket 110. In some aspects, there is no other rear brake mechanism on the bicycle than the rear brake mechanism of the motor unit that acts as a brake. In some aspects, the gear 102 is mounted to the hub mounting interface and the gear interface consists of a six hole pattern with holes of approximately 5m diameter on a 44mm diameter bolt circle.

The rotational axis 108 of the rear wheel 106, which is coaxial with the rotational axis of the drive gear 102, is marked by point 153 along the front-to-rear axis of the bicycle and is shown in fig. 2A. In some aspects, the bicycle frame is configured such that the rear wheel will be mounted in a fixed position in the frame such that the frame will have a rear wheel mounting axle that will be coaxial with the rear wheel rotational axis when the bicycle is assembled. The bicycle longitudinal axis 156 is used to represent the location point of the components in the fore-aft direction. The rotational axis of the motor unit 101 is marked by point 152 along the longitudinal axis of the bicycle, point 152 being forward along the longitudinal axis of the bicycle relative to point 153 of the rotational axis of the rear wheel. The forward point of the motor unit centre of mass relative to the axis of rotation of the wheel allows the motor unit to be mounted without suspending the motor behind the rear wheel axle. In some aspects, a forwardmost position 155 of the rim 106 along the longitudinal axis 156 represents a furthest forward position of the motor rotational shaft 112. In some aspects, the motor rotation shaft is located at a point along the longitudinal position axis 156 between the point 153 of the rotation shaft 108 and the point 155 of the forwardmost position 155 of the rim 106. In some aspects, the axis of rotation of the motor is not only further forward of the point 155 of the rim 106, but also at other points, and not radially outward of the rim.

The rear wheel of the bicycle may have a pedal drive side, which is where the drive gear is mounted to the crank assembly. Similarly, the side of the bicycle frame on the side of the pedal-driven side having the crank may be referred to as the pedal-driven side of the frame. In some aspects, the bicycle frame may not be left-right symmetric, for example, which may be due to the presence of a transmission release coupled to the frame.

As shown in fig. 2B, the inner edge of the pedal (not shown) coupled to the crank arm 151 is located at a distance perpendicular to the crank shaft, which is equal to or more outside the outer surface of the motor unit 101. Fig. 2B is a top view of the embodiment seen in the left side view in fig. 2A. As shown in fig. 2A, the rotational axis of the motor unit 101 and the center of mass thereof may be located in front of the rotational axis of the rear wheel. In addition, the motor unit 101 may extend no further outside than the plane of the rotational path of the inside edge of the pedal coupled to the crank, which would allow the user's foot to exit the motor unit 101 in practice. In some aspects, the motor unit is spaced from an outer side surface of the crank arm. In some aspects, the motor unit does not protrude outside the outer surface of the crank arm, whether a wider "supercharged" crank is used or a conventional "non-supercharged" crank set is used. In some aspects, the outermost portion of the motor unit will not protrude further outboard than the outer surface of the crank arm, and the innermost surface of the motor unit will be outboard of any potentially interfering portions of the tire and wheel assembly. In some aspects, the outer surface of the motor unit that is distal from the center plane of the bicycle will be generally in line with or will be inboard of the outermost surface of the pedal crank arm. In some aspects, the innermost surface of the motor unit will be outboard of the outboard surface of the rim. In some aspects, the innermost surface of the motor unit will be outboard of the outboard surface of the tire. The very thin nature of the motor unit allows the motor unit to be positioned in a location on the bicycle that was previously unavailable.

Fig. 3 illustrates a rear view of the electric bicycle system 100 according to some embodiments of the present invention. The electric bicycle system 100 comprises two tensioning mechanisms 114, 117 which allow a large amount of chain to be wound around the pinion 111 and provide dynamic stability of the chain 103 both during power transmission to the rear wheel and during braking of the rear wheel by the motor in a braking condition. The motor unit 101 may have a rotating shaft 112 coupled to an outer rotor coupled to a pinion gear 111. In some aspects, as further shown in fig. 8, the motor 101 has an outer rotor 135 that is coupled to an inner housing 134 of the motor 101 and that rotates about an inner stator 136 that is coupled to an inner stator 136. The first tensioner 114 is coupled to the first mounting pivot interface 115 and provides a tensioning force onto the chain 103 with the first spring-loaded gear 113. The second tensioner 117 is coupled to the second mounting pivot interface 118 and provides a tensioning force onto the chain 103 using the second spring loaded gear 116. The fixed outer housing 137 of the motor unit 101 is coupled to a mounting bracket 110, which mounting bracket 110 may be attached to the rear disc brake mounting interface of the bicycle with fasteners 120, 121. The drive gear mounting portion 131 is adapted to provide mounting of the drive gear 102 to the mounting interface 119 on the rear hub.

In some aspects, a center-to-center distance between the rotational axis of the drive gear and the rotational axis of the motor is in a range of 100mm to 350 mm. This widest range is generally defined by the smallest center-to-center distance between the two gears and the largest center-to-center distance defined by the radius of the bicycle rim. In some aspects, a center-to-center distance between the rotational axis of the drive gear and the rotational axis of the motor is in a range of 125mm to 290 mm. This intermediate range provides better minimum chain wrap and shorter chain length. In some aspects, a center-to-center distance between the rotational axis of the drive gear and the rotational axis of the motor is in a range of 150mm to 230 mm. This narrow range provides good chain wrap and minimal chain length. In an exemplary embodiment, the center-to-center distance is about 187 mm.

In this illustrative embodiment, the pinion has 13 teeth. The number of pinion gear teeth may be varied to provide a desired gear ratio between the pinion gear and the drive gear. In some aspects, the number of drive pinion teeth has a range between 9 and 30 teeth. In this illustrative embodiment, the drive gear has 133 teeth. The number of drive gear teeth may be varied to provide a desired gear ratio between the pinion gear and the drive gear. In some aspects, the number of drive gear teeth has a range between 60 and 200 teeth. Typically, the drive gear has more teeth to provide a gear ratio that allows the pinion gear to rotate faster than the drive gear to provide a gear reduction.

In the exemplary embodiment, the chain has a pitch of 1/4 inches. This is the standard chain pitch. In other respects, there are other standard chain pitches, smaller or larger, that will function properly. Chain pitches of imperial, metric or non-standard pitches may also be used. The approximate diameter of the pinion and drive gear is determined by the number of teeth times the chain pitch plus some additional diameter of the tooth form.

In some embodiments of the present invention, as shown in fig. 4, the motor unit 101 is coupled to the bracket 110 by fasteners 122, 123. The outer motor housing 137 may have a slot 124, the slot 124 being adapted to allow some adjustment of the position of the motor unit 101 relative to the bracket 110. Fig. 5 shows the motor unit 101 in a sectional view. In this view, the vertical alignment of the teeth of pinion 111, chain 103, and drive gear 102 is shown.

Fig. 6A and 6B show different embodiments of a mounting bracket for the motor unit 101. Fig. 6A shows a bracket 110, which bracket 110 is coupled to the motor unit and also to the bicycle frame, and in some aspects may be coupled to the disc brake caliper mounting interface. Fig. 6B shows a bracket portion 110a, which bracket portion 110a is part of a bicycle frame.

Although discussed in the context of a bicycle, in some aspects, the present invention may be seen in something other than a bicycle, such as a tricycle with two front wheels and a single rear wheel.

FIG. 7 illustrates a mounting bracket 110 according to some embodiments of the invention. The mounting bracket 110 includes through holes 125, 126, and the through holes 125, 126 may be sized to mate with an industry standard disk brake mounting interface. As shown in fig. 8B, the slot 131 may receive the mating portion 152 of the outer motor housing 137 of the motor unit 101. The fasteners 122, 123 attaching the motor unit to the bracket 110 may be coupled to the receiving holes 127, 128, and in some aspects the receiving holes 127, 128 may be threaded through holes. In some aspects, the bracket 110 may have an extension arm 129 with a coupling pad 130 at its lower end. In some aspects, the coupling pad may be seated against the bicycle frame to provide an additional support point adapted to counteract moment loads that may be applied into the bracket. In some aspects, radial loading by the pinion may result in some loading that is not within the plane defined by the axes of the two receiving holes 127, 128. In some aspects, the spacer can be bonded or otherwise secured to the bicycle frame to provide a contact fit of the attachment pad 130 of the bracket 110 to the bicycle frame.

Fig. 8A illustrates an exploded view of the electric bicycle system 100 according to some embodiments of the present invention. Drive gear 102 is coupled to drive gear mount 143 by fasteners 132. The drive gear mount 131 may be adapted to engage an industry standard rear disk mount on a rear wheel hub. A stationary outer motor housing 137 is coupled to the inner stator 136. The inner stator 136 may have windings and winding bars. Outboard bearing 139 is located in an outboard recess of the outer motor housing 137 and inboard bearing 138 is located in an inboard recess of the outer motor housing. The outboard bearing 139 and the inboard bearing 138 support a motor shaft integral with the rotating inner motor casing 134. A retainer 142 is coupled to the shaft of the inner housing 134 and axially constrains the inner and outer housings relative to each other. A removable cap 141 is coupled to the outer housing 137 by fasteners 140 and allows access to the retainer 142 and the outer bearing 139. The motor pinion 111 is mounted directly to an integral engagement shaft extending from the internal motor housing 134 and is coupled to the housing by a fastening coupler 133. The outer rotor 135 is coupled to the inner housing 134. The outer housing 137 is coupled to the bracket 110 by fasteners 122, 123 and is located within the slot 131, the slot 131 allowing the bracket to be mounted to the motor unit to some extent along the major axis of the slot 131. Fig. 8B illustrates further details of the outer housing 137 according to some embodiments of the present invention. Outer housing 137 may include an axial support portion 151, with axial support portion 151 having a bearing receiver portion 150 adapted to support an outer race of inner bearing 138. The slide module 152 is adapted to reside within the slot 131 in the bracket 110 or other bracket. Slots 153, 154 in the outer housing 137 allow relative movement with respect to the mounting fasteners 122, 123.

In some aspects, the motor is a brushless direct current motor (BLDC). In some aspects, the motor is an external rotor BLDC motor. In such motors, the motor rotates an outer rotor about its windings. The motor housing is lined with magnets and the stator comprises a laminated stack of steel plates with motor windings on the teeth. In some aspects, the motor is a disc motor. In some embodiments of the invention, the stator diameter of the motor stator is greater than 2 times the thickness of the laminated stack. In some embodiments of the invention, the stator diameter of the motor stator is greater than 4 times the thickness of the laminated stack. In some embodiments of the invention, the stator diameter of the motor stator is greater than 6 times the thickness of the laminated stack. In some embodiments, the stator lamination height is less than 30 mm. In some embodiments, the stator lamination height is less than 20 mm.

In some aspects, as shown in fig. 8, there is generally no directional clutch in a drive-only electric bicycle system. Since there may be some motor resistance when coasting a bicycle without such a clutch, the drive electronics may provide a minimum amount of drive power to the motor when coasting the bicycle in order to provide a frictionless feel.

In some embodiments of the invention, the motor unit is mounted between the rear stay and the chain stay, as shown in fig. 9. Similar to other embodiments described herein, the motor axis of rotation is forward of the axis of rotation of the rear wheel and rearward of the forwardmost portion of the rear rim.

In an embodiment of the present invention, the electric bicycle system will further include a battery, a motor controller, and an associated wiring harness coupling the motor, the battery, and the motor controller together. In some aspects, the battery is a battery pack comprised of lithium ion batteries. These batteries provide a large amount of energy storage in a small, lightweight package. In some aspects, other types of energy storage may be utilized, such as lead acid batteries, fuel cells, or other energy storage devices.

The motor controller takes energy from the battery and converts it into a controllable form for driving the motor. The motor controller may have other functions, such as processing rider inputs or controlling other functions. The motor controller may also have the ability to take the energy generated by the motor and convert it into a form that adds energy to the battery. These types of motor controllers are commonly referred to as controllers capable of regeneration or regeneration, but may be of many names and types. In some aspects, an electric bicycle system will include a motor controller having regenerative capability.

Fig. 18 illustrates an electrical subsystem 400 that can be used in conjunction with an electric bicycle system according to some embodiments of the present invention. Battery 401 is coupled to motor controller/driver 402, which motor controller/driver 402 is in turn coupled to motor 403. In a driving scenario, the battery provides power 404 to the motor controller/driver, which can then condition the power and provide it 405 to the motor 403. In a regenerative braking scenario, the motor may be provided power 407 through the motor driver/controller 402 and to 406 and the battery 401.

In another exemplary embodiment of the present invention, as shown in fig. 9, the electric bicycle system is mounted at a position below a rear stay of a bicycle frame. In other embodiments, the location of the motor may also be above or below the chain stay. Further embodiments may have no or no chain stays or seat stays, or may have asymmetrical stays that are present or absent only on the left or right side. Many examples of structures for attaching the rear wheel to the rest of the bicycle frame are possible.

In other embodiments, the rear portion of the bicycle frame may be movable to provide a suspension. This is sometimes, but not exclusively, referred to as the rear suspension.

In some embodiments of the present invention, as shown in fig. 12, the electric bicycle system 300 includes a disc brake system incorporated into the electric drive system. The motor unit 301 is coupled to the bicycle by a mounting bracket 310. Chain 306 drives drive gear 302 in a similar manner to the embodiments described above. Gear mounting bracket 308 supports drive gear 302 and also supports brake disc 303. The fastener 305 of the attachment bracket 308 may also attach to the disc 303. The disc brake caliper mechanism 304 may also be supported by a bracket 310 and adapted to provide a clamping force on the disc 303 to provide braking to the wheel. As shown in the cross-sectional view of fig. 13, the thin profile of the components allows assembly of the combined motor and disc brake assembly and similarly avoids the tire, wheel, crank and user according to the embodiments described above.

Fig. 14 shows an exploded view of the electric bicycle system 300. In some aspects, the motor unit may have a directional clutch 308 adapted to allow the motor to transmit torque in a driving direction, but adapted to rotate freely to allow relative rotation between the motor and the drive gear to be free when the motor is not driving the drive gear. Outer housing 310 is coupled to inner stator 316, while inner housing 313 is coupled to outer rotor 317. The shaft 309 is coupled to the interior of the clutch 309 and is supported by bearings 311, 312. An outer shaft is formed in the inner housing 313 and is coupled to the outside of the clutch 309. The outer shaft is supported by bearings 318, 314 to provide support of the inner housing 313 relative to the outer housing 310. Chain 306 drives drive gear 302 which is supported by bracket 308. The disk uses the same mounting fasteners as the bracket 308 and is attached to the disk mounting interface of the wheel hub.

Fig. 15 illustrates a mounting bracket 170 according to some embodiments of the invention. Mounting brackets of this type are made to facilitate mounting of both the motor and the disc brake caliper to the vehicle frame. The mounting bracket 170 includes through holes 171, 172, and the through holes 171, 172 may be sized to mate with an industry standard disc brake mounting interface on a vehicle frame. Additional holes 173 and 174 are provided for reinstalling the disc brake caliper in alternative locations that may comply with brake caliper installation standards. This criterion may be applied to smaller or larger disc rotors.

Fig. 16 illustrates a mounting bracket 180 according to some embodiments of the invention. This mounting bracket is a variation of the bracket shown in fig. 7, but includes threaded holes 181 and 182. Threaded fasteners, such as set screws or bolts, may be installed in these holes to provide adjustable multiple points of contact with the vehicle frame.

In some embodiments of the present invention, as shown in fig. 17A and 17B, an enhanced mounting system is used. The bracket 440 has an interface portion 446 adapted to engage with the motor unit. The first bracket 441 has a through hole 442 adapted to receive a fastener that can secure the bracket 440 to a bicycle frame. The second seat 443 has a through hole 441 adapted to receive a fastener that can secure the bracket 440 to a bicycle frame. Mounting pad portion 445 includes an extended interface region that provides increased lateral stability and load distribution when the bracket is mounted to its mating component. The bicycle frame rear portion 450 can include a bracket mounting area having a first mounting interface 451, the first mounting interface 451 having a fastener receiving portion 452. The second mounting interface 453 can include a second mounting interface 453 having an expanded interface region 455, and the expanded interface region 455 can mate with the expanded interface region of the mounting pad portion 445 of the bracket 440. In some aspects, the interface size other than the expanded pad portion is a standard size for a rear disc brake mounting interface.

It is apparent from the above description that various embodiments may be configured in accordance with the description given herein, and additional advantages and modifications will readily occur to those skilled in the art. The invention in its broader aspects is therefore not limited to the specific details and illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the spirit or scope of the applicant's general invention.