Connector components for drive housings, drive housings, and test methods

Abstract

The proposed solution relates in particular to a connector component for a drive housing (G) of an electric bicycle (1), which is provided to close a connector opening (O) of the drive housing (G) and comprises a base (30) having at least one connector portion (3A, 3B) on the outer surface, which is the first surface of the base (30), for providing an interface on the outside of the drive housing (G). The base is provided with at least one membrane hole (32) which extends from the outer surface, which is the first surface, to the inner surface, which is the second surface of the base (30), and is closed by a membrane.

Description

Technical Field

[0001] The proposed solution relates to connector parts for a drive housing, particularly suitable for use in an electric bicycle.

Background Art

[0002] Particularly in the case of a drive housing for an electric bicycle, there is a difficulty in ensuring that the drive housing is sealed against the ingress of liquid while at the same time ensuring pressure equalization between the internal space of the drive housing and the external space surrounding the drive housing. Appropriate pressure equalization reduces the load on the seals provided in the drive housing. Furthermore, pressure equalization also makes it possible to escape harmful gases from the inside of the housing to the outside. In this context, it is well known to provide at least one pressure equalization opening in the drive housing and to close it with a membrane. Such a membrane is gas permeable to allow pressure equalization, but at the same time prevents liquid and dirt from entering the inside of the drive housing.

Summary of the Invention

Problems to be Solved by the Invention

[0003] However, it is not always possible to permanently attach such a membrane to the pressure equalization opening of the housing. For example, when a metal drive housing is provided to allow efficient heat dissipation to the outside for electronic components and / or at least one motor (particularly an electric motor) housed within the drive housing, the membrane for the pressure equalization opening can typically only be fixed by adhesive bonding. However, it is not uncommon to observe that such fixing is at least partially damaged over the service life and the membrane is no longer securely held at the pressure equalization opening.

Means for Solving the Problems

[0004] Against this backdrop, the proposed solution is based on the challenge of providing an improved means for equalizing pressure between the internal space of the drive housing for electric bicycles and the external space surrounding the drive housing.

[0005] This problem is solved, in particular, by the connector component described in claim 1 and the method described in claim 13.

[0006] A connector component for the drive housing of an electric bicycle is proposed, comprising a base having at least one connector portion for providing an interface (e.g., for connecting at least one cable) on the outside of the drive housing. The base is provided to close the connector opening of the drive housing, so that when the connector component is installed in the drive housing as intended, at least one connector portion is positioned on the outer surface, which is the first surface of the base. The base also has at least one membrane hole extending from the first surface (outer surface) to the second surface (inner surface), which is closed by a membrane, particularly on the second surface (inner surface).

[0007] In the proposed connector component, at least one membrane hole, closed by a membrane, is further provided on the base that holds the connector component, and this can function as a pressure equalization opening in the drive housing. In other words, when the connector component is attached to the drive housing, a pressure equalization opening is provided through the membrane hole of the connector component, which is closed by the membrane. In this way, it is not necessary to provide a pressure equalization opening in the drive housing itself. This offers the special advantage that the connector component can be made of plastic material, and it is possible to easily weld the membrane to the base, for example, on a second surface (inner surface) of the membrane hole. This also makes it easier to provide a pressure equalization opening closed by a membrane in the drive housing.

[0008] Therefore, the base of the connector component is used not only to provide a connector portion for providing an interface to the outside of the drive housing, but also to integrally form membrane holes for pressure equalization of the drive housing. The interface defined by at least one connector portion may be set up and provided, for example, to connect cables for supplying electrical energy to at least one motor housed within the drive housing, and / or for the electronic control of at least one motor.

[0009] The membrane pores formed as through-openings at the base can be formed, for example, as perforations.

[0010] In one embodiment, a membrane hole connecting a first surface (outer surface) and a second surface (inner surface) is provided for a ventilation test in the drive housing. In this case, the membrane hole of the connector component may be designed and provided for the purpose of performing a ventilation test with the connector component attached to the drive housing in order to verify the reliability of pressure equalization.

[0011] As mentioned above, for the sake of simplified assembly, and especially for industrial production, it may be advantageous for the membrane to be welded to the second surface (inner surface) of the base.

[0012] In principle, the base can be made of plastic material, at least in the area of ​​the membrane pores, or entirely. Manufacturing from plastic material is advantageous, for example, in terms of cost and weight, but in this case, it is also advantageous for easier and more secure fastening of the membrane to the base by welding, for example.

[0013] In one embodiment, the base of the connector component further has at least one inspection hole for airtightness testing in the drive housing. The inspection hole extends from a first surface (outer surface) of the base to a second surface (inner surface) of the base. In such a modification, the connector component incorporates an additional function, providing an inspection hole that allows for airtightness testing of the drive housing when mounted on the drive housing. Therefore, if the connector component is used on the drive housing itself, it is not necessary to provide an inspection hole. Only a connector opening for the embodiment of the proposed connector component needs to be provided on the drive housing. However, such a connector opening must be provided on the drive housing in any case if an interface for connecting at least one cable to the outside is provided, for example, to supply electrical energy to an electric motor inside the drive housing and / or to transmit control signals to the electric motor.

[0014] In one embodiment, at least one inspection hole is provided for attaching a closure element to the outside. The connector component may be provided, for example, together with a closure element already attached to the inspection hole to seal the inspection hole. Alternatively, the corresponding closure element is provided separately and attached to the inspection hole only during the assembly process of the drive housing, for example, after an airtightness test has been performed.

[0015] For example, at least one inspection hole for screwing in a sealing screw, which is provided as a closing element, is set and provided from a first surface (outer surface) of the base. Then, for example, to seal the inspection hole, a corresponding sealing screw is screwed from the outside into at least one inspection hole of the connector component.

[0016] As a general rule, the cross-sectional area of ​​at least one inspection hole can be set to be larger than or equal to the cross-sectional area of ​​at least one membrane hole, and in particular, it can be, for example, at least 1.2 times or 1.5 times larger. The inspection holes and / or membrane holes may generally have a circular cross-section. Therefore, the diameter of at least one inspection hole may also be larger than or equal to the diameter of at least one membrane hole.

[0017] The proposed solution also relates to a drive housing for an electric bicycle, which has a connector opening on the outer surface of the drive housing, and this connector opening is closed by an embodiment of the proposed connector component. The connector component provided in the drive housing may be manufactured as a separate part and attached and fixed to the connector opening of the drive housing. Through a membrane hole closed by a membrane (for example on the inside), the connector component of the drive housing has a pressure equalizing opening that is gas permeable but prevents liquids and dirt from entering the drive housing through the membrane hole.

[0018] As already described in relation to the embodiment of the proposed connector component, a variation of the proposed drive housing may also be provided, wherein the base of the connector component further has at least one inspection hole that is sealed from the outside and extends from a first surface (outer surface) to a second surface (inner surface). The first surface (outer surface) of the base faces the external space surrounding the drive housing, while the second surface (inner surface) of the base faces the internal space of the drive housing which houses drive components for an electric bicycle, such as at least one electric motor or a gearbox for transmitting auxiliary or driving torque provided by at least one electric motor to an output element capable of driving the rear wheel of the electric bicycle.

[0019] An inspection hole provided in a connector component can be sealed by a closing element, for example, by a sealing screw. In a further development, a sealing element, for example in the form of an O-ring, can be pressed against the edge surrounding the inspection hole via the screw head of such a sealing screw. This makes it possible to more reliably seal the inspection hole as needed.

[0020] In one embodiment, a sealing screw used to seal an inspection hole has a self-tapping thread. If the base of the connector component in the area where at least one inspection hole is provided is made of a plastic material, the self-tapping thread of the sealing screw first cuts the thread into the inspection hole from the plastic material. This facilitates the manufacture of the inspection hole on the one hand, and the assembly and sealing of the inspection hole on the other hand.

[0021] Another aspect of the proposed solution concerns a method for testing the functionality of a drive housing for an electric bicycle. Here, the drive housing has a connector opening on its outer surface, which is closed by a connector component having a base. The base of the connector component has at least one connector portion accessible from the outside on a first surface (outer surface) of the base. At least one membrane hole is provided at the base of the connector portion, which extends from the first surface (outer surface) to a second surface (inner surface) facing the inside of the drive housing. At least one membrane hole is further closed by a membrane (for example, on the second surface of the base, i.e., the inner surface). As part of the proposed method, it is planned to perform a ventilation test on the assembled drive housing against the membrane hole closed by the membrane.

[0022] Therefore, the proposed method is based on the fundamental idea of ​​performing a ventilation test for pressure equalization of the drive housing through membrane holes, which are closed by a membrane and provided in the connector component of the drive housing. Modifications of the proposed method can be carried out in particular by using a modified version of the proposed connector component, and thus by using a modified version of the proposed drive housing. Accordingly, the features and advantages described above and below for embodiments of the proposed connector component and / or embodiments of the proposed drive housing also apply to embodiments of the proposed method, and vice versa.

[0023] In the process of an embodiment of the proposed method, for example, the base of the connector component may further have at least one inspection hole extending from a first surface (outer surface) to a second surface (inner surface), and it may be provided that a tightness test is performed against the assembled drive housing through the open inspection hole. Such a tightness test through the inspection hole on the connector component side may be provided in particular before a ventilation test through at least one membrane hole. Thus, a tightness test can be performed first through at least one inspection hole of the connector component. Thereafter, at least one inspection hole is closed and a ventilation test is performed against at least one membrane hole of the connector component. Thus, in one embodiment of the proposed method, the inspection hole may further be sealed from the outside after the (successful) tightness test. Thus, the inspection hole is sealed on the first surface (outer surface) of the base facing the external space surrounding the drive housing, in particular before flow measurement at the membrane hole is performed.

[0024] The inspection hole can be sealed by a closing element, such as a sealing screw. Such a sealing screw may have self-tapping threads, through which the sealing screw is screwed into the inspection hole and / or, as it enters the inspection hole, the screw head presses the sealing element against the edge of the base surrounding the inspection hole in a sealed manner. [Brief explanation of the drawing]

[0025] The attached drawings show possible embodiments of the proposed solution. [Figure 1A] An embodiment of the proposed drive housing with an interface having two connector parts is shown from the (longitudinal) side of the drive housing. [Figure 1B] The drive housing is shown from the opposite side. [Figure 2] An enlarged detail of the interface of the drive housing with an embodiment of the proposed connector part is shown, having both a membrane hole for pressure equalization with the inside closed by a membrane and an inspection hole for the airtight test of the drive housing closed by a seal screw on the base. [Figure 3] A flowchart of an embodiment of the proposed method for performing a functional test of the drive housing is shown. [Figure 4] A schematic view of an electric bicycle in which a drive device with an embodiment of the proposed drive housing is used is shown.

Mode for Carrying Out the Invention

[0026] Figure 4 shows an electric bicycle 1 equipped with a drive unit A. The electric bicycle 1 has a frame 10 to which the drive unit A is mounted. Part of the drive unit AS is a control electronic device SE and a sensor device 15, which consists of, for example, a torque sensor and a position sensor for sensing the torque introduced by human power to the drive shaft in the form of a bottom bracket shaft T of the drive unit A. The sensor device 15 may optionally or additionally include a speed sensor for detecting the speed of the bottom bracket shaft T. The output element of the drive unit A, for example, a hollow output shaft mounted coaxially with the bottom bracket shaft T, is connected to the rear wheel 12 of the electric bicycle 1 via a belt or chain 13 as a power transmission element to enable the electric bicycle 1 to be driven. A wheel sensor for determining the speed of the electric bicycle 1 is assigned to this rear wheel 12 as an example. Of course, the wheel sensor 14 could instead be provided on the front wheel 11 of the electric bicycle 1.

[0027] The drive unit A is part of the drive system of an electric bicycle, further comprising an operating unit 2. In Figure 4, for example, the operating unit 2 is mounted in the area of ​​the handlebars of the electric bicycle 1 and is coupled to the control electronics SE of the drive unit A. User input is recorded via the operating unit 2 and can be used to control the drive unit A. For example, the operating unit 2 also includes at least one display for informing the user of the electric bicycle 1 about the current operating status of the drive unit A, such as the currently set assist class, the charge status of the battery supplying energy to the drive unit A, and / or the setting gear which specifies the gear ratio at which the drive torque generated by human power on the bottom bracket shaft T is transmitted to the output shaft.

[0028] Figures 1A and 1B show the drive unit A, with a drive housing G interposed between the drive unit A and the frame 10, from two longitudinal sides facing opposite directions. In this case, the drive housing consists of two housing components G1 and G2 fixed to each other, which define the internal space of the drive housing G. At least one electric motor and gear mechanism of the drive unit A are housed protected within this internal space, through which the drive torque applied by human power to the bottom bracket shaft T and the assist torque applied by the at least one electric motor by external force are transmitted to an output element, such as the aforementioned output shaft mounted coaxially with the bottom bracket shaft T, in order to drive the rear wheel 11 of the electric bicycle 1.

[0029] A connector opening O is formed in the housing component G1. An interface for connecting one or more cables protrudes from the inside to the outside of the drive housing G through this connector opening O. The connector opening O is sealed by the base 30 of the connector component 3, in which case the base 30 holds two connector parts 3A and 3B for the interface. These connector parts 3A and 3B protrude from the outer surface of the drive housing G. This is shown in Figure 2 in a side view and at a magnified scale.

[0030] Connectors 3A and 3B protrude from the first surface (outer surface) of the base 30 and are designed as sockets for inserting cable-side plugs. The interface defined by sockets 3A and 3B can be used, for example, with the help of the operating unit 2 and control electronic equipment SE to supply power to and electronically control at least one electric motor housed in the drive housing G of the drive unit A.

[0031] The illustrated connector component 3 also has a membrane hole 32 and an inspection hole 33 in the base 30. The membrane hole 32 is closed on the second surface (inner surface) of the base 30 facing inward, i.e., the interior of the drive housing G, by a membrane welded to the base 30. In this way, the membrane hole 32 is gas permeable, thus allowing pressure equalization in the drive housing G. However, the membrane prevents liquids and contaminants from entering the interior of the drive housing G through the membrane hole 32.

[0032] An additional inspection hole 33 provided in the base 30 is used to test for leaks (airtightness) of the assembled drive housing G. After the airtightness test is complete, the inspection hole 33 is sealed with a sealing screw 31. This sealing screw 31 may have self-tapping threads. Alternatively or additionally, an O-ring is provided, which is pressed tightly against the edge of the inspection hole 33 via the screw head of the sealing screw 31.

[0033] In this case, the drive housing G is made of metal, while the connector component 3 is made of plastic. Due to the design of the metal drive housing G, it is typically not possible to weld the membrane to the pressure equalization opening formed in the drive housing G. However, since the pressure equalization opening is formed through the membrane hole 32 of the plastic connector component 3, the membrane can be welded to the inside of the base 30 without any problems. Furthermore, it is not necessary to provide an additional pressure equalization opening in either the housing component G1 or G2 in addition to the connector opening O.

[0034] Further integrally forming an inspection hole 33 in the base 30 for airtightness testing of the drive housing G further facilitates functional testing and assembly of the drive housing G. This is not only because the corresponding inspection hole 33 can be easily manufactured in the plastic material of the connector part 3, but rather, the inspection hole 33 can also be used to perform airtightness testing of the drive housing G in close proximity to the membrane hole 32 before performing airflow testing on the membrane hole 32 that is closed by the membrane. After the inspection hole 33 is sealed by screwing in the sealing screw 31, flow measurement can be performed on the membrane hole 32 that is only a short distance from the inspection hole 33.

[0035] The flowchart in Figure 3 shows the corresponding procedure for functional testing of the drive housing G.

[0036] For example, in the case of a drive housing G attached to the connector opening O together with the connector component 3, the drive housing G is first subjected to an airtightness test while the inspection hole 33 is still open. This is specified in step 40 of Figure 3. Subsequently, in step 41, the inspection hole 33 is closed on the outside of the drive housing G using a sealing screw 31 (or a closing element of a different design). Next, in step 42, a ventilation test is performed on the membrane hole 32 of the drive housing G to confirm whether there is sufficient pressure equalization through the membrane of the membrane hole 32 welded to the inside of the base 30. [Explanation of Symbols]

[0037] 1. Electric bicycle 10 frames 11 Front Wheel 12 Rear wheels 13. Chains / Belts (Power Transmission Components) 14 Wheel Sensors 15 Sensor device 2 Control Unit 3. Connector parts 30 base 31 Seal screws 32 membrane pores 33 Inspection holes 3A, 3B Socket (Connector part) 40, 41, 42 Process Steps G drive housing G1, G2 Housing Parts O Connector opening SE Control Electronics T Bottom Bracket Axle

Claims

1. A connector component for the drive housing (G) of an electric bicycle (1), It comprises a base (30), The base portion (30) is provided to close the connector opening (O) of the drive housing (G), The base (30) has at least one connector portion (3A, 3B) on its outer surface, which is the first surface of the base (30), in order to provide an interface on the outside of the drive housing (G). A connector component characterized in that at least one membrane hole (32) is provided in the base, the membrane hole (32) extends from the first surface, which is the outer surface, to the second surface, which is the inner surface, of the base (30), and is closed by a membrane.

2. The connector component according to claim 1, characterized in that the at least one membrane hole (32) is provided for a ventilation test in the drive housing (A).

3. The connector component according to claim 1 or 2, characterized in that the membrane is arranged on the inner surface which is the second surface of the base, and in particular is welded to the inner surface which is the second surface of the base (30).

4. The connector component according to any one of claims 1 to 3, characterized in that the base (30) is made of a plastic material at least in the region of the at least one membrane hole (32) or in whole.

5. The connector component according to any one of the preceding claims, wherein the base (30) of the connector component (3) further has at least one inspection hole (33) for airtightness testing in the drive housing (G), and the at least one inspection hole (33) extends from the first surface, which is the outer surface, to the second surface, which is the inner surface of the base (30).

6. The connector component according to claim 5, characterized in that the at least one inspection hole (33) is positioned and formed on the outer surface which is the first surface of the base (30) for screwing in a seal screw (31).

7. The connector component according to claim 5 or 6, characterized in that the cross-sectional area of ​​the at least one inspection hole (33) is larger than the cross-sectional area of ​​the at least one membrane hole (32).

8. A drive housing for an electric bicycle (1), wherein the drive housing (G) has a connector opening (O) on its outer surface, and comprises a connector component (3) according to any one of the preceding claims, wherein the connector component (3) closes the connector opening (O).

9. The drive housing according to claim 8, wherein the base (30) of the connector component (3) further has at least one inspection hole (33) of the base (30) that extends from the outer surface, which is the first surface, to the inner surface, which is the second surface, and is sealed from the outside.

10. The drive housing according to claim 9, characterized in that the inspection hole is sealed by a sealing screw (31).

11. The drive housing according to claim 10, characterized in that a sealing element, particularly an O-ring, is pressed against the edge surrounding the inspection hole (33) via the screw head of the sealing screw (31).

12. The drive housing according to claim 10 or 11, characterized in that the seal screw (31) has a self-tapping screw thread.

13. A method for testing the function of a drive housing (G) for an electric bicycle (1), The drive housing (G) has a connector opening (O) on its outer surface, the connector opening is closed by a connector component (3) having a base (30), and the base (30) has at least one connector portion (3A, 3B) accessible from the outside on its outer surface, which is the first surface of the base. At least one membrane hole (32) is provided in the base (30) of the connector component (3), and the at least one membrane hole (32) extends from the outer surface, which is the first surface, to the inner surface, which is the second surface of the base (30) facing the internal space of the drive housing (G), and the at least one membrane hole (32) is closed by a membrane. A method characterized in that, when the drive housing (G) is assembled, a ventilation test is performed on the membrane holes (32) that are closed by the membrane.

14. The method according to claim 13, wherein the base (30) of the connector component (3) further has at least one inspection hole (33) extending from the first surface, which is the outer surface, to the second surface, which is the inner surface, and the airtightness test of the assembled drive housing (G) is performed through the open inspection hole (33).

15. The method according to claim 14, characterized in that after the airtightness test, the inspection hole (33) is sealed from the outside.

16. The method according to claim 15, characterized in that the inspection hole (33) is sealed by a sealing screw (31).

17. The method according to claim 16, characterized in that the seal screw (31) has self-tapping threads, and the seal screw (31) is screwed into the inspection hole via the self-tapping threads.

18. The method according to claim 16 or 17, characterized in that a sealing element is provided, and the sealing element is pressed in a sealed manner against the edge surrounding the inspection hole (33) by the screw head of the sealing screw (31) when the sealing screw (31) is screwed into the inspection hole (33).

Images