Frame unit, method of manufacturing thereof, prefabricated structures adapted to different motor systems

Abstract

The present invention relates to a frame unit, a manufacturing method thereof, and a prefabricated structure suitable for different motor systems. The manufacturing method comprises a stamping step of stamping a metal plate into shell pieces that can be lapped together; a lapping step of lapping the shell pieces and forming a lapping line; a joining step of joining the shell pieces along the lapping line to form a motor seat preform having side plate portions and a motor mounting space; and a motor seat forming step of cutting the side plate portions of the motor seat preform to conform to a predetermined motor system to form a bicycle frame unit having a motor seat. The bicycle frame prefabricated structure produced by the manufacturing method of the present invention can be used as a standard product and is suitable for different motor systems. When the prefabricated structure is completed, it can be processed into a frame unit according to different motor systems, and manufacturers will not have the risk of inventory management of specific types of motor seats, so the manufacturing method of the present invention has the effects of low inventory, instant production, and low manufacturing cost.

Description

Technical Field

[0001] This invention relates to metal bicycle frame units and methods for manufacturing the same, and more particularly to a prefabricated structure for making bicycle frames adaptable to different motor systems. Background Technology

[0002] Electric bicycles, powered by motors, offer users a relaxed and comfortable riding experience, leading to their increasing popularity. As the power of electric bicycle motors gradually increases, the proportion of motor weight in the overall weight of the bicycle also rises. Therefore, the position and angle of the motor integrated into the frame have a significant impact on the center of gravity of current electric bicycles.

[0003] Generally, existing electric bicycle frames include a motor mount for housing the motor. This motor mount is designed and manufactured according to a predetermined motor system and is made independently or integrally with other frame components through methods such as casting or forging. In other words, in the manufacturing process of existing frame units, the motor mount is specifically designed for individual motor systems.

[0004] However, motor systems manufactured by different companies have different shapes and sizes, so when different motor systems are assembled into motor mounts, the motor mounts must have corresponding shapes and locking points. Therefore, existing electric bicycle motor mounts cannot be adapted to different types of motor systems. For the above reasons, the frame units of existing electric bicycles are manufactured individually for each system, resulting in higher costs for mold development and higher warehousing costs due to slower inventory turnover.

[0005] Furthermore, European Patent No. 3294616 discloses a bicycle frame with a receiving device for drive housing. By inserting a separate adapter between the motor mount and the corresponding motor system, the bicycle frame can be adapted to different motor systems by simply manufacturing corresponding adapters for different motor systems. However, since the adapter occupies space between the motor mount and the motor system, the motor system may not be positioned to achieve the optimal center of gravity for existing electric bicycles. Moreover, producing multiple adapters also increases mold and warehousing costs. Summary of the Invention

[0006] The present invention aims to provide a prefabricated structure for producing bicycle frames, and to provide a housing mechanism with a housing housing that can be adapted to different motor systems through this cost-effective manufacturing method, thereby solving the above-mentioned problems.

[0007] This invention provides a method for manufacturing a bicycle frame unit, which includes the following steps:

[0008] Stamping process: Two shell parts that can be joined together are stamped out of sheet metal. Each shell part includes a motor connection section, a lower tube section integrally formed with the motor connection section, and a connecting edge. The motor connection section has a side plate portion. The connecting edge extends from the motor connection section to the lower tube section and matches the connecting edge of the other shell part.

[0009] Docking steps: Place the two shell parts together so that the connecting edges align and form a pair of wires;

[0010] Joining Steps: Join the two housings along the connecting line, connecting the motor connection sections of the two housings to form a motor mount preform, and joining the lower tube sections of the two housings to form a lower tube portion. This motor mount preform can be machined to accommodate different motor systems and includes the side plate portion, a front end portion, a top portion connecting the front end portion and located between the side plate portions, and a motor mounting space formed between the front end portion and the side plate portions. The side plate portions are flat, and the lower tube portion connects to the front end portion of the motor mount preform; and

[0011] Motor mount forming steps: Select one of the different motor systems, cut the side plate portion to make its shape match the shape of the selected motor system, thereby forming a frame unit with a motor mount.

[0012] The bicycle frame prefabricated structure produced by the manufacturing method of the present invention can be used as a standard product and is applicable to different motor systems. After the prefabricated structure is manufactured, it can be processed into frame units according to different motor systems. Manufacturers do not have the risk of inventory management of specific types of motor mounts. Therefore, the manufacturing method of the present invention has the advantages of low inventory, just-in-time production and low manufacturing cost. Attached Figure Description

[0013] Figure 1 This is a perspective view of a preferred embodiment of the prefabricated bicycle frame structure of the present invention.

[0014] Figure 2 for Figure 1 A side view of the exterior of a preferred embodiment of the prefabricated structure.

[0015] Figure 3 for Figure 1 Another perspective view of the preferred embodiment of the prefabricated structure.

[0016] Figure 4 for Figure 1 Rear view of a preferred embodiment of the prefabricated structure.

[0017] Figure 5 for Figure 1A schematic diagram showing how a prefabricated structure is processed to form a bicycle frame.

[0018] Figure 6 This is a flowchart of a first preferred embodiment of the bicycle frame manufacturing method of the present invention.

[0019] Figure 7 and Figure 8 for Figure 6 A schematic diagram of the stamping and docking steps in the manufacturing method.

[0020] Figure 9 This is a flowchart of a second preferred embodiment of the bicycle frame manufacturing method of the present invention.

[0021] Figure 10 and Figure 11 for Figure 9 Schematic diagrams of different types of internal support components used in the manufacturing process of setting internal support components.

[0022] Figure 12 for Figure 9 A schematic diagram of one of the joining means used in the joining steps of the manufacturing method.

[0023] Figure 13 for Figure 12 A magnified view of a portion of the image.

[0024] Figure 14 for Figure 9 A schematic diagram of another joining means used in the joining steps of the manufacturing method.

[0025] Figure 15A , Figure 15B and Figure 15C for Figure 9 A schematic diagram of the joining steps in the manufacturing method using different welding paths.

[0026] Figures 16 to 18 This is a schematic diagram of the process steps of the third preferred embodiment of the bicycle frame manufacturing method of the present invention.

[0027] Figure 19A and Figure 19B This is a schematic diagram illustrating different implementations of the third preferred embodiment of the bicycle frame manufacturing method of the present invention.

[0028] Figures 20 to 24 This is a schematic diagram illustrating the application of the frame unit manufactured by the above method to different types of bicycles.

[0029] Figure 25 and Figure 26 This is a schematic diagram illustrating other bicycle frame unit manufacturing methods provided by the present invention. Detailed Implementation

[0030] The following, in conjunction with the accompanying drawings and preferred embodiments of the present invention, further illustrates the technical means employed by the present invention to achieve its intended purpose.

[0031] This invention provides a prefabricated structure for a bicycle frame, a preferred embodiment of which is, for example... Figures 1 to 4 As shown, it includes two shell components 100. These two shell components 100 are made of metal and are connected to form a frame. Please refer to [link / reference]. Figure 1 The frame includes a motor mount preform 10 and a lower tube 20 connected thereto. The motor mount preform 10 can be processed to form a motor mount for a bicycle frame unit for matching a selected motor system.

[0032] It should be understood that bicycle frames are designed starting from a single origin, which, for those skilled in the art, is the center of the bottom bracket (BB center). In the case of electric bicycle frames, this bottom bracket center is defined by the drive shaft of the motor system to which it is coupled. Please refer to [link / reference]. Figures 1 to 3 The motor mount preform 10 has an origin O and a reference axis A, along which a drive shaft is arranged, and the reference axis A passes through the origin O. As described above, the bicycle frame preform is designed starting from the origin O.

[0033] Each of the aforementioned housing parts 100 is integrally formed and includes a motor coupling section 101 and a lower tube section 102 that are interconnected. Specifically, the motor base preform 10 is formed by joining the motor coupling sections 101 of the two housing parts 100 together, and the lower tube section 20 is formed by joining the lower tube sections 102 of the two housing parts 100 together.

[0034] like Figure 2 and Figure 3As shown, the motor mount preform 10 includes a front end portion 11, two side plate portions 12, a top 13, a rear end portion 14, an opening 15, and a motor mounting space 16. The front end portion 11 is formed on one side of the motor mount preform 10, facing the bicycle frame formed by the prefabricated structure, and is located on the front side of the bicycle frame. Each side plate portion 12 is formed in the motor engagement section 101 of a corresponding housing 100, and the side plate portion 12 is flat. The reference axis A passes perpendicularly through the side plate portion 12, forming the origin O; therefore, the area of ​​the side plate portion 12 covers the origin O. In a preferred embodiment of the present invention, each side plate portion 12 has a linear bottom edge 121 located below the origin O; the top 13 connects the front end portion 11 and the rear end portion 14, and the two side plate portions 12, and the front end portion 11, the top 13 and the rear end portion 14 are formed by joining the motor coupling section 101 of the two housings 100.

[0035] Please see as follows Figure 3 As shown, the opening 15 is formed at the bottom of the motor mount preform 10 and is located between the two side plates 12; the motor mounting space 16 is formed between the two side plates 12 and the top 13 and is located inside the opening 15, for accommodating the motor system. That is, the motor mount preform 10 forms an inverted U-shaped structure.

[0036] Please see as follows Figure 2 As shown, viewed from the side of the prefabricated structure of the bicycle frame, the motor mount preform 10 is surrounded by a circle C defined with the origin O as its center and the distance between the reference axis A (the origin O) and the front end 11 as its radius R. Specifically, as Figure 2 As shown, the circle C surrounds the side plate portion 12, and the rear end portion 14 is located between the circle C and the origin O. In a preferred embodiment of the invention, the radius R is approximately 160 mm.

[0037] Please see as follows Figures 1 to 4 As shown, the lower tube 20 is connected to the front end 11 of the motor mount preform 10 and extends obliquely forward and upward. Figure 4 As shown, to avoid interference with the cyclist's riding motion, the first width W1, defined by the width of the motor mount preform 10, is less than or equal to the second width W2, defined by the width of the lower tube 20. Preferably, as... Figure 4 As shown, the first width W1 is smaller than the second width W2, and the first width W1 is between 40 and 80 millimeters, including the endpoint values.

[0038] By utilizing the aforementioned technical features, when manufacturing a bicycle frame unit using the prefabricated structure of the bicycle frame of the present invention, the manufacturer can cut and drill holes in the side plate portion 12 according to a specific motor system 30', 30'', 30''', to form cutting edges 122', 122'', 122''' and multiple predetermined connection points (locking points), thus forming a bicycle frame unit with motor mounts 10', 10'', 10'''. The specific motor system 30', 30'', 30''' matches the shape of the cutting edges 122', 122'', 122'''' of the motor mounts 10', 10'', 10''', and can be fixed to the motor mounts 10', 10'', 10''' by bolts through the connection points. The bicycle frame unit described in this invention generally refers to the entirety or part of an electric bicycle frame.

[0039] For example, such as Figure 5 As shown, after processing according to different motor systems, the motor base preform 10 is suitable for assembling a motor system 30' of type I, a motor system 30'' of type II, and a motor system 30''' of type III. For illustrative purposes, Figure 5 The motor systems 30', 30'', and 30''' shown are supplied by well-known motor manufacturers such as Shimano, Yamaha, and Bosch. The motor mount preform 10 can also be machined to fit other motor systems that comply with relevant electric bicycle standards.

[0040] Although in such Figures 1 to 4 In the preferred embodiment of the present invention shown, the prefabricated structure of the bicycle frame has an integrally formed motor mount preform 10 and a downtube portion 20. The prefabricated structure may only include the motor mount preform 10 or may also include other frame components, such as the head tube, as long as the prefabricated structure of the bicycle frame has the technical features described in the preceding paragraphs and is suitable for different motor systems. Other frame components can be connected to the bicycle frame unit in subsequent processes.

[0041] Please see as follows Figure 6 As shown, a first preferred embodiment of the method for manufacturing a bicycle frame unit of the present invention includes at least the following steps: stamping step S1, butt joint step S21, joining step S3, and motor mount forming step S41.

[0042] Stamping forming step S1: as follows Figure 7As shown, two shell members 100 suitable for subsequent rigid unit formation are stamped from a sheet metal. Each shell member 100 includes a motor coupling section 101, a lower tube section 102 integrally connected to the motor coupling section 101, and a connecting edge 103 extending from the motor coupling section 101 to the lower tube section 102. The motor coupling section 101 includes a side plate portion 12, and the connecting edge 103 matches and can be mated with the connecting edge 103 of the other shell member 100. That is, the connecting edges 103 of the two shell members 100 can contact and overlap each other, allowing the two shell members 100 to be connected. Preferably, the sheet metal can be made of aluminum alloy or aluminum-magnesium alloy. Furthermore, the two shell members 100 are preferably symmetrical structures.

[0043] Docking step S21: As Figure 7 and Figure 8 As shown, the connecting edges 103 of the two housing parts 100 abut against each other to complete the docking and form a pair of wiring 103'.

[0044] Joining step S3: as follows Figures 1 to 3 and Figure 8 As shown, the two housing parts 100 are joined along the connecting line 103', connecting the motor connection section 101 of the two housing parts 100 to form a motor mount preform 10. The motor mount preform 10 includes two side plates 12, a front end 11, a top 13 connecting the front end 11 and located between the two side plates 12, and a motor mounting space 16 formed between the two side plates 12 and the top 13. The lower tube sections 102 of the two housing parts 100 are connected to form a lower tube section 20, and the lower tube section 20 is connected to the front end 11 of the motor mount preform 10. After the joining step S3 is completed, the two housing parts 100 form the prefabricated structure of the bicycle frame described in the previous paragraph. Specifically, various joining techniques can be used to join the two housing parts 100, such as bonding, riveting, screwing, filler welding, non-filler welding, etc., as long as the two housing parts 100 can be fixed to each other to form a rigid body suitable for heavy riding.

[0045] Motor housing forming step S41: as follows Figure 1 , Figure 2 , Figure 3 and Figure 5 As shown, the side plate portion 12 of the motor mount preform 10 is cut according to the pre-selected motor system 30', 30'', 30''', thereby forming a bicycle frame unit having motor mounts 10', 10'', 10'''. Furthermore, in this step, computer numerical control (CNC) cutting and laser cutting can be used to cut and drill the side plate portion 12.

[0046] Through the steps described above, the two shell parts 100 are manufactured by stamping, and the side plate portion 12 is processed by computer numerical control (CNC) cutting or laser cutting according to a predetermined corresponding motor system. Therefore, the two shell parts 100 are relatively thinner and lighter than cast or forged bicycle frames. Thus, the manufacturing method of the present invention consumes less material, produces a lighter product, and improves the practicality of the electric bicycle frame unit.

[0047] Furthermore, since the side plate portion 12 formed in the housing 100 is relatively thin, CNC cutting or laser cutting can be completed in a very short time. Using laser cutting in the motor housing forming step S41 can further improve production efficiency, because once laser cutting is complete, there is no need to trim or polish the cut edge. Laser-cut products also have higher quality.

[0048] The bicycle frame prefabricated structure produced by the manufacturing method of the present invention can be used as a standard product and is applicable to different motor systems. After the prefabricated structure is manufactured, it can be processed into frame units according to different motor systems. Manufacturers do not have the risk of inventory management of specific types of motor mounts. Therefore, the manufacturing method of the present invention has the advantages of low inventory, just-in-time production and low manufacturing cost.

[0049] In a first preferred embodiment of the present invention, the lower tube portion 20 and the motor mount preform 10 are integrally formed, thus the finished frame unit has high shape and dimensional accuracy, as well as good structural strength. In the stamping step S1, the formed shell 100 may also include only the motor coupling section 101, with other tubes of the frame structure subsequently connected to the motor coupling section 101. As described in the preceding paragraphs, the bicycle frame preform including the shell 100 can be manufactured before the corresponding motor system is determined. Alternatively, the manufacturer can stock shells 100 with the side plate portion 12, and once the corresponding motor system is determined, cut the side plate portion of the shell 100 first, and then join the two shells 100 together to form a motor mount. In this case, the shell 100 is equivalent to the motor mount preform. In short, the order of operations in the joining step S3 and the motor mount forming step S41 can be interchanged.

[0050] Please see Figure 9 The second preferred embodiment of the manufacturing method of the present invention, compared with the first embodiment, further includes a step S22 of setting an inner support member and a step S42 of removing the inner support member:

[0051] Step S22 for setting the internal support: (as follows) Figures 9 to 11As shown, before the joining step S3, an inner support member 60, 60A is provided between the lower pipe sections 102 of the two shell members 100. The inner support member 60, 60A includes support bodies 61, 61A that can be driven to expand or contract and can support the two shell members 100 from the inside during the joining step S3. The inner support member 60, 60A includes, but is not limited to, an air bag, a rigid inner liner, or a mechanical support assembly, and can be made of materials such as metal, foam, or wax. Figure 10 and Figure 12 As shown, in one embodiment, the support 61 is an air bag that expands or contracts via an air supply pipe 62 to allow air in or out. The inner support members 60 and 60A further include two heat insulation pads 63, located on both sides of the support 61, to abut against the connecting line 103' and to insulate against heat conduction.

[0052] like Figure 11 As shown, in another configuration, the inner support 60A includes the support body 61A and two contact materials 62A for abutting against the connecting wire 103'. The support body 61A is a mechanical support assembly and has multiple actuators 611A inside. The actuators 611A can be pneumatic, hydraulic, or electric driven. Specifically, the actuator 611A can be a pneumatic cylinder, a hydraulic cylinder, or an electric cylinder to drive the support body 61A to expand or contract. The inner supports 60 and 60A can extend across the motor engagement section 101 and the lower pipe section 102 of the housing 100. Furthermore, the order of the steps S22 and S21 for setting the inner support member can be reversed. That is, the inner support members 60 and 60A can be positioned first, and then the shell 100 can be docked and cover the inner support members 60 and 60A; or, the two shells 100 can be docked first, and then the inner support members 60 and 60A can be inserted between the two shells 100.

[0053] In the joining step S3, as Figure 9 , Figure 12 and Figure 13 As shown, the two housing parts 100 are connected by welding along the connection line 103'. The inner support members 60 and 60A support the portions of the two housing parts 100 near the connection line 103'. Specifically, the portions of the two housing parts 100 near the connection line 103' are welded to form a connection area 104. The portion of the motor connection section 101 of the two housing parts 100 near the lower tube section 102 thus forms the front end portion 11 of the motor mount preform 10, and so on. In short, after welding, the two housing parts 100 form the bicycle frame prefabricated structure.

[0054] Preferably, the welding method used is non-filler welding, which refers to a welding method in which the contact areas of two separated workpieces are plastically deformed or melted to join them together without the addition of external solder. For example... Figure 12or Figure 13 As shown, for example, the non-filler welding can be friction stir welding, which uses a tool head 70, which includes a spindle 71 and a stirring pin 72 located at the end of the spindle 71. As the spindle 71 rotates, the two housing parts 100 are subjected to friction, and the portion near the mating line 103' is heated and undergoes plastic deformation. The stirring pin 72 then stirs and mixes the overlapping, plastically deformed portions, thus joining the two housing parts 100 together. More preferably, the portion of the two housing parts 100 near the connecting edge 103 can be formed as a thickened area, reserving space for plastic deformation. After the friction stir welding, the surfaces of the lower tube portion 20 and the motor housing preform 10 formed by the joint are relatively smooth, eliminating the need for further grinding. Furthermore, this method avoids the generation of vaporized metal gases, molten metal, and high-voltage electricity, providing a safe and environmentally friendly process.

[0055] Furthermore, as another embodiment, the non-filler welding can also be performed as follows: Figure 14 The illustrated robotic arm 80 includes a welding head 81, which can be used to join the housing 100 by laser welding or plasma welding. The aforementioned friction stir welding tool head 70 can also be mounted on the robotic arm 80 to automate the welding process and improve production efficiency.

[0056] The above process provides the following technical advantages:

[0057] 1. During non-filler welding, the portion of the shell 100 near the mating wire 103' will soften due to increased temperature. The inner support members 60 and 60A can prevent the shell 100 from deforming inward and causing product defects.

[0058] 2. The heat insulation pad 63 or the contact material 62A prevents the melted or softened portions from seeping into the interior of the two housings 100 and forming excess material. This allows for easy assembly when the energy storage unit or wiring is inserted into the lower tube 20, or when the motor system is installed into the motor mount formed by the motor mount preform 10, without being blocked or jammed by the excess material. Therefore, the significant time required for removing the excess material is also saved.

[0059] 3. Non-filler welding can be automated, saving manpower and increasing production efficiency.

[0060] Step S42: After step S3, remove the inner support components 60 and 60A from the shell 100. If the inner support components 60 and 60A are removed immediately after step S3, the prefabricated structure of the bicycle frame is completed. If necessary, the order of operations for step S42 (removing the inner support components) and step S41 (forming the motor mount) can be reversed.

[0061] Furthermore, the housing 100 can be pre-cut with CNC or laser to form a symmetrical pattern to create the mating lines, such as... Figure 15B and Figure 15C The diagram shown. Therefore, through these diagrams, the connecting lines and the resulting connection area have higher strength. Additionally, as... Figure 15A , Figure 15B and Figure 15C As shown, the tool head 70 of friction stir welding, or the welding head 81 of laser welding or plasma welding, can join the two housing parts 100 along the mating line 103' and in different paths P1, P2, P3. For example, as Figure 15A As shown, path P1 is a straight line; Figure 15B As shown, path P2 is jagged; Figure 15C As shown, path P3 can be wavy like a sine curve. The path can also be a right-angled square (not shown in the figure).

[0062] Please see Figures 16 to 18 The differences between the third preferred embodiment of the vehicle frame unit manufacturing method of the present invention and the aforementioned embodiments are detailed below.

[0063] Stamping forming step S1: as follows Figure 16 As shown, a frame 200 is integrally formed by stamping metal sheet. The frame 200 includes the two shell parts 100 and a sheet-like head tube 201 connected between the lower tube sections 102 of the two shell parts 100. The motor connection section 101 of each shell part 100 is connected to the corresponding lower tube section 102 at a position away from the head tube 201, and the connecting edge 103 extends from the motor connection section 101 to the lower tube section 102.

[0064] Docking step S21: As Figure 17 and Figure 18 As shown, an inner liner tube 202 is attached to the head tube portion 201, and the frame shell 200 is bent with the head tube portion 201 as the center, so that the connecting edges 103 of the two shell parts 100 are joined together, so as to facilitate the subsequent joining step S3, joining the two shell parts 100 together, so that the head tube portion 201 and the two shell parts 100 form a head tube 201', the lower tube portion 20 and the motor base preform 10.

[0065] Since the motor coupling section 101, the lower tube section 102, and the head tube section 201 of the two shell parts 100 are integrally formed, the finished product of the third preferred embodiment of the manufacturing method of the present invention has its shape and size accuracy further improved.

[0066] If the first width W1 of the motor mount preform 10 is large, the motor mount preform 10 can accommodate more motor systems. Thus, when the corresponding motor system being coupled has a smaller width, a width adjustment member can provide a narrower coupling space. For example... Figure 19A and Figure 19B As shown, after the motor base forming step S41, the width adjustment members 90A and 90B can be fixed to the position of the through hole 105 (i.e., locking point) on the motor base 10', thereby allowing different motor systems to be securely attached to the motor base 10'.

[0067] For example, such as Figure 19A As shown, the width adjustment component 90A is attached to the inner surface of the motor housing 10' by means of bonding, filler welding, or non-filler welding. Figure 19B In another embodiment shown, the width adjustment component 90B can be manufactured by the following steps: First, a tube is inserted into the through hole 105 to narrow the inner width of the motor seat 10'. The tube is then fixed to the through hole 105 by means of bonding, filler welding, or non-filler welding. The protruding part of the tube is removed by cutting and / or grinding. The remaining part of the tube forms the width adjustment component 90B.

[0068] Please see Figure 5 The present invention provides a bicycle frame unit manufactured by the above-described manufacturing method. Furthermore, each of the motor systems 30', 30'', 30''' has a drive shaft that coincides with the reference axis A, thus the reference axis A is located below the cutting edge lines 122', 122'', 122''' of the side plate portion 12. In practical terms, the motor mount preform 10 of this bicycle frame prefabricated structure can be adapted to various existing motor systems. In addition, the motor mounts 10', 10'', 10''' may have diverse shapes, such as inverted U-shapes, L-shapes, etc. In other embodiments, the motor mount preform 10 can be formed into an inverted U-shape or other shapes by stamping a relatively wide sheet metal or other possible technical means.

[0069] like Figures 20 to 24As shown, taking the Type III bicycle frame unit as an example, this bicycle frame unit only includes the motor mount 10''' and the downtube 20. Other components can be subsequently attached to this bicycle frame unit, therefore this bicycle frame unit can be used to manufacture various different types of bicycles. The end of the downtube 20 away from the motor mount 10''' is connected to a head tube; the top of the motor mount 10''' is connected to a main tube. For example... Figures 20 to 23 As shown, the rear end of the motor mount 10''' is connected to the lower rear fork, and the lower rear fork is connected to the seat tube via the upper rear fork; also, as Figures 21 to 24 As shown, the seat tube is connected to the lower tube section 20 via an upper tube. The above-described variations are only for existing bicycle frame structures of different models, and their detailed differences will not be described in detail here.

[0070] like Figure 20 As shown, the head tube makes an angle of 69 degrees with the horizontal line, while the seat tube makes an angle of 77 degrees with the horizontal line; Figure 21 As shown, the head tube makes an angle of 69 degrees with the horizontal line, while the seat tube makes an angle of 74 degrees with the horizontal line; Figure 22 As shown, the head tube makes an angle of 69 degrees with the horizontal line, while the seat tube makes an angle of 74 degrees with the horizontal line. However, its angle with... Figure 21 The upper tube structure of the vehicle types shown is different; for example... Figure 23 As shown, the head tube makes an angle of 66 degrees with the horizontal line, while the seat tube makes an angle of 73 degrees with the horizontal line; Figure 24 As shown, the head tube has an angle of 64 degrees with the horizontal line, while the seat tube has an angle of 75 degrees with the horizontal line. If the motor mount preform 10 is cut and drilled according to the minimum head tube angle, the motor mount 10''' can be used to produce frames for different types of bicycles that meet the relevant bicycle frame standards. Only the frame unit needs to be rotated to the correct angle before subsequent processing.

[0071] Please see as follows Figure 25 and Figure 26 As shown, the present invention further provides another method for manufacturing a bicycle frame unit, wherein a metal sheet is stamped into a housing having motor coupling portions 41 and 51 in a stamping step, the motor coupling portions 41 and 51 corresponding to a specific motor system. By using a non-filler welding method in the joining step, the bicycle frame unit manufacturing method described in this paragraph also intends to have the aforementioned technical advantages of non-filler welding.

[0072] like Figure 25 As shown, in the stamping step, a metal sheet is stamped to form a housing integrally connected with two motor couplings 41, two lower tubes 42, and a head tube 43. These are joined together to form a motor mount corresponding to the specific motor system. Locking points for securing the motor system can be set before the joining step. Details of this manufacturing method are consistent with... Figures 10 to 12 , Figures 16 to 18 The technical content described in the relevant paragraphs of the instruction manual.

[0073] like Figure 26 As shown, in the stamping process, two shell parts are stamped from sheet metal, each shell part having an integrally formed motor coupling portion 51 and a lower tube portion 52. The details of this manufacturing method conform to… Figures 7 to 14 The technical content described in the relevant paragraphs of the instruction manual.

[0074] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention in any way. Although the present invention has been disclosed above with reference to preferred embodiments, it is not intended to limit the present invention. Any person skilled in the art can make some modifications or alterations to the above-disclosed technical content to create equivalent embodiments without departing from the scope of the present invention. Any simple modifications, equivalent changes, and alterations made to the above embodiments based on the technical essence of the present invention without departing from the scope of the present invention shall still fall within the scope of the present invention.

Claims

1. A method for manufacturing a bicycle frame unit, characterized in that, It includes the following steps: Stamping process: Two shell parts that can be joined together are stamped out of sheet metal. Each shell part includes a motor connection section, a lower tube section integrally formed with the motor connection section, and a connecting edge. The motor connection section has a side plate portion. The connecting edge extends from the motor connection section to the lower tube section and matches the connecting edge of the other shell part. Docking steps: Place the two shell parts together so that the connecting edges align and form a pair of wires; Joining Steps: Join the two housings along the connecting line, connecting the motor connection sections of the two housings to form a motor mount preform, and joining the lower tube sections of the two housings to form a lower tube portion. This motor mount preform can be machined to accommodate different motor systems and includes the side plate portion, a front end portion, a top portion connecting the front end portion and located between the side plate portions, and a motor mounting space formed between the front end portion and the side plate portions. The side plate portions are flat, and the lower tube portion connects to the front end portion of the motor mount preform; and Motor mount forming steps: Select one of the different motor systems, cut the side plate portion to make its shape match the shape of the selected motor system, thereby forming a frame unit with a motor mount.

2. The method for manufacturing a bicycle frame unit according to claim 1, characterized in that, In the stamping process, a frame is stamped out from a sheet metal. The frame includes two shell parts and a head tube. The head tube is integrally formed and connected between the lower tube sections of the two shell parts. The motor connection section of each shell part is connected to the corresponding lower tube section at a position away from the head tube. In the docking step, the frame is bent around the head tube to dock the two shell parts and perform the joining step.

3. The method for manufacturing a bicycle frame unit according to claim 1 or 2, characterized in that, In the motor mount forming step, the side plate portion is cut using laser technology.

4. The method for manufacturing a bicycle frame unit according to claim 1 or 2, characterized in that, The manufacturing method includes the following steps: Step for setting the inner support member: Before the joining step, place an inner support member between the two shell members; Step to remove the inner support member: After the joining step, remove the inner support member from the two shell members; In the joining step, the two shells are welded along the mating line using a non-filler welding method, and the inner support supports the two shells near the mating line.

5. The method for manufacturing a bicycle frame unit according to claim 3, characterized in that, Step for setting the inner support member: Before the joining step, place an inner support member between the two shell members; Step to remove the inner support member: After the joining step, remove the inner support member from the two shell members; In the joining step, the two shells are welded along the mating line using a non-filler welding method, and the inner support supports the two shells near the mating line.

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