Torque sensor for electric bicycle system

Abstract

A torque sensor for an electric bicycle system. The torque sensor can include a support that can be disposed about a device of the bicycle such that the support and the device of the bicycle are separated by an air gap. The torque sensor can also include an excitation coil supported by the support and a sense coil supported by the support a distance away from the excitation coil in an axial direction of the support. The excitation coil is configured to induce a voltage and / or a current in the sense coil via the device of the bicycle when the support is disposed about the device of the bicycle. The induced voltage is related to a torque in the device.

Description

Technical Field

[0001] This disclosure generally relates to a sensor for bicycles, and more specifically to a torque sensor for electric bicycles. Background Technology

[0002] Bicycles with pedal-assisted electric motors (e.g., e-bikes or electric vehicles) may include sensors that monitor parameters at the bicycle. The monitored parameters may include, for example, the input torque at the bicycle's crank arm assembly.

[0003] Sensors that monitor the input torque at the crank arm assembly of a bicycle include, for example, strain gauges. However, strain gauges are expensive, may be incompatible with concentric motors, and do not allow for non-contact sensing. Summary of the Invention

[0004] In one example, a torque sensor for a bicycle includes a support member disposed around the bicycle's assembly such that the support member and the bicycle's assembly are separated by an air gap. The torque sensor also includes: an excitation coil supported by the support member; and a sensing coil supported by the support member at a distance in the axial direction of the support member away from the excitation coil. The excitation coil is configured to induce a voltage in the sensing coil via the bicycle's assembly when the support member is disposed around the bicycle's assembly. The induced voltage is related to the torque in the assembly.

[0005] In one example, the torque sensor further includes a shield covering the excitation coil and the sensing coil, such that the excitation coil and the sensing coil are enclosed within the torque sensor.

[0006] In one example, the shield is a first shield. The torque sensor also includes a second shield. The second shield at least partially covers the first shield.

[0007] In one example, the bicycle is an electric bicycle, and the device of the bicycle is the clutch mechanism of the electric bicycle. The support member is a hollow cylinder that can be disposed around a portion of the clutch mechanism of the electric bicycle.

[0008] In one example, the support includes a first groove and a second groove extending circumferentially around the outer side of the support. The second groove is offset relative to the first groove along the axial direction of the support. The excitation coil is disposed within the first groove, and the sensing coil is disposed within the second groove.

[0009] In one example, the sensing coil is a first sensing coil, and the axial direction is a first axial direction. The support also includes a third groove extending circumferentially around the outer side of the support. The third groove is offset relative to the first groove along a second axial direction of the support. The second axial direction is opposite to the first axial direction of the support. The torque sensor also includes a second sensing coil disposed around and supported by the support. The second sensing coil is disposed within the third groove.

[0010] In one example, the excitation coil is a first excitation coil. The support also includes a fourth groove extending circumferentially around the outer side of the support. The fourth groove is offset relative to the first groove along either the first axial direction or the second axial direction. The torque sensor also includes a second excitation coil disposed around and supported by the support. The second excitation coil is disposed within the fourth groove.

[0011] In one example, the first excitation coil and the first sensing coil form a first magnetic circuit, and the second excitation coil and the second sensing coil form a second magnetic circuit. The support has a first portion accommodating the first magnetic circuit and a second portion accommodating the second magnetic circuit. The torque sensor also includes a shield that separates the first portion and the second portion of the support, thereby separating the first and second magnetic circuits. The shield covers at least a portion of the support.

[0012] In one example, the shield covers at least the first groove, the second groove, the third groove, and the fourth groove. The shield is made of ferrite.

[0013] In one example, the shield is a first shield. The torque sensor also includes a second shield that at least partially covers the first shield. The second shield is made of a non-ferromagnetic conductive material.

[0014] In one example, the support is formed from a plurality of stacked printed circuit boards. The excitation coil is formed on a first printed circuit board, in the first printed circuit board, or on and in the first printed circuit board, and the sensing coil is formed on a second printed circuit board, in the second printed circuit board, or on and in the second printed circuit board, among the plurality of stacked printed circuit boards.

[0015] In one example, a clutch mechanism for an electric bicycle includes: an inner ring; an outer ring positioned around the inner ring; and a torque sensor positioned around the inner and outer rings such that the torque sensor and the rings are separated by an air gap. The torque sensor is configured to measure torque within the clutch mechanism. The torque sensor includes a housing that can be disposed around the rings. The torque sensor also includes: an excitation coil disposed around and supported by the housing; a first sensing coil disposed around and supported by the housing at a first axial distance away from the excitation coil in a first axial direction; and a second sensing coil disposed around and supported by the housing at a second axial distance away from the excitation coil in a second axial direction. The second axial direction of the housing is opposite to the first axial direction. The excitation coil is configured to induce a voltage in the first sensing coil via the rings. The induced voltage is related to the torque in the clutch mechanism.

[0016] In one example, the ring is the outer ring, and the outer ring is the axis of the chain link of the electric bicycle.

[0017] In one example, the excitation coil is a first excitation coil. The torque sensor also includes a second excitation coil, which is disposed around and supported by the housing. The second excitation coil is offset relative to the first excitation coil in the second axial direction.

[0018] In one example, the housing includes a first groove, a second groove, a third groove, and a fourth groove extending circumferentially around the outer side of the housing. The first groove, the second groove, the third groove, and the fourth groove are offset relative to each other along a first axial direction of the housing. A first excitation coil is disposed in the first groove, a first sensing coil is disposed in the second groove, a second sensing coil is disposed in the third groove, and a second excitation coil is disposed in the fourth groove.

[0019] In one example, the torque sensor further includes a shield that separates the first excitation coil and the first sensing coil from the second sensing coil and the second excitation coil, and covers the first groove, the second groove, the third groove, and the fourth groove.

[0020] In one example, the shield is a first shield and is made of a first material. The torque sensor also includes a second shield. The second shield partially covers the first shield and is made of a second material. The second material is different from the first material.

[0021] In one example, the voltage is a first voltage. The second excitation coil is configured to induce a second voltage in the second sensing coil via the coil. The clutch mechanism further includes a processor configured to determine the torque in the clutch mechanism based on the induced first voltage and the induced second voltage.

[0022] In one example, the processor is further configured to determine the difference between the sensed first voltage and the sensed second voltage. The processor is configured to determine the torque in the clutch mechanism based on the sensed first voltage and the sensed second voltage, including the processor being configured to determine the torque in the clutch mechanism based on the determined difference between the sensed first voltage and the sensed second voltage.

[0023] In one example, a torque sensor for a bicycle includes a support member disposed around a clutch mechanism of the bicycle. The support member has a first portion and a second portion. The torque sensor also includes a first magnetic circuit supported by and disposed around the first portion of the support member. The first magnetic circuit includes a first excitation coil and a first sensing coil. The first excitation coil and the first sensing coil are offset relative to each other in an axial direction of the support member. The torque sensor also includes a second magnetic circuit supported by and disposed around the second portion of the support member. The second magnetic circuit includes a second excitation coil and a second sensing coil. The second excitation coil and the second sensing coil are offset relative to each other in the axial direction of the support member. The torque sensor also includes a first shield separating the first portion and the second portion of the support member, such that the first magnetic circuit and the second magnetic circuit are separated. The first shield at least covers the first excitation coil, the first sensing coil, the second excitation coil, and the second sensing coil. The torque sensor also includes a second shield covering at least a portion of the first shield. The first excitation coil is configured to induce a first voltage in the first sensing coil via a portion of the clutch mechanism when the support is positioned around the clutch mechanism, and the second excitation coil is configured to induce a second voltage in the second sensing coil via the same portion of the clutch mechanism when the support is positioned around the clutch mechanism. The torque in the clutch mechanism can be determined based on the induced first voltage and the induced second voltage.

[0024] In one example, a torque sensor for a bicycle is provided. The torque sensor includes a coil. The coil is circumferentially arranged around the entire assembly of the bicycle. The coil is configured to sense current and / or voltage related to torque in the assembly. The torque sensor may also include a support that can be disposed around or near the assembly of the bicycle. The coil may be supported by the support. The assembly may be a clutch of the bicycle's drive unit. The coil may be circumferentially arranged around the clutch. Attached Figure Description

[0025] The objects, features, and advantages of the present invention will become apparent from the following description taken in conjunction with the accompanying drawings.

[0026] Figure 1 This is a side view of an example electric bicycle including a torque sensor, based on the teachings of this disclosure;

[0027] Figure 2 This is a side view of an example of a rear derailleur;

[0028] Figure 3 This is a perspective view of a first embodiment of a torque sensor for a bicycle;

[0029] Figure 4A yes Figure 3 The first cross-section of the torque sensor;

[0030] Figure 4B It is similar to Figure 3 The torque sensor and the cross-section of the torque sensor including the protective cover;

[0031] Figure 5 yes Figure 4A A magnified view of the cross-section;

[0032] Figure 6 yes Figure 3 The second cross-section of the torque sensor;

[0033] Figure 7 This is a circuit diagram of one embodiment of an excitation coil driver for a torque sensor;

[0034] Figure 8 This is a circuit diagram of a first example of sensor signal conditioning;

[0035] Figure 9 This is a circuit diagram of a second example of sensor signal conditioning;

[0036] Figure 10 This is an example of a graph of input torque versus time;

[0037] Figure 11 It is the corresponding first sensing coil for the torque sensor Figure 10 An example of a graph showing the sensed voltage versus time for the input torque;

[0038] Figure 12 It is the corresponding second sensing coil used for the torque sensor Figure 10 An example of a graph showing the sensed voltage versus time for the input torque;

[0039] Figure 13 This is an example of a curve showing the excitation voltage in the excitation coil of a torque sensor versus time.

[0040] Figure 14 It corresponds to the sensing coil used in the torque sensor. Figure 13 An example of a graph of the sensed voltage versus time for the excitation voltage is shown.

[0041] Figure 15 It corresponds to clamping. Figure 13An example of a graph of the sensed voltage versus time for the excitation voltage is shown.

[0042] Figure 16 This corresponds to clamping and peak detection. Figure 13 An example of a graph of the sensed voltage versus time for the excitation voltage is shown.

[0043] Figure 17 This is a perspective view of a second embodiment of a torque sensor for a bicycle;

[0044] Figure 18 yes Figure 17 The first cross-section of the torque sensor;

[0045] Figure 19 yes Figure 18 A magnified view of the cross-section;

[0046] Figure 20 yes Figure 17 The second cross-section of the torque sensor;

[0047] Figure 21 yes Figure 18 An exploded view of the coil of the torque sensor;

[0048] Figure 22 This is a front view of a first embodiment of a bicycle drive system including a third embodiment of a torque sensor;

[0049] Figure 23 yes Figure 22 A three-dimensional diagram of the drive system;

[0050] Figure 24 yes Figure 22 A top view of the drive system;

[0051] Figure 25 yes Figure 22 The cross-section of the drive system;

[0052] Figure 26 This is an exploded view of the third embodiment of the torque sensor;

[0053] Figure 27 yes Figure 22 An enlarged view of a portion of an embodiment of the drive unit of the drive system;

[0054] Figure 28 yes Figure 27 A cross-section of a portion of the drive unit is shown, illustrating a third embodiment of the torque sensor;

[0055] Figure 29 yes Figure 28 A first enlarged view of a cross-section of a portion of the drive unit shows a third embodiment of the torque sensor;

[0056] Figure 30 yes Figure 28 A second enlarged view of a cross-section of a portion of the drive unit shows a third embodiment of the torque sensor;

[0057] Figure 31 This is a cross-section of a second embodiment of a bicycle drive system, including a third embodiment of a torque sensor;

[0058] Figure 32 This is a block diagram of an exemplary bicycle control system for implementing a method of controlling a bicycle; and

[0059] Figure 33 This is a block diagram of an exemplary control device used in implementing a method for controlling a bicycle.

[0060] Other aspects and advantages of the embodiments disclosed herein will become apparent from the following detailed description, wherein similar or identical structures have similar reference numerals. Detailed Implementation

[0061] A bicycle with an electric pedal assist motor capable of driving the chain links independently of the crank (e.g., in an e-bike) is provided. Accurate, robust, and cost-effective torque sensing will be provided for the control of the e-bike. To proportionally control the electric pedal assist motor, the bicycle's controller can vary the electric assist provided by the assist motor based on the amount of input torque generated by the rider at the bicycle's crank assembly. For example, as the sensed input torque increases, the controller increases the electric assist provided by the assist motor, and as the sensed input torque decreases, the controller decreases the electric assist provided by the assist motor.

[0062] For bicycle derailleurs using electronic shifting, the controller, running an automatic shifting algorithm, initiates shifts as the cadence increases. However, when riding leisurely, a cyclist might prefer a lower cadence, while during aggressive riding, they might prefer a higher cadence. Automatic cadence adjustments can be provided based on the sensed riding scenario. For example, the controller can increase the target cadence for automatic shifting and thus increase the target cadence band when high input torque is sensed, and decrease the target cadence and target cadence band when low input torque is sensed.

[0063] The torque sensor according to this disclosure can be integrated into a roller bearing or a sprag-type rotary clutch mechanism in an electric bicycle system. For example, the sprag-type rotary clutch mechanism can be positioned between the crank input (e.g., crank axle) and the chain link output and / or motor input of the electric bicycle system. The sprag-type rotary clutch mechanism transmits torque in a first rotational direction but rotates freely in a second rotational direction opposite to the first rotational direction. For example, the crank input drives the chain link output in the first rotational direction via the sprag-type rotary clutch mechanism, but rotates freely in the second rotational direction. When the auxiliary motor of the electric bicycle system drives the chain link output, causing the chain link output to rotate faster than the crank input (e.g., by pedaling by the cyclist), the sprag-type rotary clutch mechanism slips or overruns.

[0064] For example, a wedge-type rotary clutch mechanism generates a high strain in the ring portion of the outer ring of the clutch mechanism (e.g., a portion of the chain link output end) that is proportional to the reaction torque. The torque sensor of this disclosure can measure the strain in the ring portion of the outer ring by incorporating this outer ring into the magnetic circuit of an electric transformer and by making the outer ring from a material (e.g., an alloy) having linear or predictable magnetostrictive properties. This material has a permeability that varies with the applied strain.

[0065] The torque sensor includes a transformer having at least one excitation coil and at least one sensing coil. The at least one excitation coil is excited by an alternating current (AC) voltage, which induces an AC voltage in the at least one sensing coil. For example, the at least one excitation coil and the at least one sensing coil are arranged around an outer ring (e.g., a portion of the chain link output end) such that the magnitude of the AC voltage induced in the at least one sensing coil is related to the reaction torque in a wedge-type rotary clutch mechanism.

[0066] Various embodiments of the invention will be described herein with reference to the accompanying drawings. It should be understood that the drawings and descriptions provided herein are for illustrative purposes only and do not limit the invention as defined by the appended claims and any and all their equivalents. For example, the terms “first” and “second,” “front” and “rear,” “left” and “right” are used for clarity and not as limiting terms. Furthermore, unless otherwise stated, these terms refer to a bicycle mechanism conventionally mounted on a bicycle and used when the bicycle is oriented and used in a standard manner.

[0067] It should be understood that the specific arrangement and illustrated components of the frame, front wheels, rear wheels, drivetrain, front brake, rear brake, and saddle are not limited to the disclosed embodiments. For example, although the front and rear brakes are illustrated as hydraulic disc brakes, hydraulic rim brakes are conceivable and are also included within the scope of this disclosure. Furthermore, mechanical systems including mechanical rim brakes and mechanical disc brakes, as well as other electronic, hydraulic, pneumatic, and mechanical systems or combinations thereof (such as suspension systems), are conceivable and are also included within the scope of this disclosure.

[0068] Now turn to the attached image. Figure 1 A bicycle 100 is generally shown, wherein one or more system control units 150 may be used to implement a bicycle control system using the torque sensor described herein. In this example, the bicycle 100 may be a mountain bike. In some cases, the bicycle 100 may be an electric bicycle. The bicycle 100 has a frame 102, handlebars 104 located near the front end of the frame 102, and a seat or saddle 106 for supporting the rider above the top of the frame 102. The bicycle 100 also has a first wheel or front wheel 108 carried by a fork 110 of the frame 102 and supporting the front end of the frame 102. The bicycle 100 also has a second wheel or rear wheel 112 supporting the rear end of the frame 102. The rear end of the frame 102 may be connected to a rear suspension component 114. The bicycle 100 also has a drivetrain 116, which includes a crank assembly 118 operably connected via a chain 120 and a rear derailleur 122 to a rear cassette 124 located near the axis of rotation of the rear wheel 112. The crank assembly 118 includes two cranks 123 located on opposite sides of the frame 102 of the bicycle 100 and two pedals 125 respectively connected to the two cranks 123.

[0069] In the example shown, the rear derailleur 122 includes a power source (e.g., a battery) and a motor, and receives instructions (e.g., wirelessly) from a controller 126 (e.g., a shifter or central controller) mounted to, for example, the handlebars 104 or the frame 102, to shift gears on the rear cassette 124. In one embodiment, the rear derailleur 122 receives instructions from an e-bike control system 128 (e.g., including one or more processors, control circuitry, and / or a power source 130; system control unit 150) to shift gears on the rear cassette 124. The rear derailleur 122 uses, for example, its own power source and motor, to shift gears based on the received instructions.

[0070] In one embodiment, the rear derailleur 122 is powered by a power source located external to the rear derailleur 122. For example, the rear derailleur 122 is powered by a power source 130 (e.g., a battery) of the e-bike control system 128. In another embodiment, the rear derailleur 122 is also connected, for example, via a shifter cable to an input on the handlebars 104 (e.g., a shifter), and shifts gears on the rear freewheel 124 based on the movement of the shifter (e.g., by the rider) and thus via the shifter cable.

[0071] The battery 130 of the electric bicycle control system 128 is also supported by the frame 102 of the bicycle 100. For example, the battery 130 of the electric bicycle control system 128 is supported by the bottom tube 137 of the frame 102 of the bicycle 100. One or more components of the bicycle 100 (e.g., controller 126) may be connected to the power supply 130 of the electric bicycle control system 128 via other wires.

[0072] Battery 130 powers, for example, a drive unit 138 (e.g., including an electric bicycle motor) operatively coupled to crank assembly 118. In one embodiment, when battery 130 of electric bicycle control system 128 is not attached to bicycle 100, drive unit 138 may also be powered by a separate battery to provide access to electric bicycle control.

[0073] Drive unit 138 is mounted to the frame 102 of bicycle 100. For example, drive unit 138 is mounted to the frame 102 of bicycle 100 via one or more threaded openings and bolts within the frame 102 of bicycle 100. Drive unit 138 may be attached to frame 102 in other ways. Crank axle 140 (e.g., crank shaft) extends through the opening in drive unit 138 and connects the two cranks 123 of crank assembly 118. During operation, the rider rotates the two cranks 123 via two pedals 125, thereby rotating crank axle 140. Crank assembly 118 and / or drive unit 138 may include sensors 141 configured to measure axle rotation and force on crank axle 140. At least some of the sensors in sensor 141 may be disposed, for example, on crankshaft 140 and / or at least one of the two cranks 123, adjacent to crankshaft 140 and / or at least one of the two cranks 123, and / or within crankshaft 140 and / or at least one of the two cranks 123. Crankshaft 140 drives the output ring (e.g., chain link shaft) of drive unit 138 in the forward drive direction but not in the rear pedaling direction by using, for example, a one-way clutch (e.g., a wedge-type rotary clutch mechanism) located between crankshaft 140 and output ring.

[0074] The axle rotation and force measured on crankshaft 140 (e.g., via sensors) can be used to control the electric drive motor 146 (e.g., an auxiliary motor) of drive unit 138. The auxiliary motor 146 can drive the rotation of the output ring directly or by means of gears. Thus, the output ring provides output power to drivetrain 116, which is a combination of the rider's input power and the output power of the auxiliary motor 146.

[0075] Although Figure 1 The bicycle 100 depicted herein is a mountain bike and may include suspension components such as a shock-absorbing fork; however, the specific embodiments and examples disclosed herein, as well as alternative embodiments and examples, can be implemented on other types of bicycles. For example, the disclosed torque sensor can be used on road bicycles and bicycles with mechanical (e.g., cable, hydraulic, pneumatic, etc.) drive systems and non-mechanical (e.g., wired, wireless) drive systems. For example, the handlebar 104 shown relates to an aerodynamic handlebar configuration; however, the controller 126 and / or bicycle control system can also be used with other types of handlebar assemblies, such as drop handlebars, bullhorn handlebars, lift handlebars, or any other type of bicycle handlebar. For example, the controller 126 may be a joystick integrated with the drop handlebar configuration. Moreover, while the embodiments described herein depict manual controls attached to the handlebars, those skilled in the art will recognize that controls may be located in other areas of the bicycle, such as locations throughout the frame 102 or other locations. The disclosed bicycle shifting control method can also be implemented on other types of two-wheeled, three-wheeled, and four-wheeled human-powered vehicles.

[0076] The forward and / or forward orientation of bicycle 100 is determined by Figure 1 The direction of the arrow "A" is indicated by the arrow. Thus, the forward direction of the bicycle 100 is indicated by the direction of arrow A.

[0077] Drive unit 138 may include internal electronics to control the operation of auxiliary motor 146, measure axle input, measure the tilt of bicycle 100, measure the acceleration of bicycle 100, measure the temperature of bicycle 100, and / or reduce the voltage of battery 130 of electric bicycle control system 128 to accommodate and power external devices if a lower voltage is required. For example, the internal electronics of drive unit 138 may include one or more of sensors 141 (e.g., one or more torque sensors, power meters, cadence sensors, wheel speed sensors, speed sensors, GPS sensors, tilt sensors, direction sensors, seat pressure sensors, mechanical switches, pedal force sensors, accelerometers, gyroscopes, lidar sensors, and / or other sensors). Additional, fewer, and / or different internal electronics may be provided within drive unit 138. At least one of the sensors 141 may be alternatively or additionally located on or elsewhere in bicycle 100 (e.g., an accelerometer may be located on or in the rear suspension component 114).

[0078] The controller of the drive unit 138 (e.g., an electric bicycle central control system or controller; system control device 150) may be housed on the housing of the drive unit 138 and wired to the internal electronics of the drive unit 138. Alternatively or additionally (e.g., as part of the same housing), the electric bicycle controller may be supported by the same housing as the power supply 130. The electric bicycle controller may be made of a material through which wireless control signals can pass. In one embodiment, the electric bicycle controller is wired to the electric bicycle control system 128.

[0079] The electric bicycle controller can control the power from power source 130 to components on the bicycle 100 (e.g., the electric drive motor 146 of drive unit 138). The electric bicycle controller can also control the power to other and / or different components on the bicycle 100. The electric bicycle controller can send signals (e.g., commands and / or sensor data) to components on the bicycle 100 (e.g., rear derailleur 122, suspension system, and / or seatpost assembly) and / or receive data (e.g., commands and / or sensor data) from components on the bicycle 100 to actuate and / or control components of the bicycle 100.

[0080] In other embodiments, the e-bike controller may be located at other locations on the bicycle 100 (e.g., mounted on the handlebars 104), or alternatively, may be distributed among various components of the bicycle 100, with communication links provided to accommodate the necessary signal and power paths. For example, a control unit 152 (e.g., used as an e-bike controller; system control device 150) may be mounted to the handlebars 104 to actuate the motor of the rear derailleur 122 and operate the rear derailleur 122 to perform gear shifting and gear selection. However, the control unit 152 and / or the e-bike controller may be located anywhere on the bicycle 100, or alternatively, may be distributed among various components of the bicycle 100, with communication links provided to accommodate the necessary signal and power paths. In one example, the e-bike controller may be integrated with the rear derailleur 122 to transmit control commands between components. The control unit 152 and / or the e-bike controller may also be located in locations other than the bicycle 100, for example, on the rider's wrist or in a sweatshirt pocket. The communication link can be wired, wireless, or a combination of wired and wireless. The control unit 152 and / or the electric bicycle controller may include a processor, a communication device (e.g., a wireless communication device), a memory, and one or more communication interfaces.

[0081] The controller and / or e-bike controller of the rear derailleur 122 wirelessly actuates the motor module and / or electric drive motor 146 of the rear derailleur 122 and operates the rear derailleur 122 to perform gear shifting and gear selection. Alternatively or additionally, the controller and / or e-bike controller of the rear derailleur 122 may be configured to control the shifting of the front gear shifter.

[0082] Data from drive unit 138 (e.g., sensor 141 of drive unit 138) and / or crank assembly 118 (e.g., sensor 141 of drive unit 138) can be transmitted to the electric bicycle controller. The data can be transmitted via one or more wired connections and / or wirelessly. For example, a crank axle-based torque sensor generates data representing the input torque and / or power applied to crank axle 140 and transmits the data to the electric bicycle controller.

[0083] All communication between one or more system control units 150 of bicycle 100 (e.g., electric bicycle control system 128) and each component is achieved via wired or wireless communication. Discrete control may exist for individual wires from the respective system control unit 150 to each component controlled by the respective system control unit 150 (e.g., the motor of the rear derailleur 122), or at least one of the system control units 150 may use a Controller Area Network (“CAN”) bus configured to allow microcontrollers and devices to communicate with each other in the application.

[0084] Data transmitted to system control unit 150 can be used to determine the amount of assistance provided by electric drive motor 146 via drive unit 138. Alternatively or additionally, data transmitted to system control unit 150 can be used for automatic gear shifting. Reference Figure 2 In these examples, the rear derailleur 122 is depicted as a radio-actuated rear derailleur that can be mounted to the frame 102 of the bicycle 100. The electric rear derailleur 122 has a base member 200 (e.g., a b-joint) that can be mounted to the frame 102. A linkage mechanism 201 has two links pivotally connected to the base member 200, namely an outer link 202 and an inner link 204. A movable member 206 (e.g., a p-joint) is connected to the linkage mechanism 201. A chain guide assembly 208 (e.g., a cage) has a cage plate 210 with a proximal end 212 pivotally connected to a portion of the movable member 206, as further described below.

[0085] Motor module 214 is mounted on electric rear derailleur 122 and has battery 216. Battery 216 supplies power to motor module 214. In one example, such as Figure 2 As shown, the motor module 214 is located in the base member 200. However, the motor module 214 may alternatively be located elsewhere, such as in the outer link 202 or the inner link 204, or in the movable member 206. Although not shown herein, the motor module 214 may include a gear mechanism or a transmission. As is known in the art, the motor module 214 and the gear mechanism may be coupled to the linkage mechanism 201 to laterally move the retainer plate 210, and thus switch the chain 120 between the rear sprockets on the rear flywheel 124.

[0086] The cage plate 210 also has a distal end 218 that carries a tensioning gear or wheel 220 (e.g., a tensioner wheel). The tensioner wheel 220 also has teeth 222 around its circumference. The cage plate 210 is biased in the chain tensioning direction to maintain tension in the chain 120. The chain guide assembly 208 may also include a second gear or wheel, such as a guide wheel 224 positioned closer to the proximal end 212 of the cage plate 210 and the movable member 206. In operation, the chain 120 is arranged around the rear sprocket of the rear cassette 124. The upper section of the chain 120 extends forward to and is arranged around the link 143 of the crank assembly 118. The lower section of the chain 120 returns from the link 143 to the tensioner wheel 220 and then proceeds to the guide wheel 224. The guide wheel 224 guides the chain 120 to the rear cassette 124. The lateral movement of the retaining plate 210, tension wheel 220 and guide wheel 224 determines the lateral position of the chain 120 and aligns it with the selected rear sprocket of the rear flywheel 124.

[0087] Alternatively, battery 216 can be an alternative power source or power source and can operate other electrical components of bicycle 100 within the linked system. Battery 216 or other power sources can also be located in other locations, such as attached to frame 102. Furthermore, multiple power sources can be provided, which can jointly or individually power electrical components of the system, including rear derailleur 122, such as electric drive motor 146. However, in this example, battery 216 is configured to be directly attached to rear derailleur 122 and to provide power only to components of rear derailleur 122.

[0088] Data transmitted to system control unit 150 may include torque data from one or more sensors 141 (e.g., drive unit 138 and / or crank assembly 118). The torque data may correspond to the torque input by the rider at crank 123 and may be used by system control unit 150 to control the amount of assistance provided by electric drive motor 146 (e.g., proportional control for electric drive motor 146) and / or as input for controlling the automatic shifting mode of bicycle 100.

[0089] Figures 3 to 6 A first example of a torque sensor is shown, for instance, that can generate such torque data for use by the system control unit 150. (Reference) Figure 3 and Figure 4A The crankshaft 140 drives the output ring 300 of the drive unit 138 (e.g., chain link output end and motor input end) in the forward driving direction but not in the rear pedaling direction by using a wedge-type rotary clutch mechanism 302 (e.g., a clutch mechanism) located between the crankshaft 140 and the output ring 300 of the drive unit 138. The crankshaft 140 serves as the inner ring of the clutch mechanism 302, and the output ring 300 serves as the outer ring of the clutch mechanism 302.

[0090] The crankshaft 140 and output ring 300 are cylindrical in shape. For example, the crankshaft 140 is a solid cylinder, and the output ring 300 is a hollow cylinder. In one embodiment, the crankshaft 140 is also a hollow cylinder. The crankshaft 140 can be made of any material, including, for example, steel or aluminum alloy.

[0091] refer to Figures 4A to 6 The clutch mechanism 302 includes an element 304 disposed between the crankshaft 140 and the output ring 300. Element 304 is, for example, a wedge element (e.g., a cam-shaped wedge). [Reference] Figure 6 The clutch mechanism 302 may include any number of wedge elements 304 disposed within a volume between the crankshaft 140 and the output ring 300. For example, Figure 6 As shown, the clutch mechanism 302 may include eighteen wedge elements 304 disposed around the crankshaft 140. In other embodiments, the clutch mechanism 302 may include more or fewer wedge elements 304. The wedge elements 304 may be equidistant from each other around the crankshaft 140.

[0092] Each wedge element in the wedge element 304 (e.g., along the longitudinal axis of the respective wedge element 304) is angled relative to the radius of the crankshaft 140 passing through the center of mass of the respective wedge element 304. In one embodiment, the wedge elements in the wedge element 304 are angled at the same angle. This orientation of the wedge element 304 relative to the crankshaft 140 and the output ring 300 when the crankshaft 140 rotates in a first rotational direction D1 provides that the crankshaft 140 and the output ring 300 rotate together (e.g., locked like a solid shaft). When the crankshaft 140 rotates in a second rotational direction D2 opposite to the first rotational direction D1, or when the output ring 300 rotates faster than the crankshaft 140 (e.g., via the electric drive motor 146), the wedge element 304 slides or overshoots, thereby allowing the crankshaft 140 to rotate relative to the output ring 300, and vice versa.

[0093] The clutch mechanism 302 generates high strain in the annular portion of its outer ring (e.g., output ring 300). The strain in the annular portion is proportional to the reaction torque. Therefore, for example, the input torque at crank 123 can be determined by measuring the strain in the annular portion of the output ring 300.

[0094] For example, strain in the ring portion of the output ring 300 can be measured by integrating the output ring 300 into the magnetic circuit of the electric transformer. The output ring 300, serving as, for example, the outer ring of a clutch mechanism 302, is made of a material (e.g., an alloy) having linear or predictable magnetostrictive properties. The permeability of this material changes with applied strain. The electric transformer includes at least one excitation coil excited by an AC voltage, which induces an AC voltage in at least one sensing coil (e.g., at least one sensing coil). The magnitude of the AC voltage induced in the at least one sensing coil is proportional to the reaction torque in the clutch mechanism 302.

[0095] Figures 3 to 6 A first example of a torque sensor 306 is shown, for example, measuring strain in a ring portion of an output ring 300 in this manner. (Reference) Figures 3 to 5 The torque sensor 306 includes a support 308 (e.g., a spool) that supports an excitation coil 310 and at least one sensing coil 312 (e.g., two sensing coils). The support 308 is positioned fixed relative to a portion of the frame 102, and both the crankshaft 140 and the output ring 300 are rotatable relative to the support 308. However, in one embodiment, the support 308 can rotate together with the output ring 300 and can also rotate relative to said portion of the frame 102.

[0096] Support 308 can have any number of shapes and can be made of any number of different materials. For example, support 308 can be a hollow cylinder and can be made of ceramic or glass fiber reinforced resin (e.g., G10-FR4 glass fiber-epoxy resin laminate). Other shapes and / or materials can be provided. For example, support 308 can be made of another material with low magnetic permeability (e.g., close to 1.0), such as plastics with or without glass fiber reinforcement (e.g., nylon, acetal, and PEEK).

[0097] like Figures 3 to 5 As shown, the support 308 may be a single portion supporting the excitation coil 310 and at least one sensing coil 312. In another embodiment, for example, the support 308 may be formed of multiple separate portions / components, each portion / component being fixed in position relative to the frame 102. For example, the support 308 may include three separate portions / components respectively supporting the excitation coil 310 and the two sensing coils 312.

[0098] The support member 308 may include a groove 314, in which an excitation coil 310 and at least one sensing coil 312 may be respectively arranged. Figures 3 to 6In the example, the torque sensor 306 includes an excitation coil 310 and two sensing coils 312 (e.g., three coils in total) and three recesses 314 corresponding to the total three coils 310, 312. The torque sensor 306 may include more or fewer sensing coils 312, and therefore more or fewer corresponding recesses 314. The recesses 314 extend circumferentially around the support 308.

[0099] The excitation coil 310 can be made of any number of materials. For example, the excitation coil 310 can be made of magnetic wire (e.g., copper or aluminum magnetic wire). For example, the magnetic wire can be wound around the support 308 any number of times within the corresponding groove 314 to form the excitation coil 310. For example, the magnetic wire can be wound around the support 308 50 times (e.g., 50 turns) to form the excitation coil 310. In other embodiments, the magnetic wire is wound around the support 308 more or fewer times to form the excitation coil 310.

[0100] For example, the two sensing coils 312 can be made of any number of materials. For example, the two sensing coils 312 can be made of magnetic wire (e.g., copper or aluminum magnetic wire). For example, the magnetic wire can be wound around the support 308 any number of times in corresponding grooves 314 to form the two sensing coils 312. For example, in each corresponding groove 314, the magnetic wire can be wound around the support 308 50 times (e.g., 50 turns) to form the corresponding sensing coil 312. In other embodiments, the magnetic wire is wound around the support 308 more or fewer times to form the sensing coils 312 respectively. In one embodiment, each of the two sensing coils 312 has a different number of turns than the excitation coil 310 (e.g., 50 turns), but the two sensing coils 312 have the same number of turns (e.g., 60 turns). Changing the ratio of the number of turns in the excitation coil 310 to the number of turns in the two sensing coils 312 allows for changing the signal gain.

[0101] refer to Figure 4A and Figure 5 The excitation coil 310 and the two sensing coils 312 are concentrically positioned around the support 308, and therefore, for example, concentrically positioned around the output ring 300. The first sensing coil 312a of the two sensing coils 312 is positioned over the region of maximum circumferential strain of the clutch mechanism 302. For example, the first groove 314a of the groove 314 and the first sensing coil 312a are positioned over the wedge element 304. In one embodiment, as... Figure 4A and Figure 5 As shown, the first sensing coil 312a is axially centered relative to the wedge element 304. In another embodiment, the first sensing coil 312a overlaps with the wedge element 304, but is not axially centered relative to the wedge element 304.

[0102] The excitation coil 310 is positioned adjacent to the maximum circumferential strain region of the clutch mechanism 302. For example, the second groove 314b in the groove 314 and the excitation coil 310 are adjacent to the first groove 314a and the first sensing coil 312a (e.g., offset by 1 mm, 2 mm, 3 mm or 4 mm in the axial direction relative to the first groove 314a and the first sensing coil 312a).

[0103] The second sensing coil 312b of the two sensing coils 312 is positioned adjacent to the excitation coil 310. For example, the third groove 314c in the groove 314 and the second sensing coil 312b are adjacent to the excitation coil 310 (e.g., offset in the axial direction by 1 mm, 2 mm, 3 mm, or 4 mm relative to the second groove 314b and the excitation coil 310), such that the second sensing coil 312b and the first sensing coil 312a, as well as the corresponding grooves 314c and 314a, are respectively on opposite sides of the excitation coil 310 and the second groove 314b. In one embodiment, as Figure 4A and Figure 5 As shown, the third groove 314c and the second sensing coil 312b are offset by the same amount relative to the second groove 314b and the excitation coil 310, but in opposite directions, because the first groove 314a and the first sensing coil 312a are offset relative to the second groove 314b and the excitation coil 310.

[0104] like Figure 4B As shown in the embodiments presented herein, the torque sensor 306A may further include a protective cover 303. The protective cover 303 may include an outer protective cover 305 and an inner protective cover 307. In this document, by way of comparison with... Figures 29 to 30 The discussion related to the full text further describes the shield.

[0105] Refer again Figures 4A to 6 The torque sensor 306 is electrically connected to the electronics to power the excitation coil 310 and process the signal at the sensing coil 312. Figures 7 to 9 This illustrates torque sensors that may be included in torque sensor 306 and / or other torque sensors in this embodiment (see [link]). Figures 22 to 30 Examples of such electronic devices (e.g., circuits) used within and / or with torque sensor 306 and / or other torque sensors. Figure 7 An example of an excitation coil drive circuit 700 that can power an excitation coil 310 is shown. The electronics may include multiple excitation coil drive circuits 700, for example, the number of excitation coil drive circuits 700 corresponding to the number of excitation coils of a particular torque sensor (e.g., for...). Figures 22 to 30 For a torque sensor, there are two excitation coil drive circuits. The generated AC voltage can be sinusoidal, square, triangular, or another shape.

[0106] exist Figure 7 In the example shown, the excitation coil drive circuit 700 includes an oscillator circuit 702, a power amplifier 704, and an H-bridge circuit 706. The excitation coil drive circuit 700 may include additional, fewer, and / or different circuitry, and / or may include additional, fewer, and / or different electronic components. For example, the excitation coil drive circuit 700 may include a tank oscillator, such as a Corbitz oscillator circuit.

[0107] exist Figure 7 In the example shown, oscillator circuit 702 is a crystal oscillator circuit. Crystal oscillator circuit 702 can generate, for example, a digital square wave, but another circuit that generates a different periodic signal can be used. The digital square wave controls the switching of, for example, an H-bridge circuit 706, thereby switching the voltage across excitation coil 310.

[0108] The crystal oscillator circuit 702 (which provides frequency stability) includes a crystal 708 (e.g., a piezoelectric material, such as quartz), an inverting amplifier 710 (e.g., two inverting amplifiers), a capacitor 712 (e.g., two capacitors), and a resistor 714 (e.g., two resistors). The output of the crystal oscillator circuit 702 is, for example, a digital square wave signal with an output frequency. The output frequency can depend on the crystal used and how the crystal is manufactured (e.g., shape and size).

[0109] The output of the crystal oscillator circuit 702 is input to the power amplifier 704. This input to the power amplifier 704 (e.g., the output of the crystal oscillator circuit 702) is, for example, a low-power input, and the power amplifier 704 generates a high-current drive input for the transistors of the H-bridge circuit 706.

[0110] exist Figure 7 In the example shown, power amplifier 704 is a gate driver. For example, gate driver 704 may include a level shifter combined with the amplifier. Gate driver 704 is, for example, an interface between the digital output of crystal oscillator circuit 702 (e.g., a square wave output of crystal oscillator circuit 702) and the switches of H-bridge circuit 706. Gate driver 704, for example, interfaces the digital output of crystal oscillator circuit 702 to a voltage level suitable for controlling the switches of H-bridge circuit 706.

[0111] exist Figure 7In the example shown, the H-bridge circuit 706 includes four power MOSFETs (Metal-Oxide-Semiconductor Field-Effect Transistors) 716, but other switches can be used. For example, a digital square wave signal output from the crystal oscillator circuit 702 controls the four power MOSFETs 716 via, for example, a gate driver 704. These four power MOSFETs 716 switch the voltage across the excitation coil 310. The controlled power MOSFETs 716 switch the voltage across the excitation coil 310 such that: when the square wave is high, one end of the excitation coil 310 is connected to a positive voltage and the other end is grounded; and when the square wave is low, the polarity is switched such that said one end of the excitation coil 310 is grounded and the other end is connected to a positive voltage. The output of the H-bridge circuit 706, and therefore the crystal oscillator circuit 702, is an alternating current in the excitation coil 310.

[0112] The alternating current at excitation coil 310 induces an alternating current in each of the two sensing coils 312. In one embodiment, the outputs of the two sensing coils 312 are directly connected to a microcontroller analog-to-digital converter (ADC) or a discrete ADC. Alternatively, as... Figure 8 and Figure 9 As shown in the example, the outputs of the two sensing coils 312 can first be adjusted by analog circuitry (such as, for example, clamping circuitry and / or peak detector circuitry). Figure 8 As shown in the example, the signals from each of the first sensing coil 312a and the second sensing coil 312b can be independently adjusted. For example, a first signal conditioner circuit 800a electrically connected to the first sensing coil 312a includes a first clamping circuit 802a and a first peak detector circuit 804a, and a second signal conditioner circuit 800b electrically connected to the second sensing coil 312b includes a second clamping circuit 802b and a second peak detector circuit 804b.

[0113] The induced voltage in each of the two sensing coils 312a and 312b has a peak-to-peak voltage proportional to the torque in the measured element (e.g., output loop 300). Each of the signal conditioner circuits 800a and 800b modulates the corresponding induced AC current (e.g., the corresponding high-frequency AC signal) into a low-frequency DC signal that can be sampled by the ADC. Clamping circuits 802a and 802b adjust the induced AC voltage at sensing coils 312a and 312b to be fully positive, such that the minimum voltage is approximately at ground level. By shifting the signal above ground level, the sensitivity can be doubled (e.g., because the actual peak-to-peak voltage is being measured).

[0114] Peak detector circuits 804a and 804b perform a voltage ratcheting function, which charges the corresponding capacitors 806a and 806b to the highest observed voltage and slowly depletes them. The outputs of peak detector circuits 804a and 804b can then be sampled by the corresponding ADC. Within the respective peak detector circuits 804a and 804b, the combination of capacitor and resistor voltages indicates the bandwidth of the respective peak detector circuits 804a and 804b. In one embodiment, the excitation coil 310 can operate at 90 kHz, while the corresponding peak detector circuits 804a and 804b are sensitive to approximately 100 Hz, but other frequencies can be used.

[0115] The measurement signal on the first sensing coil 312a (located in the high-strain region of the outer ring of the clutch mechanism 302) can change similarly to the torque, but with the opposite sign, compared to the measurement signal on the second sensing coil 312b (e.g., located outside the high-strain region of the outer ring of the clutch mechanism 302). A microcontroller (e.g., system controller 150 or another controller on the bicycle 100) can receive the measurement signals (e.g., converted signals from an ADC) and determine the difference between the measurement signals (e.g., a differential voltage). This differential voltage varies with the torque, but any sensor offset or drift caused by thermal expansion of the elements of the clutch mechanism 302 and / or the torque sensor 306 can be eliminated. The microcontroller can determine the reaction torque based on the differential voltage. For example, the reaction torque can be determined based on a predetermined function (e.g., determined experimentally) using the differential voltage as input.

[0116] exist Figure 9 In the example shown, the signals from the first sensing coil 312a and the second sensing coil 312b can be regulated together so that the differential voltage is measured only in a single ADS input. The first sensing coil 312a and the second sensing coil 312b are connected in series, and the outputs of the first sensing coil 312a and the second sensing coil 312b are regulated together. For example, a single signal conditioner circuit 900 electrically connected to the first sensing coil 312a and the second sensing coil 312b includes a single clamping circuit 902 and a single peak detector circuit 904.

[0117] The signal conditioner circuits 800a, 800b, and 900 may include more, different, and / or additional components. For example, the measurement signal may be further amplified, for example, by an operational amplifier before the ADC. Furthermore, a low-pass filter may be used to reduce noise in the measurement signal before the ADC. Other components may be included.

[0118] The drive unit 138 and / or frame 102 of the bicycle 100 may support the torque sensor 306, the circuitry that drives the torque sensor 306, and the circuitry that processes the signals measured by the torque sensor 306.

[0119] Figures 10 to 16 The above references are shown separately. Figures 7 to 9 The torque sensor 306 and the circuitry are discussed in the example signal graph. Figure 10 This is a graph showing an example of input torque versus time. Corresponding to... Figure 10 input torque Figure 11 and Figure 12 This illustrates how the voltage induced in the sensing coil is affected by the input torque. For example, Figure 11 and Figure 12 This is a graph showing the output voltage versus time at the first sensing coil (e.g., the first sensing coil 312a on the wedge element 304) and the second sensing coil (e.g., the second sensing coil 312b). Figure 11 As shown, the peak-to-peak voltage decreases with increasing torque applied at the first sensing coil, while... Figure 12 As shown, the peak-to-peak voltage increases with the increase of the torque applied at the second sensing coil.

[0120] Figure 13 This is a graph showing an example of voltage versus time in an excitation coil (e.g., excitation coil 310). The voltage in the excitation coil remains constant with torque. Figure 14 It is a graph showing an example of the voltage (e.g., the measured voltage) in a sensing coil (e.g., a first sensing coil 312a or a second sensing coil 312b). Figure 15 It is a graph showing an example of the measured voltage after clamping (e.g., at the output of the first clamping circuit 802a or the second clamping circuit 802b). Figure 16 This is a graph showing an example of the measured voltage after clamping and peak detection (e.g., at the output of the first peak detector circuit 804a or the second peak detector circuit 804b and before the input to the ADC). Other torque, voltage, and / or frequency can be provided.

[0121] Torque sensors with other configurations can be provided. For example, Figures 17 to 21 A second example is shown, for example, a torque sensor 1700 that can generate torque data for use by system control device 150. Figures 17 to 21 Torque sensor 1700 and Figures 3 to 6The torque sensor 306 shown differs in that both the excitation coil 1702 and the sensing coil 1704 are formed in a printed circuit board (PCB). The excitation coil 1702 and the sensing coil 1704 are arranged around the output ring 300. In other words, the torque sensor 1700 does not include a support (e.g., a spool) that is separate from the substrate, such as the PCB.

[0122] refer to Figure 21 Each PCB comprises any number of 1708 layers. For example, Figure 21 The PCB 1706 shown includes six layers 1708a to 1708f, each of which is cylindrical and includes a substrate 1710 and one or more traces 1712 (e.g., copper traces) disposed on one side of the substrate 1710. For example, each of the six layers 1708a to 1708f includes a continuous trace 1712 that is wound around the cylindrical substrate 1710 multiple times (e.g., eight or ten times) to form the windings of corresponding coils 1702, 1704. Each of the six layers 1708a to 1708f may have the same number of windings, and each of the coils 1702, 1704 may have the same number of windings. Other configurations may be provided.

[0123] The trace 1712 of the first layer 1708a of the six layers is wound inward from the input terminal 1713 of the corresponding coils 1702 and 1704 to the first via 1714 of the first layer 1708a. When the six layers 1708 are stacked to form the corresponding coils 1702 and 1704, the first via 1714 of the first layer 1708a communicates with the first via 1716 of the second layer 1708b of the six layers. The trace 1712 of the second layer 1708b is wound outward from the first via 1716 to the second via 1718 of the second layer 1708b. When the six layers 1708 are stacked, the second via 1718 of the second layer 1708b communicates with the second via 1720 of the third layer 1708c of the six layers. The trace 1712 of the third layer 1708c winds inward from the second via 1720 of the third layer 1708c to the third via 1722 of the third layer 1708c. When six layers 1708 are stacked, the third via 1722 of the third layer 1708c communicates with the third via 1724 of the fourth layer 1708d. The trace 1712 of the fourth layer 1708d winds outward from the third via 1724 of the fourth layer 1708d to the fourth via 1726 of the fourth layer 1708d. When six layers 1708 are stacked, the fourth via 1726 of the fourth layer 1708d communicates with the fourth via 1728 of the fifth layer 1708e. The trace 1712 of the fifth layer 1708e winds inward from the fourth via 1728 of the fifth layer 1708e to the fifth via 1730 of the fifth layer 1708e. When the six layers 1708 are stacked, the fifth via 1730 of the fifth layer 1708e communicates with the fifth via 1732 of the sixth layer 1708f. The trace 1712 of the sixth layer 1708f is wound outward from the fifth via 1732 to the output terminal 1734 of the corresponding coils 1702 and 1704. Other configurations are available.

[0124] Figures 22 to 31 A third example of a drive system 2200 is shown, including a torque sensor 2202 that can generate torque data for use by, for example, a system control unit 150. (Reference) Figures 22 to 24 The drive system 2200 includes a drive unit 2204 that can be mounted to a bicycle frame (e.g., the frame 102 of bicycle 100). For example, the drive unit 2204 can be mounted to the bicycle frame via a support structure 2206 (e.g., a frame portion) of the drive system 2200.

[0125] refer to Figure 23 The support structure 2206 may include a first support member 2206a and a second support member 2206b. The first support member 2206a and the second support member 2206b may respectively support the drive unit 2204 on opposite sides of the drive unit 2204. (See reference) Figure 24The first support member 2206a and the second support member 2206b of the support structure 2206 may include a recessed portion 2208 (e.g., a cylindrical recessed portion), and the opposite sides of the drive unit 2204 may be respectively positioned in the recessed portion 2208.

[0126] refer to Figure 22 and Figure 23 When the opposite sides of the drive unit 2204 are respectively disposed within the cylindrical recesses 2208 of the first support member 2206a and the second support member 2206b, the first support member 2206a and the second support member 2206b can be attached to the bicycle frame, such that the drive unit 2204 is captured within the support structure 2206, and the support structure 2206 is attached to the bicycle. In one embodiment, the bicycle frame (e.g., the frame 102 of bicycle 100) may include a hollow cylindrical portion (e.g., a bottom bracket housing), through which the drive unit 2204 extends, and the first support member 2206a and the second support member 2206b are attached to opposite sides of the hollow cylindrical portion of the bicycle frame. The support structure 2206 can be attached to the bicycle frame in any number of ways, including, for example, using bolts and openings located within the support structure 2206 and the bicycle frame.

[0127] refer to Figure 23 The support structure 2206 may include any number of openings 2210 through which bolts can extend to attach the support structure 2206 (and thus the drive unit 2204) to the bicycle frame via corresponding openings (e.g., threaded openings) in the bicycle frame. Figure 23 As shown in the example, both the first support 2206a and the second support 2206b may include one or more openings 2210a adjacent to the corresponding cylindrical recess 2208. The support structure 2206 may include any number of attachment features 2212, such as, for example, protrusions, flanges, and extensions, through which one or more of the openings 2210 extend.

[0128] The drive unit 2204 can be attached to the bicycle frame in any other way. For example, the support structure 2206 can be welded to the bicycle frame. Other attachment configurations are also possible.

[0129] refer to Figure 22 and Figure 25The drive system 2200 also includes a crank assembly 2214. The crank assembly 2214 includes a crank axle 2216 (e.g., a crank shaft) extending through an opening in the drive unit 2204 and connecting two cranks 2218 to opposite sides of the crank axle 2216. During operation, the rider rotates the two cranks 2218 via two pedals respectively attached to the two cranks 2218, thereby rotating the crank axle 2216.

[0130] refer to Figure 25 The crank assembly 2214 and / or drive unit 2204 may include a torque sensor 2202. The torque sensor 2202 may be positioned around the crankshaft 2216 (e.g., the inner ring of the clutch mechanism 2222 used as the drive unit 2204) or the outer ring 2224 of the clutch mechanism 2222 (e.g., the output ring). The crankshaft 2216 drives the output ring 2224 of the drive unit 2204 (e.g., the chain link output and motor input) in the forward drive direction but not in the rear pedaling direction using, for example, a one-way clutch mechanism 2226 (e.g., a wedge-type rotary clutch mechanism) located between the crankshaft 2216 and the output ring 2224.

[0131] refer to Figure 25 The torque sensor 2202 may be positioned around the output ring 2224 of the clutch mechanism 2222, axially aligned with the wedge-type rotary clutch mechanism 2226. The drive unit 2204 includes a housing 2228 that supports and / or surrounds components of the drive system 2200. The torque sensor 2202 may be attached to the housing 2228 of the drive unit 2204 such that the torque sensor 2202 is fixed relative to the housing 2228 of the drive unit 2204 (e.g., fixed in position). The torque sensor 2202 may be attached to the housing 2228 of the drive unit 2204 such that the torque sensor 2202 and the output ring 2224 of the clutch mechanism 2222 are separated by a radial clearance 2230 (see [link to relevant documentation]). Figure 29 and Figure 30 ).

[0132] The torque sensor 2202 can be attached to the housing 2228 of the drive unit 2204 in any number of ways. For example, the torque sensor 2202 can be attached to the housing 2228 of the drive unit 2204 using one or more fasteners (e.g., one or more screws or bolts through threaded holes). Other attachment configurations for attaching the torque sensor 2202 to the drive unit 2204 can be provided.

[0133] The drive unit 2204 may include more or additional components. For example, see reference... Figure 25The drive unit 2204's housing 2228 can accommodate a rotor 2232 that rotates with the crankshaft 2216 and a stator 2234 supported by the housing 2228. The stator 2234 can drive the rotor 2232 attached to the crankshaft 2216. The drive unit 2204 may also include a reducer 2236 (e.g., including one or more gears) coupled to an output ring 2224. The output ring 2224 may be, for example, a chain link shaft 2238 (e.g., the chain link 143 of the crank assembly 118). The drive unit 2204 may include bearings and / or bushings. For example, the drive unit 2204 may include a bushing 2240 for a wedge-type rotary clutch mechanism 2226, a bushing 2242 for the crankshaft 2216, and a bearing 2244 for the chain link shaft 2238. Additional, fewer, and / or different bushings and / or bearings may be provided. The drive unit 2204 may include more, fewer, and / or different components.

[0134] refer to Figure 29 and Figure 30 The torque sensor 2202 includes a support member 2250 (e.g., a housing). The support member 2250 includes, for example, a first support member 2252 (e.g., a first portion of the support member 2250) and a second support member 2254 (e.g., a second portion of the support member 2250). The first support member 2252 and the second support member 2254 may be separable from each other, for example, in the axial direction of the support member 2250. Each of the first support member 2252 and the second support member 2254 may be configured as, for example, a hollow cylinder (e.g., a coil carrier, a spool), but other configurations may be provided. In one embodiment, the first support member 2252 and the second support member 2254 are connected to each other. The first support member 2252 and the second support member 2254 may be made of any number of materials, including, for example, plastic. The first support member 2252 and / or the second support member 2254 may be made of different materials.

[0135] The torque sensor 2202 includes a first magnetic circuit 2256 (e.g., a measurement circuit) and a second magnetic circuit 2258 (e.g., a reference circuit). A first support 2252 supports (e.g., accommodates) the first magnetic circuit 2256, and a second support 2254 supports (e.g., accommodates) the second magnetic circuit 2258. For example, the first support 2252 includes a first groove 2260 and a second groove 2262 extending into the first support 2252 and circumferentially around an outer side 2264 of the first support 2252. The second groove 2262 is offset relative to the first groove 2260 in a first axial direction 2266 of the torque sensor 2202.

[0136] The first magnetic circuit 2256 includes a first excitation coil 2268 and a first sensing coil 2270 respectively disposed in a first groove 2260 and a second groove 2262. In one embodiment, the first excitation coil 2268 is disposed in the second groove 2262, and the first sensing coil 2270 is disposed in the first groove 2260.

[0137] The first excitation coil 2268 can be made of any number of materials. For example, the first excitation coil 2268 can be made of magnetic wire (e.g., copper or aluminum magnetic wire). For example, the magnetic wire of the first excitation coil 2268 can be wound around the first support 2252 within the first groove 2260 for any number of times to form the first excitation coil 2268. For example, the magnetic wire of the first excitation coil 2268 can be wound around the first support 2252 50 times (e.g., 50 turns) to form the first excitation coil 2268. In other embodiments, the magnetic wire of the first excitation coil 2268 is wound around the first support 2252 more or fewer times to form the first excitation coil 2268.

[0138] The first sensing coil 2270 can be made of any number of materials. For example, the first sensing coil 2270 can be made of magnetic wire (e.g., copper or aluminum magnetic wire). For example, the magnetic wire can be wound around the first support 2252 any number of times within the second recess 2262 to form the first sensing coil 2270. For example, the magnetic wire of the first sensing coil 2270 can be wound around the first support 2252 50 times (e.g., 50 turns) to form the first sensing coil 2270. In other embodiments, the magnetic wire is wound around the first support 2252 more or fewer times to form the first sensing coil 2270. In one embodiment, the first sensing coil 2270 has a different number of turns than the first excitation coil 2268 (e.g., 50 turns) (e.g., 60 turns). Changing the ratio of the number of turns in the first excitation coil 2268 to the number of turns in the first sensing coil 2270 allows for a change in signal gain.

[0139] When a rider applies torque to the crankshaft 2216 via the pedals and wedge-type rotary clutch mechanism 2226, radial stress is applied to the crankshaft 2216. The crankshaft 2216 may be made of a magnetostrictive material having magnetic reluctance that varies with the amount of physical deformation experienced by the crankshaft 2216. A torque sensor 2202 may be positioned relative to the crankshaft 2216, and the physical geometry of the crankshaft 2216 may be optimized to form a high-stress zone (HSZ) between, for example, the first excitation coil 2268 and the first sensing coil 2270. The HSZ experiences higher stress than other portions of the outer surface of the crankshaft 2216, making the torque applied by the rider easier to measure.

[0140] The permeability of many materials can be temperature-dependent, causing the zero torque point (ZTP) to drift as the drive unit 2204 heats up due to use or cools down due to other factors. Over time, this drift can make it difficult to obtain stable torque measurements.

[0141] The second support member 2254 includes a third groove 2272 and a fourth groove 2274, which extend into the second support member 2254 and circumferentially around the outer side 2276 of the second support member 2254. The third groove 2272 is offset relative to the first groove 2260 in a second axial direction 2278 of the torque sensor 2202. The second axial direction 2278 of the torque sensor 2202 is opposite to the first axial direction 2266 of the torque sensor 2202. The fourth groove 2274 is offset relative to the third groove 2272 in either the second axial direction 2278 or the first axial direction 2266 of the torque sensor 2202 (e.g., the second axial direction 2278 of the torque sensor 2202).

[0142] The second magnetic circuit 2258 includes a second sensing coil 2280 and a second excitation coil 2282 respectively disposed in a third groove 2272 and a fourth groove 2274. In one embodiment, the second sensing coil 2280 is disposed in the fourth groove 2274, and the second excitation coil 2282 is disposed in the third groove 2272.

[0143] The second excitation coil 2282 can be made of any number of materials. For example, the second excitation coil 2282 can be made of magnetic wire (e.g., copper or aluminum magnetic wire). The magnetic wire of the second excitation coil 2282 can be wound around the second support 2254 within the fourth groove 2260, for example, any number of times to form the second excitation coil 2282. For example, the magnetic wire of the second excitation coil 2282 can be wound around the second support 2254 50 times (e.g., 50 turns) to form the second excitation coil 2282. In other embodiments, the magnetic wire of the second excitation coil 2282 is wound around the second support 2254 more or fewer times to form the second excitation coil 2282.

[0144] The second sensing coil 2280 can be made of any number of materials. For example, the second sensing coil 2280 can be made of magnetic wire (e.g., copper or aluminum magnetic wire). For example, the magnetic wire can be wound around the second support 2254 any number of times within the third groove 2272 to form the second sensing coil 2280. For example, the magnetic wire of the second sensing coil 2280 can be wound around the second support 2254 50 times (e.g., 50 turns) to form the second sensing coil 2280. In other embodiments, the magnetic wire is wound around the second support 2254 more or fewer times to form the second sensing coil 2280. In one embodiment, the second sensing coil 2280 has a different number of turns than the second excitation coil 2282 (e.g., 50 turns) (e.g., 60 turns). Changing the ratio of the number of turns in the second excitation coil 2282 to the number of turns in the second sensing coil 2280 allows for a change in signal gain.

[0145] In one embodiment, the support member 2250 is a single support member having a first groove 2260, a second groove 2262, and a third groove 2272, which extend into the support member and circumferentially around the support member. In such embodiments, a first excitation coil 2268 may be disposed within the first groove 2260, a first sensing coil 2270 may be disposed within the second groove 2262, and a second sensing coil 2280 may be disposed within the third groove 2272.

[0146] Torque sensor 2202 is positioned relative to crankshaft 2216 such that a low-stress zone (LSZ) (e.g., relative to HSZ) is located between second sensing coil 2280 and excitation coil (e.g., second excitation coil 2282) of torque sensor 2202. In the LSZ of crankshaft 2216, the relative change in magnetic reluctance can be several orders of magnitude lower than in the HSZ. This provides a stable reference for where the ZTP is overheated. Since the materials in the torque sensor heat or cool at similar rates, the permeability of the first magnetic circuit 2256 and the permeability of the second magnetic circuit 2258 change at similar rates and in the same direction. A processor for torque sensor 2202 or an external processor (e.g., of bicycle 100) can generate (e.g., calculated by the processor) torque data for use by system control unit 150, for example, based on the amplitude difference between the signals from first sensing coil 2270 and second sensing coil 2280.

[0147] refer to Figure 29 and Figure 30 The torque sensor 2202 includes an inner cover 2284 (e.g., a first cover) that covers at least a portion of the support 2250. Figure 29 and Figure 30In the illustrated embodiment, for example, the inner cover 2284 includes a first inner cover 2286, a second inner cover 2288 separate from the first inner cover 2286, and a spacer 2290 disposed between the first support member 2252 and the second support member 2254. Therefore, the spacer 2290 separates the first support member 2252 and the second support member 2254, and thus separates the first magnetic circuit 2256 and the second magnetic circuit 2258. In such an embodiment, the first inner cover 2286 covers at least a portion of the first support member 2252 (e.g., at least the outer circumferential surface and outer end of the first support member 2252), and the second inner cover 2288 covers at least a portion of the second support member 2254 (e.g., at least the outer circumferential surface and outer end of the second support member 2254). For example, the first inner cover 2286 at least covers the first groove 2260 and the second groove 2262 in the first support member 2252, and the second inner cover 2288 at least covers the third groove 2272 and the fourth groove 2274 in the second support member 2254. Therefore, the first inner cover 2286 encloses the first excitation coil 2268 and the first sensing coil 2270 within the first support member 2252, and the second inner cover 2288 encloses the second excitation coil 2282 and the second sensing coil 2280 within the second support member 2254.

[0148] The inner shield 2284 helps provide a closed magnetic circuit by adding a return path of high-magnetic material (e.g., a low-resistivity return path) to induce a magnetic flux path. Adding a low-resistivity return path greatly increases the flux and coupling flowing in the first magnetic circuit 2256 and the second magnetic circuit 2258, respectively, both of which contribute to increasing the sensing amplitude and thus increasing the measurement sensitivity.

[0149] The inner shield 2284 (e.g., the first inner shield 2286 and the second inner shield 2288) can be made of any number of materials (e.g., the first shield material). For example, the first inner shield 2286 and the second inner shield 2288 can be made of the same material, such as a material with high magnetic permeability and low electrical conductivity (e.g., ferrite). In one embodiment, different ferrites are used for the first inner shield 2286 and the second inner shield 2288, respectively. The spacer 2290 can be made of any number of different materials. For example, the spacer 2290 can be made of the same material as the first inner shield 2286 and the second inner shield 2288 (e.g., the first shield material). In one embodiment, the spacer 2290 is made of a different material than the first inner shield 2286 and / or the second inner shield 2288. For example, the spacer 2290 can be made of plastic.

[0150] The permeability of the first shielding material can be as high as possible to provide a path with the lowest possible magnetic resistance for the magnetic flux. When an AC magnetic field enters a good electrical conductor, eddy currents are generated. The magnetic field of the eddy currents is opposite to the applied field (e.g., generated by the first excitation coil 2268 and / or the second excitation coil 2282), thus attenuating the applied field. Therefore, the field shielding material can have a low conductivity.

[0151] In one embodiment, the inner shield 2284 is a single portion covering at least a portion of the support member 2250. In one embodiment, the inner shield 2284 covers at least a portion of the first support member 2252 and at least a portion of the second support member 2254. This inner shield 2284 separates the second support member 2254 from the first support member 2252, and thus separates the second magnetic circuit 2258 from the first magnetic circuit 2256. The cross-section of this inner shield 2284 may have a comb-like structure. In another embodiment, in which the support member 2250 is a single portion supporting the first excitation coil 2268, the first sensing coil 2270, and the second sensing coil 2280, the inner shield 2284 is a single portion covering at least a portion of the support member 2250 and enclosing the first excitation coil 2268, the first sensing coil 2270, and the second sensing coil 2280 within the torque sensor 2202.

[0152] The first magnetic circuit 2256 allows the flux to pass through the HSZ, and the second magnetic circuit 2258 allows the flux to pass through the LSZ. The chambers of the first magnetic circuit 2256 and the second magnetic circuit 2258 (e.g., two chambers) are isolated from each other (e.g., by spacer 2290), thus increasing measurement sensitivity while reducing measurement error.

[0153] Some magnetic flux traveling in the loop passes through both the HSZ and LSZ. This can correlate the measured signal (e.g., from the first sensing coil 2270) and the reference signal (e.g., from the second sensing coil 2280), which reduces the measurement sensitivity and causes the reference signal to vary more with the torque applied by the rider.

[0154] refer to Figure 29 and Figure 30The torque sensor 2202 may also include an outer shield 2292 (e.g., a second shield) that covers at least a portion of the inner shield 2284 (e.g., a first inner shield 2286, a second inner shield 2288, and a spacer 2290). For example, the outer shield 2292 may cover the outer circumferential surface and outer end of the inner shield 2284. In the illustrated embodiment, the outer shield 2292 includes a first outer shield 2294 and a second outer shield 2296. The first outer shield 2294 may be integral with the housing 2228, or may be attached to the housing 2228 in any number of ways, including, for example, by using one or more fasteners (e.g., passing one or more bolts through one or more holes in the first outer shield 2294 and one or more holes (such as threaded holes) in the housing 2228). Thus, the torque sensor 2202 may be attached to the housing 2228 via, for example, the first outer shield 2294 attached to the housing 2228. The first outer cover 2294 may cover a first portion of the inner cover 2284 (including, for example, the outer circumferential surface and outer end of the first inner cover 2286) and a first portion of the outer circumferential surface of the spacer 2290.

[0155] The second outer cover 2296 may cover a second portion of the inner cover 2284 (including, for example, the outer circumferential surface and outer end of the second inner cover 2288) and a second portion of the outer circumferential surface of the spacer 2290. The second outer cover 2296 may be attached to the first outer cover 2294 to form an outer cover 2292. For example, the second outer cover 2296 may be attached to the first outer cover 2294 using one or more fasteners (e.g., one or more bolts respectively passing through one or more holes in the first outer cover 2294 and one or more holes in the second outer cover 2296), adhesives, welding, and / or another attachment configuration. The first outer cover 2294 and the second outer cover 2296 each include a flange 2298, which may be attached to each other via the flange 2298. Holes 2299 respectively pass through the first outer cover 2294 and the second outer cover 2296 (see...). Figure 26 The first outer cover 2294 and the second outer cover 2296 (which can be attached to each other by bolts through these holes 2299) extend through the flange 2298 respectively.

[0156] The outer shield 2292 (e.g., the first outer shield 2294 and the second outer shield 2296) can be made of any number of materials (e.g., the second shield material). For example, the first outer shield 2294 and the second outer shield 2296 can be made of the same material, such as a non-ferromagnetic (e.g., permeability of 1) conductive material. Such a non-ferromagnetic conductive material can be, for example, aluminum 7075, but other materials can be used. In one embodiment, different non-ferromagnetic conductive materials are used for the first outer shield 2296 and the second outer shield 2298, respectively.

[0157] By including an outer sheath 2294 within the torque sensor 2202, the impedance experienced by the coils of the torque sensor 2202 (e.g., the first excitation coil 2268, the second excitation coil 2282, the first sensing coil 2270, and the second sensing coil 2280) remains unchanged when the torque sensor 2202 undergoes small axial movements within the dynamic system of the drive unit 2204; thus, amplitude variations in the measured signal can be minimized. This increases the reliability of the torque sensor 2202 and keeps the magnetic field of the torque sensor 2202 almost completely contained. Furthermore, this increases the symmetry of the first sensing coil 2270 and the second sensing coil 2280, which helps to minimize measurement errors.

[0158] Components of the torque sensor 2202 (e.g., support 2250, first excitation coil 2268, first sensing coil 2270, second sensing coil 2280, second excitation coil 2282, and inner housing 2284) can be held within the torque sensor 2202 via a frictional engagement provided by attachment of a second outer housing 2296 to the first outer housing 2294. For example, bolts for attaching the second outer housing 2296 to the first outer housing 2294 can be tightened while the components of the torque sensor 2202 are housed within the outer housing 2292 to apply axial pressure to the components of the torque sensor 2202 and prevent axial and / or radial movement of the components of the torque sensor 2202. Therefore, the components of the torque sensor 2202 can be connected to and fixed in position relative to the housing 2228. The components of the torque sensor 2202 can be attached to the outer housing 2294 and / or the housing 2228 of the torque sensor 2202 in any number of other ways (including, for example, with adhesive).

[0159] In one embodiment, the outer cover 2294 is a single portion that covers at least a portion of both the first inner cover 2286 and the second inner cover 2288, as well as the spacer 2290. This single portion of the outer cover 2294 may be integral with the housing 2228, or may be attached to the housing 2228 in any number of ways, including, for example, by inserting one or more fasteners into one or more openings (e.g., threaded openings) in the housing 2228.

[0160] The components of torque sensor 2202 and the outer casing 2294 of torque sensor 2202 can have any number of shapes and / or sizes. (Reference) Figure 26For example, the components of torque sensor 2202 (e.g., support 2250 including first support 2252 and second support 2254, first excitation coil 2268, first sensing coil 2270, second sensing coil 2280, second excitation coil 2282, inner cover 2284 including first inner cover 2286 and second inner cover 2288, and spacer 2290) and the outer cover 2294 accommodating these components of torque sensor 2202 may be annular. The inner diameter of support 2250 may be set such that torque sensor 2202 can be positioned around the output ring 2224 of clutch mechanism 2222, wherein, for example, there is a radial clearance 2230 between support 2250 and output ring 2224 of clutch mechanism 2222.

[0161] By constructing two similar or identical magnetic circuits, namely the first magnetic circuit 2256 on the HSZ and the second magnetic circuit 2258 on the LSZ, strain differences between the HSZ and LSZ can be isolated. Voltages applied to the first excitation coil 2268 and the second excitation coil 2282 induce signals (e.g., voltages) in the first sensing coil 2270 and the second sensing coil 2280, respectively. For example, the torque sensor 2202 or the bicycle's processor can receive signals (e.g., converted signals from an ADC) from the first sensing coil 2270 and the second sensing coil 2280 and determine the difference between the measured signals (e.g., differential signal; differential voltage). This differential voltage varies with torque but can eliminate sensor offset or drift caused by thermal expansion of the clutch mechanism 2222 and / or the elements of the torque sensor 2202. The processor can determine the reaction torque based on the differential voltage. For example, the reaction torque can be determined based on a predetermined function (e.g., determined experimentally) using the differential voltage as input.

[0162] The torque sensor 2202 may include more, fewer, and / or different components. For example, the torque sensor 2202 may include a third shield that at least partially covers the second shield 2294. For example, the third shield may shield against external low-frequency magnetic fields. If the external magnetic field is not properly shielded, it may leak into the torque sensor 2202 and cause measurement errors. The external magnetic field may saturate the internal ferromagnetic return path or cause a permeability gradient between the two chambers, since permeability depends on the field strength. The third shield may be made of any number of different materials, including, for example, ferromagnetic ceramic materials (e.g., ferrite), such that the third shield provides a low-reluctance return path back to the source of the external magnetic field. The first shield 2284 may contain a high-frequency field within the torque sensor 2202, the second shield 2294 may shield the torque sensor 2202 from high-frequency external fields, and the third shield may shield the torque sensor 2202 from low-frequency external fields. This increases the reliability and usability of the torque sensor 2202.

[0163] The torque sensor 2202 can be mounted to other rotating fixed components of the drive unit 2204 (e.g., instead of housing 2228). For example, refer to Figure 31 The drive unit 2204 may include end caps 2300 and 2302 located at opposite ends 2304 and 2306 of the housing 2228, respectively. The end caps 2300 and 2302 may be attached to the housing 2228 of the drive unit 2204 at opposite ends 2304 and 2306 of the housing 2228 in any number of ways (including, for example, via threaded connections). Other attachment configurations may be provided.

[0164] like Figure 31 As shown in the example, torque sensor 2202 can be attached to end cap 2302 of drive unit 2204 (e.g., via second outer cover 2296) such that torque sensor 2202 and output ring 2224 of clutch mechanism 2222 are separated by radial clearance 2230. Torque sensor 2202 can be attached to end cap 2302 of drive unit 2204 in any number of ways, including attachment using one or more fasteners, for example.

[0165] Figure 32A bicycle control system 3200 is shown, comprising a plurality of manual controls 142A to 142D, a system control unit 150, at least one sensor 3202 (such as sensor 141 (e.g., a torque sensor)), a rhythm sensor and / or a speed sensor 3206, and bicycle components 3208A to 3208B (such as a rear derailleur and / or a front derailleur or one or more internal gear hubs). The manual controls 142A to 142D are communicatively connected to the system control unit 150, such as via cable or wirelessly, to transmit control signals to the system control unit 142. The system control unit 150 is configured to transmit control signals in response to received control unit signals or control signals generated by automatic shift determination to components 3208A to 3208B. In one embodiment, the system control unit 150 is configured to wirelessly transmit control signals to one or more bicycle components 3208A to 3208B. Any technology, protocol, or standard can be used to wirelessly transmit control signals. For example, you can use the Institute of Electrical and Electronics Engineers (“IEEE”) 802.11 standard, IEEE 802.15.1 or BLUETOOTH® standard, ANT TM or ANT+ TM Standards and / or AIREA TM Standard. Bicycle components 3208A to 3208B can be any bicycle component. For example, components 3208A to 3208B can be drivetrain components and / or suspension components. In one embodiment, component 3208A can be a rear derailleur, while another component 3208B can be a front derailleur. Other components may also be included. For example, system control device 150 can communicate with or provide control signals for three or more components, such as the front derailleur, rear derailleur, and front suspension system. Alternatively, system control device 150 may provide control signals only for a single component 3208A. In one embodiment, a receiver can wirelessly transmit control signals to one component 3208A, and that one component 3208A can transmit control signals to another component 3208B.

[0166] In one embodiment, the bicycle control system 3200 includes at least one manual control device 142, which includes a control mechanism for generating control signals to control at least one bicycle component 3208A. The system control device 150 may be a standalone device or may be integrated with one or more components 3208A to 3208B.

[0167] Figure 33This is a block diagram of an exemplary control system 3300 for a bicycle that can be used to implement system control device 150. Control system 3300 can be used alone to communicate with and control bicycle components, or control system 3300 can be used in conjunction with at least one other control system for bicycle components, such as a main control system that includes alternative controls, such as a shift controller integrated into the brake lever housing. Control system 3300 includes system control device 150, one or more control devices 142, and / or one or more sensors 141. System control device 150 includes a processor 3302, a memory 3304, a sensor communication interface 3306, a power supply 3308, and a control device interface 3310. Optionally, system control device 150 may also include a user interface 3312. Additional, different, or fewer components may be used with system control device 150.

[0168] Processor 3302 may include a general-purpose processor, a digital signal processor, an application-specific integrated circuit (ASIC), a field-programmable gate array (FPGA), analog circuitry, digital circuitry, combinations thereof, or other processors now known or hereafter developed. Processor 3302 may be a single device or a combination of multiple devices (e.g., through shared or parallel processing). In one embodiment, for example, the CPU 3302 used may be an Atmel® ATmega324PA microcontroller with internal EEPROM memory, and the transmitter and receiver used may be an Atmel® AT86RF231 2.4GHz transceiver utilizing AES encryption and DSS spread spectrum technology supporting 16 channels and the IEEE 802.15.4 communication protocol.

[0169] Memory 3304 may be volatile or non-volatile memory. Memory 3304 may include one or more of read-only memory (ROM), random access memory (RAM), flash memory, electronically erasable program read-only memory (EEPROM), or other types of memory. Memory 3304 may be removed from system control device 150, such as a secure digital storage (SD) card. In certain non-limiting exemplary embodiments, computer-readable media may include solid-state memory, such as a memory card, or other package housing one or more non-volatile read-only memories. Furthermore, computer-readable media may be random access memory or other volatile rewritable memory. Additionally, computer-readable media may include magneto-optical or optical media, such as magnetic disks or magnetic tapes, or other storage devices. Therefore, this disclosure is considered to include any one or more of computer-readable media and other equivalents and successor media in which data or instructions may be stored.

[0170] Memory 3304 is a non-transitory computer-readable medium and is described as a single medium. However, the term "computer-readable medium" includes single or multiple media, such as centralized or distributed memory structures, and / or associated caches operable to store one or more sets of instructions and other data. The term "computer-readable medium" should also include any medium capable of storing, encoding, or carrying a set of instructions for execution by a processor or for causing a computer system to perform any one or more of the methods or operations disclosed herein.

[0171] In alternative embodiments, dedicated hardware implementations (e.g., application-specific integrated circuits, programmable logic arrays, and other hardware devices) may be configured to implement one or more of the methods described herein. Applications that may include various embodiments of the devices and systems can broadly encompass a wide range of electronic and computer systems. One or more embodiments described herein may use two or more specific interconnect hardware modules or devices to implement functionality, said two or more specific interconnect hardware modules or devices having associated control and data signals that can be transferred between and through modules, or as part of an application-specific integrated circuit. Therefore, this system includes software, firmware, and hardware implementations.

[0172] Power source 3308 is a portable power source that can be stored internally to system control unit 150 or externally and transmitted to system control unit 150 via a power cable. Power source 3308 may involve generating electricity, for example, using a mechanical generator, fuel cell device, photovoltaic cell, or other power generation device. Power source 3308 may include batteries, such as a device consisting of two or more electrochemical cells that convert stored chemical energy into electrical energy. Power source 3308 may include a combination of multiple batteries or other power supply devices. Specially installed or configured battery types or standard battery types, such as CR 2012, CR 2016, and / or CR2032, may be used.

[0173] The control device interface 3310 provides data communication from the control device 142 to the system control device 150. The control device interface 3310 includes wired signal and / or data communication circuitry operable to interpret signals provided by the various control devices 142. For example, the control device interface 3310 may include a series of ports for receiving control device input cables. Each port may be distinguished by the processor 3302 via a packet table or array, or via physical circuitry or other circuitry providing packet control device inputs. Alternatively, as described herein, the various control devices 142 may communicate wirelessly with the system control device 150.

[0174] User interface 3312 may be one or more buttons, keypads, keyboards, mice, styluses, trackballs, rocker switches, touchpads, voice recognition circuitry, or other devices or components for transmitting data between a user and system control device 150. User interface 3312 may be a touchscreen, which may be a capacitive or resistive touchscreen. User interface 3312 may include a liquid crystal display (“LCD”) panel, a light-emitting diode (LED) screen, an LED screen, a thin-film transistor screen, or another type of display. User interface 3312 may also include audio capabilities or speakers. In embodiments, the user interface is configured to provide the user with notifications that system control device 150 has entered automatic mode, paused automatic mode, exited automatic mode, and / or that automatic mode parameters have been modified. These notifications may be audible, visual, and / or tactile. For example, an audible beep may be used. In one embodiment, the LCD panel is configured to display visual notifications.

[0175] In one embodiment, the user interface 3312 includes a plurality of buttons and an LED indicator. The buttons are used to transmit commands to the system control device 150, and the LED indicator is illuminated to indicate the input of the command.

[0176] Sensor communication interface 3306 is configured to communicate data, such as sensor values, with at least one sensor 141. Sensor communication interface 3306 uses any operable connection to transmit data. An operable connection can be a connection in which signals can be sent and / or received, physical communication and / or logical communication can occur. An operable connection can include a physical interface, an electrical interface and / or a data interface. Sensor communication interface 3306 provides wireless communication in any format now known or hereafter developed.

[0177] This document describes wireless communication between components. While this specification describes components and functions that may be implemented with reference to specific standards and protocols in particular wireless communication embodiments, the invention is not limited to these standards and protocols. For example, standards used for transmission over the Internet and other packet-switched networks (e.g., TCP / IP, UDP / IP, HTML, HTTP, HTTPS) represent examples in the art. Such standards are periodically superseded by faster or more efficient equivalents with substantially the same functionality. Therefore, alternative standards and protocols having the same or similar functionality as those disclosed herein are considered their equivalents.

[0178] In one embodiment, the components of the bicycle described herein will communicate with each other. In the case of wireless communication, the components will initially be paired to allow secure communication between the components on the bicycle without interference from devices not associated with the system. Next, one or more of the components may be paired with a separate device such as a computer, tablet, or telephone. This pairing device can provide a user interface to allow the user to communicate with the components on the bicycle (e.g., system control unit 150). Examples of communication include updating firmware, setting variables, and running diagnostic tools and analyses.

[0179] According to various embodiments of this disclosure, the methods described herein can be implemented using software programs executable by a computer system, such as system control device 150. Furthermore, in exemplary, non-limiting embodiments, implementations may include distributed processing, component / object distributed processing, and parallel processing. Alternatively, virtual computer system processing may be constructed to implement one or more of the methods or functions described herein.

[0180] The methods and techniques described herein can be implemented using the hardware configuration described herein and one or more computer programs that provide instructions for the hardware. Computer programs (also called programs, software, software applications, scripts, or code) can be written in any form of programming language, including compiled or interpreted languages, and can be deployed in any form, including as standalone programs or as modules, components, subroutines, or other units suitable for use in a computing environment. A computer program does not necessarily correspond to a file in a file system. A program can be stored as part of a file that holds other programs or data (e.g., one or more scripts stored in a markup language document), in a single file dedicated to the program in question, or in multiple coordinating files (e.g., a file storing one or more modules, subroutines, or code portions). A computer program can be deployed to execute on a single computer or on multiple computers located in one location or distributed across multiple locations and interconnected by a communication network.

[0181] The processes and logic flows described in this specification can be executed by one or more programmable processors that execute one or more computer programs to perform functions by manipulating input data and generating outputs. The processes and logic flows can also be executed by special-purpose logic circuitry (e.g., field-programmable gate arrays (FPGAs) or application-specific integrated circuits (ASICs)), and the devices can also be implemented as special-purpose logic circuitry (e.g., field-programmable gate arrays (FPGAs) or application-specific integrated circuits (ASICs)).

[0182] As used in this application, the terms “circuit system” or “circuit” mean all of the following: (a) a purely hardware circuit implementation (such as an implementation in an analog and / or digital circuit system only); and (b) a combination of circuitry and software (and / or firmware), such as (if applicable): (i) a combination of processors, or (ii) a processor / software (including digital signal processors, software, and memory that work together to enable a device (such as a mobile phone or server) to perform various functions); and (c) a circuit, such as a microprocessor or a portion thereof, that requires software or firmware to operate, even if the software or firmware is not physically present.

[0183] This definition of "circuit system / circuit" applies to all uses of the term in this application, including its use in any claim. As another example, as used in this application, the term "circuit system / circuit" will also cover only the implementation of a processor (or processors) or a portion of a processor and its accompanying software and / or firmware. The term "circuit system / circuit" will also cover (e.g., and if applicable to elements of a particular claim) baseband integrated circuits or application processor integrated circuits for mobile computing devices or similar integrated circuits in servers, cellular network devices, or other network devices.

[0184] As an example, processors suitable for executing computer programs include both general-purpose and special-purpose microprocessors, as well as any one or more processors in any kind of digital computer. Typically, a processor receives instructions and data from read-only memory or random access memory, or both. The basic components of a computer are a processor for executing instructions and one or more memory devices for storing instructions and data. Typically, a computer also includes one or more mass storage devices (e.g., disks, magneto-optical disks, or optical disks) for storing data, or is operatively coupled to receive data from or transfer data to one or more mass storage devices (e.g., disks, magneto-optical disks, or optical disks), or both. However, a computer does not need to have such a device. Furthermore, a computer may be embedded in another device, such as a mobile phone, a personal digital assistant (“PDA”), a mobile audio player, a global positioning system (“GPS”) receiver, or a system control device 150, to name just a few. Computer-readable media suitable for storing computer program instructions and data include all forms of non-volatile memory, media, and memory devices, including: semiconductor memory devices such as EPROM, EEPROM, and flash memory devices; magnetic disks such as internal hard disks or removable disks; magneto-optical disks; and CD-ROM and DVD-ROM disks. The processor and memory may be supplemented by or incorporated into dedicated logic circuitry. In one embodiment, system control device 150 is integrated with a mobile phone, PDA, mobile audio player, GPS receiver, and wirelessly communicates with bicycle components to provide automatic mode control.

[0185] The illustrations of the embodiments described herein are intended to provide a general understanding of the structure of various embodiments. These illustrations are not intended as a complete description of all elements and features of devices and systems utilizing the structures or methods described herein. Many other embodiments will be apparent to those skilled in the art upon reading this disclosure. Other embodiments can be utilized and derived from this disclosure, such that structural and logical substitutions and changes can be made without departing from the scope of this disclosure. Furthermore, the illustrations are merely representative and may not be drawn to scale. Some scales in the illustrations may be exaggerated, while others may be minimized. Therefore, this disclosure and the accompanying drawings should be considered illustrative rather than restrictive.

[0186] While this specification contains numerous details, these details should not be construed as limiting the scope of the invention or the scope that may be claimed, but rather as descriptions of features specific to particular embodiments of the invention. Certain features described in the context of individual embodiments in this specification may also be implemented in combination in a single embodiment. Conversely, various features described in the context of a single embodiment may also be implemented individually or in any suitable sub-combination in multiple embodiments. Furthermore, although features may be described above as functioning in certain combinations, and even initially claimed to be so, one or more features from a claimed combination may be removed from the combination in some cases, and the claimed combination may be for sub-combinations or variations thereof.

[0187] Similarly, although operations and / or actions are depicted in the accompanying drawings and described herein in a specific order, this should not be construed as requiring such operations to be performed in the specific order shown or sequentially, or to perform all shown operations to achieve the desired result. In some cases, multitasking and parallel processing may be advantageous. Furthermore, the separation of various system components in the embodiments described above should not be construed as requiring this separation in all embodiments, and it should be understood that any described program components and systems can generally be integrated together in a single software product or packaged into multiple software products.

[0188] One or more embodiments of this disclosure may be referred to herein individually and / or collectively by the term "invention," merely for convenience and not intended to actively limit the scope of this application to any particular invention or inventive concept. Furthermore, although specific embodiments have been shown and described herein, it should be understood that any subsequent arrangements designed to achieve the same or similar purpose may replace the specific embodiments shown. This disclosure is intended to cover any and all subsequent adaptations or variations of the various embodiments. Combinations of the above embodiments, as well as other embodiments not specifically described herein, will be apparent to those skilled in the art upon reading the specification.

[0189] This abstract of the disclosure is provided to comply with 37 CFR § 1.72(b) and is submitted in the opinion that the abstract will not be used to interpret or limit the scope or meaning of the claims. Additionally, in the foregoing detailed description, various features may be combined together or described in a single embodiment for the purpose of simplifying the disclosure. This disclosure should not be construed as reflecting an intention that the claimed embodiments require more features than expressly recited in each claim. Rather, as reflected in the appended claims, the subject matter of the invention may encompass fewer features than any of those in the disclosed embodiments. Therefore, the appended claims are incorporated into the detailed description, wherein each claim independently represents a separate claimed subject matter.

[0190] It is intended that the foregoing detailed description be considered illustrative rather than restrictive, and it should be understood that the appended claims, including all equivalents, are intended to define the scope of the invention. The claims should not be construed as limited to the described order or elements unless otherwise stated. Therefore, all embodiments falling within the scope and spirit of the appended claims and their equivalents are claimed as part of the invention.

[0191] Cross-references to related applications

[0192] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 286370, filed December 6, 2021, and U.S. Patent Application No. 18 / 073775, filed December 2, 2022, the entire contents of which are incorporated herein by reference.

Claims

1. A torque sensor for a bicycle, the torque sensor comprising: A support member, which is configured to surround the device of the bicycle such that the support member and the device of the bicycle are separated by an air gap; An excitation coil, which is supported by the support member; as well as A sensing coil is supported by the support member at a distance in the axial direction away from the excitation coil. The excitation coil is configured to induce a voltage in the sensing coil via the bicycle's device when the support is positioned around the device of the bicycle, and the induced voltage is related to the torque in the device. Wherein, the bicycle is an electric bicycle, and the device of the bicycle is a clutch mechanism of the electric bicycle, the clutch mechanism including a crank axle as an inner ring, an output ring as an outer ring, and an element disposed between the inner ring and the outer ring of the clutch mechanism, the element being configured to cause the inner ring and the outer ring to rotate together when the inner ring rotates in a first rotational direction, and to allow the inner ring to rotate relative to the outer ring when the inner ring rotates in a second rotational direction opposite to the first rotational direction or when the outer ring rotates faster than the inner ring, and The support member is a hollow cylinder that can be arranged around a portion of the clutch mechanism of the electric bicycle, and The sensing coil of the torque sensor is positioned radially relative to the element in the radial direction of the clutch mechanism, around the inner and outer rings of the clutch mechanism.

2. The torque sensor according to claim 1, wherein the torque sensor further comprises a protective cover covering the excitation coil and the sensing coil.

3. The torque sensor according to claim 2, wherein the torque sensor further comprises a second sensing coil, and the cover further covers the second sensing coil.

4. The torque sensor according to claim 1, wherein, The support member includes a first groove and a second groove extending circumferentially around the outer side of the support member, the second groove being offset relative to the first groove along the axial direction of the support member, and The excitation coil is disposed in the first groove, and the sensing coil is disposed in the second groove.

5. The torque sensor according to claim 4, wherein, The sensing coil is a first sensing coil, and the axial direction is a first axial direction. The support member further includes a third groove extending circumferentially around its outer side, the third groove being offset relative to the first groove along a second axial direction of the support member, the second axial direction being opposite to the first axial direction of the support member. The torque sensor further includes a second sensing coil, which is arranged around and supported by the support member, and is disposed within the third groove.

6. The torque sensor according to claim 5, wherein, The excitation coil is the first excitation coil. The support member further includes a fourth groove extending circumferentially around the outer side of the support member, the fourth groove being offset relative to the first groove along the first axial direction or the second axial direction; and The torque sensor further includes a second excitation coil, which is arranged around and supported by the support member, and is disposed within the fourth groove.

7. The torque sensor according to claim 6, wherein, The first excitation coil and the first sensing coil form a first magnetic circuit, and the second excitation coil and the second sensing coil form a second magnetic circuit. The support member has a first portion for accommodating the first magnetic circuit and a second portion for accommodating the second magnetic circuit. The torque sensor further includes a protective cover that separates the first portion and the second portion of the support member, thereby separating the first magnetic circuit and the second magnetic circuit. The protective cover covers at least a portion of the support member.

8. The torque sensor according to claim 7, wherein, The protective cover at least covers the first groove, the second groove, the third groove, and the fourth groove, and The protective cover is made of ferrite.

9. The torque sensor according to claim 8, wherein, The protective cover is the first protective cover. The torque sensor further includes a second shield that at least partially covers the first shield, and The second protective cover is made of a non-ferromagnetic conductive material.

10. The torque sensor according to claim 1, wherein, The support is formed of multiple stacked printed circuit boards, and The excitation coil is formed on a first printed circuit board in a plurality of stacked printed circuit boards, or on and in the first printed circuit board, and the sensing coil is formed on a second printed circuit board in a plurality of stacked printed circuit boards, or on and in the second printed circuit board.

11. A clutch mechanism for an electric bicycle, the clutch mechanism comprising: The crankshaft serves as the inner ring; As the output ring of the outer ring, the outer ring can be rotatably positioned around the inner ring; An element disposed between the inner ring and the outer ring, the element being configured to cause the inner ring and the outer ring to rotate together when the inner ring rotates in a first rotational direction, and to allow the inner ring to rotate relative to the outer ring when the inner ring rotates in a second rotational direction opposite to the first rotational direction or when the outer ring rotates faster than the inner ring; and A torque sensor, wherein the sensing coil of the torque sensor is positioned radially opposite to the element in the radial direction of the clutch mechanism around the inner and outer rings, such that the torque sensor and the rings are separated by an air gap, the torque sensor being configured to measure torque within the clutch mechanism and comprising: A housing that can be disposed around the ring; An excitation coil, which is disposed around and supported by the housing; As a first sensing coil of the sensing coil, the first sensing coil is disposed around the housing at a first distance away from the excitation coil in a first axial direction of the housing and is supported by the housing; and A second sensing coil is disposed around and supported by the housing at a second distance away from the excitation coil in a second axial direction of the housing, wherein the second axial direction of the housing is opposite to the first axial direction of the housing. The excitation coil is configured to induce a voltage in the first sensing coil via the outer ring, and the induced voltage is related to the torque in the clutch mechanism.

12. The clutch mechanism according to claim 11, wherein, The ring is the outer ring, and the outer ring is the axis of the chain link of the electric bicycle.

13. The clutch mechanism according to claim 11, wherein, The excitation coil is the first excitation coil. The torque sensor further includes: A second excitation coil is disposed around and supported by the housing, and the second excitation coil is offset relative to the first excitation coil in the second axial direction.

14. The clutch mechanism according to claim 13, wherein, The housing includes a first groove, a second groove, a third groove, and a fourth groove extending circumferentially around the outer side of the housing, the first groove, the second groove, the third groove, and the fourth groove being offset relative to each other along the first axial direction of the housing, and The first excitation coil is disposed in the first groove, the first sensing coil is disposed in the second groove, the second sensing coil is disposed in the third groove, and the second excitation coil is disposed in the fourth groove.

15. The clutch mechanism according to claim 14, wherein, The torque sensor also includes a cover that separates the first excitation coil and the first sensing coil from the second sensing coil and the second excitation coil, and covers the first groove, the second groove, the third groove, and the fourth groove.

16. The clutch mechanism according to claim 15, wherein, The shield is a first shield and is made of a first material, and The torque sensor further includes a second shield that partially covers the first shield and is made of a second material that is different from the first material.

17. The clutch mechanism according to claim 16, wherein, The voltage mentioned is the first voltage. Wherein, the second excitation coil is configured to induce a second voltage in the second sensing coil via the coil, and The clutch mechanism further includes a processor configured to determine the torque in the clutch mechanism based on the sensed first voltage and the sensed second voltage.

18. The clutch mechanism according to claim 17, wherein, The processor is also configured to determine the difference between the sensed first voltage and the sensed second voltage, and The processor is configured to determine the torque in the clutch mechanism based on the sensed first voltage and the sensed second voltage, including that the processor is configured to determine the torque in the clutch mechanism based on the difference between the determined sensed first voltage and the sensed second voltage.

19. A torque sensor for a bicycle, the torque sensor comprising: A support member is provided around the clutch mechanism of the bicycle, the clutch mechanism including a crank axle as an inner ring, an output ring as an outer ring, and an element disposed between the inner ring and the outer ring of the clutch mechanism, the element being configured to cause the inner ring and the outer ring to rotate together when the inner ring rotates in a first rotational direction, and to allow the inner ring to rotate relative to the outer ring when the inner ring rotates in a second rotational direction opposite to the first rotational direction or when the outer ring rotates faster than the inner ring; Excitation coil, the excitation coil being supported by the support member; and A sensing coil is supported by the support member at a distance in the axial direction away from the excitation coil. The excitation coil is configured such that when the support is positioned around the clutch mechanism of the bicycle, a voltage is induced in the sensing coil via the clutch mechanism of the bicycle, and the induced voltage is related to the torque in the clutch mechanism. The sensing coil is arranged circumferentially around the entire inner and outer rings, and is configured to sense current related to torque within the rings. The sensing coil of the torque sensor is positioned radially relative to the element in the radial direction of the clutch mechanism, around the inner and outer rings of the clutch mechanism.

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