Continuously variable transmission for electric bicycles

Abstract

A compact size CVT in a mid-drive motor assembly for an electric bicycle includes a planetary gear system coupled to a motor, each coaxial along a longitudinal axis through a crankshaft, the crankshaft insertable through the planetary gear system and the motor. A dual gear box CVT includes an assist subassembly having an assist motor and an assist gear box, and a shift subassembly having a shift motor and a shift gear box, for providing power output of the assist subassembly and the shift subassembly, and optional user input from the crankshaft. A triple gear box CVT includes an assist subassembly having an assist motor and an assist gear box, a shift subassembly having a shift motor and a shift gear box, and a planetary gear system for providing power output of the assist subassembly and the shift subassembly, and optional user input from the crankshaft. Controlled power from the shift and assist motor outputs facilitates CVT functionality.

Description

[0001] Cross-references to related applications

[0002] This application claims priority to U.S. Provisional Patent Application Serial No. 63 / 605,350, filed December 1, 2023, the entire contents of which are incorporated herein by reference. Technical Field

[0003] This disclosure relates to a transmission for an electric bicycle, and more particularly to a continuously variable transmission (CVT) for an electric bicycle in a compact mid-mounted drive motor assembly. Background Technology

[0004] In the e-bike industry, continuously variable transmission (CVT) technology presents challenges due to the unique constraints of e-bikes. Typically, achieving the desired reduction ratio in a transmission used in an e-bike requires multiple gear systems, each including a spur gear system and / or a planetary gear system, resulting in a larger package size. This increases the cost and complexity of the transmission and adds to the weight of the e-bike coupled with the electric transmission.

[0005] Previous attempts to adapt automatic CVT mechanisms from automobiles to e-bikes have faced several drawbacks. For example, a major disadvantage is that CVT technology is traditionally designed to operate most efficiently at high speeds, while bicycles typically operate at lower speeds. This necessitates that the CVT installed on an e-bike first increase speed to achieve optimal efficiency, and then decrease the e-bike's speed to achieve the desired continuous shifting operation. One way to offset this requirement is to incorporate numerous gear sets within the CVT, resulting in a larger overall size. Furthermore, when considering the desired speed ratios of an e-bike, if a motor is used to drive the e-bike, a typical CVT might require multiple spur gear system shafts or multi-stage planetary gear systems to output the necessary ratios, similarly increasing the CVT's package size.

[0006] Therefore, known CVT technology in electric bicycles involves complex gear arrangements and large package dimensions. Furthermore, known CVT technology in electric bicycles requires additional shaft or gear systems to achieve the desired speed ratio, further increasing the package size. Summary of the Invention

[0007] Therefore, there is a need for a compact CVT for electric bicycles that can shift gears in pedal assist mode. Embodiments of this disclosure relate to a compact CVT for electric bicycles in a mid-drive motor package. This disclosure addresses the aforementioned problem by employing a planetary gear system that draws input power from multiple motors. Output power is obtained from the planet carrier of the planetary gear system, a combination of power received from one or more motors and optionally input from the crankshaft, resulting in continuous speed variations to provide CVT technology for the electric bicycle. Embodiments of this disclosure also relate to the use of a harmonic gear system, which offers advantages through easily achievable large gear ratios. The implementation of the harmonic gear system significantly reduces the overall package size of the mid-drive motor package, addressing package constraints in electric bicycle design. Embodiments of this disclosure also relate to incorporating the use of an axial flux motor into the mid-drive motor package. The use of an axial flux motor allows for a feasible and efficient package solution, enabling the successful implementation of CVT technology in electric bicycles.

[0008] One aspect of embodiments of this disclosure is providing a planetary gear system in a CVT. In some embodiments, the input speed of the ring gear or sun gear of the planetary gear system, and the speed of the planet carrier in the planetary gear system, are variable. The speed of the planet carrier can be controlled by the input speed of the ring gear. As a result, the speed ratio is not fixed but continuously variable. Embodiments of this disclosure also relate to an axial flux motor in a CVT. In some embodiments, the axial flux motor includes a centrally hollow design, allowing direct placement on the axle or crankshaft without requiring multiple shafts, resulting in a compact package and making the mid-drive motor assembly more space-saving. Embodiments of this disclosure also relate to a planetary gear system that uses multiple gears to transmit power, thereby enabling CVT shifting with smooth changes in gear ratio while maintaining a less complex structure and a more compact package. Embodiments of this disclosure also relate to a harmonic gear system that allows for large speed ratios while maintaining a compact size to efficiently achieve a wide range of speed regulation. In this respect, the single-axis construction of the planetary gear system and motor (i.e., the planetary gear system and motor are coaxial around a longitudinal axis defined by a crankshaft inserted through or positioned through the planetary gear system and motor) enables a compact package while providing CVT operation and a large speed ratio.

[0009] Another aspect of the embodiments of this disclosure is to provide a three-gearbox CVT. The three-gearbox CVT includes an auxiliary sub-assembly having an auxiliary motor for providing auxiliary power and an auxiliary gearbox for the auxiliary motor, the auxiliary gearbox being responsible for transmitting the auxiliary power from the auxiliary motor. The three-gearbox CVT further includes a shift sub-assembly having a shift motor for providing shift power for shifting gears in the CVT and a shift gearbox for facilitating shifting operation. The three-gearbox CVT also includes a planetary gear system that receives input from both the auxiliary sub-assembly and the shift sub-assembly, and generates power as a transmission output via an output sprocket. The planetary gear system driven by the auxiliary sub-assembly and / or the shift sub-assembly enables continuous variation of the speed output. In this respect, the three-gearbox CVT of this disclosure provides versatility and control over the reducer speed ratio, thereby enhancing the overall performance and efficiency of the electric bicycle.

[0010] Another aspect of the embodiments of this disclosure is to provide a dual-gearbox CVT. The dual-gearbox CVT includes an auxiliary sub-assembly having an auxiliary motor for providing auxiliary power to the CVT, and an auxiliary gearbox for the auxiliary motor, the auxiliary gearbox being responsible for transmitting the auxiliary power from the auxiliary motor. The dual-gearbox CVT further includes a shift sub-assembly having a shift motor for providing shift power for shifting gears in the CVT, and a shift gearbox for the shift motor to facilitate shifting operation. The shift sub-assembly generates power as a transmission output from the auxiliary power and / or the shift power via an output sprocket, wherein the power allows for continuous variation in speed output. In this respect, the dual-gearbox CVT of this disclosure provides versatility and control over the reducer speed ratio, thereby enhancing the overall performance and efficiency of the electric bicycle.

[0011] Another aspect of the embodiments of this disclosure is to provide an electric bicycle. The electric bicycle includes a mid-drive motor assembly having an auxiliary sub-assembly and a shifting sub-assembly. Optionally, in addition to the auxiliary sub-assembly and shifting sub-assembly, the mid-drive motor assembly also includes a planetary gear system. The mid-drive motor assembly is communicated with the hub of a wheel via a belt or chain. The electric bicycle includes a battery pack for powering the mid-drive motor assembly. The electric bicycle includes a control system operable to monitor and / or control one or more aspects of the electric bicycle, including battery pack input / output, auxiliary motor input / output, and / or shifting motor input / output.

[0012] Another aspect of embodiments of this disclosure is to provide auxiliary subassemblies and shift subassemblies within a CVT for a mid-drive motor assembly, which contribute to the continuous variability or mechanical advantages of the speed ratio of the mid-drive motor assembly. In a three-gear CVT, the combination of the auxiliary subassemblies and shift subassemblies continuously changes the speed ratio of the planetary gear system by rotating the output of the planetary gear system at a variable speed (i.e., which is in communication with the output sprocket of the mid-drive motor assembly). Therefore, even with a fixed number of teeth and gears, the speed ratio of the planetary gear system is continuously variable. Similarly, in a two-gear CVT, the combination of the auxiliary subassemblies and shift subassemblies continuously changes the speed ratio between the user input and the modified shift power transmitted to the CVT output.

[0013] A first aspect of this disclosure is to provide a CVT for a mid-drive motor assembly in an electric bicycle. The CVT includes an auxiliary subassembly having an auxiliary motor operable to generate auxiliary power; and an auxiliary gearbox operable to receive auxiliary power via a first set of auxiliary planetary gears and to convert the auxiliary power via a second set of auxiliary planetary gears to generate modified auxiliary power. The CVT includes a shift subassembly having a shift motor operable to generate shift power; and a shift gearbox operable to receive shift power via a first set of shift planetary gears and to convert the shift power via a second set of shift planetary gears to generate modified shift power. The CVT includes a planetary gear system operable to receive modified auxiliary power from the auxiliary subassembly and to provide the modified auxiliary power to the output of the mid-drive motor assembly. The planetary gear system is also operable to receive modified shift power from the shift subassembly and to provide the modified shift power to the output of the mid-drive motor assembly. The auxiliary motor, the auxiliary gearbox, the shift motor, the shift gearbox, and the planetary gear system are coaxial along a longitudinal axis passing through the auxiliary subassembly, the shift assembly, and the planetary gear system.

[0014] The first aspect of the CVT may optionally include a clutch operable to transmit modified auxiliary power from the auxiliary gearbox to the planetary gear system.

[0015] The CVT of the first aspect may include one or more of those in the previous embodiments, and optionally, the auxiliary gearbox includes: a first auxiliary ring gear operable to engage a first set of auxiliary planetary gears, wherein the first auxiliary ring gear is fixedly positioned within the continuously variable transmission; a second auxiliary ring gear operable to engage a second set of auxiliary planetary gears; and an auxiliary planet carrier to which the first set of auxiliary planetary gears and the second set of auxiliary planetary gears are coupled. The auxiliary gearbox receives auxiliary power from the auxiliary motor via the auxiliary planet carrier. The auxiliary gearbox provides modified auxiliary power via the second auxiliary ring gear.

[0016] The CVT of the first aspect may include one or more of those in the previous embodiments, and optionally, the shift gearbox includes: a first shift ring gear operable to engage a first set of shift planetary gears, wherein the first shift ring gear is fixedly positioned within the continuously variable transmission; a second shift ring gear operable to engage a second set of shift planetary gears; and a shift planetary carrier to which the first set of shift planetary gears and the second set of shift planetary gears are coupled. The shift gearbox receives shift power from the shift motor via the shift planetary carrier. The shift gearbox provides modified shift power via the second shift ring gear.

[0017] The CVT of the first aspect may include one or more of those in the previous embodiments, and optionally, wherein the planetary gear system includes: a sun gear operable to receive modified auxiliary power provided by the auxiliary gearbox; a ring gear operable to receive modified shift power provided by the shift gearbox; and a planet carrier, a set of planetary gears coupled to the planet carrier. The set of planetary gears is operable to engage the sun gear and transmit the modified auxiliary power via the planet carrier to the output of the mid-drive motor assembly. The set of planetary gears is operable to engage the ring gear and transmit the modified shift power via the planet carrier to the output of the mid-drive motor assembly.

[0018] The CVT of the first aspect may include one or more of those in the previous embodiments, and optionally, wherein the longitudinal axis is defined along the length of the crankshaft of the mid-drive motor assembly, wherein the crankshaft is inserted through or positioned through the auxiliary motor and the auxiliary gearbox of the auxiliary subassembly, the shift motor and the shift gearbox of the shift subassembly, and the planetary gear system, wherein the sun gear is operable to receive crankshaft power generated in the crankshaft, and wherein the sun gear is operable to combine the received crankshaft power and the received modified auxiliary power before engaging with the set of planetary gears.

[0019] The CVT of the first aspect may include one or more of those in the previous embodiments, and optionally includes a clutch operable to transmit crankshaft power from the crankshaft to the sun gear of the planetary gear system.

[0020] The CVT of the first aspect may include one or more of those in the previous embodiments, and optionally, wherein a reference plane may be defined between the auxiliary subassembly and the shift subassembly, wherein, within the auxiliary subassembly, the auxiliary motor is positioned outward relative to the reference plane and the auxiliary gearbox is positioned inward relative to the reference plane, wherein, within the shift subassembly, the shift gearbox is positioned outward relative to the reference plane and the shift motor is positioned inward relative to the reference plane, and wherein the planetary gear system is positioned outward relative to the reference plane of the shift subassembly.

[0021] The CVT of the first aspect may include one or more of those in the previous embodiments, and optionally, the auxiliary motor and the shift motor are axial flux motors, and the output of the mid-drive motor assembly is an output sprocket.

[0022] A second aspect of embodiments of this disclosure is to provide a CVT for a mid-drive motor assembly in an electric bicycle. The CVT includes an auxiliary subassembly having an auxiliary motor operable to generate auxiliary power; and an auxiliary gearbox operable to receive auxiliary power via a first set of auxiliary planetary gears and to convert the auxiliary power via a second set of auxiliary planetary gears to generate modified auxiliary power. The CVT includes a shift subassembly having a shift motor operable to generate shift power; and a shift gearbox operable to receive shift power via a first set of shift planetary gears and to convert the shift power via a second set of shift planetary gears to generate modified shift power. The shift subassembly is operable to provide the modified shift power to the output of the mid-drive motor assembly. The shift subassembly is further operable to receive the modified auxiliary power and provide the modified auxiliary power to the output of the mid-drive motor assembly. The auxiliary motor, the auxiliary gearbox, the shift motor, and the shift gearbox are coaxial along a longitudinal axis passing through the auxiliary subassembly and the shift subassembly.

[0023] The second aspect of the CVT may optionally include, wherein the auxiliary gearbox comprises: a first auxiliary ring gear operable to engage a first set of auxiliary planetary gears, wherein the first auxiliary ring gear is fixedly positioned within the continuously variable transmission; a second auxiliary ring gear operable to engage a second set of auxiliary planetary gears; and an auxiliary planetary carrier to which the first set of auxiliary planetary gears and the second set of auxiliary planetary gears are coupled. The auxiliary gearbox receives auxiliary power from the auxiliary motor via the auxiliary planetary carrier. The auxiliary gearbox provides modified auxiliary power via the second auxiliary ring gear.

[0024] The second aspect of the CVT may include one or more of those in the previous embodiments, and optionally, the shift gearbox includes: a first shift ring gear operable to engage with a first set of shift planetary gears; a second shift ring gear operable to engage with a second set of shift planetary gears; and a shift planetary carrier to which the first set of shift planetary gears and the second set of shift planetary gears are coupled. The shift gearbox receives shift power from the shift motor via the shift planetary carrier. The shift gearbox provides modified shift power via the second shift ring gear. The second shift ring gear is operable to provide modified auxiliary power and modified shift power to the output of the mid-drive motor assembly.

[0025] The second aspect of the CVT may include one or more of those in the previous embodiments, and optionally includes a clutch operable to transmit modified auxiliary power from the auxiliary gearbox to the second shift ring gear.

[0026] The second aspect of the CVT may include one or more of those in the previous embodiments, and optionally, wherein the longitudinal axis is defined along the length of the crankshaft of the mid-drive motor assembly, wherein the crankshaft is inserted through or positioned through the auxiliary motor and the auxiliary gearbox of the auxiliary subassembly, and the shift motor and the shift gearbox of the shift subassembly. The first shift ring gear is operable to receive crankshaft power generated in the crankshaft. The shift planetary carrier is operable to combine the received crankshaft power and shift power.

[0027] The second aspect of the CVT may include one or more of those in the previous embodiments, and optionally include a clutch operable to transmit crankshaft power from the crankshaft to the first shift ring gear.

[0028] The second aspect of the CVT may include one or more of those in the previous embodiments, and optionally, wherein the reference plane may be defined between the auxiliary sub-assembly and the shift sub-assembly, wherein, within the auxiliary sub-assembly, the auxiliary motor is positioned outward relative to the reference plane and the auxiliary gearbox is positioned inward relative to the reference plane within the auxiliary sub-assembly, and wherein, within the shift sub-assembly, the shift motor is positioned outward relative to the reference plane and the shift gearbox is positioned inward relative to the reference plane.

[0029] The second aspect of the CVT may include one or more of those in the previous embodiments, and optionally, the auxiliary motor and the shift motor are axial flux motors, and the output of the mid-drive motor assembly is an output sprocket.

[0030] A third aspect of the embodiments of this disclosure is to provide a mid-drive motor assembly for an electric bicycle. The mid-drive motor assembly includes a CVT. The CVT includes an auxiliary subassembly having an auxiliary motor operable to generate auxiliary power; and an auxiliary gearbox operable to receive auxiliary power via a first set of auxiliary planetary gears and to convert the auxiliary power via a second set of auxiliary planetary gears to generate modified auxiliary power. The CVT includes a shift subassembly having a shift motor operable to generate shift power; and a shift gearbox operable to receive shift power via a first set of shift planetary gears and to convert the shift power via a second set of shift planetary gears to generate modified shift power. The mid-drive motor assembly includes a crankshaft inserted through or positioned through the auxiliary motor, the auxiliary gearbox, the shift motor, and the shift gearbox, wherein the auxiliary subassembly and the shift subassembly are coaxial along a longitudinal axis passing through the auxiliary motor, the auxiliary gearbox, the shift motor, and the shift gearbox, and wherein the longitudinal axis is defined along the length of the crankshaft. The mid-drive motor assembly includes an output sprocket operable to receive modified auxiliary power and modified shift power.

[0031] The mid-drive motor assembly in the third aspect may optionally include a planetary gear system operable to receive modified auxiliary power from the auxiliary subassembly and provide the modified auxiliary power to the output sprocket, the planetary gear system being further operable to receive modified shift power from the shift subassembly and provide the modified shift power to the output sprocket. The auxiliary motor and auxiliary gearbox of the auxiliary subassembly, the shift motor and shift gearbox of the shift subassembly, and the planetary gear system are coaxial along a longitudinal axis passing through the auxiliary subassembly, the shift subassembly, and the planetary gear system.

[0032] The mid-drive motor assembly of the third aspect may include one or more of those in the previous embodiments, and optionally, the shift sub-assembly is operable to provide modified shift power to the output sprocket, and the shift sub-assembly is operable to receive modified auxiliary power and provide modified auxiliary power to the output sprocket.

[0033] A fourth aspect of embodiments of this disclosure is to provide a CVT for a mid-drive motor assembly. The CVT includes an auxiliary subassembly and a shift subassembly. The auxiliary subassembly includes an auxiliary motor operable to generate auxiliary power, and an auxiliary gearbox operable to receive auxiliary power via a first set of auxiliary planetary gears and to convert the auxiliary power via a second set of auxiliary planetary gears to generate modified auxiliary power. The shift subassembly includes a shift motor operable to generate shift power, and a shift gearbox operable to receive shift power via a first set of shift planetary gears and to convert the shift power via a second set of shift planetary gears to generate modified shift power. The modified auxiliary power and modified shift power are provided to the output sprocket of the mid-drive motor assembly. The auxiliary motor, the auxiliary gearbox, the shift motor, and the shift gearbox are coaxial along a longitudinal axis passing through the auxiliary subassembly and the shift subassembly.

[0034] The fourth aspect of the CVT may include, optionally, wherein the shift sub-assembly is operable to provide modified shift power to the output sprocket, and wherein the shift sub-assembly is operable to receive modified auxiliary power and provide modified auxiliary power to the output sprocket.

[0035] The CVT of the fourth aspect may include one or more of those in the previous embodiments, and optionally, the auxiliary gearbox includes: a first auxiliary ring gear operable to engage with a first set of auxiliary planetary gears, wherein the first auxiliary ring gear is fixedly positioned within the CVT; a second auxiliary ring gear operable to engage with a second set of auxiliary planetary gears; and an auxiliary planet carrier to which the first set of auxiliary planetary gears and the second set of auxiliary planetary gears are coupled, wherein the auxiliary gearbox receives auxiliary power from the auxiliary motor via the auxiliary planet carrier, and wherein the auxiliary gearbox provides modified auxiliary power via the second auxiliary ring gear.

[0036] The fourth aspect of the CVT may include one or more of those in the previous embodiments, and optionally, the shift gearbox includes: a first shift ring gear operable to engage with a first set of shift planetary gears; a second shift ring gear operable to engage with a second set of shift planetary gears; and a shift planetary carrier to which the first set of shift planetary gears and the second set of shift planetary gears are coupled, wherein the shift gearbox receives shift power from the shift motor via the shift planetary carrier, wherein the shift gearbox provides modified shift power via the second shift ring gear, and wherein the second shift ring gear is operable to provide modified auxiliary power and modified shift power to the output sprocket.

[0037] The CVT of the fourth aspect may include one or more of those in the previous embodiments, and optionally include a clutch operable to transmit modified auxiliary power from the auxiliary gearbox to the second shift ring gear.

[0038] The CVT of the fourth aspect may include one or more of those in the previous embodiments, and optionally, wherein the longitudinal axis is defined along the length of the crankshaft of the mid-drive motor assembly, wherein the crankshaft is positioned through the auxiliary motor and the auxiliary gearbox of the auxiliary subassembly and the shift motor and the shift gearbox of the shift subassembly, wherein the first shift ring gear is operable to receive user input from the crankshaft, and wherein the shift planetary carrier is operable to combine the received user input and shift power.

[0039] The CVT of the fourth aspect may include one or more of those in the previous embodiments, and optionally include a clutch operable to transmit user input from the crankshaft to the first shift ring gear.

[0040] The fourth aspect of the CVT may include one or more of those in the previous embodiments, and optionally includes a planetary gear system coupled to the output sprocket, wherein the planetary gear system is operable to receive modified auxiliary power from the auxiliary subassembly and to provide the modified auxiliary power to the output sprocket of the mid-drive motor assembly, wherein the planetary gear system is operable to receive modified shift power from the shift subassembly and to provide the modified shift power to the output sprocket of the mid-drive motor assembly, and wherein the auxiliary motor, the auxiliary gearbox, the shift motor, the shift gearbox, and the planetary gear system are coaxial along the longitudinal axis.

[0041] The CVT of the fourth aspect may include one or more of those in the previous embodiments, and optionally include a clutch operable to transmit modified auxiliary power from the auxiliary gearbox to the planetary gear system.

[0042] The CVT of the fourth aspect may include one or more of those in the previous embodiments, and optionally, the auxiliary gearbox includes: a first auxiliary ring gear operable to engage with a first set of auxiliary planetary gears, wherein the first auxiliary ring gear is fixedly positioned within the CVT; a second auxiliary ring gear operable to engage with a second set of auxiliary planetary gears; and an auxiliary planet carrier to which the first set of auxiliary planetary gears and the second set of auxiliary planetary gears are coupled, wherein the auxiliary gearbox receives auxiliary power from the auxiliary motor via the auxiliary planet carrier, and wherein the auxiliary gearbox provides modified auxiliary power via the second auxiliary ring gear.

[0043] The CVT of the fourth aspect may include one or more of those in the previous embodiments, and optionally, the shift gearbox includes: a first shift ring gear operable to engage with a first set of shift planetary gears, wherein the first shift ring gear is fixedly positioned within the CVT; a second shift ring gear operable to engage with a second set of shift planetary gears; and a shift planetary carrier to which the first set of shift planetary gears and the second set of shift planetary gears are coupled, wherein the shift gearbox receives shift power from the shift motor via the shift planetary carrier, and wherein the shift gearbox provides modified shift power via the second shift ring gear.

[0044] The CVT of the fourth aspect may include one or more of those in the previous embodiments, and optionally, wherein the planetary gear system includes: a sun gear operable to receive modified auxiliary power provided by the auxiliary gearbox; a ring gear operable to receive modified shift power provided by the shift gearbox; and a planet carrier, a set of planetary gears coupled to the planet carrier, wherein the set of planetary gears is operable to engage the sun gear and transmit modified auxiliary power via the planet carrier to the output of the mid-drive motor assembly, and wherein the set of planetary gears is operable to engage the ring gear and transmit modified shift power via the planet carrier to the output of the mid-drive motor assembly.

[0045] The CVT of the fourth aspect may include one or more of those in the previous embodiments, and optionally, wherein the longitudinal axis is defined along the length of the crankshaft of the mid-drive motor assembly, wherein the crankshaft is positioned through the auxiliary motor and auxiliary gearbox of the auxiliary subassembly, the shift motor and shift gearbox of the shift subassembly, and the planetary gear system, wherein the sun gear is operable to receive user input from the crankshaft, and wherein the sun gear is operable to combine the received user input and the received modified auxiliary power before engaging with the set of planetary gears.

[0046] The CVT of the fourth aspect may include one or more of those in the previous embodiments, and optionally include a clutch operable to transmit user input from the crankshaft to the sun gear of the planetary gear system.

[0047] A fifth aspect of this disclosure is to provide a mid-drive motor assembly. The mid-drive motor assembly includes a CVT having an auxiliary subassembly and a shift subassembly. The auxiliary subassembly includes an auxiliary motor operable to generate auxiliary power; and an auxiliary gearbox operable to receive auxiliary power via a first set of auxiliary planetary gears and to convert the auxiliary power via a second set of auxiliary planetary gears to generate modified auxiliary power. The shift subassembly includes a shift motor operable to generate shift power; and a shift gearbox operable to receive shift power via a first set of shift planetary gears and to convert the shift power via a second set of shift planetary gears to generate modified shift power. The mid-drive motor assembly includes a crankshaft positioned through the auxiliary motor, the auxiliary gearbox, the shift motor, and the shift gearbox, wherein the auxiliary subassembly and the shift subassembly are coaxial along a longitudinal axis passing through the auxiliary motor, the auxiliary gearbox, the shift motor, and the shift gearbox, and wherein the longitudinal axis is defined along the length of the crankshaft. The mid-drive motor assembly includes an output sprocket operable to receive modified auxiliary power and modified shift power.

[0048] The fifth aspect of the mid-drive motor assembly may include, optionally, wherein the shift sub-assembly is operable to provide modified shift power to the output sprocket, and wherein the shift sub-assembly is further operable to receive modified auxiliary power and provide modified auxiliary power to the output sprocket.

[0049] The mid-drive motor assembly of the fifth aspect may include one or more of those in the previous embodiments, and optionally, wherein the CVT includes a planetary gear system operable to receive modified auxiliary power from the auxiliary subassembly and to provide the modified auxiliary power to the output sprocket, the planetary gear system also operable to receive modified shift power from the shift subassembly and to provide the modified shift power to the output sprocket, wherein the auxiliary motor and auxiliary gearbox of the auxiliary subassembly, the shift motor and shift gearbox of the shift subassembly, and the planetary gear system are coaxial along a longitudinal axis passing through the auxiliary subassembly, the shift subassembly, and the planetary gear system.

[0050] A sixth aspect of the present disclosure is to provide an electric bicycle. The electric bicycle includes a mid-drive motor assembly. The mid-drive motor assembly includes a CVT having an auxiliary subassembly and a shift subassembly. The auxiliary subassembly includes an auxiliary motor operable to generate auxiliary power; and an auxiliary gearbox operable to receive auxiliary power and generate modified auxiliary power. The shift subassembly includes a shift motor operable to generate shift power; and a shift gearbox operable to receive shift power and generate modified shift power. The mid-drive motor assembly includes a crankshaft positioned through the auxiliary motor, the auxiliary gearbox, the shift motor, and the shift gearbox, wherein the auxiliary subassembly and the shift assembly are coaxial along a longitudinal axis passing through the auxiliary motor, the auxiliary gearbox, the shift motor, and the shift gearbox, and wherein the longitudinal axis is defined along the length of the crankshaft. The mid-drive motor assembly includes an output sprocket operable to receive modified auxiliary power and modified shift power.

[0051] The electric bicycle of the sixth aspect may optionally include, wherein the shift assembly is operable to provide modified shift power to the output sprocket, and wherein the shift assembly is also operable to receive modified auxiliary power and provide modified auxiliary power to the output sprocket.

[0052] The electric bicycle of the sixth aspect may include one or more of those in the previous embodiments, and optionally, the CVT of the mid-drive motor assembly includes a planetary gear system operable to receive modified auxiliary power from the auxiliary subassembly and to provide the modified auxiliary power to the output sprocket, the planetary gear system also operable to receive modified shift power from the shift subassembly and to provide the modified shift power to the output sprocket, wherein the auxiliary motor and auxiliary gearbox of the auxiliary subassembly, the shift motor and shift gearbox of the shift subassembly, and the planetary gear system are coaxial along a longitudinal axis passing through the auxiliary subassembly, the shift subassembly, and the planetary gear system.

[0053] As used herein, the phrases “at least one,” “one or more,” and “and / or” are open-ended expressions that are both connected and separate in operation. For example, each of the expressions “at least one of A, B, and C,” “at least one of A, B, or C,” “one or more of A, B, and C,” “one or more of A, B, or C,” and “A, B, and / or C” means a single A, a single B, a single C, A and B together, A and C together, B and C together, or A, B, and C together.

[0054] Unless otherwise stated, all figures used in the specification and claims to indicate quantities, dimensions, conditions, etc., shall be understood to be modified in all cases by the terms “about” or “approximately”. As used herein, unless otherwise stated, when used in relation to numerical limits or ranges, the terms “about,” “approximately,” etc., indicate that the limit or range may vary by up to 10%. As a non-limiting example, “about 750” may mean as little as 675 or as much as 825, or any value in between. When used with regard to a ratio or relationship between two or more numerical limits or ranges, the terms “about,” “approximately,” etc., indicate that each limit or range may vary by up to 10%; as a non-limiting example, a statement that two quantities are “approximately equal” may indicate a ratio between the two quantities as little as 0.9:1.1 or as much as 1.1:0.9 (or any value in between), and a statement of a ratio of “about 5:3:1:1” for four quantities may indicate that the first number in the ratio may be any value that is at least 4.5 and no greater than 5.5, the second number in the ratio may be any value that is at least 2.7 and no greater than 3.3, and so on.

[0055] When referring to a measurable quantity (e.g., diameter or other distance) and for comparative purposes, the term “approximately” is used in this disclosure to indicate that the quantity being compared is within 5%. As used herein, the terms “approximately similar to,” “approximately the same as,” and “approximately equal to” should be interpreted as if explicitly stating and encompassing the specific cases in which the compared items are “approximately,” “the same as,” and “equal to,” respectively.

[0056] As used herein, the term "a" refers to one or more of the same entity. Therefore, the terms "a," "one or more," and "at least one" are used interchangeably herein.

[0057] The use of “comprising,” “including,” or “having,” and variations thereof in this document is intended to cover the items listed thereafter and their equivalents, as well as additional items. Therefore, the terms “comprising,” “including,” or “having,” and variations thereof are used interchangeably herein. The use of “joining with,” and variations thereof in this document is intended to cover any direct or indirect connection between components.

[0058] It should be understood that the term "device" as used herein should be given its broadest possible interpretation in accordance with 35 USC §112(f). Therefore, claims containing the term "device" should cover all structures, materials, or actions set forth herein, and all their equivalents. Furthermore, structures, materials, or actions and their equivalents should include all those described in the summary, description of the drawings, detailed description, abstract, and the claims themselves.

[0059] These and other advantages will be apparent from the disclosure of one or more inventions contained herein. The above embodiments, objects, and configurations are neither exhaustive nor exhaustive. The summary of the invention is neither intended nor should be construed as representing the full breadth and scope of this disclosure. Moreover, references herein to "the invention" or aspects thereof should be understood as indicating certain embodiments of the invention / disclosure and are not necessarily construed as limiting all embodiments to the specific description. The invention has been set forth in various degrees of detail in the summary, drawings, and specific embodiments, and the scope of the invention is not intended to be limited by including or omitting elements, components, etc., in the summary. Additional aspects of the invention will become more apparent from the specific embodiments, particularly when taken in conjunction with the accompanying drawings.

[0060] It should be understood that any feature or aspect described herein may be claimed in combination with any other feature(s) or aspect(s) described herein, regardless of whether such features or aspects are derived from the same described embodiments.

[0061] Any one or more aspects described herein may be combined with any other one or more aspects described herein. Any one or more features described herein may be combined with any other one or more features described herein. Any one or more embodiments described herein may be combined with any other one or more embodiments described herein. Attached Figure Description

[0062] Those skilled in the art will recognize that the following description is merely illustrative of the principles of this disclosure, which can be applied in various ways to provide many different alternative embodiments. This description is intended to illustrate the general principles of the teachings of this disclosure and is not intended to limit the inventive concepts disclosed herein.

[0063] The accompanying drawings, which are included in and form part of this specification, illustrate embodiments and, together with the general description of the invention given above and the detailed description of the drawings given below, serve to explain the principles of the invention.

[0064] Figure 1A A perspective view of a mid-drive motor assembly according to one or more embodiments of the present disclosure is shown, the mid-drive motor assembly including a continuously variable transmission, a crankshaft, and an output sprocket within a housing;

[0065] Figure 1B It shows Figure 1A A top plan view of the continuously variable transmission (CVT) and crankshaft, with the CVT removed from the housing;

[0066] Figure 1C It shows Figure 1A A schematic diagram of a continuously variable transmission (CVT) and its crankshaft;

[0067] Figure 1D It shows Figure 1A A top plan view of the continuously variable transmission and the cross section of the crankshaft;

[0068] Figure 1E It shows Figure 1B A top plan view of the continuously variable transmission and the cross-section of the crankshaft variant;

[0069] Figure 2 The following illustrations depict one or more embodiments of operation and use according to the present disclosure. Figure 1A A flowchart of the method or process for assembling a mid-mounted drive motor assembly;

[0070] Figure 3A A perspective view of a mid-drive motor assembly according to one or more embodiments of the present disclosure is shown, the mid-drive motor assembly including a continuously variable transmission, a crankshaft, and an output sprocket within a housing;

[0071] Figure 3B It shows Figure 3A A top plan view of the continuously variable transmission (CVT) and crankshaft, with the CVT removed from the housing;

[0072] Figure 3C It shows Figure 3A A schematic diagram of a continuously variable transmission (CVT) and its crankshaft;

[0073] Figure 3D It shows Figure 3BA top plan view of the continuously variable transmission and the cross section of the crankshaft;

[0074] Figure 3E It shows Figure 3B A top plan view of the continuously variable transmission and the cross section of the crankshaft;

[0075] Figure 4 The following illustrations depict one or more embodiments of operation and use according to the present disclosure. Figure 3A A flowchart of the method or process for assembling a mid-mounted drive motor assembly;

[0076] Figure 5A The illustration shows one or more embodiments of the present disclosure, including... Figure 1A Electric bicycles with a mid-drive motor assembly; and

[0077] Figure 5B The illustration shows one or more embodiments of the present disclosure, including... Figure 3A Electric bicycles with a mid-mounted drive motor assembly.

[0078] It should be understood that the accompanying drawings are not necessarily drawn to scale and may vary in size. In some cases, details that are not essential for understanding the invention or that make other details difficult to perceive may have been omitted. Of course, it should be understood that the invention is not necessarily limited to the specific embodiments shown herein.

[0079] Attached Figure Marker Components

[0080] 100 Mid-drive Motor Assembly

[0081] 102 Continuously Variable Transmission

[0082] 104 Crankshaft

[0083] 105 splines

[0084] 106 Output sprocket

[0085] 108 Casing

[0086] 110 Auxiliary Sub-component

[0087] 112 Auxiliary Motor

[0088] 114 Auxiliary Gearbox

[0089] 116 Gear Shift Assembly

[0090] 118 Shift Motor

[0091] 120 shift gearbox

[0092] 122 Planetary Gear System

[0093] 124 gear ring

[0094] 126 Planetary Gear Set

[0095] 128 planetary gear sets

[0096] 130 Planetary Carrier

[0097] 132 Gear Ring

[0098] 134 gear ring

[0099] 136 Planetary Gear Set

[0100] 138 Planetary Gear Set

[0101] 140 Planetary Carrier

[0102] 142 Gear Ring

[0103] 144 gear ring

[0104] 146 Planetary Gear Set

[0105] 148 Sun Gear

[0106] 150 planetary carriers

[0107] 152 Clutch

[0108] 154 Clutch

[0109] 156 shafts

[0110] 158 Opening

[0111] 160 flange

[0112] 162 wheel axle

[0113] Axes 164, 164A, and 164B

[0114] 166 axis

[0115] 168 opening

[0116] 170 flange

[0117] 172 Axles

[0118] 174 Flange

[0119] 176 Flange

[0120] 178 Axle

[0121] 180 axis

[0122] 182 bearing

[0123] 184 Seals

[0124] 186 Auxiliary Torque Path

[0125] 188 Shift Torque Path

[0126] 190 Pedal Torque Path

[0127] 200 Process Flowchart

[0128] 202. Auxiliary power is provided by auxiliary sub-components.

[0129] 204 Receive user input from crankshaft

[0130] 206. Shift power is provided by a shift assembly.

[0131] 208 Generates output power for the output sprocket.

[0132] 300 Mid-Mount Drive Motor Assembly

[0133] 302 Continuously Variable Transmission

[0134] 304 Crankshaft

[0135] 305 Spline

[0136] 306 Output Sprocket

[0137] 308 housing

[0138] 310 Auxiliary Sub-component

[0139] 312 Auxiliary Motor

[0140] 314 Auxiliary Gearbox

[0141] 316 Gear Shift Assembly

[0142] 318 shift motor

[0143] 320 shift gearbox

[0144] 324 gear ring

[0145] 326 Planetary Gear Set

[0146] 328 Planetary Gear Set

[0147] 330 Planetary Carrier

[0148] 332 gear ring

[0149] 334 gear ring

[0150] 336 Planetary Gear Set

[0151] 338 Planetary Gear Set

[0152] 340 Planetary Carrier

[0153] 342 Gear Ring

[0154] 344 Clutch

[0155] 346 Clutch

[0156] 348 axes

[0157] 350 flange

[0158] 352 wheel axle

[0159] 354 axes

[0160] 356 axes

[0161] 358 flange

[0162] 360 Axle

[0163] 362 bearing

[0164] 364 Seals

[0165] 366 Auxiliary Torque Path

[0166] 368 Shift Torque Path

[0167] 370 Pedal Torque Path

[0168] 400 Process Flowchart

[0169] 402. Auxiliary power is provided by auxiliary sub-components.

[0170] 404 uses a shift assembly to provide shift power.

[0171] 406 Receive user input from crankshaft

[0172] 408 Generates output power for the output sprocket.

[0173] 500A and 500B electric bicycles

[0174] 501 Auxiliary Sub-component Power

[0175] 502 belt or chain

[0176] 503 Shifter Components Power

[0177] 504 hub

[0178] 505 User Input

[0179] 506 wheels

[0180] 507 Electricity

[0181] 508 battery pack

[0182] 509 power output

[0183] 510 Control System

[0184] 511 Data

[0185] Pl reference plane

[0186] P2 Reference Plane

[0187] P3 Reference Plane Detailed Implementation

[0188] While the following text sets forth detailed descriptions of many different embodiments, it should be understood that the legal scope of the description is defined by the words of the claims set forth at the end of this disclosure. The detailed descriptions should be construed as exemplary only and do not describe every possible embodiment, as describing every possible embodiment of a continuously variable transmission (CVT) for an electric bicycle would be impractical, if not impossible. Many alternative embodiments can be implemented using current technology or technology developed after the filing date of this patent, which will still fall within the scope of the claims. Furthermore, additional embodiments of this disclosure can be created using any combination of features shown in the various figures. Thus, the dimensions, aspects, and features of one embodiment of a CVT can be combined with the dimensions, aspects, and features of another embodiment of a CVT to produce the claimed embodiment.

[0189] In general, embodiments of this disclosure relate to compact-sized CVTs in mid-drive motor assemblies for electric bicycles. Embodiments of this disclosure relate to planetary gear systems in CVTs. Embodiments of this disclosure also relate to axial flux motors in CVTs. Embodiments of this disclosure include a gear system and a motor, both coaxial along a longitudinal axis passing through a crankshaft, through which the planetary gear system and motor can be inserted. Embodiments of this disclosure relate to a three-gearbox CVT including an auxiliary subassembly, a shift subassembly, and a planetary gear system for providing power output (and optionally user input from the crankshaft) to the auxiliary subassembly and shift subassembly. Embodiments of this disclosure relate to a two-gearbox CVT including an auxiliary subassembly and a shift subassembly for providing power output (and optionally user input from the crankshaft) to the auxiliary subassembly and shift subassembly.

[0190] Figure 1A-1E A mid-drive motor assembly 100 according to one or more embodiments of the present disclosure is generally shown.

[0191] The mid-drive motor assembly 100 includes a continuously variable transmission 102 (“CVT”). The mid-drive motor assembly 100 also includes a crankshaft 104 having a spline 105 that passes through and communicates with the CVT 102. For example, the spline 105 may be configured to receive a pedal (pedal not shown) mounted on the crankshaft 104 and / or otherwise engage with a pedal. However, it should be noted that the pedal may include a male connector inserted into an opening at each corresponding end of the crankshaft 104, which, without departing from the scope of this disclosure, may be held in place via fasteners passing through the male connector and into the opening, via an interference fit, via an interlocking assembly, via an adhesive, or some combination thereof.

[0192] The mid-drive motor assembly 100 also includes an output sprocket 106 (or other ring output) coupled to the CVT 102 (e.g., such as...). Figure 1D (As shown in the diagram). In some embodiments, output sprocket 106 is a belt drive sprocket operable to receive and power a belt coupled to the hub of a wheel of an electric bicycle (not shown). In other embodiments, output sprocket 106 is a chain drive sprocket operable to receive and power a chain coupled to the hub of a wheel of an electric bicycle (not shown).

[0193] At least a portion of the CVT 102, crankshaft 104, and / or output sprocket 104 may be located within the housing 108 of the mid-drive motor assembly 100. For example, the CVT 102 may be substantially located within the housing 108, the crankshaft 104 may pass through the housing 108, and the output sprocket 106 may be completely located outside the housing 108, or have at least a portion located outside the housing 108. It should be noted that the housing 108 may be a single piece or an integral construction, or alternatively, without departing from the scope of this disclosure, it may be a multi-piece construction with individual and engaging components.

[0194] In some embodiments, one or more electrical connectors may be located within (or extending outward from) the outer surface of housing 108. For example, one or more electrical connectors may power auxiliary motor 112 and / or shift motor 118, as described in further detail herein. As another example, one or more electrical connectors may receive data (e.g., operating data, environmental data, etc.) from one or more sensors within the mid-drive motor assembly 100 and / or transmit data or other instructions to components within the mid-drive motor assembly 100. Without departing from the scope of this disclosure, one or more electrical connectors may be individual connectors and / or may be leads comprising one or more plugs or sockets configured to engage corresponding components on a wiring harness coupled to the mid-drive motor assembly 100.

[0195] This document will refer to CVT 102 in further detail. It should be noted that any and / or all sub-components of CVT 102 may include additional sub-components as described in further detail herein, which are all considered to be sub-components of the mid-drive motor assembly 100.

[0196] Figure 1B A CVT 102 of a mid-drive motor assembly 100 according to one or more embodiments of the present disclosure is shown. The CVT 102 includes a three-gearbox configuration in which the crankshaft 104 is not mechanically integrated into the shifting operation of the CVT 102, but cadence is instead controlled by drive-by.

[0197] CVT 102 includes an auxiliary subassembly 110 with an auxiliary motor 112 and an auxiliary gearbox 114 to assist the user in pedaling. CVT 102 also includes a shift subassembly 116 with a shift motor 118 and a shift gearbox 120 to facilitate shifting operations. CVT 102 also includes a planetary gear system 122.

[0198] In the three-gearbox configuration of CVT 102, the auxiliary sub-assembly 110 and the shift sub-assembly 116 are separated by a reference plane P1 (e.g., as shown in the figure). Figure 1E (As shown in the diagram). Within the auxiliary subassembly 110, the auxiliary motor 112 is positioned outward relative to the reference plane P1, and the auxiliary gearbox 114 is positioned inward relative to the reference plane P1. Within the shift subassembly 116, the shift gearbox 120 is positioned outward relative to the reference plane P1, and the shift motor 118 is positioned inward relative to the reference plane P1. Furthermore, the planetary gear system 122 is positioned outward relative to the reference plane P1. It should be noted that, for the purposes of this disclosure, "outward" means positioned further away from or farther from the reference plane P1, and "inward" means positioned closer to or closer to the reference plane P1.

[0199] However, it is conceivable that, without departing from the scope of this disclosure, the auxiliary motor 112 may be positioned inside relative to the reference plane P1, and the auxiliary gearbox 114 may be positioned outside relative to the reference plane P1 within the auxiliary subassembly 110. Additionally, it is conceivable that, without departing from the scope of this disclosure, the shift gearbox 120 may be positioned inside relative to the reference plane P1, and the shift motor 118 may be positioned outside relative to the reference plane P1 within the shift subassembly 116.

[0200] Similarly, in the three-gearbox configuration of CVT 102, the shift assembly 116 and the planetary gear system 122 are separated by a reference plane P2 (e.g., as shown in the image). Figure 1E(As shown in the diagram). In some embodiments, the shift gearbox 120 and the planetary gear system 122 are combined within a single gearbox housing. For example, gear oil may be limited to a single gearbox housing for both the shift gearbox 120 and the planetary gear system 122. In other embodiments, the shift gearbox 120 and the planetary gear system 122 are located in separate gearbox housings coupled together.

[0201] In this embodiment, the auxiliary motor 112 and / or the shift motor 118 are axial flux motors capable of receiving the crankshaft 104 as the crankshaft passes through the CVT 102. This allows for a configuration along a single longitudinal axis passing through the crankshaft 104, rather than a multi-axis configuration with separate parallel (or substantially parallel) axes for the auxiliary motor 112, auxiliary gearbox 114, shift motor 118, shift gearbox 120, and / or planetary gear system 122. It should be noted herein that, for the purposes of this disclosure, the longitudinal axis may be considered as a “cadence point.”

[0202] It should be noted that embodiments of CVT 102 have a shift subassembly 116 positioned between the auxiliary subassembly 110 and the planetary gear system 122. However, it is conceivable that the auxiliary subassembly 110 may be positioned between the shift subassembly 116 and the planetary gear system 122 without departing from the scope of this disclosure.

[0203] Figure 1C This diagram illustrates the power flow of the CVT 102 via the mid-mounted drive motor assembly 100. It should be understood that... Figure 1C A schematic diagram showing a cross-sectional view of CVT 102.

[0204] The auxiliary gearbox 114 includes a first ring gear 124, a first set of planetary gears 126 connected to a second set of planetary gears 128 via a planet carrier 130, and a second ring gear 132. In some embodiments, the first set of planetary gears 126 and the second set of planetary gears 128 have different numbers of teeth, thereby achieving a power transmission ratio when power is transmitted from the first set of planetary gears 126 to the second set of planetary gears 128 via the planet carrier 130. For example, this ratio may be 39:1, 40:1, 49:1, or other ratios that achieve power transmission.

[0205] It should be noted that, for the purposes of this disclosure, the components of the auxiliary gearbox 114 can be considered as "auxiliary" components (i.e., auxiliary ring gear, auxiliary planetary gear set on the auxiliary planetary carrier, etc.). Additionally, it should be noted that, for the purposes of this disclosure, the auxiliary gearbox 114 can be considered as a harmonic gear system capable of converting power from high-speed / low-torque input to low-speed / high-torque output to facilitate CVT functionality.

[0206] The shift gearbox 120 includes a first ring gear 134, a first set of planetary gears 136 connected to a second set of planetary gears 138 via a planet carrier 140, and a second ring gear 142. In some embodiments, the first set of planetary gears 136 and the second set of planetary gears 138 have different numbers of teeth, thereby achieving a power transmission ratio when power is transmitted from the first set of planetary gears 136 to the second set of planetary gears 138 via the planet carrier 140. For example, this ratio may be 39:1, 40:1, 49:1, or other ratios that achieve power transmission.

[0207] It should be noted that, for the purposes of this disclosure, the components of the shift gearbox 120 can be considered as "shifting" or "gear" components (i.e., shift ring gear or gear position ring gear, shift planetary gear set on shift planetary carrier or gear position planetary gear set on gear position planetary carrier, etc.). Additionally, it should be noted that, for the purposes of this disclosure, the shift gearbox 120 can be considered as a harmonic gear system capable of converting power from high-speed / low-torque input to low-speed / high-torque output to facilitate CVT functionality.

[0208] The planetary gear system 122 includes a ring gear 144, a set of planetary gears 146, and a sun gear 148. The set of planetary gears 146 is coupled to a planet carrier 150, which is coupled to an output sprocket 106 (not shown). In some embodiments, the planetary gear system 122 may provide a gear ratio between the ring gear 144 and the sun gear 148. For example, the gear ratio may be a 3:1 ratio or another ratio.

[0209] Power in the auxiliary subassembly 110 is generated by the auxiliary motor 112 and transmitted to the planetary carrier 130. A first ring gear 124 is fixedly positioned within the auxiliary gearbox 114, and a second ring gear 132 is rotatable when acted upon by a second set of planetary gears 128. Rotation of the second ring gear 132 via engagement of the second set of planetary gears 128 transmits power from the second ring gear 132 of the auxiliary gearbox 114 to the sun gear 148 of the planetary gear system 122 via a clutch 152. For example, the clutch 152 may be a one-way clutch that allows power to be transmitted from the second ring gear 132 of the auxiliary gearbox 114 to the sun gear 148 of the planetary gear system 122, but prevents power from being transmitted from the sun gear 148 of the planetary gear system 122 to the second ring gear 132 of the auxiliary gearbox 114.

[0210] Power in the shift assembly 116 is generated by the shift motor 118 and transmitted to the planetary carrier 140. A first ring gear 134 is fixedly positioned within the shift gearbox 120, and a second ring gear 142 is rotatable when acted upon by a second set of planetary gears 138. The rotation of the second ring gear 142 via the engagement of the second set of planetary gears 138 transmits power from the second ring gear 142 of the shift gearbox 120 to the ring gear 144 of the planetary gear system 122. It should be noted that, without departing from the scope of this disclosure, the second ring gear 142 and the ring gear 144 may be separate components joined together, or alternatively, may be a single integrated component.

[0211] In this embodiment, the power applied by the rider to the crankshaft 104 is input to the sun gear 148 via the clutch 154. For example, the clutch 154 may be a one-way clutch that allows power to be transmitted from the crankshaft 104 to the sun gear 148 of the planetary gear system 122, but prevents power from being transmitted from the sun gear 148 of the planetary gear system 122 to the crankshaft 104.

[0212] The planet carrier 150 is rotated by the rotation of the ring gear 144, which receives shift power from the shift subassembly 116, and / or by the rotation of the sun gear 148, which receives auxiliary power from the auxiliary subassembly 110 (and / or by the user input from the crankshaft). The planet carrier 150 is coupled to the output sprocket 106 (not shown), such that power is transmitted from the planet carrier 150 to the output sprocket 106. In this respect, the rotation of the planet carrier 150 causes the output sprocket 106 to rotate, thus providing power to the hub of the wheel (e.g., via a belt or chain that connects the output sprocket 106 to the hub, although not shown).

[0213] Figure 1D and Figure 1E A cross-sectional view of the auxiliary sub-assembly 110 and shift sub-assembly 116 of the CVT 102 of the mid-drive motor assembly 100 and the crankshaft 104 is shown.

[0214] In CVT 102, the planetary carrier 130 of the auxiliary gearbox 114 includes a shaft 156 to which the auxiliary motor 112 is coupled. For example, if the auxiliary motor 112 is an axial flux motor, the outer diameter of the shaft 156 may be dimensioned to the inner diameter of the opening 158 receiving the auxiliary motor 112. The flange 160 of the planetary carrier 130 includes one or more axles 162 to which a first set of planetary gears 126 and a second set of planetary gears 128 of the auxiliary gearbox 114 are coupled.

[0215] Power is transmitted via a power engagement clutch 152 to the second ring gear 132 of the auxiliary gearbox 114 through the planetary carrier 130. This clutch, in turn, engages the sun gear 148 of the planetary gear system 122. For example, power can be transmitted via the shaft 164 of the sun gear 148. Figure 1D As shown, shaft 164 can be a single component. However, as... Figure 1E As shown, without departing from the scope of this disclosure, shaft 164 may be multiple components (164A, 164B). It should be noted herein that portions of shaft 164 may be formed or coupled to the second gear ring 132 without departing from the scope of this disclosure.

[0216] The planetary carrier 140 of the shift gearbox 120 includes a shaft 166 to which the shift motor 118 is engaged. For example, in the case where the shift motor 118 is an axial flux motor, the outer diameter of the shaft 166 can be dimensioned to the inner diameter of the opening 168 receiving the shift motor 118. The flange 170 includes one or more axles 172 to which a first set of planetary gears 136 and a second set of planetary gears 138 of the shift gearbox 120 are coupled.

[0217] Clutch 154 engages flange 174 of sun gear 148 of planetary gear system 122 to transmit power from crankshaft 104 to sun gear 148. Thus, planetary gear system 122 can receive power from crankshaft 104 and / or auxiliary power supplied from auxiliary subassembly 110 via sun gear 148, and additionally receive power supplied from shift subassembly 116 via ring gear 144.

[0218] The planetary carrier 150 of the planetary gear system 122 includes a flange 176 having one or more axles 178 to which a set of planetary gears 146 are coupled. The planetary carrier 150 also includes a shaft 180 coupled to (or integrated with) an output sprocket 106 to supply power from the CVT 102 to the output sprocket 106 (and thus to the hub of the wheel via a belt or chain driven by the output sprocket 106). In some examples, the shaft 180 includes splines for the output sprocket 106. For example, the splines may be on the outer surface of the shaft 180, such that the output sprocket 106 slides on the shaft 180 and engages with the shaft via the splines. Alternatively, the splines may be on the inner surface of the shaft 180, such that a portion of the output sprocket 106 is inserted into the shaft 180 via the splines and engages with the shaft. In other examples, the output sprocket 106 is press-fitted onto (or into) the shaft 180.

[0219] It should be noted that one or more bearings 182 may be positioned along the longitudinal axis passing through the crankshaft 104 to improve the rotation of components of the auxiliary gearbox 114 and / or shift gearbox 120. Additionally, it should be noted that one or more seals 184 (e.g., O-rings, washers, rope seals, etc.) may be positioned along the longitudinal axis passing through the crankshaft 104. For example, the seals may be used to prevent gear oil from escaping from the CVT 102. As another example, the seals may be used to prevent fluid or particles from entering the CVT 102.

[0220] like Figure 1E As shown, CVT 102 includes an auxiliary torque path 186, a shift torque path 188, and a pedal torque path 190. In the auxiliary torque path 186, power is generated by an auxiliary motor 112 and transmitted to the sun gear 148 of the planetary gear system 122 via the planet carrier 130 of the auxiliary gearbox 114 before being transmitted to the output sprocket 106 by the planet carrier 150 of the planetary gear system 122. In the shift torque path 188, power is generated by a shift motor 118 and transmitted to the ring gear 144 of the planetary gear system 122 via the planet carrier 140 of the shift gearbox 120 before being transmitted to the output sprocket 106 by the planet carrier 150 of the planetary gear system 122. In the pedal torque path 190, power applied by the rider to the crankshaft 104 is provided to the sun gear 148 of the planetary gear system 122 before being transmitted to the output sprocket 106 by the planet carrier 150 of the planetary gear system 122.

[0221] Power is supplied to the planetary gear system 122 from one or more of three sources (e.g., crankshaft 104, auxiliary sub-assembly 110, and / or shift sub-assembly 116) and then to the output sprocket 106, allowing the continuously variable transmission (CVT) to operate with smooth, efficient gear shifting. Specifically, the compact CVT 102 outputs the required torque and speed from the auxiliary motor 112, shift motor 118, and crankshaft 104 to the output sprocket 106, which drives the hub and wheels of an electric bicycle (not shown).

[0222] Figure 2 This is a flowchart 200 illustrating a method or process for operating a mid-drive motor assembly 100 according to one or more embodiments of the present disclosure. Although in Figure 2 The general order of steps of method or process 200 is shown, but method or process 200 may include more or fewer steps, or may be combined with... Figure 2 The different arrangement steps shown are in sequence (including simultaneous, substantially simultaneous, or sequential). It should be noted that reference should be made to the combination of... Figure 1A-1E The method or process 200 is explained by describing the components, devices, sub-components, environment, etc. For example, it should be noted that without departing from the scope of this disclosure, such as Figure 1A-1EThe embodiments shown should be understood as reading about Figure 2 The described embodiments are, conversely, also true.

[0223] In this embodiment, auxiliary power 202 is provided by an auxiliary sub-assembly of the mid-drive motor assembly. The auxiliary sub-assembly 110 may be a component of the CVT 102 of the mid-drive motor assembly 100. The auxiliary power is generated by the auxiliary motor 112 of the auxiliary sub-assembly 110 and transmitted to the planet carrier 130 of the auxiliary gearbox 114 of the auxiliary sub-assembly 110. The auxiliary power is converted by two sets of planetary gears 126 and 128 connected to the planet carrier 130 and output from the auxiliary gearbox 114 via a second ring gear 132. The output auxiliary power is transmitted to the sun gear 148 of the planetary gear system 122 via a clutch 152.

[0224] In this embodiment, user input 204 is received from the crankshaft of the mid-drive motor assembly. When the rider supplies torque to the crankshaft 104, the user input is provided as crankshaft power to the sun gear 148 of the planetary gear system 122 via clutch 154. It should be noted that this can be supplemental to or alternative to auxiliary power. It should be noted that, for the purposes of this disclosure, the receipt of user input can be considered optional. For example, both auxiliary power and crankshaft power can be provided to the sun gear 148, such that both are provided to the planetary carrier 150 via the sun gear 148. As another example, only auxiliary power can be provided to the planetary carrier 150 via the sun gear 148 (i.e., when the rider is not pedaling). Furthermore, only crankshaft power can be input to the planetary carrier 150 via the sun gear 148 (i.e., when the auxiliary motor 112 is not providing auxiliary power).

[0225] In this embodiment, shift power 206 is provided by a shift subassembly of the mid-drive motor assembly. The shift subassembly 116 may be a component of the CVT 102 of the mid-drive motor assembly 100. For example, the shift power is generated by the shift motor 118 of the shift subassembly 116 and transmitted to the planetary carrier 140 of the shift gearbox 120 of the shift subassembly 116. The shift power is converted by two sets of planetary gears 136, 138 connected to the planetary carrier 140 and output from the shift gearbox 120 via a second ring gear 142. The output shift power is transmitted to the ring gear 144 of the planetary gear system 122.

[0226] In this embodiment, output power is generated 208 for the output sprocket of the mid-drive motor assembly. The planetary gear system 122 provides auxiliary power (optionally crankshaft power from user input) and / or shift power from the ring gear 144 as output power via a set of planetary gears 146 on the planetary carrier 150. The planetary carrier 150 is coupled to the output sprocket 106 such that rotation of the planetary carrier 150 causes rotation of the output sprocket 106 (and thus, via a belt or chain connecting the output sprocket 106 to the hub, causes rotation of the hub of the wheel, although not shown). In this respect, the CVT 102 achieves variable transmission functionality by appropriately controlling the auxiliary motor 112 and the shift motor 118, combined with the torque input from the pedal via the crankshaft 104 when applied.

[0227] Figures 3A-3E A mid-drive motor assembly 300 according to one or more embodiments of the present disclosure is generally shown. It should be understood that, unless otherwise stated, components, sub-assemblies, and / or parts of the mid-drive motor assembly 300 may be similar to or identical to components, sub-assemblies, and / or parts of the mid-drive motor assembly 100. Furthermore, it should be understood that, unless otherwise stated, components, sub-assemblies, and / or parts of the mid-drive motor assembly 300 may be combined and / or interchanged with components, sub-assemblies, and / or parts of the mid-drive motor assembly 100.

[0228] The mid-drive motor assembly 300 includes a continuously variable transmission 302 (“CVT”). The mid-drive motor assembly 300 also includes a crankshaft 304 having a spline 305 that passes through and is coupled to the CVT 302. For example, the spline 305 may be configured to receive a pedal (pedal not shown) mounted on the crankshaft 104 and / or otherwise engage with a pedal. However, it should be noted that the pedal may include a male connector inserted into an opening at each corresponding end of the crankshaft 104, which, without departing from the scope of this disclosure, may be held in place via fasteners passing through the male connector and into the opening, via an interference fit, via an interlocking assembly, via an adhesive, or some combination thereof.

[0229] The mid-drive motor assembly 300 also includes an output sprocket 306 (or other annular output) in communication with the CVT 302. In some embodiments, the output sprocket 306 is a belt drive sprocket operable to receive and power a belt coupled to the hub of a wheel of an electric bicycle (not shown). In some embodiments, the output sprocket 306 is a chain drive sprocket operable to receive and power a chain coupled to the hub of a wheel of an electric bicycle (not shown).

[0230] At least a portion of the CVT 302, crankshaft 304, and / or output sprocket 306 may be located within the housing 308 of the mid-drive motor assembly 300. For example, the CVT 302 may be substantially located within the housing 308, the crankshaft 304 may pass through the housing 308, and the output sprocket 306 may be completely located outside the housing 308, or have at least a portion located outside the housing 308. It should be noted that, without departing from the scope of this disclosure, the housing 308 may be a single piece or an integrated construction, or alternatively a multi-piece construction with individual and engaging components.

[0231] In some embodiments, one or more electrical connectors may be located within (or extending outward from) the outer surface of housing 308. For example, one or more electrical connectors may power auxiliary motor 312 and / or shift motor 318, as described in further detail herein. As another example, one or more electrical connectors may receive data (e.g., operating data, environmental data, etc.) from one or more sensors within the mid-drive motor assembly 300 and / or transmit data or other instructions to components within the mid-drive motor assembly 300. Without departing from the scope of this disclosure, one or more electrical connectors may be individual connectors and / or may be leads comprising one or more plugs or sockets configured to engage corresponding components on a wiring harness coupled to the mid-drive motor assembly 300.

[0232] This document will refer to CVT 302 in further detail. It should be noted that any and / or all sub-components of CVT 302 may include additional sub-components as described in further detail herein, which are all considered to be sub-components of the mid-drive motor assembly 300.

[0233] Figure 3B A CVT 302 of a mid-drive motor assembly 300 according to one or more embodiments of the present disclosure is shown. The CVT 302 includes a dual gearbox configuration in which a crankshaft 304 is mechanically integrated into the shifting operation of the CVT 302.

[0234] The CVT 302 includes an auxiliary sub-assembly 310 with an auxiliary motor 312 and an auxiliary gearbox 314 to assist the user in pedaling. The CVT 302 also includes a shift sub-assembly 316 with a shift motor 318 and a shift gearbox 320 to facilitate shifting operations.

[0235] In the dual-gearbox configuration of CVT 302, the auxiliary sub-assembly 310 and the shift sub-assembly 316 are separated by a reference plane P3 (e.g., as shown in the image). Figure 3E(As shown in the diagram). Within the auxiliary subassembly 310, the auxiliary motor 312 is positioned outward relative to the reference plane P3, and the auxiliary gearbox 314 is positioned inward relative to the reference plane P3. Within the shift subassembly 316, the shift motor 318 is positioned outward relative to the reference plane P3, and the shift gearbox 320 is positioned inward relative to the reference plane P3. It should be noted that, for the purposes of this disclosure, "outward" means positioned further away from or more distant from the reference plane P3, and "inward" means positioned closer to or more distant from the reference plane P3.

[0236] However, it is conceivable that, without departing from the scope of this disclosure, the auxiliary motor 312 may be positioned inside the reference plane P3, and the auxiliary gearbox 314 may be positioned outside the reference plane P3 within the auxiliary sub-assembly 310. Additionally, it is conceivable that, without departing from the scope of this disclosure, the shift motor 318 may be positioned inside the reference plane P3, and the shift gearbox 320 may be positioned outside the reference plane P3 within the shift sub-assembly 316.

[0237] In some embodiments, the auxiliary gearbox 314 and the shift gearbox 320 are combined within a single gearbox housing. For example, gear oil may be limited to a single gearbox housing for both the auxiliary gearbox 314 and the shift gearbox 320, rather than the gearboxes 314 and 320 being separate. In other embodiments, the auxiliary gearbox 314 and the shift gearbox 320 are located in separate gearbox housings joined together.

[0238] In this embodiment, the auxiliary motor 312 and / or the shift motor 318 are axial flux motors capable of receiving the crankshaft 304 as the crankshaft passes through the CVT 302. This allows for a configuration along a single longitudinal axis passing through the crankshaft 304, rather than a multi-axis configuration with separate parallel (or substantially parallel) axes for the auxiliary motor 312, auxiliary gearbox 314, shift motor 318, and / or shift gearbox 320. It should be noted herein that, for the purposes of this disclosure, the longitudinal axis may be considered as a “pedal point”.

[0239] It should be noted that, compared to the CVT 102 described earlier herein, which has a shift sub-assembly 116 positioned between the auxiliary sub-assembly 110 and the planetary gear system 122 / output sprocket 106, the embodiment of CVT 302 has an auxiliary sub-assembly 310 positioned between the shift sub-assembly 316 and the output sprocket 306. Additionally, it should be noted that the dual-gearbox configuration of CVT 302 does not include the planetary gear system 122, as previously described. It is conceivable that shifting may require adjusting the orientation of components within the shift gearbox 320 relative to the longitudinal axis passing through the crankshaft 304 (e.g., the orientation of the first ring gear 334, the second ring gear 342, and / or the planet carrier 340 having multiple sets of planetary gears 336, 338). For example, it may be necessary to adjust the orientation clockwise about the longitudinal axis or cadence point, or alternatively, it may be necessary to adjust the orientation counterclockwise about the longitudinal axis or cadence point. It is also conceivable that, without departing from the scope of this disclosure, the shifter assembly 316 may be positioned between the auxiliary subassembly 310 and the output sprocket 306.

[0240] Figure 3C A schematic diagram of power flow is shown through the CVT 302 within the mid-mounted drive motor assembly 300. It should be understood that... Figure 3C This shows a cross-sectional view of CVT 302.

[0241] The auxiliary gearbox 314 includes a first ring gear 324, a first set of planetary gears 326 connected to a second set of planetary gears 328 via a planet carrier 330, and a second ring gear 332. In some embodiments, the first set of planetary gears 326 and the second set of planetary gears 328 have different numbers of teeth, thereby achieving a power transmission ratio when power is transmitted from the first set of planetary gears 326 to the second set of planetary gears 328 via the planet carrier 330. For example, this ratio may be 39:1, 40:1, 49:1, or other ratios that achieve power transmission. It should be noted that the ratio based on the second ring gear 342 depends at least in part on the input received from the crankshaft 304 via the first ring gear 334 driven by the crankshaft 304, as described in further detail herein.

[0242] It should be noted that, for the purposes of this disclosure, the components of the auxiliary gearbox 314 can be considered as “auxiliary” components (i.e., auxiliary ring gear, auxiliary planetary gear set on the auxiliary planetary carrier, etc.). Additionally, it should be noted that, for the purposes of this disclosure, the auxiliary gearbox 314 can be considered as a harmonic gear system capable of converting power from high-speed / low-torque input to low-speed / high-torque output to facilitate CVT functionality.

[0243] The shift gearbox 320 includes a first ring gear 334, a first set of planetary gears 336 connected to a second set of planetary gears 338 via a planet carrier 340, and a second ring gear 342. In some embodiments, the first set of planetary gears 336 and the second set of planetary gears 338 have different numbers of teeth, thereby achieving a power transmission ratio when power is transmitted from the first set of planetary gears 336 to the second set of planetary gears 338 via the planet carrier 340. For example, this ratio may be 39:1, 40:1, 49:1, or other ratios that achieve power transmission.

[0244] It should be noted that, for the purposes of this disclosure, the components of the shift gearbox 320 can be considered as "shifting" components (i.e., shift ring gear or gear position ring gear, shift planetary gear set on the shift planetary carrier or gear position planetary gear set on the gear position planetary carrier, etc.). Additionally, it should be noted that, for the purposes of this disclosure, the shift gearbox 320 can be considered as a harmonic gear system capable of converting power from high-speed / low-torque input to low-speed / high-torque output to facilitate CVT functionality.

[0245] Power in the auxiliary subassembly 310 is generated by the auxiliary motor 312 and transmitted to the planetary carrier 330. A first ring gear 324 is fixedly positioned within the auxiliary gearbox 314, and a second ring gear 332 is rotatable when acted upon by a second set of planetary gears 328. Rotation of the second ring gear 332 via the engagement of the second set of planetary gears 328 transmits power from the second ring gear 332 of the auxiliary gearbox 314 to the output sprocket 306 (not shown) via a clutch 344. For example, the clutch 344 may be a one-way clutch that allows power to be transmitted from the second ring gear 332 of the auxiliary gearbox 314 to the output sprocket 306, but prevents power from being transmitted from the output sprocket 306 to the second ring gear 332 of the auxiliary gearbox 314.

[0246] Power in the shift assembly 316 is generated by the shift motor 318 and transmitted to the planetary carrier 340. The second ring gear 342 is rotatable when acted upon by the second set of planetary gears 338. The rotation of the second ring gear 342 via the engagement of the second set of planetary gears 338 transmits power from the shift gearbox 320 to the output sprocket 306 (not shown).

[0247] In one embodiment, power applied by the rider to the crankshaft 304 is input to the first ring gear 334 of the shift gearbox 320 via a clutch 346. For example, the clutch 346 may be a one-way clutch that allows power to be transmitted from the crankshaft 304 to the first ring gear 334 of the shift gearbox 320, but prevents power from being transmitted from the first ring gear 334 of the shift gearbox 320 to the crankshaft 304.

[0248] In this respect, power from crankshaft 304 and / or shift motor 318 can be supplied to output sprocket 306 via shift gearbox 320. Additionally, power from auxiliary subassembly 310 and shift subassembly 316 can be supplied to output sprocket 306. The power (either individually or in combination) from auxiliary subassembly 310 and shift subassembly 316 causes output sprocket 306 to rotate, thereby supplying power to the hub of the wheel (e.g., via a belt or chain connecting output sprocket 306 to the hub, although not shown).

[0249] Figure 3D and 3E A cross-sectional view of the auxiliary subassembly 310 and shift subassembly 316 of the CVT 302 of the mid-drive motor assembly 300 and the crankshaft 304 is shown.

[0250] In CVT 302, the planetary carrier 330 of the auxiliary gearbox 314 includes a shaft 348 to which the auxiliary motor 312 is engaged. The flange 350 of the planetary carrier 330 includes one or more axles 352 to which a first set of planetary gears 326 and a second set of planetary gears 328 of the auxiliary gearbox 314 are coupled. Power is transmitted via the planetary carrier 330 to a second ring gear 332 of the auxiliary gearbox 314 via a clutch 346 to drive the shaft 354 of the second ring gear 342, which is coupled to the output sprocket 306 (and thus via the hub of a belt or chain drive pulley driven by the output sprocket 306). In some examples, the shaft 354 includes splines for the output sprocket 306. For example, the splines may be on the outer surface of the shaft 354, such that the output sprocket 106 slides on the shaft 354 and engages with the shaft via the splines. Alternatively, the splines may be on the inner surface of the shaft 354, such that a portion of the output sprocket 106 is inserted into the shaft 354 via the splines and engages with the shaft. In other examples, the output sprocket 106 is press-fitted onto (or into) shaft 354.

[0251] Clutch 346 engages the first gear ring 334 of shift gearbox 320 to transmit power from crankshaft 304 to the first gear ring 334. Therefore, shift gearbox 320 can combine power from crankshaft 304 with power supplied via shift motor 318.

[0252] The planetary carrier 340 of the shift gearbox 320 includes a shaft 356 to which the shift motor 318 is engaged. The flange 358 of the planetary carrier 340 includes one or more axles 360 to which a first set of planetary gears 336 and a second set of planetary gears 338 of the shift gearbox 320 are coupled. Power transmitted through the planetary carrier 340 to the second ring gear 342 of the shift gearbox 320 drives the shaft 354 of the second ring gear 342, which is coupled to the output sprocket 306. Therefore, the shaft 354 of the second ring gear 342 can combine power from the auxiliary subassembly 310 and the shift subassembly 316.

[0253] It should be noted that one or more bearings 362 may be positioned along the longitudinal axis passing through the crankshaft 304 to improve the rotation of components of the auxiliary gearbox 314 and / or shift gearbox 320. Additionally, it should be noted that one or more seals 364 (e.g., O-rings, washers, rope seals, etc.) may be positioned along the longitudinal axis passing through the crankshaft 304. For example, the seals may be used to prevent gear oil from escaping from the CVT 302. As another example, the seals may be used to prevent fluid or particles from entering the CVT 302.

[0254] like Figure 3E As shown, the CVT 302 includes an auxiliary torque path 366, a shift torque path 368, and a pedal torque path 370. In the auxiliary torque path 366, power is generated by an auxiliary motor 312 and transmitted via a planetary carrier 330 of an auxiliary gearbox 314 before being transmitted from the second ring gear 332 to the shaft 354 of the second ring gear 332 connected to the output sprocket 306 via a clutch 344. In the shift torque path 368, power is generated by a shift motor 318 and transmitted via a planetary carrier 340 of a shift gearbox 320 to the shaft 354 of the second ring gear 342 connected to the output sprocket 306. In the pedal torque path 370, power applied by the rider to the crankshaft 304 is provided to the first ring gear 334 via a clutch 346 before being transmitted by the planetary carrier 340 to the second ring gear 342 and shaft 354 connected to the output sprocket 306.

[0255] Providing power to the output sprocket 306 from one or more of three sources (e.g., crankshaft 304, auxiliary sub-assembly 310, and / or shift sub-assembly 316) allows the continuously variable transmission (CVT) to perform smooth, efficient shifting operations. Specifically, the compact CVT 302 outputs the required torque and speed from the auxiliary motor 312, shift motor 318, and crankshaft 304 to the output sprocket 306, which drives the hub and wheels of an electric bicycle (not shown).

[0256] Figure 4 This is a flowchart 400 illustrating a method or process for operating a mid-drive motor assembly 300 according to one or more embodiments of the present disclosure. Although in Figure 4 The general order of steps of method or process 400 is shown, but method or process 400 may include more or fewer steps, or may be combined with... Figure 4 The different arrangement steps shown are in sequence (including simultaneous, substantially simultaneous, or sequential). It should be noted that reference should be made to the combination of... Figures 3A-3E The method or process 400 is explained by describing the components, devices, sub-components, environment, etc. For example, it should be noted that without departing from the scope of this disclosure, such as Figures 3A-3E The embodiments shown should be understood as reading about Figure 4 The described embodiments are, conversely, also interchangeable. Furthermore, it should be understood that the steps of method or process 400 may be interchanged with the steps of method or process 200 without departing from the scope of this disclosure.

[0257] In this embodiment, auxiliary power 402 is provided by an auxiliary sub-assembly of the mid-drive motor assembly. The auxiliary sub-assembly 310 may be a component of the CVT 302 of the mid-drive motor assembly 300. The auxiliary power is generated by the auxiliary motor 312 of the auxiliary sub-assembly 310 and transmitted to the planet carrier 330 of the auxiliary gearbox 314 of the auxiliary sub-assembly 310. The auxiliary power is converted by two sets of planetary gears 326 and 328 connected to the planet carrier 330 and output from the auxiliary gearbox 314 via a second ring gear 332. The output auxiliary power is transmitted to the output sprocket 306 via a clutch 344.

[0258] In this embodiment, shift power 404 is provided by a shift subassembly of a mid-drive motor assembly. The shift subassembly 316 may be a component of the CVT 302 of the mid-drive motor assembly 300. The shift power is generated by the shift motor 318 of the shift subassembly 316 and transmitted to the planetary carrier 340 of the shift gearbox 320 of the shift subassembly 316. The shift power is converted by two sets of planetary gears 336 and 338 connected to the planetary carrier 340 and output from the shift gearbox 320 via a second ring gear 342.

[0259] In this embodiment, user input 406 is received from the crankshaft of the mid-drive motor assembly. When the rider supplies torque to the crankshaft 304, the user input is provided as crankshaft power to the first ring gear 334 of the shift gearbox 320 via the clutch 346. It should be noted that this can be supplemental to or alternative to shift power. It should be noted that, for the purposes of this disclosure, the receipt of user input can be considered optional. For example, shift power and crankshaft power can be provided via the planetary carrier 340 before being output via the second ring gear 342, such that both are provided to the output sprocket 306 via the second ring gear 342. As another example, only crankshaft power can be input from the first ring gear 334 to the second ring gear 342 via the planetary carrier 340 (i.e., when the shift motor 318 does not provide auxiliary power).

[0260] In this embodiment, output power is generated 408 for the output sprocket of the mid-drive motor assembly. Auxiliary power from the auxiliary subassembly 310 and / or shift power from the shift subassembly 316 (optionally as crankshaft power input by the user) is provided as output power via shaft 354 of the second gear ring 342 coupled to the output sprocket 306. Rotation of shaft 354 causes rotation of the output sprocket 306 (and thus, via a belt or chain connecting the output sprocket 306 to the hub, causing rotation of the hub of the wheel, although not shown). In this respect, the CVT 302 achieves variable transmission functionality by appropriately controlling the auxiliary motor 312 and the shift motor 318, combined with the torque input from the pedal via crankshaft 304 when applied.

[0261] Figure 5A and 5B A schematic diagram of an electric bicycle according to one or more embodiments of the present disclosure is shown. In particular, Figure 5A An electric bicycle 500A with a mid-mounted drive motor assembly 100 is shown, as described throughout this disclosure. Additionally, Figure 5B An electric bicycle 500B having a mid-drive motor assembly 300 is shown, as described throughout this disclosure. It should be understood that, unless otherwise stated, components, sub-assemblies, and / or parts of the electric bicycle 500A (e.g., including the mid-drive motor assembly 100 and its sub-assemblies and / or parts) may be similar to or identical to those of the electric bicycle 500B (e.g., including the mid-drive motor assembly 300 and its sub-assemblies and / or parts). Furthermore, it should be understood that, unless otherwise stated, components, sub-assemblies, and / or parts of the electric bicycle 500A (e.g., including the mid-drive motor assembly 100 and its sub-assemblies and / or parts) may be combined and / or interchanged with those of the electric bicycle 500B (e.g., including the mid-drive motor assembly 300 and its sub-assemblies and / or parts).

[0262] Now refer to Figure 5A The electric bicycle 500A includes a mid-drive motor assembly 100 with a CVT 102, the CVT including an auxiliary subassembly 110, a shift subassembly 116, and a planetary gear system 122; a crankshaft 104; and an output sprocket 106. The electric bicycle 500A has a belt or chain 502 connected to the output sprocket 106 of the mid-drive motor assembly 100. The belt or chain 502 is connected to a hub 504 of the wheel 506, and this rotation of the output sprocket 106 causes actuation of the belt or chain 504 and subsequent rotation of the hub 504 and the wheel 506.

[0263] Power 501 from the auxiliary subassembly is supplied to the planetary gear system 122 by the auxiliary subassembly 110. Power 503 from the shift subassembly is also supplied to the planetary gear system 122 by the shift subassembly 116. User input 505 from the crankshaft 104 is optionally received by the planetary gear system 122.

[0264] Electricity 507 is supplied to the auxiliary subassembly 110 and the shift subassembly 116 to generate auxiliary subassembly power 501 and shift subassembly power 503, respectively. For example, the electric bicycle 500A includes a battery pack 508 that powers the auxiliary motor 112 of the auxiliary subassembly 110 and the shift motor 118 of the shift subassembly 116.

[0265] Power from the planetary gear system 122 is provided to the output sprocket 106 as generated output power 509. For example, output power 509 can be generated from a combination of one or more of the auxiliary sub-component power 501, the shift sub-component power 503, and the user input 505.

[0266] The electric bicycle 500A includes a control system 510 that controls the power input and / or power output of the battery pack 508, the power input and / or power output of the auxiliary motor 112, and / or the power input and / or power output of the shift motor 118. The control system 510 can be connected to the battery pack 508 and / or the mid-drive motor assembly 100 via a wired connection and / or a wireless connection.

[0267] Although the components of CVT 102 are in Figure 5A The components are shown as stacked blocks in the schematic diagram; however, it should be understood that the arrangement of the blocks within CVT 102 does not indicate the actual arrangement within CVT 102. Rather, in an exemplary embodiment of the mid-drive motor assembly 100, the arrangement of components within CVT 102 may resemble... Figure 1A-1E The arrangement shown and described in the corresponding disclosure.

[0268] Now refer to Figure 5BThe electric bicycle 500B includes a mid-drive motor assembly 300, which has a CVT 302 including an auxiliary subassembly 310 and a shift subassembly 316, a crankshaft 304, and an output sprocket 306. The electric bicycle 500B has a belt or chain 502 connected to the output sprocket 306 of the mid-drive motor assembly 300. The belt or chain 502 is connected to a hub 504 of the wheel 506, and this rotation of the output sprocket 306 causes actuation of the belt or chain 504 and subsequent rotation of the hub 504 and the wheel 506.

[0269] The auxiliary sub-assembly power 501 is provided by the auxiliary sub-assembly 310. Additionally, the shift sub-assembly power 503 is provided by the shift sub-assembly 316. User input 505 from the crankshaft 304 is optionally received by the shift sub-assembly 316. Electricity 507 is provided to the auxiliary sub-assembly 110 and the shift sub-assembly 116 to generate the auxiliary sub-assembly power 501 and the shift sub-assembly power 503, respectively. For example, the electric bicycle 500B includes a battery pack 508 that powers the auxiliary motor 312 of the auxiliary sub-assembly 310 and the shift motor 318 of the shift sub-assembly 316.

[0270] Power from the auxiliary subassembly 310 and the shift subassembly 316 is provided to the output sprocket 106 as generated output power 509. For example, output power 509 can be generated from a combination of one or more of the auxiliary subassembly power 501 and / or the shift subassembly power 503, wherein the shift subassembly power 503 may optionally include user input 505.

[0271] The electric bicycle 500B includes a control system 510 that controls the power input and / or power output of the battery pack 508, the power input and / or power output of the auxiliary motor 312, and / or the power input and / or power output of the shift motor 318. The control system 510 can be connected to the battery pack 508 and / or the mid-drive motor assembly 300 via a wired connection and / or a wireless connection.

[0272] Typically, the control system 510 of electric bicycles 500A and 500B may include one or more control units (e.g., controllers, servers, etc.). The one or more control units may include a processor and memory (e.g., storage media, memory devices, etc.). The processor may be configured to execute program instructions held on or stored in memory. The processor of the one or more control units may perform any of the various method or process steps required to operate the electric bicycles 500A and 500B and / or their sub-components and / or parts.

[0273] The control system 510 may include a user interface that is coupled (e.g., physical, electrical, or communication) to one or more control units. For example, the user interface may be a separate device coupled to one or more control units. As another example, the user interface and one or more control units may reside within a common or shared housing. The user interface may include one or more displays, one or more user input devices, and / or one or more port connectors (e.g., for transmitting and / or receiving power and / or data, etc.).

[0274] The control system 510 may include one or more sensors, which are coupled (e.g., physically coupled, electrically coupled, communicatively coupled, etc.) to or integrated into one or more control units, electric bicycles 500A, 500B, and / or sub-assemblies and / or components of electric bicycles 500A, 500B. The one or more sensors may be operable to determine various operating parameters, physical parameters, and / or environmental parameters of the electric bicycles 500A, 500B, their sub-assemblies and / or components, and / or control system 510; the environment surrounding the electric bicycles 500A, 500B, their sub-assemblies and / or components, and / or control system 510. For example, the sensors may be operable to determine the power input and / or power output of the electric bicycles 500A, 500B, their sub-assemblies and / or components, and / or control system 510.

[0275] The control system 510 may include one or more transmitters and / or receivers, which are coupled (e.g., physically, electrically, or communicatively) to or integrated into one or more control units, electric bicycles 500A, 500B, and / or sub-components and / or parts of electric bicycles 500A, 500B. The one or more transmitters and / or receivers may be configured to transmit and / or receive data 511 (e.g., from sensors installed within the sub-components and / or parts of electric bicycles 500A, 500B, and / or parts of electric bicycles 500A, 500B) or from an external third-party control unit (e.g., a controller, server, etc.) via a wired or wireless connection. The external third-party control unit may be configured as a transmitting (Tx) unit, a receiving (Rx) unit, or a combined Tx / Rx unit.

[0276] The control system 510 can be configured to monitor electric bicycles 500A, 500B and / or sub-components and / or parts of electric bicycles 500A, 500B via received and / or transmitted data. The control system 510 can be configured to generate control signals based on the received and / or transmitted data to adjust one or more parts of electric bicycles 500A, 500B and / or sub-components and / or parts of electric bicycles 500A, 500B via a feedback loop or feedforward loop. The control system 510 can be configured to receive and / or transmit data in standardized and / or non-standardized formats. In the case of non-standardized data, the data can be converted to a standardized format upon reception and / or before transmission to sensors, third-party control units, etc.

[0277] In this respect, advantages of this disclosure include a compact CVT in a mid-drive motor assembly for an electric bicycle. Advantages of this disclosure include a planetary gear system in the CVT. Advantages of this disclosure also relate to an axial flux motor in the CVT. Advantages of this disclosure include a gear system and a motor, both coaxial along a longitudinal axis passing through a crankshaft, through which the planetary gear system and motor can be inserted. Advantages of this disclosure include a three-gearbox CVT comprising an auxiliary subassembly, a shift subassembly, and a planetary gear system for providing power output to the auxiliary subassembly and shift subassembly (and optionally user input from the crankshaft). Advantages of this disclosure include a two-gearbox CVT comprising an auxiliary subassembly and a shift subassembly for providing power output to the auxiliary subassembly and shift subassembly (and optionally user input from the crankshaft).

[0278] While embodiments of this disclosure relate to the mid-drive motor assembly described for use in electric bicycles, it should be understood that this should not be construed as a limitation of this disclosure. For example, the mid-drive motor assembly (and / or components thereof) may be mounted on other wheeled vehicles, including but not limited to scooters, wheelchairs, unicycles, tricycles, small scooters, all-terrain vehicles, multi-purpose terrain vehicles, motorcycles, automobiles, camping vehicles, construction vehicles, warehousing and freight vehicles, lawn and agricultural machinery, or any wheeled vehicle that can benefit from applied power (i.e., via a CVT) to assist in the propulsion of the wheeled vehicle.

[0279] While various embodiments of the present disclosure have been described in detail, it will be apparent to those skilled in the art that modifications and alterations to those embodiments will occur. However, it should be understood that such modifications and alterations are within the scope and spirit of the present disclosure as set forth in the appended claims. Furthermore, one or more of the inventions described herein are capable of having other embodiments and can be practiced or performed in various ways. It should be understood that the wording and terminology used herein are for illustrative purposes and should not be considered limiting.

Claims

1. A continuously variable transmission (CVT) with a mid-mounted drive motor assembly, comprising: Auxiliary sub-components, the auxiliary sub-components including: An auxiliary motor operable to generate auxiliary power; and An auxiliary gearbox, operable to receive auxiliary power via a first set of auxiliary planetary gears and to convert the auxiliary power via a second set of auxiliary planetary gears to produce modified auxiliary power; and The gear shift assembly includes: A shift motor operable to generate shifting power; and A shift gearbox operable to receive shift power via a first set of shift planetary gears and to convert the shift power via a second set of shift planetary gears to produce modified shift power. The modified auxiliary power and the modified shift power are provided to the output sprocket of the mid-mounted drive motor assembly, and The auxiliary motor, the auxiliary gearbox, the shift motor, and the shift gearbox are coaxial along a longitudinal axis passing through the auxiliary subassembly and the shift subassembly.

2. The continuously variable transmission (CVT) of claim 1, wherein the shift assembly is operable to provide the modified shift power to the output sprocket, and wherein the shift assembly is operable to receive the modified auxiliary power and provide the modified auxiliary power to the output sprocket.

3. The continuously variable transmission according to claim 1, wherein the auxiliary gearbox comprises: A first auxiliary gear ring, operable to engage with a first set of auxiliary planetary gears, wherein the first auxiliary gear ring is fixedly positioned within the continuously variable transmission; A second auxiliary gear ring, operable to engage with a second set of auxiliary planetary gears; as well as An auxiliary planetary carrier, to which the first set of auxiliary planetary gears and the second set of auxiliary planetary gears are connected. The auxiliary gearbox receives auxiliary power from the auxiliary motor via the auxiliary planetary carrier, and The auxiliary gearbox provides the modified auxiliary power via the second auxiliary gear ring.

4. The continuously variable transmission according to claim 1, wherein the shift gearbox comprises: A first shift gear ring, operable to engage with a first set of shift planetary gears; The second shift gear ring is operable to engage with the second set of shift planetary gears; as well as A shift planetary carrier, to which the first set of shift planetary gears and the second set of shift planetary gears are connected. The shift gearbox receives shifting power from the shift motor via the shift planetary carrier. The shift gearbox provides the modified shift power via the second shift ring gear, and The second shift gear ring is operable to provide the modified auxiliary power and the modified shift power to the output sprocket.

5. The continuously variable transmission according to claim 4, further comprising: A clutch operable to transmit the modified auxiliary power from the auxiliary gearbox to the second shift ring gear.

6. The continuously variable transmission (CVT) of claim 4, wherein the longitudinal axis is defined along the length of the crankshaft of the mid-mounted drive motor assembly, wherein the crankshaft is positioned through the auxiliary motor and the auxiliary gearbox of the auxiliary subassembly, and the shift motor and the shift gearbox of the shift subassembly. The first shift ring gear is operable to receive user input from the crankshaft, and The planetary gear carrier is operable to combine the received user input and the shift power.

7. The continuously variable transmission according to claim 6, further comprising: A clutch operable to transmit the user input from the crankshaft to the first shift ring gear.

8. The continuously variable transmission according to claim 1, further comprising: A planetary gear system connected to the output sprocket, wherein the planetary gear system is operable to receive the modified auxiliary power from the auxiliary subassembly and to provide the modified auxiliary power to the output sprocket of the mid-drive motor assembly, wherein the planetary gear system is operable to receive the modified shift power from the shift subassembly and to provide the modified shift power to the output sprocket of the mid-drive motor assembly, and The auxiliary motor, the auxiliary gearbox, the shift motor, the shift gearbox, and the planetary gear system are coaxial along the longitudinal axis.

9. The continuously variable transmission according to claim 8, further comprising: A clutch operable to transmit the modified auxiliary power from the auxiliary gearbox to the planetary gear system.

10. The continuously variable transmission according to claim 8, wherein the auxiliary gearbox comprises: A first auxiliary gear ring, operable to engage with a first set of auxiliary planetary gears, wherein the first auxiliary gear ring is fixedly positioned within the continuously variable transmission; A second auxiliary gear ring, operable to engage with a second set of auxiliary planetary gears; as well as An auxiliary planetary carrier, to which the first set of auxiliary planetary gears and the second set of auxiliary planetary gears are connected. The auxiliary gearbox receives the auxiliary power from the auxiliary motor via the auxiliary planetary carrier, and The auxiliary gearbox provides the modified auxiliary power via the second auxiliary gear ring.

11. The continuously variable transmission according to claim 8, wherein the shift gearbox comprises: A first shift ring gear, operable to engage with a first set of shift planetary gears, wherein the first shift ring gear is fixedly positioned within the continuously variable transmission. The second shift gear ring is operable to engage with the second set of shift planetary gears; as well as A shift planetary carrier, to which the first set of shift planetary gears and the second set of shift planetary gears are connected. The shift gearbox receives the shift power from the shift motor via the shift planetary carrier, and The shift gearbox provides the modified shift power via the second shift ring gear.

12. The continuously variable transmission according to claim 8, wherein the planetary gear system comprises: A sun gear, operable to receive the modified auxiliary power provided by the auxiliary gearbox; A gear ring, operable to receive the modified shift power provided by the shift gearbox; as well as Planet carrier, a set of planetary gears connected to the planet carrier, The planetary gear set is operable to engage the sun gear and transmit the modified auxiliary power to the output of the mid-drive motor assembly via the planet carrier. The set of planetary gears is operable to engage the ring gear and transmit the modified shift power to the output of the mid-drive motor assembly via the planet carrier.

13. The continuously variable transmission (CVT) of claim 12, wherein the longitudinal axis is defined along the length of the crankshaft of the mid-mounted drive motor assembly. The crankshaft is positioned through the auxiliary motor and auxiliary gearbox of the auxiliary subassembly, the shift motor and shift gearbox of the shift subassembly, and the planetary gear system. The sun gear is operable to receive user input from the crankshaft, and The sun gear is operable to combine the received user input and the received modified auxiliary power before engaging with the set of planetary gears.

14. The continuously variable transmission according to claim 13, further comprising: A clutch operable to transmit the user input from the crankshaft to the sun gear of the planetary gear system.

15. A mid-mounted drive motor assembly, comprising: Continuously variable transmission (CVT), the CVT comprising: Auxiliary sub-components, the auxiliary sub-components including: An auxiliary motor operable to generate auxiliary power; and An auxiliary gearbox, operable to receive auxiliary power via a first set of auxiliary planetary gears and to convert the auxiliary power via a second set of auxiliary planetary gears to produce modified auxiliary power; and A gear shift assembly, the gear shift assembly comprising: A shift motor operable to generate shifting power; and A shift gearbox operable to receive the shift power via a first set of shift planetary gears and to convert the shift power via a second set of shift planetary gears to produce modified shift power; A crankshaft positioned through the auxiliary motor, the auxiliary gearbox, the shift motor, and the shift gearbox, wherein the auxiliary subassembly and the shift assembly are coaxial along a longitudinal axis passing through the auxiliary motor, the auxiliary gearbox, the shift motor, and the shift gearbox, and wherein the longitudinal axis is defined along the length of the crankshaft; and An output sprocket, operable to receive the modified auxiliary power and the modified shift power.

16. The mid-drive motor assembly of claim 15, wherein the shift sub-assembly is operable to provide the modified shift power to the output sprocket, and wherein the shift sub-assembly is further operable to receive the modified auxiliary power and provide the modified auxiliary power to the output sprocket.

17. The mid-mounted drive motor assembly according to claim 15, wherein the continuously variable transmission further comprises: A planetary gear system operable to receive the modified auxiliary power from the auxiliary subassembly and provide the modified auxiliary power to the output sprocket, the planetary gear system further operable to receive the modified shift power from the shift subassembly and provide the modified shift power to the output sprocket. The auxiliary motor and auxiliary gearbox of the auxiliary sub-assembly, the shift motor and shift gearbox of the shift sub-assembly, and the planetary gear system are coaxial along a longitudinal axis passing through the auxiliary sub-assembly, the shift sub-assembly, and the planetary gear system.

18. An electric bicycle, comprising: Mid-drive motor assembly, the mid-drive motor assembly comprising: Continuously variable transmission (CVT), the CVT comprising: Auxiliary sub-components, the auxiliary sub-components including: An auxiliary motor operable to generate auxiliary power; and An auxiliary gearbox, operable to receive the auxiliary power and generate modified auxiliary power; and A gear shift assembly, the gear shift assembly comprising: A shift motor operable to generate shifting power; and A shift gearbox operable to receive the shift power and generate modified shift power; A crankshaft positioned through the auxiliary motor, the auxiliary gearbox, the shift motor, and the shift gearbox, wherein the auxiliary subassembly and the shift assembly are coaxial along a longitudinal axis passing through the auxiliary motor, the auxiliary gearbox, the shift motor, and the shift gearbox, and wherein the longitudinal axis is defined along the length of the crankshaft; and An output sprocket, operable to receive the modified auxiliary power and the modified shift power.

19. The electric bicycle of claim 18, wherein the shift assembly is operable to provide the modified shift power to the output sprocket, and wherein the shift assembly is further operable to receive the modified auxiliary power and provide the modified auxiliary power to the output sprocket.

20. The electric bicycle of claim 18, wherein the continuously variable transmission of the mid-mounted drive motor assembly further comprises: A planetary gear system operable to receive the modified auxiliary power from the auxiliary subassembly and provide the modified auxiliary power to the output sprocket, the planetary gear system further operable to receive the modified shift power from the shift subassembly and provide the modified shift power to the output sprocket. The auxiliary motor and auxiliary gearbox of the auxiliary sub-assembly, the shift motor and shift gearbox of the shift sub-assembly, and the planetary gear system are coaxial along a longitudinal axis passing through the auxiliary sub-assembly, the shift sub-assembly, and the planetary gear system.

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