Drive unit for vehicle operated with muscle and / or motor forces, and vehicle

Abstract

The utility model relates to a drive unit for a vehicle operated with muscle force and / or motor force, in particular an electric bicycle, an electric motorized bicycle or a racing-type electric motorized bicycle, comprising: a housing of the drive unit, the housing comprising a first housing half (10) and a further housing half (11), and the housing comprising a second housing half (12) and a third housing half (13), a stator (20) of the motor is fastened in the first housing half (10); a pedal shaft assembly (40); at least one first circuit board (50); a rotor shaft mechanism (30) comprising a rotor (32) and a rotor shaft (31) of the motor and comprising at least one further housing part (12); at least one transmission (60) configured for transmitting torque generated by the motor to a pedal shaft assembly (40); wherein all components are arranged in such a way that these components can be inserted from a main assembly direction (z). The utility model further relates to a bicycle.

Description

Technical Field

[0001] The present application relates to a drive unit for driving a vehicle operated by muscle power and / or motor power, a vehicle having the drive unit and a method for assembling the drive unit. The vehicle is in particular an electric bicycle, an electric power-assisted bicycle (Pedelec, electric power-assisted bicycle) or a racing electric power-assisted bicycle (S-Pedelec, high-performance power-assisted bicycle). Background Art

[0002] For example, a drive unit for an electric bicycle is known from DE 10 20 20 21 0 864 A1. In addition, drive units with preassembled components are common solutions, but require many non-value-added assembly processes, which are determined by the complex design and the partially multi-part circuit board structure. Utility Model Content

[0003] The drive unit for a vehicle operated by muscle power and / or motor power, in particular an electric bicycle, an electric assisted bicycle or a racing electric assisted bicycle according to the present application is characterized in that, compared to known drive units, all components are arranged in such a way that they can be placed (or inserted) from a main assembly direction.

[0004] To this end, the drive unit comprises:

[0005] a housing of a drive unit, wherein the housing comprises at least a first housing half and a further housing half, and wherein the stator of the motor is fastened in the first housing half,

[0006] Pedal shaft assembly,

[0007] at least one first circuit board,

[0008] a rotor shaft arrangement, which comprises the rotor and the rotor shaft of the motor and comprises at least one further housing part,

[0009] A transmission configured to transmit the torque generated by the motor to the pedal shaft assembly.

[0010] The housing of the drive unit (hereinafter referred to as “the housing”) is used to encapsulate the drive unit and form an enclosure relative to the environment.

[0011] The forces generated by the drive unit can be received in the housing, and the forces acting from the outside can be transmitted or absorbed by means of the housing. The forces generated inside the drive unit, such as the forces caused by the output power of the motor, are supported and transferred in the housing. The forces acting on the drive unit from the outside can be caused, for example, by the operator of the vehicle (driver or rider). To this end, the operator can drive the vehicle forward with the help of a crank drive mechanism. Here, the forces generated, especially the pedaling forces, are guided to the inside of the housing and received at suitable bearing locations.

[0012] Forces acting on the drive unit from the outside may be caused by an accident or a flat (falling down) of the vehicle. Here, the housing protects the components arranged therein. By encapsulation, the housing also has a protective function from weather influences.

[0013] The housing comprises at least one first housing half and one further housing half. Here, the first housing half can be a half shell, a housing section, a bottom, etc. The first housing half and the at least one further housing half can have openings or slots, which can be completely or partially passed through by components arranged inside the drive unit. The at least one further housing half can be a half shell, a housing section, a cover, etc. The first housing half and the at least one further housing half can be detachably or non-detachably connected, supported, held or fastened to each other. For example, the first housing half and the at least one further housing half can be bonded and / or screwed to each other.

[0014] The stator of the motor is fastened in the first housing half. The stator of the motor is part of the electric drive of the drive unit and is fastened in the at least one first housing half in a detachable or non-detachable manner such that the stator is firmly received relative to the first housing half. For example, the stator is pressed into, glued, clamped or installed in a similar manner in the at least first housing half.

[0015] The pedal shaft assembly comprises at least one pedal shaft, which has an interface for a vehicle crank and is configured to receive a pedaling force of a vehicle operator. The pedaling force is applied to a pedal connected to the crank for this purpose, which in turn is connected to different ends of the pedal shaft. In addition, the pedal shaft assembly comprises means for coupling in an auxiliary torque generated by the motor.

[0016] At least one first circuit board includes an electronic device component for controlling and / or adjusting the drive unit. Here, the at least one circuit board should be understood as a main circuit board or a central circuit board, which includes a basic electronic device component or module for controlling and / or adjusting the drive unit. In particular, the at least one circuit board can be composed of a maximum of one circuit board. Preferably, the at least one first circuit board is not multi-piece. The at least one first circuit board can be manufactured and structured by a whole FR4 board and / or by a circuit board manufacturing process, and the FR4 board is composed of epoxy resin and glass fiber fabric, for example. The at least one circuit board can be used for the structuring of the drive unit. Structuring can, for example, refer to a spatial structure within the drive unit. In addition, the structuring of the drive unit can refer to a functional structure. For example, all transmission stages of the transmission device can be arranged above or below at least one circuit board in a direction parallel to the axis of the pedal shaft.

[0017] In addition to the rotor, the rotor shaft arrangement also includes the rotor shaft of the motor and at least one further housing part, in particular also includes elements for supporting the rotor shaft, in particular also includes a measuring device, which includes a rotor position magnet arrangement. The rotor of the motor is arranged on the rotor shaft in a rotationally fixed manner as a further part of the electric drive.

[0018] The rotor position magnet mechanism itself particularly comprises a corresponding assembly collar, which can be used to fix the rotor assembly relative to the stator of the motor during assembly in the radial direction about the rotor shaft. The rotor position magnet of the rotor position magnet mechanism particularly has magnetic properties, preferably different magnetic properties, along the periphery, so that the rotation angle of the rotor assembly can be detected by means of a corresponding sensor. In addition, the rotor shaft mechanism particularly comprises an assembly collar. The assembly collar is arranged in a housing part of the housing of the drive unit and partially or completely passes through the housing part. In other words, the housing part surrounds the assembly collar for radial position fixation of the rotor position magnet. "Encircle" can mean radially enclosed, or it can mean elliptical encirclement or encirclement in other ways.

[0019] The transmission is a spur gear, bevel gear, worm gear or the like, which is configured to transmit the auxiliary torque generated by the motor to the pedal shaft assembly. The transmission can be embodied as a single-stage, two-stage or three-stage transmission. In addition, the transmission can have a tank, which is configured to completely or partially receive the transmission. In this case, the tank can have a notch. In this case, the tank can have an additional pocket or reservoir. The tank can be a carrier for transmission grease or transmission lubricant.

[0020] The term "assembly" includes the components explained in the drive unit according to the present application, for example the pedal shaft assembly. In this case, the assembly is arranged such that it can be inserted from a main assembly direction. The main assembly direction is the assembly direction from which the assembly is introduced. In the viewing direction parallel to the pedal shaft, the assembly can be introduced in the main assembly direction by means of the introduction device until its final position in the first housing half. In particular, the main assembly direction corresponds to the z-direction.

[0021] Preferably, the components are arranged in such a way that a further translational assembly direction x, y and / or rotational assembly direction is provided for inserting the components. For example, the further translational assembly direction x, y and / or rotational assembly direction is a linear movement in the x direction and / or in the y direction. The rotational movement can be a rotational movement and / or a swiveling movement.

[0022] Preferably, the pedal shaft assembly does not interfere with the rotor shaft mechanism and the stator of the motor. "Interference" is to be understood as overlapping components or physical collisions. Instead, this means that, for example, the assembly has a distance, an air gap, etc., when viewed in a direction of observation parallel to the axis of the pedal shaft. Preferably, alternatively or additionally, the assembly has an air gap in the arrangement before insertion, wherein the insertion requires only a translational movement and is carried out in a direction parallel to the viewing direction. For example, the assembly is guided only in the z direction, and the insertion device does not perform translational movements x, y and / or rotational movements.

[0023] Preferably, the plug device is arranged above a first plane in the y direction. The first plane is spanned by an axis arranged coaxially with the pedal axis and a further axis arranged coaxially with the rotor axis. The plug device can include one or more plug-in locations for one or more plugs. The plug device is an electrical interface of the drive unit with other components of the vehicle. For example, the electrical interface is connected to the battery module in the drive unit via a cable and is fed by the battery module, wherein a plug from the battery module can be plugged into the plug device.

[0024] “Above the first plane” means that the connector device is arranged above the first plane in the positive y direction. It is particularly advantageous if the connector device is arranged in a protected area of ​​the frame component so that it can be better protected against influences such as moisture or dust.

[0025] In an alternative configuration, the plug device can also be arranged above the fastening plane in particular. The fastening plane is a plane unfolded by the axis of the first fastening device and the axis of another fastening device. A fastening device is a device that fastens the drive unit, for example, to a frame member of a vehicle. In particular, the fastening device includes a notch, preferably a hole in the housing. In particular, "a first fastening device" and "another fastening device" refer to exactly two fastening devices, thereby excluding a drive unit with more than two fastening devices. In one configuration, the drive unit can also include more than two fastening devices. In this preferred configuration, "a first fastening device" and "another fastening device" refer to fastening devices that are arranged farthest from each other. Fastening devices can also be, for example, screws, threads, through holes, nuts, etc. The fastening device can also be a combination of the above-mentioned elements.

[0026] Preferably, the plug device is arranged below the first plane in the y-direction, wherein the first plane is spanned by an axis arranged coaxially with the pedal axis and a further axis arranged coaxially with the rotor axis. It is particularly advantageous in this configuration that the plug device is arranged to be very easily accessible and can be quickly plugged in or disconnected for maintenance or repair work. “Below the first plane” means that the plug device is arranged below the first plane in the negative y-direction. In an alternative configuration, the plug device can also be arranged below the fastening plane.

[0027] Preferably, the drive unit comprises at least one speed sensor, wherein the at least one speed sensor is arranged on at least one first circuit board and has a first distance to the rear surface of the housing, wherein the first distance is in the range of 5 mm to 50 mm, preferably 5 mm to 45 mm, particularly preferably 5 mm to 35 mm. The speed sensor operates in particular with the aid of a rim magnet. It is desirable to position the speed sensor in the vicinity of the rear surface of the housing so that the signal to be detected of the rim magnet can be detected with sufficient measurement accuracy.

[0028] The first distance to the rear surface of the housing is, in particular, the distance from the speed sensor to the rear surface of the housing, as seen in a direction parallel to the axis of the pedal shaft. The rear surface of the housing, in particular a part of the rear surface of the housing, is a surface of the drive unit, which extends at an angle to the first plane and is arranged near the pedal shaft and in a direction relative to the pedal shaft, which faces away from the rotor shaft. Here, the rear surface of the housing can also be a plane or surface formed by the axis of the apex of the housing protrusion near the pedal shaft. In a state where the drive unit is installed in the vehicle, the rear surface of the housing is the following surface, which is arranged on the side of the vehicle facing away in the direction of travel of the vehicle. The first distance to the rear surface of the housing is, in particular, the minimum distance from the speed sensor to the rear surface of the housing. The first distance to the rear surface of the housing is, in particular, a distance related to the vehicle and can vary depending on the installation position of the drive unit.

[0029] Preferably, the drive unit comprises at least one speed sensor, wherein the at least one speed sensor is arranged on the at least one first circuit board and is not less than a further distance u from the ferromagnetic component, characterised in that the further distance u is not less than 1 mm to 10 mm, preferably 1 mm to 8 mm, particularly preferably 3 to 7 mm. The further distance u to the ferromagnetic component is interpreted as a radius.

[0030] Preferably, the pedal shaft assembly further comprises a measuring device, which is suitable for detecting a torque applied to the pedal shaft. Here, the measuring device comprises at least one measuring circuit board, which has a measuring circuit board plane that is the same as the surface of the aforementioned measuring circuit board, wherein the measuring circuit board plane is arranged parallel to or orthogonal to the first plane. In a specific embodiment, the measuring circuit board plane can be arranged at an angle of 20° to 40° to the first plane.

[0031] The measuring device can be, for example, a torque sensor, in particular a magnetoelastic torque sensor, for measuring a pedaling torque which is applied to the pedal shaft, in particular by an operator of the vehicle.

[0032] “Orthogonal to the first plane” also means “substantially orthogonal to the first plane”. “Parallel to the first plane” also means “substantially parallel to the first plane”.

[0033] Preferably, the drive unit comprises a fastening device for the chain box, wherein at least two fastening devices for the chain box are arranged on a radius, wherein the radius is arranged concentrically around the axis of the pedal shaft and is in particular in the range of 80 mm to 110 mm, preferably 90 mm to 100 mm. The fastening device for the chain box is a device that supports, holds, removably or non-removably fastens or otherwise arranges the chain box on the drive unit. The fastening device for the chain box in particular comprises a notch in the housing or housing halves, preferably a hole, particularly preferably a threaded hole. The fastening device for the chain box can also be, for example, a screw, a thread, a through hole, a nut, etc. The fastening device for the chain box can also include a combination of the above-mentioned elements.

[0034] Preferably, when the output torque of the drive unit is greater than or equal to 85 Nm, the first housing length is less than 45 mm. The first housing length is the distance from the axis of the pedal shaft to the rear surface of the housing, as seen in a direction parallel to the axis of the pedal shaft. The rear surface of the housing, in particular a portion of the rear surface of the housing, is a surface of the drive unit, which extends at an angle to the first plane and is arranged near the pedal shaft and in a direction of the pedal shaft away from the rotor shaft. Here, the rear surface of the housing can also be a plane or surface formed by the axis of the vertex of the housing protrusion near the pedal shaft. When the drive unit is installed in the vehicle, the rear surface of the housing is the following surface, which is arranged on the side of the vehicle away from the direction of travel of the vehicle. The output torque refers to the auxiliary torque of the motor, which is transmitted to the output gear.

[0035] Further preferably, when the output torque of the drive unit is greater than or equal to 85 Nm, the length of the first shell is less than 42 mm, preferably less than or equal to 40 mm, and particularly preferably less than or equal to 39 mm.

[0036] Preferably, the axis of the rotor shaft is arranged below the fastening plane and the axis of the pedal shaft is arranged above the fastening plane, wherein the fastening plane is spanned by the axis of the first fastening means and the axis of the second fastening means, in particular the axis of only one second fastening means. "Below" and "above" refer to a spatial arrangement. The arrangement is viewed from a direction parallel to the axis of the pedal shaft.

[0037] The present application also relates to a vehicle, in particular an electric bicycle, an electric-driven bicycle (eBike), an electric-assisted bicycle or a racing electric-assisted bicycle, comprising a drive unit according to one of the above-described embodiments.

[0038] The present application also relates to a method for assembling a drive unit, in particular a drive unit according to one of the aforementioned embodiments, the method comprising the following steps:

[0039] providing a first housing half of the drive unit, wherein the stator of the motor is fastened in the first housing half,

[0040] Inserting a rotor shaft arrangement which comprises the rotor and the rotor shaft of the motor and at least one further housing part,

[0041] · inserting at least one first circuit board,

[0042] Insert the transmission device,

[0043] Inserting the second housing half, characterized in that the pedal shaft assembly is inserted before the rotor shaft mechanism or the pedal shaft assembly is inserted before the at least one first circuit board.

[0044] According to the present application, the assembly of the drive unit of previously assembled components is particularly efficient and can be additionally optimized with the proposed method. The previously assembled components are prefabricated on different assembly lines and provided for the proposed method. "Inserting" is also to be understood as a previously performed "providing", which is not explained for the sake of a better overview. "Providing a first housing half of the drive unit" is the first step for carrying out the method according to the present application.

[0045] In a further step, the rotor shaft arrangement is inserted, wherein in particular a pin of the rotor shaft is engaged in a bearing arrangement of the housing and at least one further housing part is engaged for carrying out an alignment of the rotor shaft.

[0046] In a further step, at least one first circuit board is inserted. Insertion of the at least one first circuit board includes centering and fastening of the at least one first circuit board. Fastening can be performed, for example, by screwing, melting plastic pins passing through the at least one first circuit board, or by cutting and clamping connections for fastening the circuit board.

[0047] In a further step, the gear is installed. Installing the gear comprises in particular aligning the toothing arranged on the rotor shaft with the first gear stage of the gear.

[0048] In a further step, the second housing half is placed. The placing may include applying a seal or adhesive and fastening the housing halves.

[0049] According to the application, the pedal shaft assembly can be inserted before the rotor shaft mechanism or before the at least one first circuit board. It is particularly advantageous that the assembly of the drive unit can be arranged more flexibly as a result. In one embodiment, the assembly process can be pre- or post-assembled in a partially or fully automated assembly process with the joining device shut down, which leads to increased availability and faster assembly. BRIEF DESCRIPTION OF THE DRAWINGS

[0050] The present application is explained in more detail with the aid of the accompanying drawings.

[0051] Figure 1 A schematic diagram showing a drive unit with all components according to the present application;

[0052] Figure 2 a schematic interior view showing a first embodiment of a drive unit in a first installation stage;

[0053] Figure 3 a schematic interior view showing a first embodiment of a drive unit in a second installation stage;

[0054] Figure 4 a schematic external view showing a first embodiment of a drive unit in a third installation stage;

[0055] Figure 5 A schematic external view showing a first housing half of a first embodiment of a drive unit in a third installation stage;

[0056] Figure 6 a schematic interior view showing a second embodiment of a drive unit in a first installation stage;

[0057] Figure 7 a schematic internal view showing a third embodiment of a drive unit in a first installation stage;

[0058] Figure 8 a schematic external view showing a third embodiment of a drive unit in a second installation phase;

[0059] Fig. 9 A schematic diagram showing a bicycle having a drive unit according to the present application;

[0060] Fig.10 A schematic diagram showing a method according to the present application. DETAILED DESCRIPTION

[0061] Figure 1 The drive unit 2 of the present application is shown in an exploded view.

[0062] The housing comprises at least one first housing half 10 and one further housing half 11. The first housing half 10 can be a half shell or a bottom. The first housing half 10 and the at least one further housing half 11 have openings through which components arranged inside the drive unit 2 can be partially or completely passed. For example, Figure 1 It is shown how a part of the pedal shaft assembly 40 passes completely through the housing halves 10, 11. The at least one further housing half 11 is a half shell or a cover. The first housing half 10 and the at least one further housing half 11 are detachably connected to each other and supported on each other. The first housing half 10 and the at least one further housing half 11 are threadedly connected.

[0063] Figure 1 Also shown is a stator 20 of the motor, which is fastened in the first housing half 10. The stator 20 of the motor is part of the electric drive of the drive unit and is fastened in the first housing half 10 detachably or non-detachably in such a way that it cannot perform movements relative to the first housing half 10. In this embodiment, the stator 20 is pressed into at least one first housing half 10 (not shown due to the exploded view).

[0064] The pedal shaft assembly 40 includes an interface for the crank 119 of the vehicle 100 and is configured to receive a pedaling force from an operator of the vehicle 100. Figure 1 A measuring device 41 of the pedal shaft assembly 40 is shown, which is configured for determining an operator torque applied to the pedal shaft 103 .

[0065] At least one first circuit board 50 comprises electronic components for controlling and / or regulating the drive unit 2. The at least one circuit board 50 is to be understood as a main circuit board or central circuit board which comprises basic electronic components or modules for controlling and / or regulating the drive unit. Figure 1 In this embodiment, only one main circuit board 50 is installed. At least one first circuit board 50 is manufactured and structured by a circuit board manufacturing process. At least one first circuit board 50 can be used for structuring of the drive unit. Structuring refers to the spatial structure within the drive unit. In addition, structuring refers to a functional structure. Figure 1 As shown, all transmission stages of the transmission device 60 are arranged (in the z direction) above at least one first printed circuit board, so that these transmission stages do not require a change or abrupt change in the force profile from the printed circuit board front side to the printed circuit board back side.

[0066] In addition to the rotor shaft 31 , the rotor shaft arrangement 30 also includes elements for supporting the rotor shaft 31 , a further housing part 12 and a rotor position magnet arrangement (not shown). The rotor 32 of the motor is arranged on the rotor shaft 31 in a rotationally fixed manner as a further part of the electric drive.

[0067] The transmission 60 is a spur gear transmission configured to transmit the torque generated by the motor to the pedal shaft assembly 40. The transmission can be implemented as a single-stage, double-stage, or three-stage. Figure 1 , the transmission 60 has a trough, which is configured to at least partially receive the transmission 60. Here, the trough has a notch. The trough has an additional pocket or reservoir (not shown), which serves as a carrier for transmission grease or transmission lubricant.

[0068] Figures 2 to 5 Schematic interior and exterior views of a first embodiment of a drive unit in different installation stages (or rather completion stages) are shown. In other words, all views relate to the same first embodiment.

[0069] In particular, Figure 2A schematic internal view of a first embodiment of a drive unit in a first installation phase is shown. A first housing half 10 with an already inserted circuit board 50 and a pedal shaft assembly 40 is shown here. In addition, a speed sensor 51 is shown which is arranged on the circuit board 50 and is positioned at a first distance S relative to the housing rear surface 10a. In the first embodiment shown, the distance S is in the range of 26 mm to 29 mm. In addition, a further distance u from the speed sensor 51 to the ferromagnetic part is not less than 8 mm (not shown). Figure 2 Further shown is the distance D from the axis of the pedal shaft 103 to the housing rear surface 10a. In the first embodiment shown, the distance D is in the range of 35 mm to 45 mm.

[0070] Figure 3 A schematic internal view of a first embodiment of a drive unit 2 in a second installation phase is shown. A pedal shaft assembly 40 with a measuring device 41 is shown, wherein the measuring device 41 comprises a first measuring circuit board 410 and a second measuring circuit board 411. The first measuring circuit board 410 and the second measuring circuit board are arranged substantially in parallel. The first measuring circuit board 410 comprises a measuring circuit board plane 91a which is identical to a surface of the first measuring circuit board 410. The second measuring circuit board 411 comprises a measuring circuit board plane 91b which is identical to a surface of the second measuring circuit board 411. Figure 3 Also shown is a first plane 90, which is spanned by a first axis arranged coaxially with the pedal shaft 103 and a further axis arranged coaxially with the rotor shaft 31. In this specific embodiment, the measuring circuit board planes 91a, 91b are arranged at an angle of less than 45° to the first plane 90. Also shown is a fastening plane 92, which is spanned by the axis of the first fastening means 93a and the axis of the second fastening means 93b. The fastening means 93a, 93b are used to fasten the drive unit 2 to the frame member 102 (such as the frame member 102 of the vehicle 100). Fig. 9 ) on the device.

[0071] In addition, Figure 3 In the second assembly phase shown in FIG. 1 , the first printed circuit board 50 has not yet been installed, so that the rotor shaft arrangement 30 with a further housing part 12 , in particular the bearing shield 12 , the rotor shaft 31 and the stator 20 can be seen.

[0072] exist Figure 3 It is also shown in FIG. 1 that the axis of the rotor shaft 31 is located below the fastening plane 92 in the negative y-direction and the axis of the pedal shaft is located above the fastening plane 92 in the positive y-direction.

[0073] Figure 4A schematic external view of the first embodiment of the drive unit 2 is shown in a third installation stage. The cover 11 and the pedal shaft 103 are shown here, which passes completely through the cover 11 via a slot in the cover.

[0074] Figure 5 1 shows a schematic external view of the first housing half 10 of the first embodiment of the drive unit 2 in the third installation stage. Figure 4 and Figure 5 The same installation phase is shown with the drive unit 2 rotated by 180°. The plug device 70 is arranged above the first plane in the y direction. The plug device 70 can include a plurality of plug positions or only one plug. The plug device 70 is an interface between the drive unit 2 and other components of the vehicle 100, such as the display and / or operating unit 122 (see also Fig. 9 ). It is particularly advantageous if the connector device 70 is arranged in a protected area of ​​the frame component 102 so that it can be better protected against influences such as moisture or dust. Figure 5 It is further shown that the connector device 70 is arranged above the fastening plane 92. In an alternative embodiment, the connector device 70a (schematically indicated by a straight line) can also be arranged below the fastening plane 92 or below the first plane 90.

[0075] Figure 6 A schematic interior view of a second embodiment of a drive unit 2 is shown in a first installation phase. Figure 7 A schematic internal view of a third embodiment of a drive unit is shown in a first installation phase. Figure 6 and Figure 7 The same installation stage is shown, and in particular the differences in the embodiments are shown. Here, the main focus is on the pedal shaft assembly 40 with the correspondingly existing measuring device 41 . Figures 1 to 5 The elements of the drive unit 2 which have been shown in FIG. 2 are only explained insofar as they are useful for explaining the embodiments.

[0076] Figure 6 The measuring device 41 is shown with two measuring circuit boards 410 , 411 , each having a measuring circuit board plane 91 a and a measuring circuit board plane 91 b . The first plane 90 is arranged substantially parallel to the measuring circuit board planes 91 a and 91 b .

[0077] and Figure 7 The measuring device 41 is shown with only one measuring circuit board 410 and a measuring circuit board plane 91. The first plane 90 is substantially orthogonal to the measuring circuit board plane 91.

[0078] Figure 7 and Figure 8A third embodiment of a drive unit 2 is shown. Figure 7 shows an internal view of the first installation stage, while Figure 8 An external view of the second installation stage is shown.

[0079] Here, in Figure 8 1 and the pedal axle 103 are shown. The pedal axle 103 passes completely through the cover 11 via a slot. Furthermore, three fastening means 14 for a chain case (not shown) are shown, wherein all three fastening means 14 for the chain case are arranged on a radius 13 of 95 mm. The radius 13 is arranged concentrically around the axis of the pedal axle 103. In the embodiment shown, the fastening means 14 for the chain case are threaded holes.

[0080] Figures 2 to 8 All embodiments shown in FIG. 1 have in common that the angle between the fastening plane 92 and the first plane 90 is less than 45°.

[0081] Fig. 9 A simplified schematic diagram of a bicycle, in particular an electric power-assisted bicycle or a racing electric power-assisted bicycle, with a drive unit 2 is shown. The bicycle has a front wheel 115 and a rear wheel 116, wherein the rear wheel 116 is driven by the pedaling force of the rider acting on the pedal 108 at the rear wheel hub 118 by means of a connecting element 101, in particular a gear belt or a chain, and by means of the drive unit 2. For this purpose, the pedal 108 is connected to a crank 119, which is in turn connected to different ends of the pedal shaft 103. The drive unit 2 is configured to support the operator's torque acting on the pedal shaft 103 and transmit it to an output gear 107, which directly cooperates with the connecting element 101 for driving the bicycle. The frame component 102 of the vehicle 100 includes in particular a seat tube 106, a lower tube 111 with an axis, an upper tube 110, a steering tube 112, and a chain stay 105 (Kettenstrebe), which are non-detachably connected to each other, for example welded to each other. In addition, the bicycle has a steering handle 120. The drive unit 2 is connected to the battery module 109 via a cable (not shown) and is fed by it.

[0082] Fig.10 A schematic diagram of a method 1 for assembling a drive unit 2 according to the present application is shown.

[0083] According to the present application, the assembly of the drive unit 2 from previously assembled components is particularly efficient and can be additionally optimized with the proposed method 1. The previously assembled components are prefabricated on different assembly lines and provided for the proposed method 1. Therefore, "insertion" is also to be understood as a previously completed "providing", which is not shown for the sake of a better overview.

[0084] “Providing a first housing half of the drive unit 150 ” is a first step for implementing the method according to the present application.

[0085] In a further step 151 , the rotor shaft arrangement 30 is inserted, wherein a pin of the rotor shaft 32 engages in a bearing arrangement of the housing 10 , and at least one further housing component 12 is inserted which aligns the rotor shaft 32 .

[0086] In a further step 152, at least one first circuit board 50 is inserted. The insertion of at least one first circuit board 50 includes the centering and fastening of the at least one first circuit board 50 (not shown). For example, fastening can be performed by melting plastic pins passing through the at least one first circuit board. Alternatively, a cutting fixture connection for fastening the circuit board 50 can be used.

[0087] In a further step 153 , the gearbox 60 is inserted. Inserting the gearbox 60 includes aligning the toothing arranged on the rotor shaft 32 with the first gear stage of the gearbox 60 .

[0088] In a further step 154, the second housing half is placed. The placing may include applying a seal or adhesive and including fastening the housing halves.

[0089] Depending on the application, the pedal shaft assembly can be inserted in step 150a before the rotor shaft mechanism or, in an alternative step 151a, before the at least one first circuit board 50. It is particularly advantageous that the assembly of the drive unit can be arranged more flexibly as a result. For example, in a partially or fully automated assembly process, the assembly process can be pre- or post-positioned in the event of a shutdown of the joining device, which leads to increased availability and faster assembly.

Claims

1. A drive unit for a vehicle operated by muscle power and / or motor power, the drive unit comprising: A housing of the drive unit, wherein the housing comprises a first housing half (10) and a further housing half (11), and wherein a stator (20) of the motor is fastened in the first housing half (10); Pedal shaft assembly (40); at least one first circuit board (50); a rotor shaft arrangement (30) comprising a rotor (32) of the motor, a rotor shaft (31) and at least one further housing component (12); at least one transmission device (60) configured to transmit torque generated by the motor to the pedal shaft assembly (40); It is characterized in that all components are arranged such that they can be inserted from a main assembly direction (z).

2. The drive unit according to claim 1, characterized in that: The components are arranged in such a way that a further translational assembly direction (x, y) and / or a further rotational assembly direction is provided for inserting the components.

3. The drive unit according to claim 1 or 2, characterized in that: The pedal shaft assembly (40) does not interfere with the rotor shaft mechanism (30) and the stator (20) of the motor.

4. The drive unit according to claim 1 or 2, characterized in that: The plug device (70) is arranged in a direction (y) above a first plane (90), wherein the first plane (90) is spanned by an axis arranged coaxially to the pedal shaft (103) and a further axis arranged coaxially to the rotor shaft (31).

5. The drive unit according to claim 4, characterized in that: The plug device (70) is arranged in direction (y) below a first plane (90), wherein the first plane (90) is spanned by an axis arranged coaxially to the pedal shaft and a further axis arranged coaxially to the rotor shaft (31).

6. The drive unit according to claim 1 or 2, further comprising at least one speed sensor (51), wherein: The at least one speed sensor (51) is arranged on the at least one first circuit board (50) and has a first distance (s) to the rear surface (10a) of the housing, characterized in that the first distance (s) is in the range of 5 mm to 50 mm.

7. The drive unit according to claim 1 or 2, further comprising at least one speed sensor (51), wherein: The at least one speed sensor (51) is arranged on the at least one first circuit board (50) and is at a distance from the ferromagnetic component not less than a further distance (u), characterized in that the further distance is not less than 1 mm to 10 mm.

8. The drive unit according to claim 4, wherein: The pedal shaft assembly (40) further comprises a measuring device (41), which is suitable for detecting a torque applied to the pedal shaft (103), and wherein the measuring device comprises at least one measuring circuit board (410), characterized in that the at least one measuring circuit board (410) is arranged parallel to or orthogonal to the first plane (90).

9. The drive unit according to claim 1 or 2, further comprising a fastening device (14) for a chain box, characterized in that At least two fastening means (14) of the chain case are arranged on a radius (13), wherein the radius (13) is arranged concentrically around the axis of the pedal shaft (103).

10. The drive unit according to claim 1 or 2, characterized in that: When the output torque of the drive unit (2) is greater than or equal to 85 Nm, the first shell length (D) is less than 45 mm.

11. The drive unit according to claim 1 or 2, characterized in that: When the output torque of the drive unit (2) is greater than or equal to 85 Nm, the length of the first shell is less than 42 mm.

12. The drive unit according to claim 1 or 2, characterized in that: The axis of the rotor shaft (31) is arranged below the fastening plane (92), and the axis of the pedal shaft (103) is arranged above the fastening plane (92), wherein the fastening plane (92) is spanned by the axis of the first fastening device (93a) and the axis of the second fastening device (93b).

13. The drive unit according to claim 1 or 2, characterized in that: The vehicle is an electric bicycle, an electric power-assisted bicycle or a racing electric power-assisted bicycle.

14. The drive unit according to claim 6, characterized in that The first distance (s) is in the range of 5 mm to 45 mm.

15. The drive unit according to claim 6, characterized in that The first distance (s) is in the range of 5 mm to 35 mm.

16. The drive unit according to claim 7, characterized in that The additional distance is not less than 1 mm to 8 mm.

17. The drive unit according to claim 7, characterized in that: The additional distance is not less than 3 mm to 7 mm.

18. The drive unit according to claim 9, characterized in that The radius (13) is in the range of 80 mm to 110 mm.

19. The drive unit according to claim 9, characterized in that The radius (13) is in the range of 90 mm to 100 mm.

20. The drive unit according to claim 11, characterized in that The length of the first shell is less than or equal to 40 mm.

21. The drive unit according to claim 11, characterized in that The length of the first shell is less than or equal to 39 mm.

22. The drive unit according to claim 12, characterized in that The fastening plane (92) is spanned by the axis of the first fastening means (93a) and the axis of only one second fastening means (93b).

23. A vehicle, characterized in that: The vehicle comprises a drive unit (2) according to one of claims 1 to 22.

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