Electric power-assisted vehicle five-way bottom cover mechanism with built-in controller

Abstract

The utility model is suitable for electric power-assisted bicycle technical field provides built-in controller's electric power-assisted bicycle five pass bottom cover mechanism, including five pass hanger, five pass bottom cover and controller, five pass hanger below is provided with the cutout passageway, the cutout passageway is used as the passageway of battery installation to the under tube of frame, and is closed with five pass bottom cover agreement, five pass bottom cover is recessed type semi-closed casing structure, is detachably fixed in the cutout passageway department of five pass hanger, five pass bottom cover bottom is equipped with controller louvre, controller is detachably fixed and installed in the inside of five pass bottom cover.This mechanism has many core advantages: high degree of matching of parts, few external connection points and wire bundle built-in storage, five pass bottom cover and five pass hanger agreement can still improve the rigidity of frame after, battery built-in under tube of frame, need not to take out can be charged and theftproof, controller hides in five pass bottom cover and realizes integration, whole vehicle structure is compact, realizes lightweight design, maintenance operation is convenient, the overall life of frame is long.

Description

Technical Field

[0001] This utility model belongs to the field of electric bicycle technology, and in particular relates to a bottom cover mechanism for an electric bicycle with a built-in controller. Background Technology

[0002] As a convenient and environmentally friendly mode of transportation, the performance of electric-assisted bicycles largely depends on the electric assist system. This system is mainly divided into three categories: the battery system, the motor drive system, and the electronic control system. The electronic control system includes key components such as the controller, electric handlebars, and head-up display.

[0003] Currently, popular electric-assist bicycles primarily employ two battery mounting methods: one involves placing the battery externally to the frame structure, specifically above the downtube or on a rear rack; the other involves installing the battery internally within the frame structure, either suspended inside the downtube or toptube. For rear-mounted hub motor electric-assist bicycles, the variation in battery suspension and mounting method significantly impacts the vehicle's design. Higher-end models, to enhance aesthetics and control costs, often conceal the battery assembly externally. This is typically achieved by cutting above or below the downtube, utilizing the resulting space for battery installation, while simultaneously hiding the controller within the downtube. However, this type of model has significant drawbacks. After the downtube of the frame is cut, the wall thickness of the tube needs to be more than twice that of conventional tubes to meet the frame strength requirements. This leads to a substantial increase in the overall weight of the vehicle, which is detrimental to the development of lightweight models. In addition, the tube cutting process requires extremely high precision, resulting in a very high scrap rate. This puts significant pressure on cost control to improve production efficiency and also places higher demands on the precision of the manufacturing process, making the processing cost of a single item extremely high. This makes it unsuitable for large-scale assembly line production and makes product promotion difficult. Based on this, another type of electric-assist bicycle with a rear-mounted hub motor has been developed. It uses a separate controller, and the controller and motor drive system are not designed together. It is generally composed of three main components: a rear-mounted hub motor, a controller system, and a battery system. In comparison, the first type (advanced models with hidden batteries and controllers) has a complex structure and high precision, but is expensive; the second type has a relatively simple structure, is easier to control in terms of cost, and has higher market acceptance. These two types of models also differ greatly in frame design. Mid-mounted motor electric assist models have the motor suspension unit located at the bottom bracket of the frame, while rear-mounted hub motor electric assist models still use the standard bottom bracket for bicycles. Their structure is more in line with the bicycle category, and they are more compact in appearance, resulting in a significant reduction in frame weight.

[0004] Most rear-mounted hub motor electric bicycles have various controller installation methods, but all have drawbacks: some are made into independent components and suspended outside the frame's center tube (such as behind or in front of the center tube), with the controller wiring harness and connectors exposed, which is not only unsightly and unsafe, but also prone to loosening and damage, leading to a high failure rate; some are placed inside the rear rack frame or the front basket frame, and then connected to the battery box and rear motor via wiring harnesses. However, the wiring harness connecting the controller to the motor is too long for the front basket frame controller, and the controller placed in the rear rack frame increases the difficulty of wiring through the frame. Both methods of external wiring harnesses are unsafe, unsightly, and easily damaged; still others use a water-expanding tube process to shape and expand the structure of the bottom tube of the frame's center tube to house the controller. This method requires cutting an opening at the bottom of the center tube as an installation channel, which needs to be sealed with a cover plate after placement. In addition, the wiring harness inside the center tube is still exposed except for the controller, which still presents safety and unsight problems.

[0005] In summary, while the structure of rear-mounted hub motor electric-assist bicycles is relatively simple, regardless of whether some controllers are externally mounted or other installation methods, the wiring components are generally exposed. This leads to poor signal stability of electronic components, susceptibility to external interference and contamination, and severe environmental pollution during riding, resulting in a shortened controller lifespan and easy aging and deformation of the wiring harness. Therefore, this utility model proposes a bottom cover mechanism for electric-assist bicycles with an internal controller. Utility Model Content

[0006] The purpose of this utility model is to provide a bottom cover mechanism for an electric bicycle with a built-in controller, which aims to solve the problems mentioned in the background art.

[0007] This utility model embodiment is implemented as follows: the electric assist bicycle bottom cover mechanism with built-in controller is applied to the electric assist bicycle with rear hub motor, including bottom bracket, bottom cover and controller.

[0008] The bottom bracket includes a bottom bracket sleeve with a through hole structure for mounting the bottom bracket bottom bracket of a bicycle pedal; the bottom bracket has a cable hole on its rear wall; the bottom bracket connects to the downtube of the electric bicycle frame at the front, to the rear chainstay of the electric bicycle at the rear, to the bottom tube of the electric bicycle frame at the top, and has a cut-out channel at the bottom, which serves as a channel for installing the battery into the downtube of the frame and is sealed by fitting with the bottom cover of the bottom bracket;

[0009] The bottom cover of the bottom bracket is a concave semi-enclosed shell structure, which is detachably fixed to the cut channel of the bottom bracket and used to cover the cut channel; the bottom of the bottom bracket is provided with a controller heat dissipation hole;

[0010] The controller is detachably and fixedly installed inside the bottom cover of the five-way connector;

[0011] The wiring harness connecting the controller and the rear hub motor passes through the wiring hole on the rear wall of the bottom bracket, and the wiring harness connecting the controller and the battery are together housed in the space enclosed by the bottom bracket and the bottom cover.

[0012] Furthermore, the controller heat dissipation hole of the bottom cover of the five-way valve also serves as a drainage hole, and the surface of the bottom cover of the five-way valve is provided with an anti-collision grille.

[0013] Furthermore, the battery is inserted into the lower tube of the electric bicycle frame through the cut channel of the five-way bracket and fixed therein. The lower tube of the frame has a hollow structure and a charging port is provided on the top of the lower tube of the frame. The charging port is used for charging the battery without removing it.

[0014] Furthermore, the bottom cover of the five-way connector has a bottom cover fixing hole at the front and a pair of bottom cover fixing holes at the rear; the bracket of the five-way connector has a bracket mounting hole at the front and a pair of bracket mounting holes at the rear; the bottom cover of the five-way connector is fastened to the bracket of the five-way connector by passing a front locking screw and a pair of rear locking screws through the corresponding fixing holes and mounting holes respectively.

[0015] Furthermore, the controller has two sets of controller locking holes at the bottom and two sets of controller mounting holes on the bottom cover of the five-way connector. The two sets of controller mounting holes correspond one-to-one with the two sets of controller locking holes. The controller is fixed inside the bottom cover of the five-way connector by passing the controller locking screw through the controller mounting hole and the controller locking hole.

[0016] Furthermore, the threading hole is a square hole.

[0017] Compared with the prior art, the beneficial effects of this utility model are:

[0018] The bottom bracket cover mechanism of this electric-assist bicycle with a built-in controller offers several core advantages: high component matching, precise fit between the bottom bracket cover and the bottom bracket bracket with corresponding holes, fewer external connection points, and internal storage of wiring harnesses; the bottom bracket bracket is forged as a single piece, resulting in a stable structure and excellent strength, further enhancing frame rigidity when fitted with the bottom bracket cover. The battery can be charged without removal and, being built into the frame's downtube, provides excellent anti-theft protection; the controller is hidden within the bottom bracket cover and assembled together, achieving an integrated design with the frame. Furthermore, weight reduction through water-expanded tubing technology and component integration results in a more compact and lightweight overall structure; maintenance only requires loosening screws to remove the bottom bracket cover and controller, making operation extremely convenient; simultaneously, the structure itself has strong resistance to wear and tear, protecting the controller and wiring harness from interference and abrasion, effectively extending the overall lifespan of the frame. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the bottom cover mechanism of an electric bicycle with a built-in controller.

[0020] Figure 2 An exploded view of the bottom cover mechanism of an electric bicycle with a built-in controller.

[0021] Figure 3 This is a schematic diagram of the bottom cover structure in the bottom cover mechanism of an electric bicycle with a built-in controller.

[0022] Figure 4 This is a structural diagram of the square hole and the mounting hole of the bottom bracket in the bottom cover mechanism of an electric bicycle with a built-in controller.

[0023] Figure 5 A schematic diagram of the structure of the bottom bracket cover mechanism of an electric bicycle with a built-in controller after assembling the bottom bracket shaft.

[0024] In the diagram: Rear hub motor 01, controller 02, frame downtube 03, bottom bracket bracket 04, bottom bracket sleeve 05, bottom bracket bottom bracket axle 06, rear left bottom fork 07, rear right bottom fork 08, frame bottom tube 09, square hole 10, bottom bracket bottom cover 11, controller heat dissipation hole 12, anti-collision grille 13, bottom bracket bottom cover fixing hole 14, bottom bracket bracket mounting hole 15, bottom bracket bottom cover front locking screw 16, bottom bracket bottom cover rear locking screw 17, controller locking hole 18, controller mounting hole 19, controller locking screw 20. Detailed Implementation

[0025] To make the objectives, technical solutions, and advantages of this utility model clearer, the present utility model will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain this utility model and are not intended to limit this utility model.

[0026] The specific implementation of this utility model will be described in detail below with reference to specific embodiments.

[0027] like Figure 1-5The diagram shows a bottom cover mechanism for an electric-assisted bicycle with a built-in controller, provided in one embodiment of this utility model. This mechanism is applied to an electric-assisted bicycle with a rear-mounted hub motor. The electric-assisted bicycle includes a frame, on which are mounted electronic components such as a battery, a rear-mounted hub motor 01, and a controller 02. The frame assembly constructs a frame structure that meets electric-assisted bicycle testing standards. The frame consists of a front triangle frame and a rear triangle frame. The lower tube 03 of the front triangle frame has a hollow structure, with its internal space used to install the battery. The lower tube 03 utilizes a water-expanding process to maximize the battery cavity, simultaneously reducing frame weight and increasing frame strength, achieving the design goals of lightweight and high rigidity. A charging port is located above the lower tube 03. The rear triangle frame is used to mount the rear-mounted hub motor 01.

[0028] The electric bicycle bottom cover mechanism with built-in controller includes a bottom bracket 04, a bottom cover 11 and a controller 02.

[0029] The bottom bracket 04 includes a bottom bracket sleeve 05, with a through-hole structure for installing the bicycle pedal bottom bracket 06 (a common bottom bracket 06 assembly for ordinary bicycles can be used, leveraging existing supply chain advantages to reduce product costs). The bottom bracket 04 is forged using a one-piece molding process, possessing high-strength bottom bracket support for pedaling; and the bottom bracket sleeve 05 is integrated into the bottom bracket 04, forming a single unit with high structural strength. The bottom bracket 04 has a four-way structure, serving as the core support structure for releasing pedaling force. Its front connects to the downtube 03, its rear connects to the chainstays (including the left chainstay 07 and right chainstay 08), and its top connects to the center tube 09, forming a stable frame structure. A square hole 10 is provided on the rear wall of the bottom bracket 04 as a wiring hole for the controller 02 and the rear hub motor 01 connection harness. A cut-out channel is located below the bottom bracket 04. This channel is CNC machined and fits snugly with the bottom cover 11 of the bottom bracket, serving as a passage for installing the battery into the frame downtube 03. This cut-out channel enables an innovative battery installation method without cutting the frame downtube 03. The battery is simply inserted through the cut-out channel of the bottom bracket 04, providing strong concealment and a reasonable structure.

[0030] The bottom cover 11 is a concave semi-enclosed shell structure, fixed to the bottom bracket 04 with screws. The bottom of the bottom cover 11 has a set of controller heat dissipation holes 12 (which also serve as drainage holes). These holes allow for the timely removal of heat generated by the controller 02 during prolonged operation. Furthermore, considering the potential for minor gaps at the bottom bracket 04 interface after long-term use, these holes also allow for rapid drainage of rainwater, ensuring a dry working environment inside the bottom cover 11. Additionally, the bottom of the bottom cover 11 is equipped with a crash barrier 13, which effectively resists impacts from the ground or external objects during riding, further protecting the bottom cover 11 and its built-in controller 02.

[0031] The bottom cover 11 has a bottom cover fixing hole 14 at the front and a pair of bottom cover fixing holes 14 at the rear; correspondingly, the bottom bracket 04 has a bottom bracket mounting hole 15 at the front and a pair of bottom bracket mounting holes 15 at the rear. A bottom cover front locking screw 16 passes through the fixing hole on the front side of the bottom cover 11 and the mounting hole on the front side of the bottom bracket 04, and a pair of bottom cover rear locking screws 17 pass through the fixing hole on the rear side of the bottom cover 11 and the mounting hole on the rear side of the bottom bracket 04, so as to achieve a stable fixation between the bottom cover 11 and the bottom bracket 04, and the edge of the bottom cover 11 is inserted into the cut channel of the bottom bracket 04 to ensure a stable installation.

[0032] The controller 02 has two sets of controller locking holes 18 at its bottom; the bottom cover 11 has two sets of controller mounting holes 19, corresponding to the two sets of controller locking holes 18. The controller 02 is fixed inside the bottom cover 11 by the controller locking screws 20, so as to achieve reliable installation of the controller 02, ensure its stable position during vehicle operation, and enable it to perform its control function normally.

[0033] In this embodiment of the utility model, the installation sequence is as follows: After the battery is inserted into the lower tube 03 of the frame through the cut channel of the bottom bracket 04 and fixed, the bottom bracket axle 06 is installed. Then, the controller 02 is fixed inside the bottom bracket cover 11 with screws. After the rear hub motor 01 and the battery are connected to the controller 02 respectively, the bottom bracket cover 11 with the controller 02 is installed. Then, the bottom bracket cover 11 is fixed to the cut channel of the bottom bracket 04 with screws. At this time, the edge of the bottom bracket cover 11 just fits into the cut channel of the bottom bracket 04, achieving a fitting seal and completing the installation of the entire mechanism.

[0034] The wiring harnesses connecting controller 02 to the rear hub motor 01 and to the battery are both housed within the space of the bottom bracket 04. This layout avoids exposing the wiring harnesses, reducing wear and interference from external factors, ensuring the safe and stable operation of electronic components, and thus extending the lifespan of the electronic components. At the same time, the neat layout improves the consistency of the bottom bracket pedal structure and appearance, making the overall vehicle structure more compact and aesthetically pleasing.

[0035] When the battery and controller 02 need repair, simply loosen the screws on the bottom cover 11 of the bottom bracket to remove the bottom cover 11 and the controller 02. The operation is convenient and allows for quick repair and replacement of the battery and controller 02, improving the efficiency of later maintenance and reducing the difficulty of maintenance.

[0036] When charging the battery, simply insert the charger's charging port into the charging port above the downtube 03 of the frame; there's no need to remove the battery, simplifying the charging process and improving ease of use. Furthermore, since the battery is built into the downtube 03, compared to an externally mounted battery, it effectively prevents battery theft and enhances battery security.

[0037] The seamless integration of the bottom bracket 04 and the bottom cover 11 cleverly integrates three core functions: the battery mounting port, the built-in space of the controller 02, and the installation of the bottom bracket central shaft 06. The controller 02 is completely hidden within the space formed by the bottom bracket 04 and the bottom cover 11, with ample space reserved for wiring harness connections, resulting in a compact overall structure. This concealed controller 02 assembly not only provides reliable protection for the controller 02, preventing external contaminants from entering and significantly extending its service life, but also achieves a high degree of unity between function and appearance: the neat concealed design enhances the vehicle's aesthetic appeal, making the overall shape more in line with future trends and meeting consumers' dual demands for safety and aesthetics in electric-assisted bicycles, while also catering to riders' desire for novelty and change; at the same time, the precise fit between the bottom bracket 04 and the bottom cover 11 further improves the frame's rigidity and strength, achieves lightweight design, and positively contributes to increasing production capacity and reducing manufacturing difficulty. In addition, the innovative design uses the cut-out channel of the bottom bracket 04 as the channel space for the battery to be installed into the lower tube 03 of the frame, which is reused as the hidden space for the controller 02. While creating a new structure for hiding the frame inside the controller 02 and matching the development needs of electronic technology, it ensures the safety and stability of the overall structure and comprehensively optimizes the core structural performance of the electric-assisted bicycle.

[0038] The principle of this utility model is:

[0039] During installation of the electric bicycle's bottom bracket cover mechanism with a built-in controller, the battery is inserted into the frame's lower tube 03 through the cut channel of the bottom bracket 04 and fixed. Then, the bottom bracket axle 06 is installed, and the controller 02 is fixed inside the bottom bracket cover 11 with screws. After connecting the rear hub motor 01 and the battery to the controller 02, the bottom bracket cover 11 with the controller 02 already installed is then fixed to the cut channel of the bottom bracket 04 with screws. At this point, the edge of the bottom bracket cover 11 fits perfectly into the cut channel of the bottom bracket 04, achieving a snug seal.

[0040] The above are merely preferred embodiments of this utility model. It should be noted that, for those skilled in the art, several modifications and improvements can be made without departing from the concept of this utility model, and these should also be considered within the scope of protection of this utility model. These will not affect the implementation effect of this utility model or the practicality of the patent.

Claims

1. A bottom cover mechanism for an electric-assisted bicycle with a built-in controller, applied to an electric-assisted bicycle with a rear-mounted hub motor, characterized in that: Includes bottom bracket, bottom cover and controller; The bottom bracket includes a bottom bracket sleeve with a through hole structure for mounting the bottom bracket bottom bracket of a bicycle pedal; the bottom bracket has a cable hole on its rear wall; the bottom bracket connects to the downtube of the electric bicycle frame at the front, to the rear chainstay of the electric bicycle at the rear, to the bottom tube of the electric bicycle frame at the top, and has a cut-out channel at the bottom, which serves as a channel for installing the battery into the downtube of the frame and is sealed by fitting with the bottom cover of the bottom bracket; The bottom cover of the bottom bracket is a concave semi-enclosed shell structure, which is detachably fixed to the cut channel of the bottom bracket and used to cover the cut channel; the bottom of the bottom bracket is provided with a controller heat dissipation hole; The controller is detachably and fixedly installed inside the bottom cover of the five-way connector; The wiring harness connecting the controller and the rear hub motor passes through the wiring hole on the rear wall of the bottom bracket, and the wiring harness connecting the controller and the battery are together housed in the space enclosed by the bottom bracket and the bottom cover.

2. The bottom cover mechanism of the electric bicycle with built-in controller according to claim 1, characterized in that, The controller heat dissipation hole of the bottom cover of the five-way valve also serves as a drainage hole, and the surface of the bottom cover of the five-way valve is provided with an anti-collision grille.

3. The bottom cover mechanism of the electric bicycle with built-in controller according to claim 1, characterized in that, The battery is inserted into the lower tube of the electric bicycle frame through the cut channel of the five-way bracket and fixed. The lower tube of the frame has a hollow structure and a charging port is provided on the top of the lower tube of the frame. The charging port is used for charging the battery without removing it.

4. The bottom cover mechanism of the electric bicycle with built-in controller according to claim 1, characterized in that, The bottom cover of the five-way connector has a fixing hole at the front and a pair of fixing holes at the rear; the bracket has a mounting hole at the front and a pair of mounting holes at the rear; the bottom cover is fastened to the bracket by passing a front locking screw and a pair of rear locking screws through the corresponding fixing holes and mounting holes respectively.

5. The bottom cover mechanism of the electric bicycle with built-in controller according to claim 1, characterized in that, The controller has two sets of controller lock holes at the bottom and two sets of controller mounting holes on the bottom cover. The two sets of controller mounting holes correspond one-to-one with the two sets of controller lock holes. The controller is fixed inside the bottom cover by passing the controller locking screw through the controller mounting hole and the controller lock hole.

6. The bottom cover mechanism of the electric bicycle with built-in controller according to claim 1, characterized in that, The threading hole is a square hole.

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