COMPONENT OF A HUMAN-PROPELLED VEHICLE

Abstract

A component of a human-powered vehicle (30), comprising: a resin housing (40) with a through-hole (42A) through which a crankshaft (12A) extends; and a metal bracket (50, 50A, 50B) configured to couple to a frame (16) of a human-powered vehicle (10), wherein the bracket (50, 50A, 50B) is provided on the housing (40) such that it protrudes from the housing (40), wherein the bracket (50, 50A, 50B) includes a fixed section (54A, 54B) which is attached to the housing (40), the attached section (54A, 54B) is integrally formed with the housing (40), and the attached section (54A, 54B) is cast into the housing (40).

Description

[0001] The present invention relates to a component of a human-powered vehicle.

[0002] A drive unit, which is an example of a conventional component of a human-powered vehicle, includes an electric motor that assists the propulsion of the human-powered vehicle and a resin housing in which the electric motor is provided. For example, JP 4 124 393 A discloses such a drive unit. Other components of human-powered vehicles are known from DE 10 2015 208 039 A1, JP 2003 - 164 104 A, JP 4 124 393 B2, DE 10 2017 005 825 A1, DE 60 2005 000 192 T2 and DE 10 2016 112 778 A1.

[0003] A component of a human-powered vehicle includes a bracket that is coupled to a frame. The bracket is made of resin. Metal is embedded within the bracket for reinforcement. If a screw or similar component puts stress on the bracket, the load can damage the resin that forms the bracket.

[0004] One objective of the present invention is to provide a component of a human-powered vehicle that is lightweight and stably coupled to a frame.

[0005] A component of a human-powered vehicle according to a first aspect of the present invention comprises a resin housing with a through-hole for a crankshaft and a metal bracket configured for coupling to the frame of a human-powered vehicle. The bracket is designed to protrude from the housing. According to the human-powered vehicle of the first aspect, the component can be easily weight-reduced because the housing is made of resin. Furthermore, because the metal bracket is designed to protrude from the housing, damage to the bracket during coupling to the frame is avoided, and the bracket can be stably coupled to the frame.

[0006] According to a second aspect of the present invention, the component of a human-powered vehicle according to the first aspect is configured such that the bracket includes a fixed section that is attached to the housing. According to the component of a human-powered vehicle of the second aspect, the separation of the bracket from the housing is restricted.

[0007] According to a third aspect of the present invention, the component of a human-powered vehicle according to the second aspect is configured such that the attached section is integrally formed with the housing. According to the component of a human-powered vehicle of the third aspect, the separation of the bracket from the housing is limited.

[0008] According to a fourth aspect of the present invention, the component of a human-powered vehicle according to the third aspect is configured such that the attached gate is insert-cast into the housing. According to the component of a human-powered vehicle of the fourth aspect, the separation of the bracket from the housing is limited.

[0009] According to a fifth aspect of the present invention, the component of a human-powered vehicle according to one of the first to fourth aspects is configured such that the mounting includes a first mounting section and a second mounting section. The first mounting section and the second mounting section are spaced apart from each other in the axial direction of the crankshaft. According to the fifth aspect of the human-powered vehicle component, the component of a human-powered vehicle is stably coupled to the human-powered vehicle.

[0010] According to a sixth aspect of the present invention, the component of a human-powered vehicle according to one of the second to fourth aspects is configured such that the mounting includes a first mounting section and a second mounting section. The first mounting section and the second mounting section are spaced apart from each other in the axial direction of the crankshaft, and the first mounting section and the second mounting section are integrally formed with the attached section. According to the sixth aspect of the human-powered vehicle component, it is less likely that the mounting will separate from the housing, and the human-powered vehicle component is stably coupled to the human-powered vehicle.

[0011] According to a seventh aspect of the present invention, the component of a human-powered vehicle according to the sixth aspect is configured such that the first assembly section, the second assembly section, and the attached section are formed from sheet metal. According to the component of a human-powered vehicle of the seventh aspect, the bracket is manufactured cost-effectively.

[0012] According to an eighth aspect of the present invention, the component of a human-powered vehicle, according to aspects one through seven, is configured such that the mounting includes a third mounting section and a fourth mounting section. The third mounting section and the fourth mounting section are spaced apart from each other in the circumferential direction of the crankshaft. According to aspect eight of the human-powered vehicle component, the component of a human-powered vehicle is stably coupled to the human-powered vehicle.

[0013] According to a ninth aspect of the present invention, the component of a human-powered vehicle, as defined in aspects two through four, six, and seven, is configured such that the mounting includes a third mounting section and a fourth mounting section. The third mounting section and the fourth mounting section are spaced apart from each other in the circumferential direction of the crankshaft. The third mounting section, the fourth mounting section, and the attached section are integrally formed. According to the ninth aspect of the human-powered vehicle component, the mounting is less likely to separate from the housing, and the component of the human-powered vehicle is stably coupled to the human-powered vehicle.

[0014] According to a tenth aspect of the present invention, the component of a human-powered vehicle according to the ninth aspect is configured such that the third assembly section, the fourth assembly section, and the attached section are formed from sheet metal. According to the component of a human-powered vehicle of the tenth aspect, the bracket is manufactured cost-effectively.

[0015] According to an eleventh aspect of the present invention, the component of a human-powered vehicle is configured according to one of the fifth to seventh aspects such that the mounting includes a fifth mounting section. The first mounting section and the second mounting section are spaced apart from the fifth mounting section in the circumferential direction of the crankshaft. According to the eleventh aspect of the component of a human-powered vehicle, the component of a human-powered vehicle is stably coupled to the human-powered vehicle.

[0016] According to a twelfth aspect of the present invention, the component of a human-powered vehicle according to the sixth or seventh aspect is configured such that the bracket further includes a fifth mounting section. The first mounting section and the second mounting section are spaced apart from each other in the circumferential direction of the crankshaft from the fifth mounting section. The first mounting section, the second mounting section, the fifth mounting section, and the attached section are integrally formed. According to the component of a human-powered vehicle of the twelfth aspect, it is less likely that the bracket will separate from the housing, and the component of the human-powered vehicle can be coupled accordingly with the human-powered vehicle.

[0017] According to a thirteenth aspect of the present invention, the component of a human-powered vehicle according to the twelfth aspect is configured such that the first assembly section, the second assembly section, the fifth assembly section, and the attached section are formed from sheet metal. In accordance with the component of the human-powered vehicle of the thirteenth aspect, the bracket is manufactured cost-effectively.

[0018] According to a fourteenth aspect of the present invention, the component of a human-powered vehicle, according to one of the eleventh to thirteenth aspects, is configured such that the mounting further includes a sixth mounting section. The fifth mounting section and the sixth mounting section are spaced apart from each other in the axial direction of the crankshaft. According to the vehicle component of the fourteenth aspect, the component of a human-powered vehicle is stably coupled to the human-powered vehicle.

[0019] According to a fifteenth aspect of the present invention, the component of a human-powered vehicle according to the twelfth aspect is configured such that the bracket further includes a sixth mounting section. The fifth and sixth mounting sections are spaced apart from each other in the axial direction of the crankshaft. The first, second, fifth, sixth, and attached sections are integrally formed. According to the component of a human-powered vehicle of the fifteenth aspect, the probability of the bracket separating from the housing is reduced, and the component of the human-powered vehicle is stably coupled to the human-powered vehicle.

[0020] According to a sixteenth aspect of the present invention, the component of a human-powered vehicle according to the fifteenth aspect is configured such that the first assembly section, the second assembly section, the fifth assembly section, the sixth assembly section, and the attached section are formed from sheet metal. According to the component of a human-powered vehicle of the sixteenth aspect, the bracket is manufactured cost-effectively.

[0021] According to a seventeenth aspect of the present invention, the component of a human-powered vehicle according to any of the first to sixteenth aspects further comprises a bearing that rotatably supports the crankshaft. The bearing is attached to the housing. A metal support carries the bearing. The support is coupled to the bracket. According to the component of a human-powered vehicle of the seventeenth aspect, the bearing is stably mounted.

[0022] According to an eighteenth aspect of the present invention, the component of a human-powered vehicle according to aspects two through four, six, seven, nine, ten, twelfth, thirteenth, fifteenth, and sixteenth further comprises a bearing that rotatably supports the crankshaft. The bearing is provided in the housing. A metal support carries the bearing. The support is coupled to the bracket. The support and the bracket are integrally formed. According to aspect eighteen of the component of a human-powered vehicle, the bearing is stably mounted.

[0023] According to a nineteenth aspect of the present invention, the component of a human-powered vehicle according to the eighteenth aspect is configured such that the bracket and the support are formed from sheet metal. According to the component of a human-powered vehicle of the nineteenth aspect, the bracket and the support are manufactured cost-effectively.

[0024] According to a twentieth aspect of the present invention, the component of a human-powered vehicle according to the nineteenth aspect is configured such that the bracket is cast into the housing. In accordance with the component of a human-powered vehicle of the twentieth aspect, the separation of the bracket from the housing is limited.

[0025] According to a twenty-first aspect of the present invention, the component of a human-powered vehicle according to any of the first to twenty aspects further comprises a nut. The bracket includes a hole in which the nut is provided. According to the twenty-first aspect of the human-powered vehicle component, the human-powered vehicle component is easily connected to the human-powered vehicle by screws.

[0026] According to a twenty-second aspect of the present invention, the component of a human-powered vehicle according to the twenty-first aspect is configured such that the bracket includes a first flange formed on an edge of the hole. According to the component of a human-powered vehicle of the twenty-second aspect, the distance of the nut from the bracket is limited.

[0027] According to a twenty-third aspect of the present invention, the component of a human-powered vehicle is configured according to the twenty-second aspect such that the first flange is formed by a hole-flange process. According to the component of a human-powered vehicle of the twenty-third aspect, the first flange can be easily formed.

[0028] According to a twenty-fourth aspect of the present invention, the component of a human-powered vehicle according to one of the first to twenty-third aspects is configured such that the bracket further includes a threaded hole. According to the twenty-fourth aspect of the human-powered vehicle component, the component of a human-powered vehicle is connected to the human-powered vehicle by screws.

[0029] According to a twenty-fifth aspect of the present invention, the component of a human-powered vehicle according to the twenty-fourth aspect is configured such that the bracket includes a second flange provided at an edge of the threaded hole. According to the component of a human-powered vehicle of the twenty-fifth aspect, the screw is stably attached to the bracket because the section to be connected by the screw is enlarged on the second flange.

[0030] According to a twenty-sixth aspect of the present invention, the component of a human-powered vehicle is configured according to the twenty-fifth aspect such that the second flange is formed by a hole-flange process. According to the component of a human-powered vehicle of the twenty-sixth aspect, the second flange can be easily formed.

[0031] According to a twenty-seventh aspect of the present invention, the component of a human-powered vehicle according to one of the first to twenty-sixth aspects further comprises an electric motor including a stator. The stator is injection-molded into the housing. According to the twenty-seventh aspect of the component of a human-powered vehicle, the element for coupling the electric motor to the housing can be omitted.

[0032] According to a twenty-eighth aspect of the present invention, the component of a human-powered vehicle according to one of the first to twenty-seventh aspects further comprises an electric motor provided in the housing. A metallic reinforcing element is integrally formed with the mounting and provided in the housing. The reinforcing element contacts the electric motor. According to the component of a human-powered vehicle of the twenty-eighth aspect, the heat from the electric motor is dissipated through the reinforcing element. This improves heat dissipation.

[0033] According to a twenty-ninth aspect of the present invention, the component of a human-powered vehicle is configured according to one of the first through twenty-eighth aspects such that the mounting is flexible. According to the twenty-ninth aspect of the human-powered vehicle component, even if a gap exists between the mounting and the component, this gap is covered when the mounting is bent. Therefore, when the component is coupled to the human-powered vehicle, the component's detachment from the frame is restricted.

[0034] The component of a human-powered vehicle of the present invention is lightweight and stably mounted on a frame.

[0035] A more comprehensive assessment of the invention and many of its associated advantages is easily achieved, as it is better understood through the following detailed description when considered in conjunction with the accompanying drawings, wherein: Fig. 1 a side view of a bicycle with a component of a human-powered vehicle according to a first embodiment; Fig. 2 is a perspective exploded view of the component of a human-powered vehicle and a bracket; Fig. 3 a front view of the component of a human vehicle made of Fig. 1 is; Fig. 4 a cross-sectional view along line IV-IV in Fig. 3 is; Fig. 5 is a perspective view of a first housing of the component of a human-powered vehicle; Fig. 6 a perspective view of the first housing of Fig. 5 from a different perspective; Fig. 7A is a front view of a fastener; Fig. 7B is a cross-sectional view of the fastener; Fig. 8 is a perspective view of a bracket of the component of a human-powered vehicle; Fig. 9 a front view of the bracket of Fig. 8 is; Fig. 10 is a perspective view of another mounting of the component of a human-powered vehicle; Fig. 11 is a perspective view of another mounting of the component of a human-powered vehicle; Fig. 12 is a perspective view of a second housing of the component of a human-powered vehicle; Fig. 13 a perspective view of a reinforcement element of the second housing of Fig. 12 is; Fig. 14A and Fig. 14B Side views showing a mounting structure of the bracket and clamp are; Fig. 15 is a perspective exploded view of another example of the mounting structure of the bracket and clamp; Fig. 16 a cross-sectional view of the bracket of Fig. 15 is; Fig. Figure 17 shows a cross-sectional view, which shows a fastening structure of the bracket and the clamp in Fig. 15 shows; Fig. 18 a perspective view of a first housing of a component of a human-powered vehicle according to a second embodiment; Fig. 19 a perspective view of a bracket of a component of a human-powered vehicle Fig. 18 is; Fig. 20 is a spread view, which is shown before the bracket is folded in Fig. 19 is recorded; Fig. 21 is a cross-sectional view of an engine of a component of a human-powered vehicle according to a third embodiment; Fig. 22 a cross-sectional view of a motor according to another example of Fig. 21 is; Fig. 23 is a perspective exploded view of a rotor core of a motor; Fig. 24 is a top view of a first lamella of the rotor core; Fig. 25 is a top view of a second lamella of the rotor core; Fig. 26 is a top view of the rotor core; Fig. 27 a perspective exploded view of part of an engine in the component of a human-powered vehicle according to a fourth embodiment; Fig. 28 a perspective view of a motor mount in Fig. 27 is; Fig. 29 a perspective view of a stop element made of Fig. 27 is; Fig. 30 a cross-sectional view of the motor's stop element in Fig. 27 is; Fig. 31A is a cross-sectional view of a support in a component of a human-powered vehicle according to a modified example; and Fig. 31 B is a cross-sectional view showing a fastening structure of the bracket and clamp in Fig. 31A is shown.

[0036] Selected embodiments are now described with reference to the associated drawings, where the same reference numbers denote corresponding or identical elements in the different drawings.

[0037] A human-powered vehicle 10, which includes a component of a human-powered vehicle 30 according to a first embodiment, is now described with reference to Fig. As described in section 1, a human-powered vehicle 10 is a vehicle that can be propelled by at least one human propulsion force. For example, a human-powered vehicle 10 includes a bicycle. It also includes a unicycle and a vehicle with, for example, three or more wheels. The number of wheels is not limited. Human-powered vehicles include various types of bicycles, such as a mountain bike, a racing bike, a city bike, a cargo bike, a recumbent bike, and an electrically assisted bicycle (e-bike). In the following description, a human-powered vehicle 10 is a bicycle.

[0038] The human-powered vehicle 10 includes a crank 12 and a drive wheel 14. The human-powered vehicle 10 also includes a frame 16. A human driving force H is applied to the crank 12. The crank 12 includes a crankshaft 12A, which is rotatable relative to the frame 16, and crank arms 12B, which are provided at two axial ends of the crankshaft 12A. A pedal 18 is coupled to each crank arm 12B. The drive wheel 14 is driven by the rotation of the crank 12. The drive wheel 14 is supported by the frame 16. The crank 12 and the drive wheel 14 are coupled via a drive mechanism 20. The drive mechanism 20 includes a first rotating body 22, which is coupled to the crankshaft 12A. The crankshaft 12A and the first rotating body 22 can be coupled by a first one-way coupling.The first one-way coupling is configured to rotate the first rotating body 22 forward when the crank 12 rotates forward, and not to rotate the first rotating body 22 backward when the crank 12 rotates backward. The first rotating body 22 comprises a sprocket, a pulley, or a bevel gear. The drive mechanism 20 further comprises a connecting element 26 and a second rotating body 24. The connecting element 26 transmits the rotational force of the first rotating body 22 to the second rotating body 24. The connecting element 26 comprises, for example, a chain, a belt, or a shaft.

[0039] The second rotating body 24 is coupled to the drive wheel 14. The second rotating body 24 includes a sprocket, a pulley, or a bevel gear. A second one-way coupling is preferably provided between the second rotating body 24 and the drive wheel 14. The second one-way coupling is configured to rotate the drive wheel 14 forward when the second rotating body 24 is rotating forward, and to prevent the drive wheel 14 from rotating backward when the second rotating body 24 is rotating backward.

[0040] The human-powered vehicle 10 comprises a front wheel and a rear wheel. The front wheel is attached to the frame 16 by a front fork 16A. A handlebar 16C is connected to the front fork 16A via a stem 16B. In the following embodiments, the rear wheel is referred to as the drive wheel 14, and the front wheel can also be the drive wheel 14.

[0041] The component of a human-powered vehicle 30 is provided on the frame 16. With reference to Fig. 2 is the component of a human-powered vehicle 30 attached to a clamp 28, which is part of the frame 16. The clamp 28 is attached, for example, to a down tube and a seat tube. The clamp 28 can be connected to a chainstay.

[0042] The component of a human-powered vehicle 30 comprises a resin housing 40 and a metal bracket 50. The metal used in the present embodiment is iron or an alloy containing at least aluminum. The bracket 50 is movable. For example, polyamide (PA), polybutylene terephthalate (PBT), polyphenylene sulfite (PPS), or the like is preferably used for the housing 40. In a case where, for example, polyphenylene sulfite is used for the housing 40, the heat dissipation of the housing 40 is improved. An example of the housing 40 can be formed by mixing glass fibers into a resin. An example of the housing 40 can be formed by mixing at least one carbon filler and one metal filler in a resin. In a case where the carbon filler and the metal filler are mixed in the housing 40, the noise level can be reduced.For example, stainless steel (SUS) or a cold-rolled special steel strip (SAE 1010) is preferably used for the holder 50.

[0043] The component of a human-powered vehicle 30 further includes the crankshaft 12A. The crankshaft 12A extends through the housing 40 and projects from both sides of the housing 40 in the left and right directions of the human-powered vehicle 10. The housing 40 is provided with a through-hole 42A through which the crankshaft 12A extends. The housing 40 rotatably supports the crankshaft 12A, which is inserted through the through-hole 42A. The bracket 50 is attached to the housing 40 such that it projects from the housing 40. Furthermore, the bracket 50 is configured to be coupled to the frame 16 of the human-powered vehicle 10. Fig. 2 the bracket 50 is configured to be coupled with the clamp 28, which is part of the frame 16.

[0044] As in Fig. As shown in Figure 3, the component of the human-powered vehicle 30 of the present embodiment includes a drive unit that assists the propulsion of the bicycle. The component of a human-powered vehicle 30 includes an electric motor 32. The electric motor 32 is configured to assist the propulsion of the human-powered vehicle 10. In an example, as shown in Figure 3, the component of the human-powered vehicle 30 includes an electric motor 32. The electric motor 32 is configured to assist the propulsion of the human-powered vehicle 10. Fig. As shown in Figure 4, the component of a human-powered vehicle 30 further includes a driver circuit 34 configured to drive the electric motor 32. The electric motor 32 is housed in the casing 40. The driver circuit 34 is also housed in the casing 40.

[0045] The housing 40 comprises a first housing 40A and a second housing 40B. The first housing 40A is recessed and opens on one side in a direction parallel to an axis C of the crankshaft 12A. The direction parallel to the axis C of the crankshaft 12A is hereinafter referred to as the axial direction CA of the crankshaft 12A. The second housing 40B closes the opening of the first housing 40A. As shown in Fig. As shown in Figure 2, the second housing 40B is attached to the first housing 40A, for example by a large number of screws 41A.

[0046] As in Fig. As shown in Figure 2, the bracket 50 preferably includes a first mounting section 52A and a second mounting section 52B. The bracket 50 includes the third mounting sections 52C and 52D and the fourth mounting sections 52E and 52F. As shown in Figure 2, the bracket 50 preferably includes a first mounting section 52A and a second mounting section 52B. Fig. As shown in Figure 2, the first assembly section 52A and the second assembly section 52B are spaced apart axially CA of the crankshaft 12A. The third assembly section 52C and the fourth assembly section 52E are spaced apart circumferentially of the crankshaft 12A. The third assembly section 52D and the fourth assembly section 52F are spaced apart circumferentially of the crankshaft 12A. The third assembly section 52C and the third assembly section 52D are spaced apart axially CA of the crankshaft 12A, and the fourth assembly section 52E and the fourth assembly section 52F are spaced apart axially CA of the crankshaft 12A. As shown in the Fig. 2 and Fig. As shown in Figure 3, the first assembly section 52A and the second assembly section 52B are located in overlapping positions, viewed in the axial direction CA of the crankshaft 12A. Viewed in the axial direction CA of the crankshaft 12A, the third assembly section 52C and the third assembly section 52D are located in overlapping positions, and the fourth assembly section 52E and the fourth assembly section 52F are located in overlapping positions.

[0047] The component of a human-powered vehicle 30 is configured to be coupled to the clamp 28 by screws 36. The clamp 28 includes an upper wall 28A and a pair of flanges 28B. The upper wall 28A covers the component of a human-powered vehicle 30 from above. The two flanges 28B extend from the upper wall 28A such that they abut the first mounting section 52A, the second mounting section 52B, the third mounting sections 52C and 52D, and the fourth mounting sections 52E and 52F in the axial direction CA of the crankshaft 12A. The two flanges 28B include through holes 28C at positions opposite the first mounting section 52A, the second mounting section 52B, the third mounting sections 52C, 52D, and the fourth mounting sections 52E, 52F in the axial direction CA of the crankshaft 12A. The screw 36 is inserted into the through hole 28C and fastened to the bracket 50.

[0048] Fig. Figure 4 shows an example of an internal structure of a component of a human-powered vehicle 30. As in Fig. As shown in Figure 4, the component of a human-powered vehicle 30 includes an output unit 38, a one-way clutch 60, a sensing shaft 61, a first bearing 62A, a second bearing 62B, a fifth bearing 62E, a reduction gear 64, a one-way clutch 66 and a sensor 68.

[0049] The housing 40 accommodates part of the crankshaft 12A, part of the output unit 38, part of the electric motor 32, the driver circuit 34, the one-way clutch 60, the first bearing 62A, the second bearing 62B, the third bearing 62C, the fourth bearing 62D, the fifth bearing 62E, the reduction gear 64, the one-way clutch 66 and the sensor 68.

[0050] The through-hole 42A of the housing 40 includes a first hole 42B and a second hole 42C. The first hole 42B is provided in the second housing 40B. The second hole 42C is provided in the first housing 40A. A first bearing 62A is provided in the first hole 42B of the housing 40. The first bearing 62A rotatably supports the crankshaft 12A near one end in the axial direction CA. The output unit 38 is coaxial with the crankshaft 12A. The output unit 38 covers an outer circumferential section of the crankshaft 12A near the other end in the axial direction CA. The housing 40 supports the output unit 38. In particular, the second bearing 62B, which is provided in the second hole 42C of the housing 40, rotatably supports the output unit 38. The fifth bearing 62E is provided between the output unit 38 and the crankshaft 12A. The fifth bearing 62E supports the output unit 38 rotatably relative to the crankshaft 12A. The fifth bearing 62E includes a needle bearing.

[0051] The electric motor 32 transmits the torque to assist the drive of the human-powered vehicle 10 to the output unit 38. The electric motor 32 includes a brushless motor. The in Fig. The driver circuit 34 shown in Figure 4 includes a processor that executes a pre-set control program. The processor is, for example, a central processing unit (CPU) or a microprocessor unit (MPU). The driver circuit 34 can include one or more microcomputers. In one example, the driver circuit 34 also includes memory. The memory stores various control programs and information used for different control processes. The memory includes, for example, non-volatile memory and volatile memory.

[0052] The reduction gear 64 comprises a first rotating shaft 64A, a second rotating shaft 64B, third bearings 62C, and fourth bearings 62D. The first rotating shaft 64A is rotatably mounted relative to the housing 40 by the third bearings 62C. The second rotating shaft 64B is rotatably mounted relative to the housing 40 by the two fourth bearings 62D. A first gear 64V and a second gear 64W are provided on the first rotating shaft 64A. A third gear 64X and a fourth gear 64Y are provided on the second rotating shaft 64B. The first gear 64V meshes with a gear 32B, which is provided on the output shaft 32A of the electric motor 32. The second gear 64W meshes with a third gear 64X, which is provided on the second rotating shaft 64B. The fourth gear 64Y engages with a gear 38A, which is provided on the outer circumferential section of the output unit 38.The rotation of the electric motor 32 is reduced in three stages: during the transmission from gear 32B of the output shaft 32A to the first gear 64V, the transmission from the second gear 64W to the third gear 64X, and the transmission from the fourth gear 64Y to the gear 38A of the output unit 38, before it is delivered to the output unit 38. In the present embodiment, the reduction gear 64 reduces the rotational speed in three stages from the electric motor 32 to the output unit 38. However, the reduction gear 64 can be configured to reduce the rotational speed in one stage, two stages, or four or more stages. The reduction gear 64 can incorporate a reduction mechanism other than parallel shaft gears. For example, the reduction gear 64 can incorporate a planetary gear, a worm gear, a spur gear, or a roller reduction gear.Furthermore, several types of reduction gears can be combined.

[0053] The one-way coupling 66 is provided in the transmission path of the motor drive force, which extends from the output shaft 32A of the electric motor 32 to the output unit 38. For example, the one-way coupling 66 is provided between the first rotating shaft 64A and the first gear 64V. The one-way coupling 66 transmits the rotation in one direction from the first gear 64V to the first rotating shaft 64A and not in the other direction from the first gear 64V to the first rotating shaft 64A. The one-way coupling 66 is configured to transmit the rotation of the electric motor 32 in a case where the electric motor 32 assists the drive of the human-powered vehicle 10 and does not allow the output shaft 32A of the electric motor 32 to be rotated by the human drive force. The one-way coupling 66 includes, for example, a roller coupling.A one-way coupling 66A, similar to the one-way coupling 66, can be provided between the third gear 64X and the second rotating shaft 64B, or between the fourth gear 64Y and the second rotating shaft 64B. In this case, the one-way coupling 66 can be omitted.

[0054] The sensing shaft 61 is tubular and located on the outer circumferential section of the crankshaft 12A. One end of the sensing shaft 61 is axially attached to the crankshaft 12A, for example by means of splines, while the other end is coupled to the one-way coupling 60. The sensing shaft 61 can be integrally formed with an inner ring of the one-way coupling 60.

[0055] The one-way coupling 60 is provided in the transmission path of the human drive force, which extends between the crankshaft 12A and the output unit 38. The one-way coupling 60 includes, for example, a roller coupling or a ratchet coupling. The one-way coupling 60 is configured to rotate the first rotating body 22 forward when the crankshaft 12 rotates forward and not to rotate the first rotating body 22 backward when the crankshaft 12 rotates backward. The one-way coupling 60 can be omitted. In this case, the sensing shaft 61 and the output unit 38 can be formed as an integral unit.

[0056] Sensor 68 outputs a signal corresponding to the force applied to the crankshaft 12A. Sensor 68 is located on the sensing shaft 61 or on the outer circumferential section of the sensing shaft 61. Sensor 68 may include, for example, a strain gauge or a magnetostrictive sensor. Sensor 68 communicates with the driver circuit 34 via a wireless or wired connection. The driver circuit 34 controls the electric motor 32 according to the output signal from sensor 68.

[0057] The Fig. 5 and Fig. Figure 6 shows the first 40A housing. The first 40A housing, which was installed in the Fig. 5 and Fig. Figure 6 shows a front wall 44A and a side wall 44B. The side wall 44B is designed to enclose an outer edge of the front wall 44A. The front wall 44A and the side wall 44B are integrally cast. As shown in Fig. As shown in Figure 5, the first housing 40A includes a receiving section 44C, a motor mount 44D, a first support 44E, a second support 44F and a plurality of first attached sections 44G.

[0058] The receiving section 44C is recessed in the end wall 44A. The receiving section 44C is defined by an essentially cylindrical receiving area. The second hole 42C is formed in the receiving section 44C. As shown in Fig. As shown in Figure 4, part of the crankshaft 12A, part of the output unit 38, the one-way coupling 60 and the second bearing 62B are housed in the receiving section 44C.

[0059] As in Fig. As shown in Figure 5, the motor mount 44D is provided on the end wall 44A. The motor mount 44D is integrally cast with the end wall 44A. The motor mount 44D includes a number of insertion holes 44H and a support 44I. The insertion holes 44H are configured to fasten the electric motor 32 to the motor mount 44D with screws 41B (see Figure 5). Fig. 4) The support 44I includes a through-hole through which the output shaft 32A of the electric motor 32 extends and on which a bearing for rotatably holding a rotor of the electric motor 32 is attached. The support 44I extends from the end wall 44A in the axial direction CA of the crankshaft 12A in a direction opposite the side wall 44B. As shown in Fig. As shown in Figure 4, the screws 41B are inserted into the insertion holes 44H such that the screws 41B are attached to threaded holes provided in a housing 32C of the electric motor 32 with corresponding screw heads arranged inside the housing 40.

[0060] The first support 44E rotatably carries the first rotary shaft 64A of the reduction gear 64. The first support 44E is located on the end wall 44A. The first support 44E is located in the motor mount 44D. The first support 44E accommodates and carries the third bearing 62C. The first support 44E is integrally cast with the end wall 44A.

[0061] The second support 44F is embedded in the end wall 44A. The second support 44F is located adjacent to the receiving section 44C in the first housing 40A. The second support 44F rotatably carries the second rotary shaft 64B of the reduction gear 64. The second support 44F receives and supports the fourth bearing 62D. The second support 44F is integrally cast with the end wall 44A.

[0062] As in Fig. As shown in Figure 5, each of the plurality of first fixed sections 44G comprises a main body of the first fixed section and a first metal fastening element 46A. The main body of the first fixed section is provided on the side wall 44B. The main body of the first fixed section is integrally formed with the side wall 44B. The first fastening element 46A is attached to the main body of the first fixed section. In one example, the first fastening element 46A is inserted into the main body of the first fixed section. The first fastening element 46A can be pressed into a hole formed in the main body of the first fixed section, or it can be inserted into a hole formed in the main body of the first fixed section and attached to the main body of the first fixed section.The first fastening element 46A has a substantially cylindrical outer circumferential surface. As in . Fig. As shown in Figure 7A, knurling 46C is preferably formed on the outer circumferential surface of the first fastening element 46A. An example of knurling 46C is knurling along a body line. A groove 46D, in which no knurling is formed, is preferably formed in the outer circumferential section of the first fastening element 46A at an intermediate section in the axial direction of the first fastening element 46A. The groove 46D can be formed around the entire circumference around the axis extending in the axial direction of the first fastening element 46A or it can be discontinuous. As shown in Fig. As shown in Figure 7B, the first fastening element 46A includes a hole 46E that opens axially at one end of the first fastening element 46A. An internal thread 46F is formed on the inner circumferential surface of the first fastening element 46A that defines the hole 46E. A groove 46D, preferably without knurling, is also formed in the outer circumferential section of the first fastening element 46A, preferably near the opening. The first fastening element 46A can be firmly connected to the main body of the first fastened section if the first fastening element 46A is cast into the main body of the first fastened section by forming the knurling 46C and the groove 46D. The hole 46E preferably does not extend axially over the first fastening element 46A.In a case where the first fastening element 46A is inserted into the main body of the first fastened section, no resin enters the hole 46E. The first fastening element 46A is provided on the main body of the first fastened section with the exposed hole 46E. Preferably, the first fastening element 46A is attached to the main body of the first fastened section such that the axial direction of the first fastening element 46A is parallel to the axial direction CA of the crankshaft 12A.

[0063] As in Fig. As shown in Figure 6, the first housing 40A comprises a first wall section 44J, a second wall section 44K, and a third wall section 44L. The first wall section 44J, the second wall section 44K, and the third wall section 44L are integrally formed with the side wall 44B and extend in the axial direction CA of the crankshaft 12A. The first wall section 44J, the second wall section 44K, and the third wall section 44L each include a portion of the side wall 44B and have a section extending from the end wall 44A to the side opposite the side wall 44B. The first wall section 44J is located near the motor mount 44D. A first plane extends through the axis of the crankshaft 12A and the axis of the output shaft 32A of the electric motor 32. A second plane extends orthogonally to the first plane and through the axis of the output shaft 32A of the electric motor 32.Preferably, the first wall section 44J is provided in a region on one side opposite the region where the crankshaft 12A is located, with respect to the first and second planes. The second wall section 44K and the third wall section 44L are integrally formed with the receiving section 44C. The second wall section 44K and the third wall section 44L are spaced apart from each other circumferentially around the crankshaft 12A. Preferably, the second wall section 44K and the third wall section 44L are spaced apart from each other by 90 degrees or more around the crankshaft 12A.

[0064] The first housing 40A is equipped with the bracket 50. The bracket 50 is integrally formed with the first housing 40A. As in Fig. As shown in Figure 5, the bracket 50 comprises a plurality of brackets 50A, 50B, and 50C. Bracket 50A is attached to the first wall section 44J. Bracket 50B and bracket 50C are attached to the receiving section 44C, the second wall section 44K, and the third wall section 44L, respectively. Bracket 50B and bracket 50C are spaced apart axially CA of the crankshaft 12A.

[0065] The bracket 50A includes a first mounting section 52A and a second mounting section 52B. The first mounting section 52A and the second mounting section 52B each project from the first wall section 44J to the outside of the first housing 40A along a plane orthogonal to the axial direction CA of the crankshaft 12A.

[0066] The bracket 50B includes a third mounting section 52C and a fourth mounting section 52E. The third mounting section 52C projects from the second wall section 44K to the outside of the first housing 40A along a plane orthogonal to the axial direction CA of the crankshaft 12A. The fourth mounting section 52E projects from the third wall section 44L to the outside of the first housing 40A along a plane orthogonal to the axial direction CA of the crankshaft 12A.

[0067] The bracket 50C includes a third mounting section 52D and a fourth mounting section 52F. The third mounting section 52D projects from the second wall section 44K to the outside of the first housing 40A along a plane orthogonal to the axial direction CA of the crankshaft 12A. The fourth mounting section 52F projects from the third wall section 44L to the outside of the first housing 40A along a plane orthogonal to the axial direction CA of the crankshaft 12A.

[0068] The brackets 50A and 50B each include attached sections 54A and 54B, which are fastened to the housing 40. The attached sections 54A and 54B are integrally formed with the housing 40. The attached sections 54A and 54B are preferably injection-molded into the housing 40. The attached sections 54A and 54B can be fastened to the housing 40 by at least one fastener and an adhesive. The fastener includes a screw. Preferably, the component of a human-powered vehicle 30 also includes a nut 56. The brackets 50A, 50B, 50C, and 50C preferably include a hole 52G in which a nut 56 is provided. The component of a human-powered vehicle 30 further preferably includes a bearing that rotatably supports the crankshaft 12A, in which the bearing is provided on the housing 40, and a metal support 54C that supports the bearing, in which the support is coupled to the bracket 50C.The bearing that rotatably supports the crankshaft 12A includes the second bearing 62B.

[0069] As in the Fig. 8 and Fig. As shown in Figure 9, the attached section 54A of the bracket 50A couples the first mounting section 52A and the second mounting section 52B. The attached section 54A is formed by a sheet-like metal plate. In the present embodiment, the attached section 54A is cast into and embedded in the first wall section 44J. The first mounting section 52A, the second mounting section 52B, and the attached section 54A are preferably formed integrally. Preferably, the first mounting section 52A, the second mounting section 52B, and the attached section 54A are formed from sheet metal. The first mounting section 52A, the second mounting section 52B, and the attached section 54A can be formed by pressing sheet metal. In this case, the bracket 50A can be formed by bending the first mounting section 52A and the second mounting section 52B with respect to the attached section 54A.

[0070] Each hole 52G of the first mounting section 52A and the second mounting section 52B, for example, contains an elongated hole. The elongated hole extends in the direction in which the first mounting section 52A and the second mounting section 52B protrude. As shown in the Fig. 5 and Fig. As shown in Figure 6, the nut 56, which is attached to the hole 52G, comprises a first section 56A and a second section 56B. Each of the first section 56A and the second section 56B is cylindrical. The outer diameter of the first section 56A is smaller than the outer diameter of the second section 56B. The width in the end-face direction of the elongated hole is preferably substantially equal to the outer diameter of the first section 56A. The first section 56A is preferably pressed into the hole 52G. The second section 56B lies at the edge of the hole 52G of the first mounting section 52A and the second mounting section 52B in a state in which the first section 56A is inserted into the hole 52G. The nut 56 includes a through-hole 56C that extends through the first section 56A and the second section 56B. An internal thread is formed on the wall surface of the through-hole 56C.In the present embodiment, the longitudinal width of the elongated hole is designed to be larger than the outer diameter of the first section 56A, allowing the nut 56 to move longitudinally within the elongated hole. The longitudinal direction of the elongated hole is preferably parallel to the direction in which the first mounting section 52A and the second mounting section 52B project from the housing 40. This sets the position of the nut 56 relative to the housing 40. The shape of each hole 52G of the first mounting section 52A and the second mounting section 52B can be arbitrarily modified. For example, the shape of at least one of the holes 52G of the first mounting section 52A and 52G of the second mounting section 52B can be circular, viewed in the direction in which the hole 52G extends.

[0071] The attached section 54A includes a plurality of through holes 54D. The through holes 54D are spaced apart from one another. The through holes 54D extend through the attached section 54A in the direction of the sheet thickness. The through holes 54D are filled with the resin material that forms the first housing 40A when the attached section 54A is inserted into the first housing 40A. The number, position, and shape of the through holes 54D can be varied as desired. In one example, at least one of the through holes 54D can be elongated.

[0072] The fixed section 54B of the bracket 50B extends over the second wall section 44K, the receiving section 44C and the third wall section 44L (see Fig. 5) The attached section 54B is preferably cast into the second wall section 44K, the receiving section 44C, and the third wall section 44L, and is thereby embedded in the second wall section 44K, the receiving section 44C, and the third wall section 44L. As shown in Fig. As shown in Figure 10, the third assembly section 52C, the fourth assembly section 52E, and the attached section 54B are preferably integrally formed. The third assembly section 52C, the fourth assembly section 52E, and the attached section 54B are preferably formed from sheet metal. The third assembly section 52C, the fourth assembly section 52E, and the attached section 54B can be formed by pressing sheet metal.

[0073] The holes 52G of the third assembly section 52C and the fourth assembly section 52E are identical to the holes 52G of the first assembly section 52A and the second assembly section 52B. A nut 56 is attached to the hole 52G of the third assembly section 52C and to the hole 52G of the fourth assembly section 52E.

[0074] The attached section 54B includes a plurality of through holes 54F. The through holes 54F are spaced circumferentially about the axial direction CA of the crankshaft 12A. The through holes 54F extend through the attached section 54B in the direction of the sheet thickness. In a case where the attached section 54B is inserted into the first housing 40A, the through holes 54F are filled with the resin material that forms the first housing 40A. The number, position, and shape of the through holes 54F can be varied as desired. For example, at least one of the through holes 54F can be circular in a top view.

[0075] The mounted section 54B comprises a first coupling section 54G, which is coupled to the third mounting section 52C, and a second coupling section 54H, which is coupled to the fourth mounting section 52E. Preferably, the first coupling section 54G and the second coupling section 54H are each bent from the mounted section 54B. Preferably, each of the first coupling sections 54G and 54H is bent at a 90-degree angle from the mounted section 54B. The third mounting section 52C is preferably bent from the first coupling section 54G to a side opposite the mounted section 54B. Preferably, the third mounting section 52C is bent at a 90-degree angle to the first coupling section 54G. Preferably, the fourth mounting section 52E is bent from the second coupling section 54H to a side opposite the mounted section 54B.Preferably, the fourth mounting section 52E is bent at a 90-degree angle to the second coupling section 54H. Preferably, the first coupling section 54G is embedded in the second wall section 44K, and the second coupling section 54H is embedded in the third wall section 44L. At least one of the first coupling section 54G and one of the second coupling section 54H can be omitted from the bracket 50B. The first coupling section 54G need not be bent from the attached section 54B. In such a case, the third mounting section 52C is not bent from the first coupling section 54G. The second coupling section 54H need not be bent from the attached section 54B. In this case, the fourth mounting section 52E is not bent from the second coupling section 54H.

[0076] As in Fig. As shown in Figure 11, the bracket 50C and the support 54C are preferably integrally formed. The bracket 50C includes the third mounting section 52D, the fourth mounting section 52F, and the attached section 54I. The support 54C is provided on the attached section 54I. The support 54C is cylindrical. The second bearing 62B (see Figure 11) Fig. 4) is attached to the inner circumferential surface of the support 54C. In one example, the attached section 54I is annular. Preferably, the third mounting section 52D, the fourth mounting section 52F, and the attached section 54I are integrally formed. Preferably, the third mounting section 52D, the fourth mounting section 52F, and the attached section 54I are formed from sheet metal. The third mounting section 52D, the fourth mounting section 52F, and the attached section 54I can be formed by pressing sheet metal.

[0077] The support 54C is integrally formed with the attached section 54I. In one example, the support 54C is cylindrical and extends in the axial direction CA of the crankshaft 12A from the inner circumferential edge of the attached section 54I. The support 54C and the attached section 54I are formed, for example, by a hole-flange process or a drawing process. The support 54C is coaxial with the crankshaft 12A. The support 54C is preferably insert-cast into the housing 40. The support 54C is, for example, insert-cast into and embedded in the receiving section 44C. The support 54C includes an outer ring support 54J, which is provided to support the outer ring of the second bearing 62B in the axial direction CA of the crankshaft 12A. The outer ring support 54J is provided at one end of the support 54C in the axial direction CA of the crankshaft 12A.The outer ring carrier 54J and the inner circumferential surface of the carrier 54C are exposed by the receiving section 44C.

[0078] The attached section 54I includes a first coupling section 54K, which couples the third mounting section 52D, and a second coupling section 54L, which couples the fourth mounting section 52F. Preferably, each of the first coupling section 54K and the second coupling section 54L is bent from the attached section 54I. The third mounting section 52D is bent from the first coupling section 54K. The fourth mounting section 52F is bent from the second coupling section 54L.

[0079] The holes 52G of the third assembly section 52D and the fourth assembly section 52F are identical to the holes 52G of the first assembly section 52A and the second assembly section 52B. A nut 56 is attached to the hole 52G of the third assembly section 52D and to the hole 52G of the fourth assembly section 52F.

[0080] As in Fig. As shown in Figure 12, the second housing 40B includes an end wall 48A and a side wall 48B. The side wall 48B encloses the outer edge of the end wall 48A. The second housing 40B includes a receiving section 48C, a first support 48D, a second support 48E, a third support 48F, and a plurality of second attached sections 48G. The side wall 48B of the second housing 40B abuts the side wall 48B of the first housing 40A. The side wall 48B of the second housing 40B can be omitted.

[0081] The receiving section 48C is recessed into the end wall 48A. The receiving section 48C forms an essentially cylindrical receiving area. The first hole 42B is formed in the receiving section 48C. As shown in Fig. As shown in Figure 4, the first storage unit 62A is located in the receiving section 48C.

[0082] The first support 48D and the second support 48E are embedded in the end wall 48A. The first support 48D rotatably carries the first rotary shaft of the reduction gear 64. The first support 48D receives and supports the third bearing 62C. The second support 48E is located adjacent to the first support 48D in the second housing 40B. The second support 48E rotatably carries the second rotary shaft of the reduction gear 64. The second support 48E receives and supports the fourth bearing 62D. The third support 48F is designed to project from the end wall 48A. The third support 48F is located on the side of the first support 48D opposite the receiving section 48C. The third support 48F carries the circuit board 34A (see Fig. 4), on which the driver circuit 34 is formed.

[0083] Each of the multiple second fixed sections 48G comprises a main body of the second fixed section and a second metal fastener 46B. The main body of the second fixed section is provided on the side wall 44B. The main body of the second fixed section is integrally formed with the side wall 44B. The second fastener 46B is attached to the main body of the second fixed section. In one example, the second fastener 46B is inserted into the main body of the second fixed section. The second fastener 46B may be pressed into a hole formed in the main body of the second fixed section, or it may be inserted into a hole formed in the main body of the second fixed section and attached to the main body of the second fixed section. The second fastener 46B has a substantially cylindrical outer circumferential surface.Like the first fastening element 46A, the second fastening element 46B also has knurling 46C on its outer circumferential surface. Unlike the first fastening element 46A, the second fastening element 46B includes a through-hole 46G, allowing the screw 41A to extend through the through-hole 46G. The second fastening element 46B can be omitted. In such a case, an insertion hole is formed in the multiple second fastened sections 48G, into which the screw 41A is inserted. Like the first fastening element 46A, the outer circumferential surface of the second fastening element 46B can also include a groove 46D.

[0084] The second housing 40B includes a metal reinforcing element 49. The reinforcing element 49 is integrally formed with the second housing 40B. The reinforcing element 49 is cast into the second housing 40B. The reinforcing element 49 is attached to the receiving section 48C and its circumference.

[0085] As in Fig. As shown in Figure 13, the reinforcing element 49 comprises a first flat plate section 49A, a second flat plate section 49B, and a bent section 49C. The first flat plate section 49A, the second flat plate section 49B, and the bent section 49C are formed from sheet metal. The first flat plate section 49A, the second flat plate section 49B, and the bent section 49C are integrally formed by pressing sheet metal.

[0086] The first flat plate section 49A includes a through-hole 49D into which the crankshaft 12A can be inserted, and a flange 49E that forms the through-hole 49D and extends from the first flat plate section 49A in the axial direction CA of the crankshaft 12A. The inner circumferential surface of the flange 49E forming the through-hole 49D is exposed by the receiving section 48C. A plurality of through-holes 49F are formed in the first flat plate section 49A. The through-holes 49F extend through the first flat plate section 49A in the thickness direction. The through-holes 49F are circular in a top view, for example. The through-holes 49F are spaced apart from each other circumferentially around the crankshaft 12A. The through holes 49F are filled with the resin material that forms the second housing 40B when the reinforcing element 49 is inserted into the second housing 40B.

[0087] The second flat plate section 49B encloses part of the first flat plate section 49A. The second flat plate section 49B is provided along the side wall 48B. The second flat plate section 49B includes a plurality of through holes 49F. The through holes 49F are spaced apart circumferentially around the crankshaft 12A. The through holes 49F are elongated in a top view, e.g. The through holes 49F are filled with the resin material that forms the second housing 40B when the reinforcing element 49 is inserted into the second housing 40B. The number, position, and shape of the through holes 49F can be varied as desired. In the axial direction CA of the crankshaft 12A, the first flat plate section 49A and the second flat plate section 49B are offset from each other, and the first flat plate section 49A and the second flat plate section 49B are connected by the curved section 49C.

[0088] An example of a method for attaching the component of a human-powered vehicle 30 to the clamp 28 is now described with reference to Figures 14A and 14B. Fig. 14A and Fig. Figure 14B illustrates the procedure for mounting the component of a human-powered vehicle 30 to the clamp 28 using the bracket 50A. The procedure for attaching the component of a human-powered vehicle 30 to the clamp 28 using the bracket 50B and the bracket 50C is similar. Figures 14A and 14B show the shape of the clamp 28 simplified for clarity.

[0089] As in Fig. As shown in Figure 14A, the first assembly section 52A is located near one of the flanges 28B of the clamp 28. Fig. At step 14A, a state is reached in which the first assembly section 52A touches the flange 28B. The first assembly section 52A is then fastened to the flange 28B with the screw 36. As shown in Fig. As shown in 14A, a gap G1 can be formed between the other flange 28B of the clamp 28 and the second assembly section 52B.

[0090] Then, as in Fig. As shown in Figure 14B, the second mounting section 52B is attached to the other flange 28B by the screw 36. When the screw 36 tightens the nut 56, the second mounting section 52B bends towards the other flange 28B, narrowing the gap G1. This limits the loosening of the human-powered vehicle component 30 from the clamp 28. Thus, the human-powered vehicle component 30 is securely attached to the clamp 28.

[0091] For example, the one in the Fig. 15, Fig. 16 to Fig. The structure shown in Figure 17 can be used to attach the component of a human-powered vehicle 30 to the clamp 28. Fig. 15, Fig. 16 to Fig. Figure 17 shows the structure of the first assembly section 52A and the fastening structure of the first assembly section 52A and the clamp 28. In the Fig. 15, Fig. 16 to Fig. The structure shown in Figure 17 is different from the structure of part of the nut 56 and the structure of part of the first assembly section 52A.

[0092] The bracket 50 further preferably includes a first flange formed on an edge of the hole 52G. The first flange is preferably manufactured using the hole-flange method. In one example, the first mounting section 52A of the bracket 50 further includes a first flange 52H formed on the edge of the hole 52G and a knurling 52I formed on the edge of the hole 52G. The first flange 52H is manufactured using the hole-flange method. Although not shown, the second mounting section 52B, the third mounting sections 52C, 52D, and the fourth mounting sections 52E, 52F may also include the first flange 52H or the knurling 52I. The knurling 52I can be omitted.

[0093] The nut 56 includes a knurling 56D, which is provided on the outer circumferential section of the first section 56A, and a slot 56E, which is connected to the through-hole 56C from the outer circumferential section of the first section 56A. The slot 56E extends circumferentially along the first section 56A. The knurling 56D extends axially CA along the crankshaft 12A. When the first section 56A of the nut 56 is fastened to the hole 52G of the first assembly section 52A, the knurling 52I of the first assembly section 52A and the knurling 56D of the first section 56A interlock, thereby limiting rotation about the axis of the nut 56.

[0094] The nut 56 incorporates a clamping element 58 located in the slot 56E. The clamping element 58 is made of a material with a lower hardness than the nut 56. For example, the clamping element 58 is made of resin. The clamping element 58 is designed to close the slot 56E of the nut 56. The clamping element 58 has, for example, the shape of an arc. The clamping element 58 can be pressed into the slot 56E or bonded to the nut 56 with an adhesive. The clamping element 58 is preferably made of a deformable material. The thickness of the clamping element 58 in the radial direction of the nut 56 is greater than the depth of the slot 56E in the radial direction of the nut 56.

[0095] In the direction of the axis of the nut 56, the length L1 of the first section 56A is greater than the thickness L2 of the first assembly section 52A with the first flange 52H. The distal end face of the first section 56A of the nut 56, in the axial direction CA of the crankshaft 12A, projects from the first assembly section 52A in the axial direction CA to contact the flange 28B of the clamp 28 in a state where the nut 56 is pressed into the hole 52G of the first assembly section 52A. The outer circumferential surface of the clamping element 58 contacts the knurling 52I. The inner circumferential surface of the clamping element 58 is arranged radially to the nut 56 at the same location as the internal thread formed in the through hole 56C of the nut 56 or slightly projecting from the wall surface of the internal thread.

[0096] As in Fig. As shown in Figure 17, the first assembly section 52A is connected to the clamp 28 by the screw 36 inserted into the through-hole 56C of the nut 56. The screw 36 is fastened to the nut 56 in a state in which the end face of the nut 56 contacts the flange 28B of the clamp 28 in the axial direction CA of the crankshaft 12A, or the gap between the end face of the nut 56 and the flange 28B is minimal in the axial direction CA. The flange 28B is clamped between the first assembly section 52A and the screw head 36A of the screw 36. The external thread 36B of the screw 36 is engaged in the clamping element 58 in a state in which the inner circumferential surface of the clamping element 58 is plastically deformed. The material of the clamping element 58 can be any material as long as the external thread 36B of the screw 36 can be engaged in the clamping element 58. The material can be, for example, aluminum instead of resin. Clamping element 58 can be omitted.

[0097] As in the Fig. 16 and Fig. As shown in Figure 17, a gap G2 is formed between the second section 56B of the nut 56 and the first mounting section 52A in the axial direction CA of the crankshaft 12A. The first section 56A of the nut 56 projects from the first mounting section 52A towards the flange 28B of the clamp 28 by adjusting the position of the nut 56 relative to the first mounting section 52A to reduce the gap G2. The first section 56A of the nut 56 and the flange 28B of the clamp 28 either come into contact with each other, or the gap between the first section 56A of the nut 56 and the flange 28B of the clamp 28 is reduced by the gap between the first mounting section 52A and the flange 28B. This restricts the detachment of the component of a human-powered vehicle 30 from the clamp 28, and the component of a human-powered vehicle 30 is stably attached to the clamp 28.

[0098] The design of the component of a human-powered vehicle 30 according to a second embodiment is now described with reference to the Fig. 18, Fig. 19 to Fig. 20 described. The component of a human-powered vehicle 30 of the present embodiment differs from the component of a human-powered vehicle 30 of the first embodiment in the design of the mounting. The parts that are identical to the corresponding parts of the component of a human-powered vehicle 30 in the first embodiment are given the same reference numerals. A detailed description of these components is omitted.

[0099] As in Fig. As shown in Figure 18, the housing 40 includes a first housing 40A, a second housing 40B (see Figure 18). Fig. 12) and a metal bracket 70. The bracket 70 is provided on the housing 40, protruding from the housing 40 and on the frame 16 (see Fig. 1) of the human-powered vehicle 10 attached.

[0100] The first housing 40A includes the bracket 70. The bracket 70 is flexible. The bracket 70 is integrated into the first housing 40A. As in Fig. As shown in Figure 18, the bracket 70 includes brackets 70A and 70B. Bracket 70A has the same configuration as bracket 70A of the first embodiment. Bracket 70A is integrally formed with the housing 40, like bracket 50A of the first embodiment.

[0101] As in the Fig. 18 and Fig. As shown in Figure 19, the bracket 70B includes a first mounting section 72A and a second mounting section 72B. The first mounting section 72A and the second mounting section 72B are spaced apart axially CA of the crankshaft 12A. The bracket 70 includes a fifth mounting section 72C and a sixth mounting section 72D. The first mounting section 72A and the second mounting section 72B are spaced apart circumferentially around the fifth mounting section 72C and the sixth mounting section 72D. The fifth mounting section 72C and the sixth mounting section 72D are spaced apart axially CA of the crankshaft 12A.

[0102] Each of the first assembly section 72A and the second assembly section 72B projects from the second wall section 44K to the outside of the first housing 40A along a plane orthogonal to the axial direction CA of the crankshaft 12A. The fifth assembly section 72C and the sixth assembly section 72D project from the third wall section 44L to the outside of the first housing 40A along a plane orthogonal to the axial direction CA of the crankshaft 12A.

[0103] The bracket 70B includes a hole 72E in which a nut 56 is provided. The hole 72E is formed in the first assembly section 72A, the second assembly section 72B, the fifth assembly section 72C, and the sixth assembly section 72D. The hole 72E of the first assembly section 72A, the hole 72E of the second assembly section 72B, the hole 72E of the fifth assembly section 72C, and the hole 72E of the sixth assembly section 72D have the same shape. The nut 56 is attached to each hole 72E. The hole 72E and the nut 56 can be aligned with the Fig. 15, Fig. 16 to Fig. The structure shown in section 17 will be rearranged.

[0104] The bracket 70B preferably includes the fixed sections 74A, 74B and 74I, which are attached to the housing 40. The fixed sections 74A, 74B, 74I are preferably integrally formed with the housing 40. The fixed parts 74A, 74B, 74I are preferably cast into the housing 40.

[0105] The fixed section 74A couples the first mounting section 72A and the second mounting section 72B. The fixed section 74A is preferably cast into and embedded in the second wall section 44K. The first mounting section 72A, the second mounting section 72B, and the fixed section 74A are preferably integrally formed. The first mounting section 72A, the second mounting section 72B, and the fixed section 74A are preferably formed from sheet metal. The first mounting section 72A, the second mounting section 72B, and the fixed section 74A can be formed by pressing sheet metal. In this case, the bracket 70A can be formed by bending the first mounting section 72A and the second mounting section 72B from the fixed section 74A. The fixed section 74A includes a through-hole 74C.For example, the through-hole 74C in the front view of the attached section 74A is rectangular. In a case where the attached section 74A is inserted into the first housing 40A, the through-hole 74C is filled with the resin material that forms the first housing 40A.

[0106] The fixed section 74B couples the fifth mounting section 72C and the sixth mounting section 72D. The fixed section 74B is preferably cast into and embedded in the third wall section 44L. The fifth mounting section 72C, the sixth mounting section 72D, and the fixed section 74B are preferably integrally formed. The fifth mounting section 72C, the sixth mounting section 72D, and the fixed section 74B are preferably formed from sheet metal. The fifth mounting section 72C, the sixth mounting section 72D, and the fixed section 74B can be formed by pressing sheet metal. In this case, the bracket 70A can be formed by bending the fifth mounting section 72C and the sixth mounting section 72D from the fixed section 74B. The fixed section 74B includes a through-hole 74D.The through-hole 74D, for example, has a rectangular shape in the front view of the attached section 74B. The through-hole 74D is, in a case where the attached section 74B is inserted into the first housing 40A, filled with the resin material that forms the first housing 40A.

[0107] The component of a human-powered vehicle 30 further includes a metal support 74E, which is coupled to the bracket 70B and carries a bearing that rotatably supports the crankshaft 12A. The bracket 70B and the support 74E are integrally formed. The bearing that rotatably supports the crankshaft 12A includes the second bearing 62B.

[0108] Bracket 70B and support 74E are coupled via the attached section 74I. As shown in Fig. As shown in Figure 19, the bracket 70B and the support 74E are preferably integrally formed. The support 74E is provided on the attached section 74I. The support 74E is cylindrical. The second bearing 62B (see Figure 19) Fig. 4) is attached to the inner circumferential surface of the support 74E.

[0109] In one example, the attached section 74I is annular. The second assembly section 72B, the sixth assembly section 72D, and the attached section 74I are preferably integrally formed. The second assembly section 72B, the sixth assembly section 72D, and the attached section 74I are preferably formed from sheet metal. The second assembly section 72B, the sixth assembly section 72D, and the attached section 74I can be formed by pressing sheet metal. The attached section 74I includes a first coupling section 78A, which is coupled to the second assembly section 72B, and a second coupling section 78B, which is coupled to the sixth assembly section 72D.

[0110] The support 74E is integrally formed with the attached part 74I. In one example, the support 74E is cylindrical and extends from the inner circumferential edge of the attached section 74I in the axial direction CA of the crankshaft 12A. The support 74E and the attached section 74I are formed, for example, by a hole-flange process or a drawing process. The support 74E is coaxial with the crankshaft 12A. The support 74E is preferably insert-cast into the housing 40. For example, the support 74E is insert-cast into and embedded in the receiving section 44C. The support 74E includes an outer ring support 74J to support the outer ring of the second bearing 62B in the axial direction CA of the crankshaft 12A. The outer ring support 74J is provided at an end section of the support 74E in the axial direction CA of the crankshaft 12A.The inner circumferential surfaces of the outer ring carrier 74J and the carrier 74E are exposed from the receiving section 44C.

[0111] The shape of the support 74E is the same as the shape of the support 54C of the first embodiment. The shape of the attached section 74I is the same as the shape of the attached section 54I of the first embodiment. The shape of the outer ring support 74J is the same as the shape of the outer ring support 54J of the first embodiment.

[0112] As in Fig. As shown in Figure 19, the first assembly section 72A, the second assembly section 72B, the fifth assembly section 72C, and the attached section 74A are preferably formed integrally. Preferably, the first assembly section 72A, the second assembly section 72B, the fifth assembly section 72C, and the attached section 74A are formed from sheet metal. Preferably, the first assembly section 72A, the second assembly section 72B, the fifth assembly section 72C, the sixth assembly section 72D, and the attached sections 74A and 74B are formed integrally. Preferably, the first assembly section 72A, the second assembly section 72B, the fifth assembly section 72C, the sixth assembly section 72D, and the attached sections 74A and 74B are formed from sheet metal. Fig. 19. The first assembly section 72A, the second assembly section 72B, the fifth assembly section 72C, the sixth assembly section 72D, and the attached sections 74A, 74B, and 74I are integrally formed. The first assembly section 72A, the second assembly section 72B, the fifth assembly section 72C, the sixth assembly section 72D, and the attached sections 74A, 74B, and 74I are made of sheet metal.

[0113] Fig. Figure 20 shows a spread view of bracket 70B. As in Fig. As shown in Figure 20, the second assembly section 72B is provided in the through-hole 74C of the fastened section 74A. Fig. 20. Part of the through-hole 74C is filled with the second mounting section 72B. A rectangular through-hole 74C is formed by bending the attached section 74A from the second mounting section 72B. The sixth mounting section 72D is provided in the through-hole 74D of the attached section 74B. In Fig. 20 is part of the through-hole 74D filled with the sixth assembly section 72D. A rectangular through-hole 74D is formed by bending the attached section 74B from the sixth assembly section 72D.

[0114] The design of the component of a human-powered vehicle 30 according to a third embodiment is now described with reference to the Fig. 21, Fig. 22, Fig. 23, Fig. 24, Fig. 25 to Fig. 26. The component of a human-powered vehicle 30 of the present embodiment differs from the component of a human-powered vehicle 30 of the first embodiment in the design for attaching the electric motor 32 to the housing 40. The parts that are identical to the corresponding parts of the component of a human-powered vehicle 30 in the first embodiment are given the same reference numerals. A detailed description of these parts is omitted.

[0115] As in Fig. As shown in Figure 21, the electric motor 32 is provided in the housing 40. The electric motor 32 includes a stator 32D. The electric motor 32 further includes a rotor 32E, which rotates integrally with an output shaft 32A, a first bearing 32F and a second bearing 32G, which rotatably supports the output shaft 32A, and a support element 32H, which supports the second bearing 32G. The stator 32D includes a stator core and coils wound around the stator core.

[0116] The stator 32D is cast into the housing 40. Fig. 21 The stator 32D is cast into the first housing 40A. The motor mount 44D of the first housing 40A includes a molded section 44M that covers the entire stator 32D and a support 44N that carries the first bearing 32F. The molded section 44M includes a receiving section 44Q that receives the rotor 32E. The receiving section 44Q includes a through-hole with substantially the same inner diameter as the inner diameter of the stator 32D. In the axial direction CA of the crankshaft 12A, an internal thread 44P is formed in the receiving section 44Q on the side opposite the support 44N.

[0117] The support element 32H is cup-shaped and includes an end section 32I and a cylindrical section 32J. An external thread 32K is formed on the outer circumferential section of the cylindrical section 32J. The support element 32H is attached to the molded section 44M by engaging the external thread 32K with the internal thread 44P.

[0118] An example of the first bearing 32F and the second bearing 32G is a rolling bearing. The first bearing 32F rotatably supports the output shaft 32A by attaching the outer ring to the carrier 44N and the inner ring to the output shaft 32A. The second bearing 32G rotatably supports the output shaft 32A by attaching the outer ring to the carrier element 32H and the inner ring to the output shaft 32A.

[0119] The component of the human-powered vehicle 30 can further include a metal reinforcement element 31. In an example, as in Fig. As shown in Figure 22, the reinforcing element 31 is preferably provided in the housing 40. Preferably, the reinforcing element 31 contacts the electric motor 32. Preferably, the reinforcing element 31 is integrally formed with the holder 50A.

[0120] The reinforcing element 31 comprises a support 31A, which carries the first bearing 32F, and a contact section 31B, which contacts the stator 32D. The support 31A is provided on the support 44N of the first housing 40A. The support 31A carries the outer ring of the first bearing 32F in the axial direction of the output shaft 32A. The contact section 31B is, for example, essentially cylindrical. The contact section 31B contacts the outer circumferential surface of the stator 32D.

[0121] The reinforcing element 31 and the bracket 50A can be formed separately. In this case, the reinforcing element 31 and the bracket 50A can be coupled or spaced apart from each other. The reinforcing element 31 can be formed from sheet metal.

[0122] The shape of the reinforcing element 31 can be modified as desired. For example, the contact section 31B of the reinforcing element 31 can surround the entire stator 32D in the axial direction of the output shaft 32A. A portion of the contact section 31B can be cut out circumferentially around the output shaft 32A. The reinforcing element 31 can have the shape of a flat plate with at least one of the supports 31A and the contact section 31B cut out.

[0123] The Fig. 23, Fig. 24, Fig. 25 to Fig. Figure 26 shows an example of the design of rotor 32E. As shown in the Fig. 23, Fig. 24, Fig. 25 to Fig. As shown in Figure 26, the rotor 32E has a magnetically embedded rotor structure and includes a rotor core 80 and permanent magnets 86. The rotor core 80 is attached to the output shaft 32A (see Figure 26). Fig. 21 and Fig. 22).

[0124] As in Fig. As shown in Figure 23, the rotor core 80 consists of a soft magnetic material. The rotor core 80 comprises two types of lamellae: the first lamellae 82A and the second lamellae 82B. The first lamellae 82A form the two ends of the rotor core 80 in the axial direction of the output shaft 32A. The second lamellae 82B form an intermediate section of the rotor core 80, located between the first lamellae 82A at the two ends. The rotor core 80 is formed by stacking the first lamellae 82A and the second lamellae 82B in the axial direction of the output shaft 32A. The first lamellae 82A and the second lamellae 82B are formed, for example, by pressing. Fig. For convenience, the number of second slats 82B is reduced in 23.

[0125] As in Fig. As shown in Figure 24, each first lamella 82A includes a first hole 84A into which the output shaft 32A is inserted, and a plurality of second holes 84B into which the permanent magnets 86 are inserted. The second holes 84B are spaced apart circumferentially around the output shaft 32A. In one example, the displacement between the second holes 84B is uniform in the circumferential direction. The second hole 84B is configured to be substantially rectangular, with the radial direction being the longitudinal side in a top view of the first lamella 82A.

[0126] The first lamella 82A includes a plurality of projections 84C configured to position the permanent magnets 86 radially. The projection 84C includes a first projection 84D located at the outer edge of the second hole 84B and a second projection 84E located at the inner circumferential section of the second hole 84B. The circumferential width of the outer edge of the second hole 84B is reduced by the two first projections 84D located in every second hole 84B. The circumferential width of the inner circumferential section of the second hole 84B is reduced by the two second projections 84E located in a second hole 84B. The radial movement of the permanent magnet 86 is limited by the plurality of projections 84C. The second projection 84E can be omitted from the projection 84C.

[0127] As in Fig. As shown in Figure 25, the second lamella 82B differs from the first lamella 82A in that a third hole 84F connects two adjacent second holes circumferentially around the output shaft 32A. In the second hole 84B connected to the third hole 84F, one of the second projections 84E is omitted. The first lamella 82A includes a first tooth segment coupled to the central segment and a second tooth segment separated from the central segment. The first lamella 82A is stacked on the adjacent first lamella 82A in a state rotated by a predetermined angle around the center of the axis of rotation. In the present embodiment, the first lamella 82A is stacked such that the first tooth segment and the second tooth segment alternately overlap in the stacking direction.

[0128] As in Fig. As shown in Figure 26, the permanent magnets 86 are designed as flat plates. The permanent magnets 86 are inserted into the second holes 84B. The permanent magnets 86 are attached to the inner surface of the rotor core 80, for example by an adhesive, and form the second hole 84B. As shown in Fig. As shown in Figure 26, the permanent magnet 86 is magnetized such that the N pole and the S pole lie next to each other circumferentially around the output shaft 32A. The magnetic poles of the permanent magnets 86 that are adjacent circumferentially have opposite polarities. That is, the magnetic poles of the permanent magnets 86 that are opposite each other circumferentially have the same polarity.

[0129] The design of the component of a human-powered vehicle 30 according to a fourth embodiment is now described with reference to the Fig. 27, Fig. 28, Fig. 29 to Fig. 30 described. The component of a human-powered vehicle 30 of the present embodiment differs from the component of a human-powered vehicle 30 of the first embodiment in the design for attaching the electric motor 32 to the housing 40. The parts that are identical to the corresponding parts of the component of a human-powered vehicle 30 in the first embodiment are given the same reference numerals. A detailed description of these parts is omitted.

[0130] As in Fig. As shown in Figure 27, the electric motor 32 includes a busbar assembly 90 and a clamp 92. The busbar assembly 90 connects the U-phase coils, V-phase coils, and W-phase coils of the stator 32D. The clamp 92 secures the electric motor 32 to the housing 40.

[0131] The busbar unit 90 includes an annular support 90A. The clamp 90A is attached to the stator 32D to cover the stator 32D in the axial direction of the output shaft 32A. The support 90A includes a first terminal block 90B, a second terminal block 90C, and a third terminal block 90D. The first terminal block 90B, the second terminal block 90C, and the third terminal block 90D are spaced apart circumferentially around the output shaft 32A. A first terminal 90U is attached to the first terminal block 90B. A second terminal 90V is attached to the second terminal block 90C. A third terminal 90W is attached to the third terminal block 90D. The U-phase coils are electrically connected to the first terminal 90U. The V-phase coils are electrically connected to the second terminal 90V. The W-phase coils are electrically connected to the third terminal 90W.

[0132] The clamp 92 is attached to the housing 32C to cover the busbar assembly 90 in the axial direction of the output shaft 32A. The clamp 92 covers the opening of the housing 32C. The busbar assembly 90 is located between the stator 32D and the clamp 92 in the axial direction of the output shaft 32A. The clamp 92 includes a first hole 92A, a plurality of second holes 92B, and a third hole 92C. For example, the clamp 92 includes in Fig. 27 a plurality of brackets 92D on the outer circumferential section. The brackets 92D are spaced apart from each other in the circumferential direction around the output shaft 32A.

[0133] The first hole 92A is a through hole into which the output shaft 32A is inserted. The first hole 92A extends through the middle section of the clamp 92. The first terminal block 90B, the second terminal block 90C, and the third terminal block 90D of the busbar unit 90 are inserted into the second holes 92B. A stop element 98 is attached to the third hole 92C.

[0134] As in Fig. As shown in Figure 28, the bracket 92 includes a support 92E. The support 92E has a cylindrical shape formed at the edge of the first hole 92A. A first bearing 32F (see Figure 28) Fig. 21) is attached to the support 92E.

[0135] A plurality of radially projecting projections 92F and a plurality of ribs 92G are provided on the outer circumferential section of the carrier 92E. The projections 92F are spaced apart from each other circumferentially around the output shaft 32A. The ribs 92G are spaced apart from each other circumferentially around the output shaft 32A. The ribs 92G are provided between the projections 92F that are adjacent to each other circumferentially. The ribs 92G reduce the vibrations of the electric motor 32.

[0136] A printed circuit board 94 is attached to the end face of the support 92E. In a top view, the printed circuit board 94 has the shape of an arc. The printed circuit board 94 is positioned over two circumferentially adjacent projections 92F. The printed circuit board 94 is fastened to the projection 92F of the support 92E by screws 94A. The screws 94A are made of a non-magnetic material. An example of a non-magnetic material is an aluminum alloy. The printed circuit board 94 is supported by the rib 92G. The fastening structure between the printed circuit board 94 and the support 92E can be modified as desired. For example, the printed circuit board 94 can be fastened to the clamp 92E with adhesive, double-sided tape, and thermal sealing.

[0137] Electronic components are mounted on the surface of the printed circuit board 94 on the side of the carrier 92E and on the surface opposite the carrier 92E. In one example, a position sensing element 94B, which detects the rotational position of the rotor 32E of the electric motor 32, is mounted on the surface of the printed circuit board 94 opposite the carrier 92E. In this example, the position sensing element 94B includes three Hall effect sensors. A terminal 94C is mounted on the surface of the printed circuit board 94 on the side of the carrier 92E.

[0138] As in Fig. As shown in Figure 30, a cable harness 96 is electrically connected to the connector 94C. The cable harness 96 extends from the clamp 92 through the stop element 98. The stop element 98 secures the cable harness 96. The cable harness 96 is electrically connected to the circuit board 34A provided in the housing 40 (see Figure 30). Fig. 4) connected.

[0139] As in Fig. As shown in Figure 29, the stop element 98 consists of a single element. The stop element 98 comprises a cover section 98A and a fixed section 98B. The cover section 98A covers the edge of the third hole 92C of the clamp 92. The fixed section 98B is inserted into the third hole 92C.

[0140] The cover section 98A is rectangular in plan view. The cover section 98A includes a first through-hole 98C, two second through-holes 98D, and a hinge section 98E. The first through-hole 98C is an elongated hole extending longitudinally along the cover section 98A. In plan view, the first through-hole 98C is located in the central section of the cover section 98A. The second through-hole 98D is located on two sides of the first through-hole 98C in a direction orthogonal to the longitudinal direction of the cover section 98A in plan view. The hinge section 98E is designed such that the thickness of the central section of the cover section 98A decreases in a side view.

[0141] The fixed section 98B comprises a first fixed section 98F and a second fixed section 98G. The first fixed section 98F and the second fixed section 98G are spaced apart from each other in a plan view orthogonal to the longitudinal direction of the cover section 98A. An entry hole 98H for inserting the cable harness 96 is formed between the first fixed section 98F and the second fixed section 98G.

[0142] The first fixed section 98F includes a first projection 98I, a first projection 98J, and a first engagement section 98K. The first projection 98I extends toward the insertion opening 98H. In the axial direction of the output shaft 32A, the first projection 98I is shown in a side view at the intermediate section of the first fixed section 98F. The first projection 98J is shown in a top view at two longitudinal ends of the first fixed section 98F. The first projection 98J is shown in a top view at two longitudinal sides of the first fixed section 98F. The first projection 98J extends toward the insertion opening 98H. The first engagement section 98K is shown in a top view at an intermediate section in the longitudinal direction of the first fixed section 98F.The first engagement section 98K is connected to the edge of the third hole 92C in a state in which it is inserted into the third hole 92C of the clamp 92.

[0143] The second fixed section 98G includes a second projection 98L, a second protrusion 98M, and a second engagement section 98N. The second projection 98L, the second protrusion 98M, and the second engagement section 98N have the same shape as the first projection 98I, the first protrusion 98J, and the first engagement section 98K of the first fixed section 98F. The second projection 98L is shown in a side view at a position separate from the first projection 98I. The second protrusion 98M is shown in a side view at the same position as the first protrusion 98J.

[0144] In a case where the cable harness 96 connected to terminal 94C is inserted into the stop element 98, the cover section 98A is first bent around the hinge section 98E, increasing the gap between the first projection 98J and the second projection 98M. In this state, the cable harness 96 is inserted into the entry hole 98H of the stop element 98. After the cable harness 96 has been inserted into the stop element 98, the stop element 98 is fastened to the third hole 92C of the clamp 92.

[0145] In a case where force is exerted on the first fixed section 98F and the second fixed section 98G, causing the insertion hole 98H to become smaller, the movement of the first fixed section 98F and the second fixed section 98G is restricted by the contact of the first projection 98J and the second projection 98M. This limits the separation of the stop element 98 from the clamp 92.

[0146] The description relating to the embodiments above illustrates, without limitation, an applicable form of a component of a human-powered vehicle according to the present invention. In addition to the embodiments described above, the component of a human-powered vehicle according to the present invention applies, for example, to modified examples of the embodiments described above and combinations of at least two of the modified examples that do not contradict each other. In the modified examples described below, the components that are identical to the corresponding components of the embodiments above are given the same reference numbers. A detailed description of these components is omitted.

[0147] In the component of a human-powered vehicle 30 of the second embodiment, at least one of the configurations of the component of a human-powered vehicle 30 of the third and fourth embodiments can be combined.

[0148] In the first, third, and fourth embodiments, at least one of the brackets 50A, 50B, and 50C can be integrally formed with the second housing 40B. In the first, third, and fourth embodiments, at least one of the brackets 50A, 50B, and 50C can be inserted into the second housing 40B.

[0149] In the first, third and fourth embodiments, one of the supports 50A and 50B, 50C can be made of resin and be integrally formed with the housing 40.

[0150] In the first and third embodiments, at least one of the first mounting section 52A and the second mounting section 52B of the bracket 50A can be provided separately from the attached section 54A. At least one of the third mounting section 52C and the fourth mounting section 52E of the bracket 50B can be provided separately from the attached section 54B. At least one of the third mounting section 52D and the fourth mounting section 52F of the bracket 50C can be provided separately from the attached section 54I.

[0151] In the first, third and fourth embodiments, at least one of the supports 50B and 50C can be integrally formed with the support 50A.

[0152] In the second embodiment, at least one of the supports 70A and 70B, and the attached section 74I can be provided separately.

[0153] In the second embodiment, at least one of the supports 50A and 70 can be formed integrally with the second housing 40B. In a case where the support 70 is formed integrally with the second housing 40B, the support 70 and the attached section 74I are provided separately.

[0154] In the fourth embodiment, at least one of the holders 50A, 50B and 50C is made of resin and can be integrally formed with the housing 40.

[0155] In each embodiment, the shapes of the first mounting sections 52A, 72A, the second mounting sections 52B, 72B, the third mounting sections 52C, 52D, the fourth mounting sections 52E, 52F, the fifth mounting section 72C, and the sixth mounting section 72D of the brackets 50, 70 can be modified as desired. For example, the brackets 50, 70 can additionally include threaded holes. The brackets 50, 70 can also include a second flange provided at the edge of the threaded hole. The second flange is formed by a hole-flange process. As an example of the shape of the brackets 50, 70, the shape of the first mounting section 52A is now shown with reference to Fig. 31 described. As in Fig. As shown in Figure 31A, the first assembly section 52A includes a threaded hole 52J. The first assembly section 52A further includes a second flange 52K, which is provided at the edge of the threaded hole 52J. The second flange 52K is manufactured using the hole-flange method. As shown in Fig. As shown in Figure 31B, the second flange 52K is located on the side opposite the side where the clamp 28 is situated relative to the first mounting section 52A. The clamp 28 is clamped between the first mounting section 52A and the screw head 36A of the screw 36. The external thread 36B of the screw 36 engages with the threaded hole 52J to fasten the first mounting section 52A to the clamp 28.

[0156] Although the component of a human-powered vehicle 30 of each embodiment applies to a drive unit, the component of a human-powered vehicle 30 can apply to a transmission, such as that disclosed in international patent publication WO 2008 / 89932 and US patent publication US 2016-257373. The expression "at least one of" used in this invention means "one or more" of a desired choice. For example, the expression "at least one of" as used in this invention means "only a single choice" or "both of two choices" when the number of choices is two. For example, the expression "at least one of" as used in this invention means "only a single choice" or "any combination of equal to or greater than two choices" when the number of choices is equal to or greater than three. REFERENCE NUMBERS 10 human-powered vehicles 12 Crank 12A Crankshaft 12B crank arm 14 drive wheel 16 frames 16A front fork 16B stem 16C handlebars 18 Pedal 20 Drive mechanism 22 first body of revolution 24 second body of revolution 26 Connecting element 28 bracket 28A upper wall 28B flange 28C Through hole 30 Components of a human-powered vehicle 31 Reinforcing element 31A carrier 31B Contact section 32 Electric motor 32A output shaft 32B gear 32C case 32D Stator / Armature 32E Rotor 32F first bearing 32G second bearing 32H support element 321 End section 32J cylindrical section 32K external thread 34 Driver circuit 34A circuit board 36 screw 36A screw head 36B external thread 38 output units 38A gear 40 cases 40A first housing 40B second case 41A screw 41B screw 42A Through hole 42B first hole 42C second hole 44A Front wall 44B Side wall 44C Recording section 44D Motor Mount 44E first carrier 44F second support 44G first fixed section 44H insertion hole 44I carrier 44J first wall section 44K second wall section 44L third wall section 44M mold section 44N carrier 44P internal thread 44Q recording section 46A first fastening element 46B second fastening element 46C knurling 46D Nut 46E Hole 46F internal thread 46G through hole 48A Front wall 48B Side wall 48C Recording Section 48D first carrier 48E second support 48F third support 48G second attached section 49 Reinforcing element 49A first flat plate section 49B second flat plate section 49C curved section 49D Through hole 49E flange 49F Through hole 50, 50A, 50B, 50C bracket 52A first assembly section 52B second assembly section 52C, 52D third assembly section 52E, 52F fourth assembly section 52G hole 52H first flange 52I Knurling 52J threaded hole 52K second flange 54, 54A, 54B, 54B, 541 fortified section 54C carrier 54D Through hole 54F Through hole 54G first coupling section 54H second coupling section 54J Outer ring carrier 54K first coupling section 54L second coupling section 56 Mother 56A first section 56B second section 56C Through hole 56D knurling 56E Slot 58 clamping element 60 one-way couplings 61st wave of data collection 62A first bearing 62B second warehouse 62C third bearing 62D fourth bearing 62E fifth warehouse 64 Reduction gears 64A first rotating shaft 64B second rotating shaft 64V first gear 64W second gear 64X third gear 64Y fourth gear 66 One-way coupling 66A One-way coupling 68 Sensor 70, 70A, 70B, 70A, 70B bracket 72A first assembly section 72B second assembly section 72C fifth assembly section 72D sixth assembly section 72E Hole 74A, 74B, 74B, 741 fortified section 74C Through hole 74D Through hole 74E carrier 74J Outer ring carrier 78A first coupling section 78B second coupling section 80 rotor core 82A first lamella 82B second lamella 84A first hole 84B second hole 84C overhang 84D first overhang 84E second overhang 84F third hole 86 permanent magnet 90 busbar unit 90A Ring-shaped support 90B first terminal block 90C second terminal block 90D third terminal block 90U first terminal 90V second terminal 90W third terminal 92 bracket 92A first hole 92B second hole 92C third hole 92D bracket 92E carrier 92F lead 92G rib 94 circuit board 94A screw 94B Position detection element 94C connector 96 Cable harness 98 Stop element 98A Cover section 98B fortified section 98C first through hole 98D second through hole 98E Hinge Section 98F first fortified section 98G second attached section 98H insertion hole 981 first overhang 98J first lead 98K first intervention section 98L second overhang 98M second lead 98N second intervention section C axis CA axial direction G1 space G2 space L1 length L2 thickness

Claims

[1] A component of a human-powered vehicle (30), comprising: a resin housing (40) with a through-hole (42A) through which a crankshaft (12A) extends; and a metal bracket (50, 50A, 50B) configured to couple to a frame (16) of a human-powered vehicle (10), wherein the bracket (50, 50A, 50B) is provided on the housing (40) such that it protrudes from the housing (40), wherein the bracket (50, 50A, 50B) includes a fixed section (54A, 54B) which is attached to the housing (40), the attached section (54A, 54B) is integrally formed with the housing (40), and the attached section (54A, 54B) is cast into the housing (40). [2] The component of a human-powered vehicle (30) according to claim 1, wherein the support (50, 50A, 50B) includes a first mounting section (52A) and a second mounting section (52B), and the first mounting section (52A) and the second mounting section (52B) are spaced apart from each other in an axial direction (CA) of the crankshaft (12A). [3] The component of a human-powered vehicle (30) according to claim 1, wherein the support (50, 50A, 50B, 50B, 50B) includes a first mounting section (52A) and a second mounting section (52B), the first mounting section (52A) and the second mounting section (52B) are spaced apart from each other in an axial direction (CA) of the crankshaft (12A), and the first mounting section (52A) and the second mounting section (52B) are formed integrally with the attached section (54A, 54B). [4] The component of a human-powered vehicle (30) according to claim 3, wherein the first assembly section (52A), the second assembly section (52B) and the attached section (54A, 54B) are formed from sheet metal. [5] The component of a human-powered vehicle (30) according to any one of claims 1 to 4, wherein the support (50, 50A, 5B) includes a third mounting section (52C, 52D) and a fourth mounting section (52E, 52F), and the third mounting section (52C, 52D) and the fourth mounting section (52E, 52F) are spaced apart from each other in a circumferential direction of the crankshaft (12A). [6] The component of a human-powered vehicle (30) according to one of claims 1, 3 and 4, wherein the bracket (50, 50A, 50B) includes a third mounting section (52C, 52D) and a fourth mounting section (52E, 52F), the third assembly section (52C, 52D) and the fourth assembly section (52E, 52F) are spaced apart from each other in the circumferential direction of the crankshaft (12A), and the third assembly section (52C, 52D), the fourth assembly section (52E, 52F) and the attached section (54A, 54B) are integrally formed. [7] The component of a human-powered vehicle (30) according to claim 6, wherein the third assembly section (52C, 52D), the fourth assembly section (52E, 52F) and the attached section (54A, 54B) are formed from sheet metal. [8] The component of a human-powered vehicle (30) according to any one of claims 2 to 4, wherein the bracket (70, 70A, 70B) includes a fifth mounting section (72C), and the first assembly section (72A) and the second assembly section (72B) are spaced apart from the fifth assembly section (72C) in a circumferential direction of the crankshaft (12A). [9] The component of a human-powered vehicle (30) according to claim 3 or 4, wherein the bracket (70, 70A, 70B) further includes a fifth mounting section (72C), the first assembly section (72A) and the second assembly section (72B) are spaced apart from the fifth assembly section (72C) in a circumferential direction of the crankshaft (12A), and the first assembly section (72A), the second assembly section (72B), the fifth assembly section (72C) and the attached section (74A, 74B) are integrally formed. [10] The component of a human-powered vehicle (30) according to claim 9, wherein the first assembly section (72A), the second assembly section (72B), the fifth assembly section (72C) and the attached section (74A, 74B) are formed from sheet metal. [11] The component of a human-powered vehicle (30) according to one of claims 8 to 10, wherein the bracket (70, 70A, 70B) further includes a sixth mounting section (72D), and the fifth assembly section (72C) and the sixth assembly section (72D) are spaced apart from each other in an axial direction (CA) of the crankshaft (12A). [12] The component of a human-powered vehicle (30) according to any one of claims 8 to 10, wherein the bracket further (70, 70A, 70B) includes a sixth mounting section (72D), and the fifth assembly section (72C) and the sixth assembly section (72D) are spaced apart from each other in an axial direction (CA) of the crankshaft (12A), and the first assembly section (72A), the second assembly section (72B), the fifth assembly section (72C), the sixth assembly section (72D) and the attached section (74A, 74B) are integrally formed. [13] The component of a human-powered vehicle (30) according to claim 12, wherein the first assembly section (72A), the second assembly section (72B), the fifth assembly section (72C), the sixth assembly section (72D) and the attached section (74A, 74B) are formed from sheet metal. [14] The component of a human-powered vehicle (30) according to any one of claims 1 to 13, further comprising: a bearing that rotatably supports the crankshaft (12A), the bearing being provided on the housing (40); and a metal support (54C, 74E) that carries the bearing, wherein the support (54C, 74E) is coupled to the bracket (50C, 70B). [15] The component of a human-powered vehicle (30) according to any one of claims 1, 3, 4, 6, 7, 9, 10, 12 and 13, further comprising: a bearing that rotatably supports the crankshaft (12A), wherein the bearing is provided in the housing (40); and a metal support (54C, 74E) that carries the bearing, wherein the support (54C, 74E) is coupled to the bracket (50C, 70B), and wherein the bracket (50C, 70B) and the support (54C, 74E) are integrally formed. [16] The component of a human-powered vehicle (30) according to claim 15, wherein the bracket (50C, 70B) and the support (54C, 74E) are made of sheet metal. [17] The component of a human-powered vehicle (30) according to claim 16, wherein the carrier (54C, 74E) is cast into the housing (40). [18] The component of a human-powered vehicle (30) according to any one of claims 1 to 17, further comprising a nut (56), wherein the holder (50A, 50B, 50C) includes a hole (52G) in which the nut (56) is provided. [19] The component of a human-powered vehicle (30) according to claim 18, wherein the support includes a first flange (52H) formed around the hole (52G). [20] The component of a human-powered vehicle (30) according to claim 19, wherein the first flange (52H) is formed by a hole-flange method. [21] The component of a human-powered vehicle (30) according to any one of claims 1 to 20, wherein the holder (50A) further includes a threaded hole (52J). [22] The component of a human-powered vehicle (30) according to claim 21, wherein the support (50, 50A, 50B) includes a second flange (52K) provided on an edge of the threaded hole (52J). [23] The component of a human-powered vehicle (30) according to claim 22, wherein the second flange (52K) is formed by a hole flange method. [24] The component of a human-powered vehicle (30) according to any one of claims 1 to 23, further comprising an electric motor (32) comprising a stator (32D), wherein the stator (32D) is cast into the housing (40). [25] The component of a human-powered vehicle (30) according to any one of claims 1 to 24, further comprising an electric motor (32) provided in the housing (40); and a metal reinforcement element (31) that is integrally formed with the support (50, 50A, 50B) and provided in the housing (40), wherein the reinforcing element (31) contacts the electric motor (32). [26] The component of a human-powered vehicle (30) according to any one of claims 1 to 25, wherein the support (50, 70) is flexible.

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