Electric bike control unit, drive unit and electric bike

Abstract

Electric bicycle control unit for a drive unit of an electric bicycle, comprising a housing, a circuit board, a contact device and a cable penetrating into the housing, wherein the housing comprises a first housing part and a second housing part, characterized in that the cable is integrally connected to the housing of the electric bicycle control unit.

Description

[0001] The invention relates to an electric bicycle control unit, a drive unit with an electric bicycle control unit according to the invention and an electric bicycle with a drive unit. State of the art

[0002] Plug connections with contact devices fully embedded in plastic are well known and are used, for example, in safety plugs. In various applications, such as connecting individual modules in a vehicle, pre-assembled cables are used to transmit a variety of signals and currents. A wiring harness with standardized or normed connectors is often used to enable quick and usually manual assembly. However, standardized connector designs require a compromise in terms of the required installation space. In addition, pre-assembled cables often feature a multitude of cables with different cross-sections, which can further negatively impact the configuration of the connector in terms of installation space.Therefore, there is a need for further improvements of connectors intended for use in electric bicycle control units. Disclosure of the invention

[0003] The electric bicycle control unit according to the invention with the features of claim 1 has the advantage that the cable is integrally connected to the housing of the control unit. The electric bicycle control unit (hereinafter "control unit") is in particular an electronic component which is used for controlling and in particular for regulating a drive unit of the electric bicycle. The control unit comprises a printed circuit board which is arranged in the housing of the control unit, in particular pressed-in, riveted, glued, screwed or the like. The printed circuit board comprises in particular electronic components and circuits and in particular has a carrier and a connection function for the electronic components. The printed circuit board is in particular a component of the control unit, which is required for controlling and in particular for regulating various functions of the electric bicycle.For example, the control unit prepares, evaluates, and further processes electrical signals from a sensor unit mounted on the electric bicycle. Furthermore, the control unit also includes the power electronics, which, for example, defines the frequency and current that powers the electric motor.

[0004] The drive unit of the electric bicycle generates, in particular, a torque that enables the electric bicycle to propel itself forward. The torque is generated by an electric motor of the drive unit and transfers the power to a rear wheel or a front wheel, depending on the positioning of the drive unit on a frame component. Preferably, the drive unit is arranged on a hub of the electric bicycle. Further preferably, the drive unit is arranged on a rear wheel hub of the bicycle.

[0005] The contact device can preferably be a connector for contacting the circuit board. In a general form, the contact device can be a mechanical and / or electromechanical connection that enables the transmission of electrical signals and / or current between components of the control unit and / or the drive unit. In particular, the contact device can be detachably or permanently attached to one end of an electrical conductor.

[0006] The cable serves in particular to connect the control unit to the drive unit. The cable preferably has a sheath, wherein the sheath of the cable protects at least one conductor arranged in an interior of the sheath from external influences. Furthermore, the sheath can enable electrical insulation and / or shielding of the conductor. In particular, the cable can consist of several individual conductors which are combined in the sheath or insulation. The at least one conductor can in particular conduct electrical current. Alternatively or additionally, the cable can have signal conductors which transmit electrical signals or data. In particular, the number of conductors in the cable can vary. Furthermore, in one embodiment, the cable can also comprise fluid lines or the like in addition to electrical conductors.

[0007] The housing comprises a first housing part and a second housing part. The housing is in particular a solid shell which protects the components arranged in the interior of the housing, for example electronic components, from external influences such as moisture, dust, vibrations and mechanical damage. In particular, the housing or the housing parts thus fulfill a protective function so that the function of the control unit is essentially unaffected by external influences. Furthermore, the housing has in particular mounting and / or fastening devices in order to attach the control unit arranged in its interior to a frame component of the electric bicycle in a simple manner. The housing or the housing parts can completely or at least partially surround the components arranged in the interior of the housing, in particular surround them in a form-fitting manner.In other words, the housing can completely or at least partially surround the components arranged therein, for example allowing a stationary arrangement of the components. The housing or the housing parts can also ensure the dissipation of heat generated inside the housing. The housing or the housing parts can, for example, serve for electromagnetic shielding to protect electronic components from electromagnetic interference. The housing or the housing parts can, for example, be made of ABS (acrylonitrile butadiene styrene), PA (polyamide), PBT (polybutylene terephthalate), PP (polypropylene) or the like. In an alternative embodiment, the housing can be made of sheet metal, aluminum, magnesium or a composite material, for example a carbon fiber reinforced plastic.

[0008] The cable is integrally connected to the housing, in particular integrally connected to the first housing part or the second housing part. Preferably, the cable is firmly and inseparably connected to the housing of the control unit. The connection between cable and housing is characterized in particular by its robustness, tightness, and durability. In particular, the connection has essentially no gaps or crevices between the cable and the housing. The integrally connected connection ensures in particular a secure and reliable connection between the cable and the housing of the control unit, thereby preventing the penetration of moisture, dust, or other harmful influences. Preferably, the term "integrally connected" means that the materials of the cable and housing are bonded to one another. In other words, the materials form a firm bond in which they mix or interlock, in particular at the molecular level.

[0009] The cable preferably penetrates the second housing part such that a circumferential surface of the cable ends within the second housing part. The circumferential surface of the cable is in particular an outer surface of an insulation or a protective sheath that runs in a direction of extension of the cable. The circumferential surface preferably completely encloses the conductor, in particular from all sides when viewed radially. Starting from an outer surface of the second housing part, which forms an interface between the housing and the environment, the cable penetrates this outer surface. In particular, the circumferential surface of the cable ends within the housing. This ensures that, depending on the wall thickness of the second housing part, an intersection of the wall thickness and the circumferential surface engage with one another. More preferably, a conductor of the cable only exits the cable within the housing.

[0010] The cable is preferably arranged within the housing in a sheath. The sheath can be a form-fitting and / or material-fitting sheath of the cable. For example, the cable can be embedded in a potting compound. Furthermore, the cable can be embedded in the sheath by means of an injection molding process or a shrinking process. More preferably, the sheath is designed such that it can be oriented using defined geometric features. For example, the sheath can be a polyhedron, such as a cuboid, cube, pyramid, or the like. In particular, the sheath is characterized by surfaces and edges. Surfaces and edges are suitable for an automated production process, for example for a handling unit. Particularly preferably, the sheath is designed such that it surrounds the aligned cable and / or in particular an aligned conductor in a form-fitting and / or material-fitting manner.Furthermore, the sheath is designed to make the cable manageable and / or orientable, such that the sheath comprises positioning elements. For example, the sheath can have geometric features that make the sheath orientable with respect to a stop. Alternatively or additionally, the cable can have a stop or a device that can be used to define the position of the cable. In particular, a conductor of the cable can be pre-aligned in the sheath such that an open end of the conductor can be contacted at a predefined position.

[0011] : More preferably, the second housing part at least partially surrounds the envelope. In particular, the second housing part generatively surrounds the envelope in such a way that the envelope makes the envelope at least partially encloseable by means of a generative process. Preferably, the second housing part completely encloses the envelope. In particular, the second housing part has a receiving area for this purpose which makes the envelope alignable. In particular, the receiving area can have positioning elements. A positioning element can be a positive and / or non-positive positioning element, such as a recess, a locking lug, a stop or the like. In particular, the receiving area can be penetrated by the envelope. In one embodiment, the receiving area can be free of positioning elements, so that the envelope is movable in the second housing part.

[0012] The cable preferably comprises a conductor, wherein the conductor is permanently connected to the contact device. The contact device is particularly designed to contact the printed circuit board. The permanent connection of the conductor to the contact device can be produced, for example, by means of a welding, soldering, or crimping process. A resulting advantage is a reliable electrical connection between the conductor and the contact device. The contact device is, in particular, specifically designed to contact a printed circuit board. In other words, the contact device is, in particular, constructed such that it establishes a secure and stable connection to the printed circuit board. The contact device is preferably designed such that it can be assembled automatically. The contact device can, for example, be a contact pin that can be contacted with a socket arranged on the printed circuit board.

[0013] The cable preferably has a plurality of current-carrying conductors and / or a plurality of signal conductors, wherein the plurality of current-carrying conductors are permanently connected to the first contact devices, wherein the plurality of signal conductors are connected to the second contact devices (hereinafter referred to as "contact devices"). The current-carrying conductors are preferably phase conductors of the electric motor. The current-carrying conductors and / or the signal conductors are permanently connected to the contact devices, for example by means of a welding, soldering, or crimping process. This means that the conductors are firmly and permanently connected to the contact devices to ensure a reliable electrical connection. The permanent connection ensures that the conductors are securely and stably connected to the contact devices without any loosening or interruption of a current or signal.In an alternative embodiment, the current-carrying conductors and / or the signal conductors can be attached to the circuit board using a press-fit process. In other words, no connector is used in this alternative embodiment.

[0014] The current-carrying conductors are specifically designed for high currents and voltages and feature appropriate conductivity and insulation. The current-carrying conductors also have a larger cross-sectional area than the signal conductors. The current-carrying conductors are made of copper or aluminum, for example. The signal conductors primarily transmit electrical signals containing information or control commands, with the signals being analog or digital in nature.

[0015] The material bond between the cable and the second housing part can preferably be produced by means of a casting or injection molding process. In particular, in an injection molding process, the cable is overmolded, whereby, for example, liquid plastic is injected around the peripheral surface of the cable and then cooled and solidified. This creates a firm and tight connection between the cable and the surrounding plastic. In particular, the material bond offers high strength and firmly arranges the cable in the housing. In particular, in a casting process, liquid material, such as plastic, is poured into a mold and then cooled or cured to obtain a solid shape. Alternatively, an adhesive can be used, which is, for example, poured at room temperature and cures when heated. During the casting process, the liquid material can flow around the cable and bond with it.

[0016] Preferably, the sheath is materially bonded to the second housing part, wherein the material bond can be produced in particular by means of a casting or injection molding process. The sheath can in particular be completely overmolded by the second housing part, wherein the material bond can be produced by a connection of the materials of the sheath and the second housing part. The second housing part and the sheath are in particular inseparably bonded to one another. The materials of the second housing part and the sheath in particular form a firm bond in which they mix or interlock, in particular at the molecular level. In particular, the material bond can be produced by pretreating the sheath. The pretreatment can comprise tempering, applying an adhesion promoter, cleaning, or the like of the sheath.In a preferred embodiment, the casing can be inserted into an injection molding tool, wherein the second housing half completely encloses the casing.

[0017] The first housing half preferably comprises a device for receiving the printed circuit board. The device preferably makes the printed circuit board alignable. In particular, the printed circuit board is geometrically aligned and fixed. For this purpose, the device has, for example, screws and spacers, retaining clips, snap-in connection elements, terminal blocks or the like. In a preferred embodiment, the device comprises a pin, in particular a conical pin, by means of which the printed circuit board is aligned. For this purpose, the printed circuit board has a bore or a recess into which the pin penetrates. The pin can in particular have a pressing zone in which the printed circuit board is held. Alternatively or additionally, the pin can have a melting zone, wherein the pin is designed to be remeltable.

[0018] Preferably, the contact device is arranged in a fixed position within the enclosure. The contact device is arranged in particular such that it occupies a predefined position within the enclosure. The predefined position corresponds in particular to a counterpart of the contact device, for example, a contact device of the circuit board. Furthermore, the cable, the conductor, and the contact device are arranged in a fixed position within the enclosure. This arrangement ensures, in particular, stable positioning of the contact device, the conductor, and the cable within the enclosure and prevents, for example, undesired slipping or twisting. The enclosure forms, in particular, an insulator for the contact device.A further advantage is that the sheathing forms the cable, including the conductor and the contact device, into a compact and protected component that is easy to install and connect. The contact device arranged in the sheathing also offers improved handling, especially for automated downstream processes.

[0019] The invention further relates to a drive unit comprising an electric bicycle control unit according to one of the preceding embodiments. The invention further relates to an electric bicycle with a drive unit according to the invention.

[0020] The invention will be explained in more detail with reference to the figures. Fig. 1: an electric bicycle with an electric bicycle control unit according to the invention in a schematic representation, and Fig. 2: a view of part of an electric bicycle control unit, Fig. 3: an electric bicycle control unit according to the invention, Fig. 4: an electric bicycle control unit according to the invention in a sectional view. Embodiments of the invention

[0021] Identical elements or elements with the same function are provided with the same reference numerals in the figures.

[0022] Fig. 1 shows a simplified schematic view of an electric bicycle 100 with a drive unit 2. The bicycle 100 has a front wheel 115 and a rear wheel 116, each with a front wheel hub 13 and a rear wheel hub 12. The rear wheel 116 is driven by a connecting element 101, in particular a chain, by the cyclist's pedaling force and by the drive unit 2 on the pedals 108. The pedals 108 are connected to cranks 119, which in turn are connected to different ends of the pedal shaft 103. The drive unit 2 is arranged on the rear wheel hub 12 and configured to assist the rider's torque. By means of a chainring 107, a torque applied to the cranks 119 is transmitted to the connecting link 101, which is in direct engagement with the rear wheel 116 to drive the electric bicycle 100.The frame component 102 of the electric bicycle 100 comprises, in particular, a seat tube 106, a seat stay 104, a down tube 111, a top tube 110, a head tube 112, and a chainstay 105, which are permanently connected to one another, for example, welded together. Furthermore, the electric bicycle 100 has a steering unit 120. Schematically illustrated is an input device 10, which, like a user display 122 and a braking device 121, is attached to the steering unit 120. The drive unit 2 is connected to a battery module 109 via a cable (indicated) and is powered by the latter. Furthermore, FIG. Fig. 1 schematically shows a gear shifting device 102. An indicated electric bicycle control unit 124 is attached to a chainstay and connected to the drive unit by means of a cable 21.

[0023] The Fig. 2, Fig. 3 and Fig. 4 show the same electric bicycle control unit 124 according to the invention in different levels of detail. Fig. Figure 2 first shows a view of a part of the electric bicycle control unit 124. In particular, Fig. 2 without the second housing part 42. Fig. Figure 2 provides a view into the housing 40, showing a first housing part 41 which is provided with a thermally conductive paste and is in contact with a printed circuit board 30 via the thermally conductive paste. The housing 40 comprises the illustrated first housing part 41 and a second housing part 42 (illustrated, for example, in Fig. 3). The housing 40 is a rigid shell that protects the components 22, 30 arranged inside the housing from external influences such as moisture, dust, vibrations, and mechanical damage. Fig. 4 indicates a seal 43, which prevents the ingress of foreign matter or moisture. The seal 43 can be designed as an insert or a dispensing bead. Centering and / or connecting devices 45 are also shown, which allow the first housing part 41 to be aligned and screwed onto the second housing part 42.

[0024] The circuit board is geometrically aligned by means of devices 31 and fastened in the second housing part 42 by means of screws. For this purpose, the device has at least two (only one shown) conical pins 31. The circuit board 30 comprises a bore into which the pin 31 penetrates, wherein tolerances can be compensated by means of the conical shape of the pin 31. The pin 31 can have a press zone in which the circuit board 30 is held. Alternatively or additionally, the pin 31 can have a melting zone at its tip, wherein the pin 31 is designed to be remeltable and represents a riveted connection between the first housing part 41 and the circuit board 30. Fig. 2 further shows the enclosure 22, wherein a cable 21 is arranged within the enclosure 22. The enclosure 22 is integrally connected to the cable. A sheath 25 of the cable 21 is embedded in the enclosure 22 by means of an injection molding process. The enclosure 22 is configured such that it can be oriented using defined geometric features 23, 24. The interfaces 23, 24 form part of a cuboid of the enclosure 22, which can be easily positioned and aligned. Fig. 2 indicates the contact devices 26 and 27 below the envelope 22, which are arranged in a fixed position in the envelope 22. In particular in Fig. 4, the contact devices are shown in a sectional view. The contact devices 26, 27 are arranged such that they assume predefined positions in the casing 22, which correspond to a counterpart of the contact device, in particular the printed circuit board 30. This arrangement ensures, in particular, a stable positioning of the contact device 26, 27, the conductors 24, 25 (shown in Fig. 4) and the cable 21 within the sheath 22 and prevents unwanted slipping, twisting, or tilting during assembly. The sheath 22 forms an insulator for the contact device 26, 27. A further advantage is that the sheath 22 transforms the cable 21 with the conductors 24, 25 and contact devices 26, 27 into a compact and protected component that is easy to install and connect. The contact device 26, 27 arranged in the sheath 22 also offers improved handling, particularly for automated downstream processes.

[0025] Fig. Figure 3 shows the electric bicycle control unit 124 according to the invention as a unit. In particular, the second housing part 42 is shown, through which the cable 21 passes. Furthermore, exemplary fastening devices 46 are shown, which enable simple mounting of the electric bicycle control unit 124 on a frame component 102. The overview of the Fig. 2, Fig. 3 and Fig. 4 shows that the envelope 22 is completely enclosed by the second housing part 42 and thus results in a very compact and at the same time robust unit.

[0026] Fig. 4 shows an electric bicycle control unit 124 according to the invention in a sectional view. The section is selected such that it intersects the envelope 22 in a line parallel to the interface 23, wherein the section is selected not far from the interface 23 in order to provide a view into the interior of the . In particular, the sectional view is selected such that the envelope is shown transparently. The cable 21 serves to connect the electric bicycle control unit 124 to the drive unit 2. The cable 21 has the sheath 25, wherein the sheath 25 of the cable 21 protects several conductors arranged inside the sheath 25 from external influences. The sheath 25 can enable additional electrical insulation of the conductors 24, 25. The Fig. The cable 21 shown in Figure 4 has a plurality of current-carrying conductors 24 and a plurality of signal conductors 25; in particular, three current-carrying conductors 24 and four signal conductors 25 are shown. The current-carrying conductors 24 are phase conductors 24 of the electric motor (not shown) of the drive unit 2. The four signal conductors 25 transmit, in particular, electrical signals containing information or control commands, for example a temperature of the drive unit, wherein the signals are of an analog or digital nature. The phase conductors 24 are each permanently connected to the contact devices 27, and the signal conductors 25 are each permanently connected to the contact devices 26. The phase conductors 24 and the signal conductors are each permanently connected to the contact devices 26, 27, wherein the permanent connection is established by a welding process.This means that the conductors 24, 25 are firmly and permanently connected to the contact devices 26, 27 to ensure a reliable electrical connection. The permanent connection ensures that the conductors 24, 25 are securely and stably connected to the contact devices 26, 27 without any loosening or interruption of a current or signal. The phase conductors 24 are designed in particular for high currents and voltages and have corresponding conductivity and insulation, wherein the phase conductors 24 additionally have a larger cross-sectional area than the signal conductors 25. Due to the current intensities, the phase conductors 24 are permanently connected by means of larger contact devices 27. The contact devices 26, 27 are arranged such that they assume a predefined position in the enclosure 22.The predefined position corresponds in particular to a counterpart of the contact device, the circuit board 30. . Fig. Figure 4 shows the arrangement of the contact devices 26, 27 and the conductors 24, 25 attached thereto, which are compact and oriented toward the cable 21, taking into account the bending radius of the cable. This orientation enables a compact shape of the sheath 22, which arranges the conductors 24, 25 and the contact devices 26, 27 in a fixed position within the sheath 22. Undesired slipping or twisting during assembly or connection of the contact devices 26, 27 is avoided. The sheath 22 forms an insulator for the metallic contact devices 26, 27.

[0027] Fig.4 further shows that the sheath 22 is enclosed by the second housing part 42. The sheath 22 is integrally connected to the second housing part 42, wherein the integral connection can be produced by means of an injection molding process. The second housing part 42 and the sheath form a firm, inseparable connection. For this purpose, the materials of the second housing part 42 and the sheath 22 bond at the molecular level, mix, or interlock. The pretreatment can include tempering, applying an adhesion promoter, cleaning, or the like to the sheath. The sheath can be inserted into an injection molding tool, wherein the second housing half 42 encloses the sheath 22 such that the second housing half 42 is injection-molded around the sheath 22. The second housing half 42 is penetrated by the cable 21.The material bond between the cable 21 and the second housing part 42 can be produced using an injection molding process. The cable 21, which is firmly arranged in the casing 22, is overmolded with plastic, thereby enclosing the peripheral surface 25 of the cable 21. In a cooled, solidified state, the connection between the cable 21 and the second housing half 42 is a material bond. This creates a firm and tight connection between the cable 21 and the surrounding plastic of the second housing part 42. In particular, the material bond offers high strength and firmly positions the cable in the housing. In particular, in a casting process, liquid material, such as plastic, is poured into a mold and then cooled or hardened to obtain a solid shape. During the casting process, the liquid material can flow around the cable and bond with it.

Claims

[1] Electric bicycle control unit (124) for a drive unit (2) of an electric bicycle (100), comprising a housing (40), a circuit board (30), a contact device (26, 27) and a cable (21) penetrating into the housing (40), wherein the housing (40) comprises a first housing part (41) and a second housing part (42), characterized by that the cable (21) is integrally connected to the housing (40, 41, 42) of the electric bicycle control unit (124). [2] Electric bicycle control unit (124) according to claim 1, characterized by that the cable (21) penetrates the second housing part (42) such that a circumferential surface (25) of the cable (21) ends within the second housing part (42). [3] Electric bicycle control unit (124) according to one of claims 1 or 2, characterized by that the cable (21) is arranged in a sheath (22). [4] Electric bicycle control unit (124) according to claim 3, characterized bythat the second housing part (42) at least partially surrounds the casing (22). [5] Electric bicycle control unit (124) according to one of the preceding claims, characterized by in that the cable (21) comprises a conductor (24, 25), wherein the conductor (24, 25) is indetachably connected to the contact device (26, 27) and the contact device (26, 27) is in particular designed to contact the printed circuit board (30). [6] Electric bicycle control unit (124) according to one of the preceding claims, characterized by in that the cable (21) has a plurality of current-carrying conductors (24) and a plurality of signal conductors (25), wherein the plurality of current-carrying conductors (24) are indetachably connected to the first contact devices (27) and the plurality of signal conductors (25) are connected to the second contact devices (26). [7] Electric bicycle control unit (124) according to one of the preceding claims, characterized bythat the material connection between the cable (21) and the second housing part (42) can be produced by means of a casting or injection molding process. [8] Electric bicycle control unit (124) according to one of claims 3 to 7, characterized by that the envelope (22) is materially connected to the second housing part (42), wherein the material connection can be produced in particular by means of a casting or injection molding process. [9] Electric bicycle control unit (124) according to one of the preceding claims, characterized by that the first housing half (41) comprises a device (31) for receiving the printed circuit board (30). [10] Electric bicycle control unit (124) according to one of claims 3 to 9, characterized by that the contact device (26, 27) is arranged in a stationary manner in the envelope (22). [11] Drive unit (2) with an electric bicycle control unit (124) according to one of claims 1 to 10. [12] Electric bicycle (100) with a drive unit (2) according to claim 11.

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