Braking device for e-bikes

Abstract

Braking device for preventing wheel locking for an e-bike (1) comprising: one or more wheel speed sensors (2) arranged on a wheel and designed to provide speed data; a brake lever (3) arranged on a handlebar and emitting brake signals when actuated; an ABS hydraulic module (4) for controlling the brake pressure; a control unit (5) which processes the speed data and the brake signals into brake pressure signals which are sent from the ABS hydraulic module (4) to brake components for implementation, wherein the ABS hydraulic module (4) is arranged in the control tube (10).

Description

[0001] The present invention relates to a braking device for an e-bike according to the preamble of the claim. Technological background

[0002] Electric bicycles, commonly known as e-bikes, represent a major development in the world of cycling, combining the traditional riding experience with modern technology. These bikes expand the functionality of a conventional bicycle by integrating an electric drive system consisting of a motor, a battery, and a controller. The motor provides additional power while pedaling, which is especially beneficial on inclines or longer rides. The rechargeable battery powers the motor, and the controller allows the rider to regulate the intensity of assistance as needed.

[0003] E-bikes vary in design, with the most common types being pedelecs and S-pedelecs. Pedelecs assist the rider up to a speed of 25 km / h and are classified as regular bicycles in many countries. S-pedelecs, on the other hand, can reach speeds of up to 45 km / h and are therefore often subject to stricter regulations. There are also e-mountain bikes designed specifically for off-road use, which feature more robust components and powerful motors.

[0004] The advanced controls and functionality of electric bikes have significantly improved the riding experience by giving the rider precise control over various aspects of the bike. At the heart of these innovations is the control of motor power. The rider can adjust the intensity of the motor assistance using a handlebar-mounted controller. This can be a small control panel or a rotary knob that allows the rider to switch between different assistance levels. This adaptability is crucial, as it directly impacts the bike's range and battery life.

[0005] Another feature of modern e-bikes is their braking systems. Due to their greater weight and stronger motor support, e-bikes place special demands on their brakes. Therefore, high-performance braking systems are usually used.

[0006] Hydraulic disc brakes are predominantly used on modern e-bikes because they offer the best braking performance and safety. Disc brakes usually work with hydraulic fluid, which exerts pressure on the brake pads on the caliper when the brake lever is pulled. Disc brakes are characterized by high braking power, good controllability, reliable operation even in wet and muddy conditions, and low maintenance. However, they are more expensive and require more maintenance than mechanical systems.

[0007] Mechanical disc brakes and rim brakes are mainly found on cheaper or older models. Mechanical disc brakes work with a Bowden cable that presses the brake pads against the brake disc. Rim brakes, on the other hand, have brake pads that grip the wheel rim. These brakes offer less braking power, are subject to greater wear, and are less modulated than hydraulic brakes.

[0008] Some e-bike models are also equipped with regenerative braking systems. These innovative systems use the kinetic energy generated during braking to partially recharge the battery. This is achieved through a special circuit in the motor and brake lever that allows energy to be recovered during braking.

[0009] Finally, in addition to their technical advantages, e-bikes also offer important environmentally friendly alternatives for urban commuters. As an emission-free mode of transport, they help reduce traffic jams and are often a faster and more flexible alternative to conventional public transport in densely populated cities.

[0010] ABS stands for anti-lock braking system and is a safety technology that originally came from the automobile and motorcycle sectors, but is now also used on e-bikes. ABS prevents the front wheel from locking during heavy braking. Sensors on the wheels monitor the speed and a control unit automatically regulates the brake pressure. This keeps the bike steerable and maintains stability, even on slippery surfaces. Modern e-bike ABS systems also feature rear wheel lift control. This detects when the rear wheel is about to lift during emergency braking and specifically reduces the brake pressure on the front wheel to prevent a rollover. The system operates from around 6 km / h and remains active for some time even after the motor is switched off.

[0011] Various ABS modes ensure that the braking system is optimally tailored to the specific e-bike type and its typical operating conditions. This means that both everyday riders and sporty cyclists and cargo bike users benefit from maximum safety and optimal braking performance.

[0012] The current state of the art presents several challenges and disadvantages. For example, the complexity, operation, or layout of advanced systems can cause problems while riding. Likewise, the placement and size of some components on the handlebars or bicycle can cause interference with other parts of the bicycle, which can impair clarity, usability, or functionality. Maintenance and replacement are complicated, especially for systems with complex wiring, power supply, and communication units. Description of the invention

[0013] One object of the invention is to avoid at least some of the disadvantages of the prior art. The braking device of an e-bike, as well as other units or components, should be arranged in a stable and reliable manner, thereby ensuring stability and increasing riding safety.

[0014] These problems are at least partially solved by the features of the independent claim.

[0015] According to a first aspect of the invention, a braking device for preventing wheel lock for an e-bike is disclosed. This device comprises one or more wheel speed sensors arranged on a wheel and configured to provide speed data; a brake lever arranged on a handlebar and emitting brake signals when actuated; an ABS hydraulic module for controlling the brake pressure; and a control unit that processes the speed data and the brake signals into brake pressure signals, which are transmitted from the ABS hydraulic module to brake components for implementation. The ABS hydraulic module is arranged in the head tube. The control unit can also be arranged in the head tube and form a unit with the ABS hydraulic module.

[0016] By locating the ABS hydraulic module with an ABS hydraulic system in the head tube, previously unused space can be utilized to advantage. This allows for shortened or optimized cable and line routing. The ABS hydraulic module is protected within the head tube and is not visible from the outside. The ABS hydraulic module with the control unit regulates the brake pressure on the front brake with high precision and in real time via solenoid valves and a dedicated oil reservoir. This ensures that the front wheel does not lock, steerability is maintained, and the risk of rollover is minimized.

[0017] The head tube has different diameters at both ends. The head tube is preferably reinforced. Different diameters allow for direct connection to components with different connection sizes, without additional reducers. The conical or stepped shape ensures better sealing and a secure fit. Since additional reducers are not required, space and weight are saved in the overall system. Integrating the taper directly into the head tube enables a more compact design. A larger diameter at one end increases stability, while the other end remains narrower to save weight.

[0018] The head tube has a taper. The head tube has at least one cutout in a taper area. In a preferred embodiment, two or more cutouts are provided. Wires and cables can be routed through each cutout. The taper thus allows for the routing of cables / wires into the interior of the head tube. However, the cutouts have an impact on the stability of the head tube and are dimensioned to minimize their impact on stability.

[0019] In one embodiment, the steering tube has a receiving area inside for the ABS hydraulics or the ABS hydraulic module and, if applicable, the control unit. The receiving area is designed to accommodate the ABS hydraulic module.

[0020] The ABS hydraulics and the control unit can be designed as a module or a unit.

[0021] In a further embodiment, the control tube has a first receiving area for the ABS hydraulic module and a second receiving area for the control unit.

[0022] The steering tube may have grooves inside to accommodate the ABS hydraulic module and control unit to ensure precise positioning and a secure fit.

[0023] A size-defining module for the e-bike, a so-called head tube adapter, can be mounted around the head tube. This allows the e-bike to be adjusted in size and made available to different users. The size-defining module is available in various sizes and is mounted on or around the head tube.

[0024] The head tube is designed to allow for the routing of wires and / or cables inside and outside the head tube. This allows for efficient wire and cable routing. Guides for wires and / or cables can be provided inside the head tube.

[0025] The ABS hydraulic module has a cuboid shape. The sides may be slightly rounded to ensure stable attachment to the inner wall of the head tube.

[0026] The head tube can be connected to a parallelogram-shaped front fork design. This design improves overall handling and stability. The head tube can also be used with rigid forks and standard suspension forks with a suitable crown.

[0027] The ABS hydraulic module is detachably mounted in the head tube. This allows the ABS hydraulic module to be removed or replaced at any time without damaging or permanently altering the head tube. The ABS hydraulic module can be removed, replaced, or serviced with or without the control unit.

[0028] ABS integrated into the steer tube offers advantages over conventional solutions, such as reduced cable lengths and better weight distribution. The head tube is reinforced and hollow inside to accommodate sensors, valves, and cables without compromising stability.

[0029] It will be understood by a person skilled in the art that all of the described preferred and particular embodiments can be implemented in any combination in an embodiment according to the invention, provided that they do not exclude one another.

[0030] The present invention will now be explained in more detail below using specific embodiments and figures, but is not limited to these. Further advantageous embodiments will become apparent to a person skilled in the art upon studying these specific embodiments. For the sake of simplicity, the same parts are provided with the same reference numerals in the figures. Character description

[0031] Embodiments of the invention are described with reference to the following figures. They show: Fig. 1 shows a side view of an electric bicycle or e-bike. Fig. Figure 2 shows a section of an e-bike with a focus on a front wheel assembly and a handlebar area. Fig. 3 shows a control tube with an ABS hydraulic module arranged therein. Implementation of the invention

[0032] Fig. Figure 1 shows a side view of an electric bicycle, or e-bike, 1. The e-bike 1 has a frame with a distinctive design and mounting areas for various components. The bicycle has front and rear wheels with spokes running to the rims. A motor is located in the rear wheel. At the front of the e-bike 1 are handlebars 6 with controls and a brake lever 3. Typically, one brake lever is provided for a rear brake and one for a front brake. The front wheel assembly includes a disc brake system, while the rear wheel is equipped with an electric drive system. The front and / or rear wheels are equipped with wheel speed sensors 2.

[0033] The E-Bike 1 is equipped with practical features such as mudguards on both wheels to protect against water and dirt. A luggage rack is mounted above the rear wheel, providing storage space. The frame design accommodates a battery compartment integrated into the main frame structure.

[0034] Below the handlebar 6 is a head tube 10 in which an ABS hydraulic module 4 is located. The ABS hydraulic module 4 is not visible from the outside, nor are any lines or cables visible. These run inside the head tube 10 and are thus protected. The head tube 10 is connected to a front fork structure in the lower area. A size-defining module 20 encloses the head tube 10.

[0035] Fig. Figure 2 shows a section of an e-bike 1 with a focus on a front wheel assembly and a handlebar area. Shown are handlebars 6 with grips at both ends and brake levers 3 mounted near the grips. The brake lever 3 on the right side acts on the front wheel brake when actuated. The handlebar 6 is connected to a front fork of the e-bike 1 via a stem assembly comprising a head tube 10. The stem contains fasteners that enable secure attachment to the fork shaft. The front fork has a parallelogram-shaped front fork construction 40. Fork legs extend downwards to accommodate the wheel assembly. An ABS hydraulic module 4 is arranged in the head tube 10. A control unit 5 can also be arranged in the head tube 10 and form a unit with the ABS hydraulic module 4. The control unit 5 can also be arranged in other positions in the e-bike 1.

[0036] A mudguard is mounted above the wheel. The wheel itself is depicted with a tire mounted on a rim, with several spokes and a rim visible. A disc brake is mounted on the front wheel, where a wheel speed sensor 2 is also located. A brake hydraulic line 33 runs there (see Fig. 3), which is led from the ABS hydraulic module 4 to the brake.

[0037] The ABS hydraulic module 4 with the ABS hydraulics is a central component of the e-bike ABS system and is located in the area of ​​the head tube 10 below the handlebar 6. The ABS hydraulic module 4, together with the control unit 5, precisely controls the brake pressure on the front wheel brake to prevent the front wheel from locking and to maintain driving stability.

[0038] During heavy braking, at least one wheel speed sensor 2 continuously monitors the speed of the front wheel. The speed of the rear wheel can also be taken into account. If the control unit 5 detects that the front wheel is about to lock, the ABS hydraulics of the ABS hydraulic module 4 intervene. Solenoid valves in the hydraulic unit rapidly regulate the oil pressure in the brake line. The brake pressure is reduced and rebuilt in short intervals so that the front wheel always remains at the limit of grip and does not lock. This process occurs several times per second and can cause a noticeable pulsation on the brake lever 3. With ABS Gen3, this pulsation is no longer noticeable. In addition, the rear wheel lift control can be controlled to minimize the risk of rollover during heavy deceleration.

[0039] Fig.Figure 3 shows a head tube 10 with an ABS hydraulic module 4 arranged therein. The head tube 10 rests on and is connected to a parallelogram-shaped front fork structure 40. The head tube 10 has different diameters at both ends. The diameter at the bottom, towards the front fork, is larger than the diameter at the top, where a mounting area for a handlebar 6 is provided.

[0040] The head tube 10 has a receiving area 11 for the ABS hydraulic module 4. The ABS hydraulic module 4 is cuboid-shaped. The head tube 10 has a taper 12. Two recesses 14 are provided in a taper area 13. Lines 30 or cables are routed inside and outside the head tube 10. The lines 30 or cables are routed through the recesses 14. A brake line 31 leads to the brake lever 3. A signal and power cable 32 delivers signals from the wheel speed sensors 2 and / or the control unit 5. The power supply via the power cable comes from the main battery of the e-bike 1, which is located in the frame. A brake line 33 leads from the ABS hydraulic module 4 to the disc brake on the front wheel.

[0041] The ABS hydraulic module 4 is detachably arranged in the control tube 10, preferably with screw connections on the control tube wall.

[0042] The present invention discloses a braking device for an e-bike. It goes without saying that a person skilled in the art will be able to conceive numerous other embodiments in this field based on the exemplary embodiments described. List of reference symbols 1 e-bike 2 wheel speed sensors 3 brake levers 4 ABS hydraulic module 5 Control unit 6 handlebars 10 Head tube 11 Recording area 12 Rejuvenation 13 Rejuvenation area 14 Recess 20 size-defining module 30 lines 31 Brake line to brake lever 32 signal and power cables 33 Brake line to the disc brake 40 parallelogram-shaped front fork construction

Claims

[1] Brake device for preventing wheel locking for an e-bike (1) comprising: one or more wheel speed sensors (2) arranged on a wheel and designed to provide speed data; a brake lever (3) arranged on a handlebar and emitting brake signals when actuated; an ABS hydraulic module (4) for controlling the brake pressure; a control unit (5) which processes the speed data and the brake signals into brake pressure signals which are sent from the ABS hydraulic module (4) to brake components for implementation, wherein the ABS hydraulic module (4) is arranged in the control tube (10). [2] Braking device according to claim 1, wherein the control tube (10) has different diameters at both ends. [3] Braking device according to claim 1 or 2, wherein the control tube (10) has a receiving area (11) for the ABS hydraulic module (10) in the interior. [4] Braking device according to one of the preceding claims, wherein the control tube (10) has a taper (12). [5] Braking device according to one of the preceding claims, wherein the control tube (10) has at least one recess (14) in a tapered region (13). [6] Braking device according to one of the preceding claims, wherein a size-defining module (20) for the e-bike (1) encloses the head tube (10). [7] Braking device according to one of the preceding claims, wherein the control tube (10) is designed such that lines (30) can be guided in the control tube and outside the control tube (10). [8] Braking device according to one of the preceding claims, wherein the ABS hydraulic module (4) is cuboid-shaped. [9] Braking device according to one of the preceding claims, wherein the head tube (10) is connected to a parallelogram-shaped front fork construction (40). [10] Braking device according to one of the preceding claims, wherein the ABS hydraulic module (4) is detachably arranged in the control tube.

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