Drive assembly for a vehicle driven using muscle force, and vehicle having a drive assembly of this type

Abstract

A drive assembly (10) for a vehicle driven using muscle force, comprising the following coaxial units which are connected to form the drive assembly (10) and which are composed of a plurality of components: a housing unit (100) having a housing (102); a pedal crankshaft unit (200) having a pedal crankshaft (202); a drive unit (300) having a drive (312) in the form of an electric motor; a bearing unit (400) for supporting the pedal crankshaft (202); and an electronics cover unit (500), which closes the housing unit (100) axially; wherein at least two of said units (100, 200, 300, 400, 500) comprise a plurality of preassembled components and one of these is the drive unit (300). A vehicle which can be driven using muscle force and which comprises the following: the drive assembly (10); a device for rotating the pedal crankshaft unit (200) of the drive assembly (10) using muscle force; and a device for transmitting the force outputted by the drive assembly (10), in order to move the vehicle in a direction of travel.

Description

[0001] Drive assembly for a muscle-powered vehicle and vehicle with such a drive assembly Technical field The invention relates to a drive assembly for a muscle-powered vehicle and to a vehicle with such a drive assembly. State of the art DE 102015100676 B3 discloses a drive assembly with a manual drive, an electric auxiliary drive, a strain wave gear, and a common output element. The drive unit has a complex structure with a large number of individual components and bearing points. EP 2724926 A1 discloses a central drive unit with a bottom bracket shaft for a manual drive and an auxiliary drive with a motor and a planetary gear connected downstream of the motor. This drive unit also has a comparatively complex structure with a large number of individual components.DE 102014108611 A1 discloses a bicycle drive device with a drive housing for accommodating a bottom bracket crankshaft, a tension wave transmission arranged within the drive housing and connectable to a traction mechanism carrier, a first freewheel clutch for coupling the bottom bracket crankshaft to the traction mechanism carrier, and a second freewheel clutch for coupling the tension wave transmission to the traction mechanism carrier. This bicycle drive device also has a complex structure. Assembly is laborious.Description of the invention According to one aspect, the invention relates to a drive assembly for a muscle-powered vehicle, comprising the following coaxial units made up of several components and connected to the drive assembly: a housing unit with a housing, a pedal crankshaft unit with a pedal crankshaft, a drive unit with a drive designed as an electric motor, a bearing unit for bearing the pedal crankshaft, and an electronics cover unit which axially closes off the housing unit, wherein at least two of these units, one of which is the drive unit, comprise several pre-assembled components. The pedal crankshaft unit and the bearing unit can be connected to one another in a rotationally fixed manner and form a single shaft which has a connection option for a pedal crank at both ends axially.This allows an overall coaxial design of the drive assembly to be achieved, according to which all units are coaxial. The drive unit can comprise at least one drive, for example an electric motor, and electronics for the drive. The pedal crankshaft unit can comprise at least one gear and one output element. The housing unit can comprise at least one housing, a ring gear, a bearing, and a shaft seal. The bearing unit can comprise at least one bearing and an eccentric. In a further embodiment, it can be provided that the electronics cover unit has a rib structure for cooling on one of its axial sides. The rib structure can comprise multiple ribs. The number of ribs can be two or more. The number of ribs can be between ten and 30, for example between 15 and 25, such as 21.The rib structure can alternatively have ribs running parallel to one another and across the entire side of the electronics cover unit. The ribs can extend over a first end of the electronics cover unit. Alternatively, a rib structure can be provided that provides ribs in any pattern. Alternatively, a rib structure can have ribs in a generally random arrangement. In a further embodiment, the rib structure can comprise a plurality of radially running ribs which have a chamfer at their radially outer end. The ribs can be arranged at equal angular distances from one another around the axis of the electronics cover unit. The projecting cross-sectional areas of the ribs can increase with increasing radial distance from the axis of the electronics cover unit. The electronics cover unit can combine features for sealing, bearing, heat dissipation, and product design.To optimise heat dissipation to the environment, the outer surface, i.e. the surface located at the first axial end of the electronics cover unit, can advantageously be designed to obtain the largest possible surface area, which positively influences convection. This can be achieved by the ribs, whereby the ribs form the rib structure to enlarge the surface area. In addition, heat conduction to the housing unit can be ensured via the corresponding interface or connection point. On the inside of the electronics cover unit, i.e. the side facing the axial second end of the electronics cover unit, connection options can be provided to the electronics of the drive unit via thermal pastes or pads in order to improve heat dissipation.In a further embodiment, a cover can be provided which is arranged at an axial end of the drive assembly at an axial distance from the air guide to the outside. In a further embodiment, it can be provided that the cover is connected in a rotationally fixed manner to the pedal crankshaft unit and has a structure for guiding the air to the outside. Alternatively, the cover can be connected in a rotationally fixed manner to the electronics cover unit, for example by means of the rib structure. The outer surface, i.e. the side of the cover facing away from the housing unit, can offer the possibility of a design in terms of product design. For example, a brand-specific design can be provided on the cover, for example by printing. In order not to prevent the heat dissipation required at this point, a free space or a structure for guiding the air can be formed between the cover and the outer surface of the electronics cover unit that faces the cover.This structure can correspond to the rib structure already described. In a further embodiment, a spider can be provided which is connected to the pedal crankshaft unit and at least partially accommodates the housing unit. In a further embodiment, it can be provided that the spider has a chainring with a toothing plane which lies in an axial region between the axially furthest apart bearings of the pedal crankshaft unit, for example the pedal crankshaft. With a small size and a cylindrical outer geometry of the drive assembly, the chainring can advantageously be positioned axially to introduce the forces into the pedal crankshaft unit, taking into account a chain line which is optimal for the respective vehicle. For this purpose, in the most extreme embodiment, the toothing plane of the chainring can be extended by means of a suitably designed spider up to over the cylindrical outer skin, i.e.up to the housing unit of the drive assembly. In a further embodiment, a lubricant chamber can be provided which is designed to hold lubricant and to allow direct contact of a lubricant located therein with at least one component of the housing unit and the drive unit. The lubricant chamber can be connected to a rotating component, for example a rotor of the electric motor, in order to enable lubricant circulation in the lubricant chamber. Furthermore, the lubricant chamber can exclude muscle-powered components of the drive assembly in order to avoid resistance caused by the inertia of the lubricant during muscle-powered operation.In a further embodiment, it can be provided that the lubricant chamber is designed at least for direct contact of the lubricant contained therein with the housing and the drive designed as an electric motor, for example the rotor of the electric motor. The uniaxial and largely rotationally symmetrical design can be advantageous in order to achieve lubrication of all necessary units by means of a defined lubricant filling, for example an oil filling, through dynamic distribution of the lubricant, for example oil, during operation. This allows a lubricant to flow at least partially around not only the units themselves, but also specifically at least a selection of the components of a unit. At the same time, the movement of the lubricant can improve the heat dissipation of the individual components to the housing unit.In addition, the acoustics can be advantageously influenced by dampening the vibrations generated in the drive assembly via the fluid. In contrast to conventional lubrication using grease, consistent lubricating properties can be achieved over the service life. According to a further aspect, the invention relates to an electronics cover unit of a drive assembly. The electronics cover unit can have the features described here. According to a further aspect, the invention relates to a cover of a drive assembly. The cover can have the features described here, wherein the drive assembly can be limited only to the units and components required to identify the cover. According to a further aspect, the invention relates to a spider of a drive assembly.The spider can have the features described here, whereby the drive assembly can be limited only to the units and components required to identify the spider. According to a further aspect, the invention relates to a lubricant chamber of a drive assembly. The lubricant chamber can have the features described here, whereby the drive assembly can be limited only to the units and components required to identify the lubricant chamber. According to a further aspect, the invention relates to a vehicle, for example a bicycle, with one of the drive assemblies described. It can furthermore have a device for rotating the pedal crankshaft unit of the drive assembly using muscle power and a device for transmitting the power output by the drive assembly to move the vehicle in a direction of travel.Embodiments or features described in relation to one aspect of the invention can be combined with embodiments or features described in relation to another aspect of the invention. Brief description of the figures Figure 1 shows a central longitudinal section through a drive assembly, which can also be referred to as a drive system, for a manually powered vehicle, for example a bicycle. Figure 2 shows the housing unit of the drive assembly from Figure 1. Figure 3 shows the pedal crankshaft unit of the drive assembly from Figure 1. Figure 4 shows the drive unit of the drive assembly from Figure 1. Figure 5 shows the bearing unit of the drive assembly from Figure 1. Figure 6 shows a perspective view of the electronics cover unit of the drive assembly from Figure 1.Figure 7 shows a side view of the drive assembly from Figure 1 with a cover at the first end of the drive assembly and a spider and chainring at the second end of the drive assembly. Figure 8 shows a perspective view of the drive assembly from Figure 7 in which the cover is axially spaced from the drive assembly and the electronics cover element has the alternative rib structure. Figure 9 shows the central longitudinal section through the drive assembly from Figure 1 with the spider and the chainring. Figure 10 shows the central longitudinal section through the drive assembly from Figure 9 with an alternative design of the spider. Figure 11 shows the central longitudinal section through the drive assembly from Figure 1 with a lubricant chamber.Detailed Description of Embodiments Figure 1 shows a central longitudinal section through a drive assembly 10, which can also be referred to as a drive system, for a muscle-powered vehicle, for example a bicycle. The drive assembly 10 has an axial first end 12 and an axial second end 14. It also comprises a plurality of units from which it is assembled. These units include a housing unit 100 (see also Figure 2), a pedal crankshaft unit 200 (see also Figure 3), a drive unit 300 (see also Figure 4), a bearing unit 400 (see also Figure 5), and an electronics cover unit 500 (see also Figure 6). The drive assembly 10 can be provided for small electric vehicles, for example bicycles, in particular EPACs (“Electrically Power Assisted Cycles”). Previous drive assemblies usually have a multi-axle structure.To equip the corresponding housing unit or housing with the functional components, a structure with at least two shells was therefore previously necessary. Figure 2 shows the housing unit 100 of the drive assembly 10 from Figure 1. The housing unit 100 comprises a housing 102, which here is tubular and has an axial through-opening that extends along its axis, represented by a dash-dot line, between an axial first end of the housing unit 104 and an axial second end of the housing unit 106. While the outer side of the housing 108 has a substantially constant outer diameter, the inner side of the housing 110 has inwardly projecting step sections of different inner diameters.These stepped sections serve as stops and axial limits for an inner bearing of the housing unit 112, which here is inserted into the housing 102 from the first end of the housing unit 104, a ring gear 114, which here is also inserted into the housing 102 from the first end of the housing unit 104, and for a shaft seal of the housing unit 116, which here is inserted into the housing 102 from the second end of the housing unit 106. The assembly created on the basis of the components mentioned in this paragraph forms the housing unit 100 shown in Figure 2. Figure 3 shows the pedal crankshaft unit 200 of the drive assembly 10 from Figure 1. The pedal crankshaft unit 200 comprises a pedal crankshaft 202 with an outer side of the pedal crankshaft 204 and an axial first end of the pedal crankshaft unit 206 and an axial second end of the pedal crankshaft unit 208.The outer side of the pedal crankshaft 204 has outwardly projecting stepped sections. These stepped sections serve as stops and axial limits for a gear 210, which here is pushed from the first end of the pedal crankshaft unit 206 onto the pedal crankshaft 202, and for an output element of the pedal crankshaft unit 212, which here is pushed from the second end of the pedal crankshaft 208 onto the pedal crankshaft 202. The output element of the pedal crankshaft unit 212 is connected to the gear 210 via a first freewheel 214. At the same time, the output element of the pedal crankshaft unit 212 is connected to the pedal crankshaft 202 via a second freewheel 216 and an inner bearing of the pedal crankshaft unit 218.The pedal crankshaft 202 and the output element of the pedal crankshaft unit 212 are connected to one another via a shaft seal of the pedal crankshaft unit 220, which is arranged axially between the inner bearing of the pedal crankshaft unit 218 and the output element of the pedal crankshaft unit 212. In addition, the output element of the pedal crankshaft unit 212 comprises an outer bearing of the pedal crankshaft unit 220. The assembly created on the basis of the components mentioned in this paragraph forms the pedal crankshaft unit 200 shown in Figure 3. Figure 4 shows the drive unit 300 of the drive assembly 10 from Figure 1. The drive unit 300 comprises a drive sleeve 302 with a radially outwardly projecting radial collar 304 and an axial first end of the drive unit 306 and an axial second end of the drive unit 308.In addition, the drive unit 300 includes electronics 310 and a drive 312, with the electronics 310 mounted on the side of the radial collar 304 facing the first end of the drive unit 306, and the drive 312 mounted on the side of the radial collar 304 facing the second end of the drive unit 308. The drive is an electric motor connected to the matching electronics 310. The assembly created on the basis of the components mentioned in this paragraph forms the drive unit 300 shown in Figure 4. Figure 5 shows the bearing unit 400 of the drive assembly 10 from Figure 1. The bearing unit 400 comprises a bearing element 402 with an outer side of the bearing element 404 and an axial first end of the bearing unit 406 and an axial second end of the bearing unit 408. The outer side of the bearing element 404 has outwardly projecting step sections.These stepped sections serve as stops and axial limits for an outer bearing of the bearing unit 410, which here is pushed from the first end of the bearing unit 406 onto the bearing element 402, and for an eccentric 412, which here is pushed from the second end of the bearing unit 408 onto the bearing element 402. The assembly created on the basis of the components mentioned in this paragraph forms the bearing unit 400 shown in Figure 5. Figure 6 shows a perspective view of the electronics cover unit 500 of the drive assembly 10 from Figure 1. The electronics cover unit 500 comprises an electronics cover element 502 with an axial first end of the electronics cover unit 504 and an axial second end of the electronics cover unit 506. The electronics cover unit 500 is formed integrally from the electronics cover element 502 in Figure 5.The electronics cover element 502 has a rib structure 508, which here has 21 ribs 510 extending axially at the first end of the electronics cover unit 504. The ribs 510 are arranged at equal angular distances from one another around the axis of the electronics cover unit 500, wherein their projecting cross-sectional area increases with increasing radial distance from the axis of the electronics cover unit 500. In addition, the ribs 510 have a chamfer 512 at their radially outer ends. The composite created on the basis of the components mentioned in this paragraph forms the electronics cover unit 500 shown in Figure 6. The electronics cover unit 500 combines features for sealing, bearing, heat dissipation and product design. To optimize heat dissipation to the environment, the outer surface, ieThe surface located at the first axial end of the electronics cover unit 406, i.e., the area located at the first axial end of the electronics cover unit 406, can advantageously be designed to obtain the largest possible surface, which positively influences convection. This can be achieved by the ribs 510, wherein the ribs 510 form the rib structure 508 to enlarge the surface. In addition, heat conduction to the housing unit 100 can be ensured via the corresponding interface or connection point. Towards the inside of the electronics cover unit 500, i.e., the side facing the axial second end of the electronics cover unit 408, connection options to the electronics 310 can be provided via thermal pastes or pads in order to improve heat dissipation. Figure 7 shows a side view of the drive assembly 10 of Figure 1 with a cover 600 at the first end of the drive assembly 12 and a spider 700 and chainring 702 at the second side of the drive assembly 14.The drive assembly 10 is located here between a cover 600 on the one hand and a spider 700 with an integral chainring 702 on the other. The cover 600 axially covers the first end of the electronics cover unit 504. The spider 700 and the chainring 702 are pushed from the side of the second end of the pedal crankshaft unit 208 onto the output element of the pedal crankshaft unit 212. In this Figure 7, the electronics cover element 502 has an alternative rib structure 508 that differs from that in Figure 6. Of course, the electronics cover element 502 can also have the same rib structure 508 as in Figure 6. The outer surface, i.e., the side of the cover 600 facing away from the housing unit 100, offers the possibility of a design in terms of product design. For example, a brand-specific design can be provided on the cover, for example by printing.In order not to prevent the heat dissipation required at this point, a free space or a structure for air guidance can be formed between the cover 600 and the outer surface of the electronics cover unit 500, which faces the cover 600. This structure can correspond to the previously described rib structure 508. Figure 8 shows a perspective view of the drive assembly 10 from Figure 7, in which the cover 600 is axially spaced from the drive assembly 10 and the electronics cover element 502 has the alternative rib structure 508. The alternative rib structure 508 has 14 ribs 510 running parallel to one another and across the entire side of the electronics cover element 502. Here, too, the ribs 510 extend over the first end of the electronics cover unit 504. Alternatively, a rib structure 508 could be provided which has ribs 510 in any pattern or in a general random arrangement.Of course, the cover 600 can be part of the drive assembly 10. Figure 9 shows the central longitudinal section through the drive assembly 10 from Figure 1 with the spider 700 and the chainring 702. The chainring 702 is detachably attached to the spider 700 here. The toothing plane 704, shown with a vertical dash-dot line, lies beyond the second end of the housing unit 106 and essentially in a plane with the bottom bracket of the pedal crankshaft unit 218. Of course, the chainring 702 can alternatively be designed as a belt pulley. Figure 10 shows the central longitudinal section through the drive assembly 10 from Figure 9 with an alternative design of the spider 700. The spider 700 here has an axial collar 706 extending over the housing 102. The axial collar 706 allows the toothing plane 704 to be moved further towards the axial center of the drive assembly 10.Here, the toothing plane 704 lies between the inner bearing of the housing unit 112 and the outer bearing of the pedal crankshaft unit 222, which mounts the output element of the pedal crankshaft unit 212 on the housing 102. Figure 11 shows the central longitudinal section through the drive assembly 10 from Figure 1 with a lubricant chamber 800. The lubricant chamber 800 comprises interconnected cavities in the assembled drive assembly 10 and serves to hold and circulate lubricant within the drive assembly 10. This allows the waste heat, in particular the waste heat from the drive 312, to be better distributed across the entire drive assembly 10 and accordingly also dissipated to the outside. At the same time, the wear of the individual components in contact with the lubricant can be reduced.The lubricant chamber 800 extends through the drive assembly 10 such that it has direct contact with at least parts of the following units of the drive assembly 10 (from the first end of the drive assembly to the second end of the drive assembly): drive unit 300, housing unit 100 and pedal crankshaft unit 200.The lubricant chamber 800 can extend through the drive assembly 10 such that it has direct contact with at least parts of the following components of the units of the drive assembly 10 (from the first end of the drive assembly to the second end of the drive assembly): radial collar 304, drive 312, drive sleeve 302, housing 102, gear 210, ring gear 114, inner bearing of the housing unit 112, shaft seal of the housing unit 116, output element of the pedal crankshaft unit 212, first freewheel 214, second freewheel 216, inner bearing of the pedal crankshaft unit 218, shaft seal of the pedal crankshaft unit 220 and pedal crankshaft 202.In the assembled state of the drive assembly 10 shown in Figure 1, first the pedal crankshaft unit 200 was inserted into the housing unit 100 from the second end of the housing unit 106, then the drive unit 300 from the first end of the housing unit 104, then the electronics cover unit 500 from the first end of the housing unit 104, and finally the bearing unit 400 from the first end of the housing unit 104. Thus, the housing unit 100 and the electronics cover unit 500 form a rotationally fixed connection. Likewise, the pedal crankshaft unit 200 and the bearing unit 400 form a rotationally fixed connection. The units 200, 400 are rotatably mounted to the units 100, 500 via the inner bearing of the housing unit 112, the outer bearing of the pedal crank unit 222 and the outer bearing of the bearing unit 410.The output element of the pedal crankshaft unit 212 is in turn rotatably mounted to both the housing unit 100 and the pedal crankshaft 202 by the inner bearing of the housing unit 112, the outer bearing of the pedal crank unit 222, the inner bearing of the pedal crank unit 218, and the second freewheel 216. The drive unit 400 is connected in a rotationally fixed manner to the housing unit 100 via the radial collar 304. At the same time, the gear 210, which is operatively connected to the ring gear 114 of the housing unit 100, is connected on the input side to the drive unit 400 and on the output side to the first freewheel 214, which is coupled to the output element of the pedal crankshaft unit 212.The two freewheels 214, 216 are configured such that transmission of a rotation of the drive unit 300 to the output element of the pedal crankshaft unit 212 is enabled and prevented to the pedal crankshaft 202, and that transmission of a rotation of the pedal crankshaft 202 to the output element of the pedal crankshaft unit 212 is enabled and prevented to the drive unit 300.

[0002] Reference numeral 10 Drive assembly 12 First end of the drive assembly 14 Second end of the drive assembly 100 Housing unit 102 Housing 104 First end of the housing unit 106 Second end of the housing unit 108 Outside of the housing 110 Inside of the housing 112 Inner bearing of the housing unit 114 Ring gear 116 Shaft seal of the housing unit 200 Crankshaft unit 202 Crankshaft 204 Outside of the crankshaft 206 First end of the crankshaft unit 208 Second end of the crankshaft unit 210 Gear 212 Output element of the crankshaft unit 214 First freewheel 216 Second freewheel 218 Inner bearing of the crankshaft unit 220 Shaft seal of the crankshaft unit 222 Outer bearing of the crankshaft unit 300 Drive unit 302 Drive sleeve 304 Radial collar 306 first end of the drive unit 308 second end of the drive unit 310 electronics 312 drive 400 bearing unit 402 bearing element 404 outside of the bearing element 406First end of the bearing unit 408 Second end of the bearing unit 410 Outer bearing of the bearing unit 412 Eccentric 500 Electronics cover unit 502 Electronics cover element 504 First end of the electronics cover unit 506 Second end of the electronics cover unit 508 Rib structure 510 Ribs 512 Chamfer 600 Cover 700 Spider 702 Chain ring 704 Toothing plane 706 Axial collar 800 Lubrication chamber

Claims

Claim 1. Drive assembly (10) for a muscle-powered vehicle, comprising the following coaxial units of several components connected to the drive assembly (10): - a housing unit (100) with a housing (102), - a pedal crank unit (200) with a pedal crank (202), - a drive unit (300) with a drive (312) designed as an electric motor, - a bearing unit (400) for bearing the pedal crank (202), and - an electronics cover unit (500) which axially closes the housing unit (100), wherein at least two of these units (100, 200, 300, 400, 500), one of which is the drive unit (300), comprise several pre-assembled components.

2. Drive assembly (10) according to claim 1, wherein the electronics cover unit (500) has a rib structure (508) for cooling on one of its axial sides. 3.

4. Drive assembly (10) according to claim 2, wherein the rib structure (508) comprises several radially extending ribs (510) which have a chamfer (512) at their radially outer end.

5. Drive assembly (10) according to any one of claims 1 to 3, further comprising: - an aperture (600) which is arranged at an axial end (12, 14) of the drive assembly (10) at an axial distance to the outside air guide.

6. Drive assembly (10) according to claim 4, wherein the aperture (600) is rotationally fixed to the pedal crank assembly (200) and has a structure for the outside air guide.

6. Drive assembly (10) according to any one of claims 1 to 5, further comprising: - a spider (700) which is connected to the crankset assembly (200) and at least partially incorporates the housing unit (100).

7. Drive assembly (10) according to claim 6, wherein the spider (700) has a chainring (702) with a toothing plane (704) which is located in an axial region between the axially furthest apart bearings (218, 410) of the crankset assembly (200).

8. Drive assembly (10) according to any one of claims 1 to 7, further comprising: - a lubricant chamber (800) which is designed to receive lubricant and for direct contact between a lubricant located therein and at least one component of the housing unit (100) and the drive unit (300). 9.Drive assembly (10) according to claim 8, wherein the lubricant chamber (800) is configured at least for direct contact between the lubricant contained therein and the housing (102) and the drive (312) designed as an electric motor.

10. Muscle-powered vehicle comprising: - a drive assembly (10) according to any one of claims 1 to 9, - a device for rotating the pedal crank unit (200) of the drive assembly (10) by muscle power, and - a device for transmitting the force output by the drive assembly (10) to move the vehicle in a direction of travel.

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