Connection of the drive unit to the wheels

Abstract

The device couples a drive unit to a wheel such that the drive unit drives rotation of the wheel about a central axis of the wheel. The device includes a drive member (10), a mounting member (12), a drive element (16), and prevention means (15, 36, 38). The drive member (10) is mounted to the wheel such that rotation of the drive member (10) about the central axis drives rotation of a hub (22) about the central axis. The mounting member (12) is attached to the drive member and is rotatable about the central axis independently of the drive member. The drive element (16) has a drive element shaft fixedly disposed relative to the mounting member and is coupled to the drive unit such that the drive unit drives rotation of the drive element about the drive element shaft. The prevention means prevents rotation of the mounting member (12) about the central axis. The drive member (19) includes a coupling means (10d) coupled to the drive element (16) such that rotation of the drive element (16) drives rotation of the drive member (12). The drive member has a first surface facing away from the wheel when the drive member (10) is mounted on the wheel. The coupling means (10d) and the drive element (16) are at least partially disposed in a concave region of the first surface.

Description

Technical Field

[0001] The present invention relates to a device for coupling a drive unit to a wheel, for example a bicycle wheel, and more particularly to a bicycle in which some devices are mounted in place of a conventional disc brake rotor, but is not limited thereto. The present invention further relates to a wheel with such a device mounted on the wheel. The present invention further relates to a method of attaching parts to a hub and a method of attaching a drive unit for coupling the drive unit to the hub. In particular, it is a method when some of the parts are mounted in the place of a conventional disc brake rotor, but is not limited thereto.

Background Art

[0002] Electric drive systems that can be mounted on conventional bicycles to assist the rider in pedaling are well known. In the known document, US9359040, a drive system is disclosed in which a disc rotor for a disc brake system is modified to include teeth with which a gear can engage. The gear is attached to the device, and the device is attached to the bicycle chainstay at the attachment points that were conventionally used for attaching the brake caliper mechanism of the disc brake system, and is coupled to an electric motor so that the gear can be driven by the electric motor. Therefore, the disc rotor is used to drive the rotation of the wheel or apply the brake.

[0003] Another known document, DE102016113572, discloses an electric motor configured to drive the rotation of a rotor of a disc brake system. Here, a gear is fixed to the rotor, and the gear is coupled to the drive shaft of the electric motor by a chain. Therefore, the rotor is used to drive the rotation of the wheel or apply the brake. The electric motor is attached to the bicycle frame.

[0004] In either case, the drive system becomes bulky and highly conspicuous in areas where bicycle components are densely packed. As a result, these systems can only be installed on specific bicycles, requiring modifications to the components attached to the frame. Furthermore, these drive systems require special mounting mechanisms on the bicycle frame, and such mechanisms are not present on all frames. The objective of this invention is to improve such systems. [Overview of the project]

[0005] According to a first aspect of the present invention, a device is provided for coupling a drive unit to a wheel so that the drive unit can drive the rotation of the wheel about the wheel's central axis. The device comprises a drive member mounted on a mount of the wheel's hub so that the rotation of the drive member about the central axis drives the rotation of the hub about the central axis; a mounting member attached to the drive member and rotatable independently of the drive member about the central axis; a drive element having a drive element axis fixedly positioned relative to the mounting member and coupled to the drive unit so that the drive unit can drive the rotation of the drive element about the drive element axis; and a preventing means for preventing the mounting member from rotating about the central axis, wherein the drive member includes a coupling means coupled to the drive element so that the rotation of the drive element drives the rotation of the drive member.

[0006] The drive member preferably provides a first side facing away from the wheel when the drive member is attached to the wheel, and the coupling means and drive element are arranged at least partially within a concave region of the first side.

[0007] Components such as drive units can be partially or entirely attached to and / or mounted on and / or supported by mounting members. This eliminates or reduces the need to attach components to the frame. The mounting members may be supported by the drive members.

[0008] With the drive member attached to the wheel, the mounting member may be attached to the drive member such that the drive member is positioned between the mounting member and the spokes of the wheel.

[0009] The surface of the first side of the drive member may be flat.

[0010] The coupling means and the drive element can be connected in a concave region. In other words, the connecting / engaging parts may be located in a concave region.

[0011] The drive member may have at least one cylindrical wall extending circumferentially around a central axis to which a coupling means is attached. The drive element may include a first gear, and the coupling means may include a second gear that engages with the first gear such that the rotation of the first gear drives the rotation of the drive member.

[0012] The first gear can be mounted on a mounting member. The second gear may be an internal gear extending around the central axis with teeth protruding inward. Alternatively, the second gear may extend around the central axis with teeth protruding outward.

[0013] The mount is located on the hub and may be, for example, a 6-bolt or center-lock type rotor disc mounting means. The rotor disc mounting means may be preferred for mounting the rotor disc of a disc brake system. The drive member may have means for attaching to the rotor disc mounting means on the hub, or the drive member may be mounted in place of the rotor disc. The mounting means may occupy a portion of the same space that the rotor disc would conventionally occupy.

[0014] The drive member may include a radially extending annular rotor disc portion configured for use in the caliper mechanism of a disc brake system. The mounting means and the annular rotor disc portion may be on the same plane and occupy the same space that the rotor disc would conventionally occupy.

[0015] The device may further include a bearing assembly between the drive member and the mounting member. The drive member and the mounting member are each fixed to the bearing assembly, allowing the mounting member to rotate independently of the drive member relative to its central axis.

[0016] The drive member may have an opening on its first side to allow access to the concave region. The mounting member may extend across the opening in the concave region and cover the concave region so that the drive element is enclosed by the drive member and the mounting member.

[0017] The bearing assembly may be positioned at least partially within a concave region. Optionally, but not limited to, especially when the mount is a disc brake rotor mount, the drive member may comprise a drive member portion and an adapter means. In this case, the drive member portion may have a first side surface providing a concave region. The adapter means may comprise a first portion for fixing to the disc brake rotor mount and a second portion extending from the first portion around the central axis of the hub and providing an outer surface with a smaller diameter than the outer surface of the disc brake rotor mount. The annular bearing assembly may be attached to the adapter means directly or indirectly in a fixed position relative to the adapter means. For example, the drive member may be fixedly attached to the first and / or second portions, or the annular bearing assembly may be attached to the drive member coaxially and fixed thereto. At least a portion of the annular bearing assembly can be positioned in a space with a diameter smaller than the outer circumference of the disc brake rotor mount.

[0018] The preventative means may be attached directly or indirectly to the mounting member. The preventative means may be configured to contact a frame member that supports the wheel when the mounting member is rotated. In addition, or alternatively, the preventative means may be provided as the housing of the drive member unit. In addition, or alternatively, the preventative means may be configured to be attached to a frame member that supports the wheel when the mounting member is rotated.

[0019] The apparatus may further include a drive unit. The drive unit can be mounted directly or indirectly to a mounting member, preferably mounted such that the mounting member bears the entire mass of the drive unit.

[0020] With the prevention means attached to the mounting member, the drive unit can be attached to the prevention means.

[0021] The drive unit is preferably detachable such that its drive shaft can be separated from the drive element, and the drive unit itself can be separated from the mounting member. The wheels can be used without the drive unit. The preventative means is preferably removable or adjustable so as not to obstruct the rotation of the mounting member.

[0022] The drive shaft of the drive unit should preferably be parallel to the central axis.

[0023] We can also provide wheels equipped with such devices, especially bicycle wheels.

[0024] A second aspect of the present invention provides a method for coupling a drive unit of a drive system, the drive system comprising: a drive member mounted on a mount of a wheel hub such that the rotation of the drive member about the wheel's central axis drives the rotation of the hub about the central axis; a mounting member attached to the drive member and rotatable independently of the drive member about the central axis; and a drive element having a drive element axis parallel to the central axis, the drive element axis being fixedly positioned relative to the mounting member, wherein the drive member includes coupling means that are coupled to the drive element such that the rotation of the drive element drives the rotation of the drive member. The method includes the step of mounting the drive unit to the mounting member, which includes coupling the drive shaft of the drive unit to the drive element such that the rotation of the drive shaft drives the rotation of the drive element about the drive element axis. After the drive unit is mounted to the mounting member, the drive shaft is preferably parallel to the wheel's central axis.

[0025] Furthermore, the method may include using anti-rotation means to attach the drive unit to a non-rotatable frame member, preferably a frame member supporting the wheels, thereby preventing rotation of the drive unit.

[0026] The drive member may have a first side facing away from the wheel in a state where the drive member is attached to the wheel, and here the coupling means and the drive element are at least partially disposed within a concave region of the first side.

[0027] The mount may be rotor disk mounting means, and the rotor disk mounting means is suitable for mounting the rotor disk of the disk brake system, where the drive member comprises means for attachment to the rotor disk mounting means on the hub, and the drive member is a member to be attached in place of the rotor disk.

[0028] The drive system including the drive unit may include any of the possible functions in the first aspect.

[0029] According to a third aspect of the present invention, a method of coupling a drive unit to a wheel is provided such that the drive unit can drive the rotation of the wheel about the central axis of the wheel. The method includes attaching the device according to the first aspect to the wheel, which includes coupling the drive element and the drive unit such that the drive unit can drive the rotation of the drive element.

[0030] The method may include attaching the adapter means of the first aspect to the mount and then attaching the remaining device to the adapter means.

[0031] A fourth aspect of the present invention provides an adapter means for fixing to a mount on a wheel hub and for mounting a drive system such that the drive system can drive the adapter means and the wheel to rotate. The adapter means includes a mounting portion for a drive system having a diameter smaller than the outer circumferential surface of the mount, and one or more components of the drive system are mounted around the mounting portion at a location where the radial distance from the hub axis is shorter than the outer circumferential surface of the mount.

[0032] The adapter means may include a first portion for fixing to the mount. The mounting portion ("second portion") extends from the first portion about the central axis of the hub and may have an outer surface with a smaller diameter than the outer surface of the mount, and one or more components of the drive system are mounted around the mounting portion.

[0033] The mount may be a disc brake rotor mount. The first part may be configured to bolt to a conventional 6-bolt design mount.

[0034] The adapter means may include locking means for preventing axial movement of the first and second parts relative to the hub. The locking means may include a locking ring configured such that the end of the locking means engages with the second part, so that the locking means locks one or more parts in place.

[0035] One or more components may comprise an annular bearing assembly, which may be directly or indirectly attached to an adapter means at least in part at a radial distance from the hub axle shorter than the outer surface of the mount, and the annular bearing assembly may be configured to allow another component (e.g., a mounting member) to rotate around the hub axle independently of the adapter. Notably, if the first component is configured to mount to a 6-bolt design mount, the attachment of the annular bearing assembly prevents access to the bolts.

[0036] The drive member component may be fixed to the adapter means, or an annular bearing assembly may be attached to the drive member component. The drive member component may include an annular flange that prevents access to a bolt. The drive member component may include a cylindrical portion extending around a second portion. In this case, the adapter means is positioned to engage the cylindrical portion with the adapter. The annular bearing assembly can be fixedly attached to the annular flange and / or the cylindrical portion.

[0037] A fifth aspect of the present invention further provides a method for coupling a drive unit to a wheel so that the drive unit drives the rotation of the wheel about the wheel's central axis, the method comprising mounting the device according to the first aspect to the wheel and coupling the drive element to the drive unit so that the drive unit drives the rotation of the drive element.

[0038] Hereinafter, embodiments of the present invention will be described only illustratively with reference to the attached figures. [Brief explanation of the drawing]

[0039] [Figure 1] This is a perspective view of a bicycle wheel equipped with a drive system according to one embodiment of the present invention. [Figure 2] This is a perspective view similar to Figure 1, but the drive system is shown in an exploded view. [Figure 3] This is an exploded view similar to Figure 2, but from a different perspective. [Figure 4] This is a perspective close-up view of the elements of the embodiment, with some elements shown in exploded view. [Figure 5] This is a close-up perspective view of the drive system in its installed state. [Figure 6] This is a close-up perspective view of the drive system in its installed state. [Figure 7] This is a diagram of a bicycle equipped with a drive system. [Figure 8] This is a diagram of a bicycle equipped with a drive system. [Figure 9] This is a diagram of a bicycle with the installed drive system, electric motor, and mounting device removed. [Figure 10] This is a diagram of a bicycle with the installed drive system, electric motor, and mounting device removed. [Figure 11] This is a first side view of the drive member of the drive system. [Figure 12] This is a perspective view of the second side of the drive member. [Figure 13] This is a perspective view of the mounting components for the drive system. [Figure 14] This is a side view of the mounting component. [Figure 15] This is a perspective view of a drive member according to another embodiment. [Figure 16] This is a cross-sectional view of a hub and drive system according to another embodiment. [Modes for carrying out the invention]

[0040] Embodiments of the present invention relate to devices for a drive system for driving the rotation of a wheel, and more particularly to devices for coupling a drive unit of a drive system to a wheel. The drive system is typically used to supplement human power that drives a wheel, such as pedaling, but may be used as a substitute for human power or to supplement other means used to drive a wheel.

[0041] Referring to Figures 1 to 14, in one embodiment, the drive system comprises a drive unit in the form of a drive member 10, a mounting member 12, an annular bearing assembly 14, an anti-rotation assembly 15, a drive element in the form of a pinion gear 16, and an electric motor 18. The drive system is mounted on the rear wheel 20 of the bicycle. The wheel includes a hub 22 and a cassette 24. An axle (not shown) extends through the hub 22 and the cassette 24 around which the hub rotates. The drive system can also optionally be mounted on the front wheel of the bicycle.

[0042] The embodiments are not limited to use with an electric motor. The embodiments can be carried out using any device capable of transmitting torque to the drive element. For example, the embodiments may be coupled to the drive shaft of a motor in the form of an internal combustion engine.

[0043] A wheel has an axle around which it rotates, and the term "central axle" shall be interpreted based on this. The term "hub axle" shall be interpreted as referring to the same axle. Unless otherwise specified in the context, the terms "outside," "inside," "external," and "internal" shall be interpreted as "inside" and "outside" with respect to the hub axle.

[0044] The drive member 10 is positioned on the hub 22 where a conventional disc rotor would normally be attached, and therefore does not have such a disc rotor. The drive member 10 has a first side facing outward in the direction opposite to the spokes of the wheel, and a second side facing the spokes. In this specification, “spoke” is to be interpreted as encompassing all arrangements that function as spokes. This includes arrangements in which an elongated member spanning between the rim and the hub is formed integrally with the rim and / or hub, and arrangements in which spokes are replaced by a disc spanning between the rim and the hub. As best seen in Figures 11 and 12, the drive member 10 includes a mounting section, an annular backplate 10c, an internal gear 10d, a second cylindrical wall 10e, and an annular brake rotor section 10f. The mounting section includes a drive member mounting plate 10a. The mounting section also includes a first cylindrical wall 10b having a cylindrical outer surface. At its first end, the first cylindrical wall 10b extends from the drive member mounting plate 10a toward the spokes of the wheel. The annular backplate 10c extends radially outward relative to the hub axis from the second end of the first cylindrical wall 10b. The second cylindrical wall 10e extends from the annular backplate 10c at its first end in the direction opposite to the spokes of the wheel. The first and second cylindrical walls 10b and 10e are both coaxial with the hub 22. The internal gear 10d is mounted on the inner surfaces of the annular backplate 10c and the second cylindrical wall 10e, and faces the outer surface of the first cylindrical wall 10b. The first and second cylindrical walls 10b and 10e are spaced apart to form an annular concave region 26 between them, in which the internal gear is located. In some modified embodiments, the internal gear 10d is mounted on the inner surface of the annular backplate 10b or the second cylindrical wall 10e.

[0045] The drive member 10 may be formed from a single piece of material. In modified embodiments, the drive member 10 may be formed from multiple pieces of material. In some modifications, the internal gear 10d may be formed separately and fixed to the other drive member 10 by welding or any suitable bonding method, or in some embodiments, by locking a corresponding portion (not shown) to the internal gear 10d and the drive member 10 modified for such locking. In some modifications, the brake rotor portion 10f may be formed separately and fixed to the other drive member 10 by welding or any suitable bonding method, or in some embodiments, by locking a portion modified for locking. The drive member 10 may be formed in other ways using various parts that are fixed together in other modified embodiments. Making the drive member 10 from multiple parts makes it easy to make different parts from different materials.

[0046] The hub 22 is conventional and includes a conventional disc rotor mount (not shown) configured to mount a mating conventional disc rotor, which is configured to be attached to a disc rotor mounting means. The mount conforms to a conventional 6-bolt design. A conventional disc rotor configured to correspond to the 6-bolt design is securely bolted to the mount and can be used in a conventional disc brake system. When the conventional disc rotor is mounted, relative rotation between the disc rotor and the hub 22 is prevented, so that the disc rotor and the hub 22 rotate synchronously, and the caliper mechanism acts on the disc rotor, braking the rotation of the wheel.

[0047] In the drive member 10, the drive member mounting plate 10a has holes corresponding to a 6-bolt design, similar to a conventional disc rotor. This allows the drive member 10 to be securely bolted to the mounting plate in place of a conventional disc rotor. To enable this and allow the drive member 10 to be positioned on the hub 22, if a conventional disc rotor is installed, it must be removed from its mount on the hub. The drive member 10 can also be removed from the mounting plate and replaced if it becomes worn. The drive member 10 is bolted to the mount in such a way that relative rotation between the drive member 10 and the hub is prevented, and the drive member 10 and the hub 22 rotate synchronously.

[0048] Instead of using a 6-bolt design mount to attach the disc rotor to the hub, other types of hubs are known that include alternative disc rotor mounts. In a modified embodiment, the drive member 10 may be configured to attach to such a mount. For example, a center-lock design can be used for the mount and a conventional disc rotor (not shown), in which the mount includes a male spline and the conventional disc rotor includes a corresponding female spline. The male and female splines are configured to mate, so that the conventional disc rotor can be placed on the hub and removed from the hub by relative axial movement. The drive member (specifically, the drive member mounting plate 10a of the drive member) may be configured with the same female spline and be placed and removed in the same manner. The male and female splines prevent relative rotation of the drive member and the hub, so that the drive member and the hub rotate synchronously. A lock ring can conventionally be used to lock a splined disc rotor in place and prevent relative axial movement. The same method can also be used to lock such a drive member in place.

[0049] In another embodiment, the drive system described above may be mounted on the hub of a wheel using a conventional rim brake. In this case, the wheel hub is modified to include a mount to which the mounting plate 10a can be attached. This mount may be a 6-bolt design, a center-lock design, or other design used for conventional disc rotors, and is therefore identical to the mount for mounting a conventional disc rotor. Alternatively, the mount may be of a different design, such as a 7-bolt design, and the mounting plate 10a may be configured accordingly. In such embodiments, the annular brake rotor portion 10f may not be present.

[0050] In another embodiment, the freehub body of the hub may function as a mount for the drive member. The mounting plate 10a may be modified to be mounted to the freehub body in place of one or more sprockets so that the rotation of the drive member in the forward direction drives the rotation of the hub. Alternatively, the drive member 10 may be mounted to the hub so as to drive the rotation of the hub. If the drive member does not replace a conventional rotor disc, the annular brake rotor portion 10f is of no significance and is therefore optional.

[0051] It is important to understand here that the aforementioned mount is part of the hub. In particular, mounts for disc brakes are manufactured as an integrated component with the hub by major manufacturers such as Shimano®. Such mounts typically conform to 6-bolt and center-lock designs. The hub 22, spokes, and rim of the wheel 20 are functionally distinct components common to all wheels. This is true whether two or all of these components are formed together.

[0052] The brake rotor portion 10f extends radially from the second end of the second cylindrical wall 10e. The brake rotor portion 10f is intended to be positioned in the same space as the annular outer portion of a conventional disc rotor and has the same or similar circular outer diameter so that it can be accommodated in a disc brake system. The drive member 10a is configured so that the disc brake system continues to function even after the disc rotor is replaced with the drive member 10, and so that the caliper of the disc brake system is pressed against the brake rotor portion 10f to provide braking action. The thickness of the brake rotor portion 10a is such that the brake rotor portion can function together with the disc brake system, and may also be the same as the thickness of the rotor disc (e.g., 1.7 mm).

[0053] The mounting plate 10a and the annular brake rotor portion 10f are on the same plane. The drive member 10 has a first side facing outward, opposite to the spokes of the wheel, when the drive member 10 is mounted on the hub. In all embodiments, these parts do not need to be planar. The first and second cylindrical walls 10b, 10e and the annular back plate 10c provide an annular concave region 26 that extends around the central axis of the hub 22. When mounted on the wheel, the opening side of the concave region 26 formed on the drive member 10 faces away from the wheel. The annular concave region 26 is wide enough (along the line AA in Figure 11) to accommodate the engaged pinion gear 16 and internal gear 10d, but not wide enough to obstruct the movement of the brake rotor portion 10f in the portion that enters the caliper. The maximum depth of the drive unit 10 may be as little as 2 to 3 mm, which is sufficient depth to accommodate the pinion gear 16 and internal gear 10d. However, the rear wheel of a bicycle usually has space to make the drive unit 10 deeper, for example, when a deeper annular recess is required.

[0054] Typically, there is little space between the first side of a conventional disc brake rotor, i.e., the side facing away from the wheel, and the bicycle frame. The annular concave region 26 usefully provides space for positioning the pinion gear 16 and internal gear 10d so that the drive shaft of the pinion gear 16 can extend in the opposite direction from the wheel. In particular, the system described in known patent document DE102016113572B3 describes the position of the gears between the device and the wheel to avoid space problems, but has various drawbacks regarding the provision of the concave region 26 to provide space for the pinion gear 16 and internal gear 10d.

[0055] In some embodiments, the pinion gear 16 and internal gear may be only partially mounted in the concave region 26, extending from the opening side of the concave region 26 to the opposite side of the wheel. Furthermore, the drive member 10 does not necessarily have to be configured to provide such an annular concave region. Other configurations are possible. For example, the drive member may be substantially planar, and the internal gear may be mounted to the drive member so as to protrude from the drive member. However, in this case, the internal gear and mounting member 12 would need to be very thin to prevent contact with the frame.

[0056] The annular backplate 10c effectively protects the internal gear 10d and pinion gear 16 from dirt and preferably seals the recessed area 26 between the wheel and the recessed area 26. The drive member 10, including the annular backplate 10c, and the mounting member 12 together effectively surround the pinion gear 16 and internal gear 10d, preventing the intrusion of dirt. In modified embodiments, the annular backplate 10c and / or the mounting member 12 may have space inside. While dirt may enter through such space, it may reduce the weight of the components.

[0057] As best seen in Figure 13, the mounting member 12 comprises a cylindrical portion 12a located within the concave region 26 and an annular mounting plate 12b extending outward from the cylindrical portion 12a relative to the hub axis. The annular bearing assembly 14 is located within the concave region 26 between the cylindrical portion 12a and the first cylindrical wall 10b and has a cylindrical outer surface. The cylindrical portion 12a is fixed to the outer surface of the bearing assembly 14, and the inner surface of the bearing assembly is fixed to the cylindrical outer surface of the first cylindrical wall 10b. Therefore, since the mounting member 12 is attached to the first cylindrical wall 10b via the bearing assembly 14, the drive member 10 can rotate freely around the hub axis relative to the mounting member 12, and vice versa. The annular mounting plate 12b is positioned to be flush with the first side surface of the drive member 10.

[0058] The mounting member 12 has an annular step 28 formed within the mounting member 12 so as to face away from the wheel 20, and the annular step 28 extends circumferentially around the hub 22. The drive system includes a circlip 30 positioned in the annular space created by the annular step 28, which grips the outside of the first cylindrical wall 10b. The circlip 30 prevents longitudinal movement of the mounting member 12 relative to the hub axis but allows rotational movement. Naturally, the annular step 28 is provided for compactness.

[0059] The mounting plate 12b has three holes 32a to c. The shaft of the pinion gear has an end that is positioned in the first hole 32a. The drive shaft 34 of the electric motor 18 extends through the first hole 32a and is fixedly connected to the shaft of the pinion gear 16. In this way, the pinion gear 16 is mounted to the end of the drive shaft 34 within the annular concave region 26. The first hole 32a has a recessed opening in which a bearing 107 is positioned, and the shaft of the pinion gear 16 also extends through this opening. A circlip 108 is fastened to the pinion gear shaft, fixing the pinion gear 16 in the hole 32a. Thus, the shaft of the pinion gear 16 is fixedly positioned relative to the mounting member 12. The axis of rotation of the pinion gear 16 is parallel to the hub axis. Therefore, the drive shaft of the electric motor 18 is also parallel to the hub axis. In a modified embodiment, the pinion gear 16 may be attached to the mounting member 12 as an alternative method. The pinion gear 16 (or its shaft) may be provided with a keyway that allows the drive shaft of the electric motor 18 to be detachably coupled to the pinion gear 16. Alternatively, the pinion gear 16 may be fixed to the end of the drive shaft 34, and the mounting member 12 may be modified to support the pinion gear 34 within the concave region 26 in that mounted state.

[0060] The anti-rotation assembly 15 comprises an arm 36, a stop element 38, a stop element mounting bolt 40, and a number of motor mounting bolts 44. The stop element 38 is attached to the end of the arm 36 by mounting holes provided in the arm 36 and the stop element mounting bolt 40. The arm 36 has two holes 33a, 33b that are aligned with holes 32b, 32c in the mounting plate 12b, and these holes are threaded. The anti-rotation assembly is attached to the mounting plate 12b by bolts 41 that extend through the aligned holes 32b, 32c, 33a, 33b, respectively. In a modified embodiment, the anti-rotation assembly is attached to the mounting member 12 in another way by alternative fastening means.

[0061] The arm 36 also has four motor mounting holes 42. The motor 18 is attached to the arm 36 by four bolts 44 that extend through the four motor mounting holes 42 and engage in threaded holes (not shown) on the body of the motor 18. The motor 18 is detachably mounted to the anti-rotation assembly 15 using the motor mounting bolts 44. When mounted in this manner, the shaft 34 passes through hole 32a as well as hole 45. Thus, the shaft 34 is synchronously coupled to the shaft of the pinion gear 16, which is secured to the mounting plate 12b by bearings 107 and circlips 108. In this way, the motor 18 is fixedly mounted and supported on the anti-rotation assembly 15. In a modified embodiment, if not, the motor 18 may be attached to the anti-rotation assembly 15 by alternative fastening means, or it may be attached directly to the mounting member 12. The motor 18 may have a battery, or alternatively, it may be coupled to a battery located elsewhere on the bicycle.

[0062] The arm 36 and stop element 38 are shaped so that the stop element 38 contacts the bicycle's chainstay when the mounting member 12 rotates. This prevents the mounting member 12 and all components attached to it (such as the electric motor 18) from rotating further. When the drive system is mounted on the front wheel of the bicycle for front wheel rotation drive, the stop element 38 contacts the fork instead of the chainstay. In a modified embodiment where the electric drive system is mounted on a wheel other than the bicycle's wheel, the stop element 38 may contact the frame member to which the wheel is mounted, or any other frame member or object that translates relative to the wheel but does not rotate.

[0063] It is worth noting that the drive member 10 does not necessarily need to be configured to have an annular concave region; the drive member may be substantially flat, with the internal gear mounted on the outward-facing surface of the drive member protruding from it. If the drive member is a replacement for a conventional disc rotor, the internal gear and mounting member 12 will need to be very thin to prevent contact with the frame. However, if the hub is designed specifically for mounting the drive system, the available space may increase.

[0064] The drive member 10, mounting member 12, anti-rotation assembly 15, pinion gear 16, and various bolts can be made of steel or other suitable material. The stop element 38 is preferably made of a material that is soft enough to avoid damage to the chainstay, such as plastic or a hard material with a soft outer layer such as rubber. Other parts may be made of other materials such as metal or plastic, as will be obvious to those skilled in the art.

[0065] The stop element 38 and / or arm 36 may be configured to allow adjustment of length using adjustment screws or stop elements of various sizes so that they can reliably and unimpededly contact the frame chainstay.

[0066] During operation, the electric motor 18 operates to drive the rotation of the pinion gear 16. The pinion gear 16 drives the rotation of the internal gear 10d, which in turn drives the rotation of the drive member 10. When the internal gear 10d is driven to rotate in one direction, a force is applied to the mounting member 12 that causes it to rotate in the opposite direction. Thus, the mounting member 12 pivots until the stop element 38 contacts the chainstay or other fixed part of the bicycle frame.

[0067] The electric motor 18 can be removed together with the anti-rotation assembly by removing the bolt 41. Figures 9 and 10 show the electric motor 18 in the removed state. The drive shaft of the electric motor 18 may be simply pulled out to disconnect the electric motor 18 from the pinion gear 16. The electric motor 18 can be reinstalled by performing the reverse steps to engage it with the pinion gear 16 and tightening the bolt 41. Figures 9 and 10 show the opening of the pinion shaft socket 300, which is configured to support the electric motor shaft 34 (optionally using a keyway as described above) when the electric motor 18 is needed.

[0068] In a further embodiment, the stop element 38 may be configured to be attached to a seat stay (not shown) of a bicycle. Since it reaches the seat stay by pivoting in the opposite direction, the stop element 38 is not pushed towards the seat stay during use. Rather, since the stop element 38 is pulled away from the seat stay, it can be attached to the seat stay using a clamp configured to prevent detachment, or an elastic or inelastic fixing mechanism.

[0069] In one modified embodiment, the stop element 38 is absent, and instead, an attachment is provided to secure the arm 36 to the chainstay. This attachment may take the form of a clamp or strap surrounding the chainstay, for example, and may also be attached to the arm 36 by bolts or other suitable means. In particular, the arm 36 is not required to mount the motor 18; rather, the anti-rotation assembly 15, including the arm 36, is provided to counteract the combined torque generated by the mounted motor 18. In one modified embodiment, the arm 36 may be attached to the mounting member 12 independently of the motor 18. As described below, it is not necessary for the motor 18 to be supported by the mounting member 12. The stop element 38 and optionally the arm may be alternatively replaced by other means of attaching the mounting member 12 to the chainstay or other frame member to prevent the mounting member 12 from rotating. For example, such mounting means may take the form of a strap with hook and loop material.

[0070] In one modified embodiment, the motor 18 and an optional associated housing (not shown) may function as a stop element. In this embodiment, the motor and associated housing may protrude longitudinally from the wheel relative to the wheel's central axis and be offset from the central axis by a distance greater than the chainstay. In this way, when the mounting element 12 rotates, the motor and associated enclosure collide directly with the chainstay. The motor enclosure hardware may be modified to facilitate contact with the chainstay within an acceptable range. Such motor enclosure hardware may also include mounting means to the chainstay, for example, with fastening means such as clamps or elastic straps. In this modified embodiment, the anti-rotation assembly 15 is not required, and the motor may be mounted directly to the mounting plate 12b.

[0071] In one variant embodiment, the electric motor 18 is not attached to the arm 36 by bolts 44. Instead, the electric motor 18 is attached using a quick-release mechanism, allowing for quick attachment and detachment of the electric motor 18. In one alternative variant embodiment, the arm is not attached to the mounting plate 12b by bolts 41; instead, it is attached using a quick-release mechanism, allowing for quick attachment and detachment of the arm and all components supported by the arm 36.

[0072] A detailed description of the operation and control functions of the electric motor is outside the scope of this disclosure. The electric motor may be operated by the user to start and stop supplying torque to the wheel. The electric motor may be configured to supply torque under certain conditions, for example, when torque is being applied by the user's pedaling motion.

[0073] In one modified embodiment, the electric motor 18 and an accompanying battery (not shown) are located elsewhere on the bicycle, for example, under the saddle. In this case, the electric motor 18 is coupled to a pinion gear 16 and drives the pinion gear 16 using a coupling mechanism. In one example, a flexible drive shaft connects the drive shaft 34 of the electric motor 18 to the gear 16. Such a flexible drive shaft (not shown) is housed in a sheath (not shown). The end of the sheath may be fixedly attached to a mounting member 12 around a hole 32a, and the drive shaft within the sheath is coupled to the pinion gear 16 via the hole 32a. In another example, the pinion gear 16 is coupled to a gear on the opposite side of the mounting member 12 from the pinion gear 16 via the hole 32a. A drive shaft (flexible or non-flexible) extends from the electric motor 16 and drives this gear, which in turn drives the pinion gear 16. This gear could be a bevel gear, but is not limited to a specific type of gear, in which the drive shaft can reach the gear at an angle where it is not aligned.

[0074] The pinion gear 16 is a spur gear, but in modified embodiments, a different gear may be used.

[0075] In some embodiments, the annular bearing assembly 14 may be absent. In this case, a similar low-friction arrangement can be provided that allows independent rotation while fixing the drive member 10 and the mounting member together.

[0076] It should be understood that the concave region is the area of ​​space that is recessed toward the spokes relative to the plane where the outward-facing surface of the disc rotor was conventionally located. As already mentioned, the annular brake rotor portion 10f can be omitted. In this case, in some modified embodiments, the second cylindrical wall 10e can be omitted, provided that the mounting member 12 is provided with sufficient structural support. Furthermore, in another modified embodiment, the annular back plate 10c may also be omitted.

[0077] Other gear configurations may be used as alternatives to the internal gear and pinion gear 16. Referring to Figure 15, in another embodiment, parts functionally corresponding to the embodiments described in association with Figures 1 to 14 are given the same reference numerals incremented by 200. The internal gear 10d is absent, and instead a gear is provided on the outside of the first cylindrical wall 210b; that is, teeth 210d are provided on its outer surface. An annular bearing assembly (not shown) is fixed to the inner circumferential surface of the second cylindrical wall 210e of the drive member 210, similar to the bearing assembly 14. The annular portion of the mounting member 212 (not shown) is modified and positioned to be flush with the inner surface of the annular bearing assembly (not shown) and fixed to it. The annular bearing assembly assists the relative rotational motion of the mounting member 212 and the drive member 210 around the hub axis.

[0078] In another modified embodiment, a ratchet may be provided on the annular backplate 10c that extends circumferentially around the hub axis. Instead of the pinion gear 16, a bevel gear may be provided to mesh with the ratchet.

[0079] In other embodiments, instead of the internal gear 12c, a spur gear may be provided on another part fixed to the drive member 12, or formed integrally with the drive member 12, and rotated coaxially with the drive member 12 around the hub axis, and a pinion gear 16 may be attached to drive the rotation of the spur gear. In one modification, the drive member may include the teeth of a spur gear on its outer edge, and a pinion gear 16 may be attached to drive the rotation of such a spur gear and, consequently, the rotation of the drive member. Another design specification for connecting the drive shaft of an electric motor to the drive member is disclosed in US9359040. In embodiments of the present invention, such a design specification may be incorporated while maintaining a mounting member that is supported on the drive member, rotatable independently of the drive member, and to which the drive unit 18 is attached.

[0080] Embodiments of the present invention are not limited to a specific method in which the drive shaft of a drive unit is connected to a drive member to drive the rotation of the drive member around a hub axis. However, this is provided that a mounting member is supported on the drive member and is rotatable independently of the drive member, and at the same time, the drive unit 18 is attached to the mounting member. Optionally, friction drive or belt drive configurations can also be used.

[0081] In one modified embodiment, the arm 36 may be hinged to the mounting member 12 and arranged to abut against the chainstay when open. The arm 36 may be folded as needed and secured in place with a clip.

[0082] Referring to Figures 1 to 14 and 15, the bearing assembly 14 described above occupies space in a concave region between the first and second cylindrical walls 10b, 10f. Referring to Figure 16, in another embodiment of the drive system, the drive system includes parts identical or functionally corresponding to those in the embodiments described above with reference to Figures 1 to 14, such as a mounting member 412, an annular bearing assembly 414, and a pinion gear 416, as well as a drive unit (not shown). Such parts are given the same reference numbers incremented by 400. However, in the embodiment shown in Figure 16, the drive member includes a drive member part 410 and an adapter assembly. The adapter assembly comprises an adapter and a lock ring 492.

[0083] The annular bearing assembly 414 is not located within the concave region, but instead is located near the first side surface of the drive member component 410. The mount 499 of the hub 422 is based on a conventional six-bolt design. Here, the first cylindrical wall 410b extends around the mount 499, so the first cylindrical wall 410b must have a minimum diameter. The adapter is annular with an L-shaped portion around it. This adapter includes an annular portion 490a extending radially around the hub axis and a cylindrical portion 490b coaxial with the hub axis. The diameter of the outer surface of the cylindrical portion 490b is smaller than the inner diameter of the first cylindrical wall 410b and smaller than the outer diameter of the mount 499. The annular portion 490a has several holes that are aligned with the bolt holes of the mount 499. The annular portion 490a is bolted to the mount 499 by several bolts 413 that extend through the holes provided therein into the bolt holes. In the conventional method, the holes in mount 499 are threaded to engage with bolt 413. Therefore, relative rotation of the adapter and mount 499 around the hub axle, as well as axial movement, is prevented.

[0084] In some of the embodiments described above, a portion of the drive member component 410 (i.e., the mounting plate 10a) that was directly attached to the 6-bolt mount is mounted in this embodiment so as to abut against the head of the bolt 413. In a modified embodiment, if the bolt head is embedded, the mounting plate 10a may be positioned to abut against the annular surface of the annular portion 490a, or in a modified embodiment, the mounting plate 10a may be positioned spaced apart from the bolt head or the annular surface. The drive member component 410 not only includes components corresponding to the above-described components 10b to 10f, but also includes an annular flange 410g that is coaxial with the hub axis and extends around the outer surface of the cylindrical portion 490b in the opposite direction to the spokes of the wheel.

[0085] The cylindrical portion 490b and the annular flange 410g each include stepped portions, which are collectively shown as 496. Each stepped portion is molded such that the stepped portion of the annular flange 410 seats the stepped portion of the cylindrical portion 490b. The stepped portions 496 prevent axial movement of the drive member 410 toward the spokes of the wheel. The annular flange 410g also has a non-circumferential recess on its inner surface, and the cylindrical portion 490b has a corresponding non-circumferential projection 494. The projection 494 is configured to engage with the recess so as to prevent relative rotation of the adapter's hub axis and the drive member 410. Embodiments of the present invention are not limited to the use of the projection 494 and recess to prevent such relative rotation. Other methods may be implemented in modified embodiments.

[0086] The cylindrical portion 490b also includes a threaded portion on its inner surface that extends around the hub 422 and is spaced apart from the hub 422. The lock ring 492 includes a cylindrical projection 492a located between the hub 422 and the cylindrical portion 490b, with a corresponding threaded portion that screw-engages with the threaded portion on the inner surface of the cylindrical portion 490b. The lock ring 492 also includes a radial flange 492b that abuts against the annular end of the cylindrical portion 490b. Thus, the annular flange 410g, which is positioned without gap between the radial flange 492b and the stepped portion of the cylindrical portion 490b, prevents axial movement of the drive member 410 that could cause rattle. In a modified embodiment, the lock ring 492 may be absent, and an alternative method for securing the drive member component 410 to the adapter may be provided.

[0087] The annular bearing assembly 414 is positioned around the cylindrical portion 490b, abutting against the annular portion 490a. The mounting member 412 includes a mounting member portion 412a attached to the annular bearing assembly 414, which extends around the bearing assembly 414 and is fixed to the bearing assembly 414. In this way, the bearing assembly 414 enables relative rotation between the mounting member 412 and the drive member 410.

[0088] The annular brake rotor portion 10f is fixed to the second cylindrical wall 10e by a fixing ring 498. The fixing ring 498, the second cylindrical wall 10e, and the brake rotor portion 10f may be fixed together, for example, by adhesive or welding. Figure 16 also shows the pinion bearing 416, the internal gear 410d, and the keyway 407 of the pinion gear 416, where the drive shaft (not shown) of the drive unit engages.

[0089] During manufacturing, all parts except the drive member component 410, the mounting member 412, and the drive unit attached to the mounting member 412 are assembled together. The mounting member 412 is attached only to the drive member 410 via an annular bearing assembly 414. Lubricating oil may be supplied between the planes of the drive member 410 and the mounting member 412, and between the mounting member 412 and the retaining ring 498.

[0090] To attach the drive system to the hub 422, first bolt the adapters 490a and 490b to the mount 499. Then, place the drive member 410 on top of the adapter. At this time, the step portions are positioned together, and the projections 494 are placed in the corresponding recesses. Next, screw the lock ring 492 onto the cylindrical portion 490b of the adapter, thereby sandwiching the annular flange 410g between the step portion of the cylindrical portion 490b and the radial flange 492b. To use it, insert the drive shaft of the drive unit into the keyway 407 and attach the drive unit. Although not shown in Figure 16, rotation of the drive unit is prevented using one of the rotation prevention methods described above in relation to other embodiments.

[0091] The adapter usefully allows the bearing assembly 414 to be positioned outside the concave region, resulting in more space available for the internal gear 410d and pinion gear 416. This is particularly beneficial when the available space is constrained by the size of the mount based on conventional 6-bolt designs (e.g., Shimano Deore rear hub 6-bolt M525). In particular, a problem that arises when designing a drive system in which the bearing assembly 414 is positioned outside the concave region is that access to the bolt holes of the mount 499 is blocked. This problem can be addressed by providing the adapter as a separate piece on the drive member 410, because the adapter is first fixed to the mount 499, and then the drive member and other components are fixed to the adapter.

[0092] In a modified embodiment, the annular portion 490a of the adapter may be modified to attach to an alternative disc rotor mount design, including a center lock design. The dimensions of other components may be modified to accommodate the various space constraints imposed by different types of mounts. In another modified embodiment, the annular portion 490a may be modified to attach to a wheel hub mount for use in a rim brake system.

[0093] A drive system in any embodiment may be provided as a kit, including a drive unit for retrofitting to a bicycle wheel having a hub with a suitable mount on the wheel.

[0094] In the embodiments described above, the wheels are those of a bicycle, but embodiments of the present invention are not limited thereto. For example, the drive system can be used to drive the rotation of wheels in wheelchairs, tricycles, pushcarts, golf carts, or other types of carts.

[0095] The drive member is configured to be mounted on a hub, but in a bicycle or other device, the drive member may be modified to be mounted on a spoke of a wheel. For example, the wheels of a golf cart typically have three to six plastic spokes, and it will be possible for those skilled in the art to configure a drive member to be mounted on such spokes to drive the rotation of the wheel. A golf cart generally has three wheels, one at the front and two at the rear. In this case, the drive system may be mounted to drive the rotation of the front wheel.

[0096] As will be apparent to those skilled in the art, various modifications can be made to the embodiments described above.

[0097] In this specification and in the claims, “equipped with” and “containing,” and variations thereof, mean that a particular feature, process, or integer value is included. This term shall not be construed to exclude the presence of other features, processes, or components.

[0098] Unless otherwise stated, all individual features and / or processes of all embodiments described herein are disclosed individually and in any combination of two or more such features, to the extent that they can be implemented under this specification, in terms of common technical knowledge for those skilled in the art.

Claims

1. A device for coupling a drive unit to a wheel so that the drive unit can drive the rotation of the wheel about the wheel's central axis, wherein the wheel includes a hub and rotor disc mounting means on the hub, the rotor disc mounting means being suitable for mounting a rotor disc of a disc brake system, and the device is A drive member is provided with means for attaching it to the rotor disc mounting means of the wheel such that the rotation of the drive member about the central axis drives the rotation of the hub about the central axis, A mounting member attached to the drive member and rotatable with respect to the central axis independently of the drive member, A drive element to be attached to the mounting member, having a drive element shaft fixedly positioned with respect to the mounting member, and coupled to the drive unit in such a manner that the drive unit can drive the rotation of the drive element about the drive element shaft, The device comprises a means for preventing the mounting member from rotating about the central axis, The drive member includes coupling means that are coupled to the drive element such that the rotation of the drive element drives the rotation of the drive member, The drive member has a first side surface that faces in the opposite direction to the wheel when the drive member is attached to the wheel, The coupling means and the drive element are arranged at least partially in the concave region of the first side surface, The aforementioned drive member is a member that is installed in place of the rotor disc. Device.

2. The apparatus according to claim 1, wherein, with the drive member attached to the wheel, the mounting member is attached to the drive member such that the drive member is positioned between the mounting member and the spokes of the wheel.

3. The device according to claim 2, wherein the concave region faces in the opposite direction to the spokes and is a space that is set back in the direction of the spokes with respect to the plane on which the surface of the disc rotor is originally positioned, when the device is attached to the rotor disc mounting means.

4. The apparatus according to any one of claims 1 to 3, wherein the coupling means and the drive element (10) are coupled in the concave region.

5. The apparatus according to any one of claims 1 to 4, wherein the drive member is provided with at least one cylindrical wall that extends circumferentially with respect to the central axis and to which the coupling means is attached.

6. The apparatus according to any one of claims 1 to 5, wherein the drive element comprises a first gear, and the coupling means comprises a second gear that engages with the first gear such that the rotation of the drive member is driven by the rotation of the first gear.

7. The drive element comprises a first gear, and the coupling means comprises a second gear that engages with the first gear such that the rotation of the first gear drives the rotation of the drive member, The apparatus according to claim 5, wherein the second gear is an internal gear extending around the central axis, with teeth protruding inward, and is attached to the at least one cylindrical wall.

8. The drive element comprises a first gear, and the coupling means comprises a second gear that engages with the first gear such that the rotation of the first gear drives the rotation of the drive member, The apparatus according to claim 5, wherein the second gear extends around the central axis, has teeth protruding outward, and is attached to the at least one cylindrical wall.

9. The apparatus according to any one of claims 6 to 8, wherein the first gear is rotatably mounted on the mounting member.

10. The apparatus according to any one of claims 1 to 9, wherein the mounting member extends above the opening side of the concave region.

11. The apparatus according to claim 1, wherein the drive member comprises a radially extending annular rotor disc portion configured for use in the caliper mechanism of the disc brake system, and the planar surface includes the surface of the annular rotor disc portion.

12. The apparatus according to any one of claims 1 to 11, further comprising a bearing assembly located between the drive member and the mounting member, wherein the drive member and the mounting member are each fixed to the bearing assembly, so that the mounting member is rotatable with respect to the central axis independently of the drive member.

13. The apparatus according to claim 12, wherein the bearing assembly is at least partially located within the concave region.

14. The apparatus according to claim 6, wherein the drive shaft of the drive unit is engageable with and detachable from the first gear, and the drive unit is engageable with and detachable from the mounting member.

15. A method for coupling a drive unit of a drive system to a rotor disc mounting means on a wheel hub, wherein the drive system is A drive member mounted on the rotor disc mounting means such that the rotation of the drive member about a central axis drives the rotation of the hub about the central axis, wherein the rotor disc mounting means is a drive member suitable for mounting a rotor disc of a disc brake system. A mounting member attached to the drive member and rotatable with respect to the central axis independently of the drive member, The method includes a drive element attached to the mounting member, having a drive element shaft parallel to the central axis and fixedly positioned relative to the mounting member, wherein the drive member includes a coupling means coupled to the drive element such that the rotation of the drive element drives the rotation of the drive member, and the method is A step of mounting the drive unit to the mounting member, comprising coupling the drive shaft of the drive unit to the drive element such that the rotation of the drive shaft drives the rotation of the drive element about the drive element axis, wherein the drive member comprises means for mounting to the rotor disc mounting means on the hub, and the drive member is a member mounted in place of the rotor disc. A method for connecting the drive units of a drive system.

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