Vehicle, drive arrangement of a vehicle and method for producing the same

Abstract

The present invention relates to a drive configuration (10) of a vehicle (100) operable, particularly by muscle force and / or motor force, comprising: a housing (1), a drive unit within the housing (1), a frame interface (2), and a screw (3), wherein the housing (1) and the frame interface (2) are screwed together along a screw axis (30) by means of the screw (3), wherein the housing (1) is partially coated with a coating (7) such that, in the screwed-together state, at least a portion of the coating (7) is disposed on Between the housing (1) and the frame interface (2), wherein the frame interface (2) has a predefined surface structure (4) designed to plastically deform a region (6) of the housing (1) by at least one predefined preload force (5) during an initial screwing together, such that the surface structure (4) and the plastically deformed region (6) form a form fit in a plane (35) perpendicular to the screw axis (30), wherein the region (6) to be plastically deformed is formed without a coating.

Description

[Technical Field]

[0001] This invention relates to a drive configuration, a vehicle including the drive configuration, and a method for using a drive configuration for a production vehicle. [Previous Technology]

[0002] The drive configuration of vehicles such as (for example) electric bicycles is known, wherein, for fastening, the drive unit is screwed to the vehicle frame via a mounting plate. To achieve a precise configuration of the drive unit relative to the vehicle frame, positioning occurs frequently during the initial screwing process using a special gauge. If the drive unit needs to be removed from the vehicle frame later, for example for maintenance or repair, reinstallation requires realigning using a special gauge to achieve a precise relative configuration again. Similarly, a special gauge may be needed to ensure precise installation of the mounting plate and drive unit relative to each other. [Summary of the Invention]

[0003] In contrast, the superiority of the drive configuration according to the invention, having the features of claim 1, lies in the fact that, by means of a particularly simple and cost-effective design, it is possible to easily and precisely rescrew the drive unit to the frame interface. Furthermore, it is possible to securely and reliably fasten the drive unit. This is achieved by a drive configuration of a vehicle comprising a housing, a drive unit disposed within the housing, a frame interface, and screws. The housing and frame interface are screwed together along the screw axis by means of screws. The housing is at least partially coated with a coating such that, in the state of screwing the housing and frame interface together, at least a portion of the coating is disposed between the housing and the frame interface. The frame interface has a predefined surface structure designed to plastically deform a region of the housing by at least one predefined preload force during the initial screwing of the frame interface and the housing together. The surface structure is configured to deform the region in such a way that the surface structure and the plastically deformed region form a form fit in a plane perpendicular to the screw axis. The area of ​​the outer casing to be plastically deformed is formed without a coating. Form fit is here considered to mean that the surface structure and the plastically deformed area at least partially engage with each other in a plane perpendicular to the screw axis.

[0004] In other words, the drive configuration includes two components that can be screwed together by means of screws: a housing and a frame interface, wherein the frame interface has a predefined surface structure, and wherein the housing has a region that is plastically deformed in a predefined manner and created by applying back pressure to the surface structure during the initial screwing. The surface structure and the plastically deformed region engage with each other in such a way that they form a form fit in a plane perpendicular to the screw axis.

[0005] The drive unit preferably includes a motor and / or gear mechanism. The frame interface can be configured as needed. For example, the frame interface may be a portion of the vehicle frame. An alternative preference is to make the frame interface a fixed plate, which is preferably provided for screwing to the vehicle frame, particularly by means of a separate screw connection.

[0006] Surface structures can be particularly considered as bulges and / or depressions on the surface of the corresponding element. For example, a bulge as a surface structure results in a corresponding depression in the housing. Specifically, a depression can cause plastic flow to deform in a region of the housing, such that a bulge at least partially corresponding to the depression can be achieved in the housing.

[0007] The drive configuration here offers the following advantages: the relative configuration of the drive unit and frame interface, particularly with respect to a plane perpendicular to the screw axis (defined during initial tightening), can be reproduced in a particularly simple manner, for example, after the screw connection is released while the drive unit is being removed. In this regard, the relative positions of the housing and frame interfaces relative to each other are defined by the plastically deformed regions generated by the surface structure during the initial tightening. That is, when the housing and frame interfaces are in a released state after the first removal and are intended to be tightened together again, their previously defined relative positions relative to each other are easily found again based on the surface structure and by the predefined plastic deformation it generates. As a result, particularly simple and rapid reconfiguration of the drive configuration can occur, especially without the need for special gauges for precise relative positioning during reconfiguration. This ensures particularly high positioning accuracy during re-tightening, especially without additional gauges.

[0008] Since the area to be plastically deformed is formed without a coating, the specially defined deformation can be achieved directly within the outer shell itself. This is particularly advantageous when the outer shell is formed of a material with a lower hardness than the coating.

[0009] In addition, a particularly good seal between the housing and the frame interface can be made possible by means of plastic deformation. Since the coating portion is still located between the housing and the frame interface and is compressed by the screw connection between the housing and the frame interface, an additional sealing surface can be provided by means of the coating to prevent, for example, water penetration.

[0010] Another advantage is that the form fit makes a particularly robust and reliable screw connection possible with respect to lateral loads. Specifically, the form fit prevents adjacent components from sliding relative to each other in a plane perpendicular to the screw axis. As a result, the housing and frame interfaces can be configured purely for permanent loads and are therefore particularly easy and cost-effective to manufacture. Furthermore, even when the load acting on one or more of the components in the screw connection configuration is varied, a particularly robust and reliable screw connection is possible throughout its service life. Preferably, there is frictional locking between the screw and frame interfaces, i.e., the contact surfaces, each perpendicular to the screw axis and pressed against each other by a preload force, have a flat design. This avoids, for example, vibrational loads on the screw and potential screw breakage when forces are applied to the drive configuration.

[0011] Preload force is considered to be the minimum installation preload force necessary, especially for tightening, in order to generate a predefined clamping force between the housing and frame interface after plastic deformation. Screw connections are preferably configured in a manner that provides a minimum preload force when the screws are tightened with a predefined tightening torque of preferably at least 8 Nm, preferably at most 12 Nm, and particularly preferably 10 Nm.

[0012] The appendix contains a preferred development of the invention.

[0013] The area to be plastically deformed preferably has a lower hardness than the surface structure. Specifically, the hardness here is considered to be Rockwell hardness and / or Brinell hardness and / or Vickers hardness and / or Martens hardness. The area to be deformed particularly preferably has a Vickers hardness that is at least 5%, and more preferably at least 20% lower. This allows for particularly simple and reliable achievement of predefined plastic deformation, wherein the surface structure remains undeformed. The frame interface preferably has a lower hardness than the screw. Furthermore, it is more preferable that the outer shell has a lower hardness than the frame interface.

[0014] The screw is preferably screwed into the hole in the housing, wherein the area of ​​the housing surrounding the hole is formed without a coating. Specifically, the area surrounding the hole without a coating corresponds to the area of ​​the housing to be plastically deformed. This achieves a particularly compact configuration and advantageous hole sealing.

[0015] The surface structure is particularly preferably characterized by an annular cutting edge, which is formed concentrically with respect to the screw axis. The annular cutting edge is considered to be an element that protrudes from the surface of the frame interface and is formed in a gradually narrowing manner (particularly conical) in cross-section. The annular cutting edge provides a particularly simple geometry that can be cost-effectively produced and allows for plastic deformation of the housing area.

[0016] The surface structure preferably has at least one annular groove, which is radially disposed inside the annular cutting edge and / or radially disposed outside the annular cutting edge, preferably concentrically disposed relative to the annular cutting edge. The annular groove is considered to be a recess in the surface of the frame interface. For example, when the annular cutting edge is pressed into the housing, the bead-like region of the housing displaced by the annular cutting edge can thus move into the annular groove.

[0017] The surface texture particularly preferably has at least one indentation. This at least one indentation is preferably in the form of knurling. For example, the knurling can be cross knurling and / or double cross knurling. Alternatively or additionally preferred, the indentation is a pit, which is particularly considered to be a circular depression having a protrusion formed by the indentation on its outer circumference. Furthermore, preferably, alternatively, or additionally, the indentation can be a star-shaped structure. Multiple indentations are particularly advantageous as a surface texture.

[0018] At least a portion of the drive unit preferably has lower strength than the frame interface. Alternatively or as an additional preference, the frame interface has lower strength than the screw.

[0019] The housing is preferably made of magnesium. The housing is particularly preferably a double-cast assembly. Furthermore, the frame interface is preferably made of aluminum or steel. The screws are preferably made of steel.

[0020] The housing particularly preferably has a sleeve, which is provided as a separate component. This sleeve is disposed within an opening in the housing. A screw is screwed into this sleeve, particularly into a hole in the sleeve. The area of ​​the housing to be plastically deformed is radially located outside the housing opening, i.e., radially outside the sleeve. This sleeve may be formed, for example, of a material different from the housing, such as aluminum, to thus allow for a particularly secure screw connection.

[0021] Furthermore, preferably, the coating is a powder coating. Specifically, this provides mechanical and corrosion protection for the housing.

[0022] Furthermore, the present invention relates to a vehicle, preferably an electric bicycle operable by muscle force and / or motor force, comprising the described drive configuration. By means of special screw connections in the drive configuration, the housing can be fitted onto the vehicle with particular precision, thus always ensuring optimal positioning relative to other components of the vehicle, such as the vehicle frame.

[0023] The vehicle preferably includes a vehicle frame, wherein the screw-connected frame interface is an integral part of the vehicle frame. Alternatively, the screw-connected frame interface is a separate component screwed to the vehicle frame, wherein the frame interface is preferably a mounting plate. This allows for precise and reproducible installation of the vehicle's drive unit in a particularly simple and cost-effective manner.

[0024] Furthermore, the present invention relates to a method for producing a drive configuration for a vehicle that can be operated, particularly by muscle force and / or motor force. The method comprises steps performed sequentially, particularly in the order described: - providing a housing in which the drive unit is located, wherein a portion of the housing is coated with a coating; - positioning the housing relative to a frame interface of the vehicle using a calibration tool; and - initially screwing the housing to the frame interface using screws with a predefined preload force, such that a predefined surface structure of the frame interface plastically deforms a region of the housing by means of the preload force. The coating is formed on the housing in such a way that, while the housing is screwed together with the frame interface, the coating is at least partially located between the housing and the frame interface, and the area to be plastically deformed is uncoated. This method thus allows for simple installation on the frame interface of the vehicle, and particularly simple reinstallation after removal of the drive unit.

[0025] In addition, the method preferably includes the following steps, especially consecutive steps: - releasing the screw connection, - positioning the housing relative to the carrier frame by means of the surface structure and the plastically deformed area of ​​the housing, and - re-screwing the housing to the frame interface by means of the screw.

[0026] The step of providing the housing preferably includes the step of coating the housing. During coating, the area to be plastically deformed is shielded by means of a masking element, in other words, the area to be plastically deformed is covered, so as to prevent the coating from being applied to the area to be plastically deformed. This makes it particularly easy to ensure that the area to be deformed is formed without a coating.

[0027] The process of providing the housing preferably includes the following steps: - coating the housing, and - removing the coating from the area to be plastically deformed. That is, during the production of the drive configuration, the area of ​​the housing to be deformed is initially coated simultaneously, wherein the coating in this area is subsequently retrospectively removed. For example, the area to be deformed may be formed in a way that protrudes from the surrounding area of ​​the housing, thus making it possible to remove the coating in this area in a particularly simple manner, such as by abrasion.

Implementation Method

[0029] FIG1 shows a cross-sectional view of a drive configuration 10 according to a first exemplary specific example of the present invention. FIG1 only illustrates the cutout of the drive configuration 10. The drive configuration 10 includes a housing 1, a frame interface 2, and screws 3, with a drive unit (not shown) located inside the housing.

[0030] The drive unit includes a motor and / or gear mechanism (not shown) and is surrounded by a housing 1.

[0031] The frame interface 2 is designed as a fixing plate to fasten the outer shell 1 to the vehicle frame 105 of the vehicle 100 (see Figure 6).

[0032] The outer casing 1 and the frame interface 2 are screwed together along the screw axis 30 by means of a screw 3. The fastening part 14 of the outer casing 1 is illustrated in FIG1. ​​The outer casing 1 has an outer casing opening 19, in which a sleeve 18, which can be considered a component of the outer casing 1, is disposed. The screw 3 is screwed into the hole 16 of the sleeve 18 by means of a thread. The frame interface 2 is disposed between the screw head 31 of the screw 3 and the outer casing 1.

[0033] Tightening the screw 3 with a predefined torque will generate a predefined preload force 5, which is applied to the frame interface 2 parallel to the screw axis 30.

[0034] During the initial screwing together of the drive configuration 10, the housing 1 and the frame interface 2 are preferably aligned relative to each other by means of a special gauge (not shown) in order to allow for precise positioning.

[0035] The frame interface 2 has a predefined surface structure 4, which is designed as a high ground on the lower side 21a of the frame interface 2. The frame interface 2 and the housing 1 are designed such that during the initial screwing together of the drive configuration 10, the surface structure 4 penetrates into the upper side 60 of the housing 1 facing the frame interface 2, that is, plastically deforms region 6 of the housing 1 in a predefined manner. Specifically, an imprint corresponding to the shape of the surface structure 4 is formed in the upper side 60 of the housing 1 at a predefined depth 63. This predefined plastic deformation can occur whenever the frame interface 2 is pressed against the housing 1 with a predefined preload force. In order to form plastic deformation in a particularly targeted manner, the housing 1 has a lower hardness than the frame interface 2.

[0036] The outer shell 1 is preferably made of magnesium, and the frame interface 2 is made of aluminum or steel.

[0037] To provide good protection against environmental influences, especially good corrosion protection, the outer casing is partially coated with coating 7. Here, coating 7 is a powder coating.

[0038] The coating 7 is also partially located between the frame interface 2 and the outer shell 1. As a result, in the screwed-together state, this portion of the coating 7 is clamped between the frame interface 2 and the outer shell 1 and is also partially deformed. The coating 7 thus forms a seal between the frame interface 2 and the outer shell 1 to prevent, for example, water penetration.

[0039] Since the coating 7 has a relatively high hardness in order to protect the outer shell 1 well, it is advantageous to form the area 6 of the outer shell 1 to be plastically deformed without the coating, so that the surface structure 4 can directly deform the material of the outer shell 1 during twisting.

[0040] In order to ensure that the area 6 to be plastically deformed is uncoated, in a first variation of the production method of the drive configuration 10, the area 6 to be deformed can be shielded, and the components of the drive configuration are illustrated in FIG2.

[0041] Specifically, in this respect, when the outer casing 1 is coated with the coating 7, as illustrated in FIG2(a), a shielding element 50 is used. The shielding element 50 has a shaft 52 that can be pushed into the outer casing opening 19 and a head end 51. The head end 51 has an outer diameter 61 corresponding to the outer diameter of the area 6 to be deformed and intended to remain uncoated, and this outer diameter is larger than the inner diameter 69 of the outer casing opening 19. During coating, the head end 51 rests on the upper side 60 of the outer casing 1 and thus prevents the area 6 to be deformed from being coated, so as to obtain the outer casing 1 illustrated in FIG2(b) with the uncoated area 6.

[0042] Figure 3 shows a part of an alternative production method similar to that in Figure 2, except that the area 6 of the outer shell 1 to be plastically deformed is initially coated, as illustrated in Figure 3(a). The coating 7 in this area 6 is then removed (see Figure 3(b)).

[0043] In order to enable simple, cost-effective and precise removal of the coating 7 only in region 6, the housing 1 has a shoulder 64 that protrudes from the rest of the housing 1 and has an outer diameter 61 corresponding to the outer diameter 61 of the region 6 to be plastically deformed. The shoulder 64 protrudes from the rest of the housing 1 by at least a predefined distance 65. The shoulder 64 makes it possible, for example by abrasion, to remove the coating 7 particularly easily, so as to provide an uncoated region 6 to the housing 1, as illustrated in FIG3(b).

[0044] The housing 1, through the special deformation of the surface structure 4 of the frame interface 2, retains its plastic deformation within region 6 even after the screw connection is released. For example, if the housing 1 with the drive unit must be removed from the carrier frame 105 for maintenance purposes, release may be necessary. When the drive configuration 10 is screwed back together, the precise positioning of the initial screwing can be easily reproduced here by aligning the surface structure 4 with the plastically deformed region 6. The drive configuration 10 thus provides a simple and cost-effective design that allows for accurate and repeatable installation with particularly low expenditure.

[0045] In addition, the interlocking of the surface structure 4 and the plastically deformed region 6 provides further additional sealing, especially to reliably prevent water from penetrating the housing 1.

[0046] Another advantage of the drive configuration 10 is the form fit between the surface structure 4 and the plastically deformed region 6, which are formed in a plane 35 perpendicular to the screw axis 30. That is, the surface structure 4 and the corresponding imprint 6 produced by the plastically deformed region engage with each other relative to the plane 35, thus causing a form fit. In addition to the frictional fit generated by the clamping force of the screw 3, the form fit also plays a role here. As a result, particularly high lateral forces can be transmitted by means of the screw connection. Specifically, this can prevent slippage between the frame interface 2 and the housing 1 with particular reliability.

[0047] In the first illustrative specific example of FIG1, the surface structure 4 is designed in the form of an annular cutting edge 41. The annular cutting edge 41 is formed concentrically with respect to the screw axis 30 or the axis of the hole on the lower side 21a of the frame interface 2. In cross-section, the annular cutting edge 41 is formed in a tapering manner, preferably conical, in the direction of the housing 1. The annular cutting edge 41 allows it to penetrate into the housing 1 during the initial screwing together in a particularly targeted and simple manner. In addition, due to the tapering geometry, the frame interface 2 and the housing 1 can be easily relocated and aligned relative to each other when screwing the frame interface 2 and the housing 1 together again, thus making it possible to screw them together in a particularly simple and precise manner.

[0048] FIG4 shows a detailed view of the frame interface 2 of the drive configuration 10 according to a second exemplary embodiment of the present invention. This second exemplary embodiment substantially corresponds to the first exemplary embodiment of FIG1 and has an alternative surface structure 4. The surface structure 4 here is designed in the form of a plurality of indentations 45, specifically in the form of circular recesses 45b, which are arranged around the opening 20 through which the screw shank 32 of the screw 3 protrudes.

[0049] As can be seen in Figure 4, three columns are formed, each having a plurality of pits 45b evenly distributed in the circumferential direction. The indentations 45 cause plastic deformation of region 6 of the outer shell 1 in a manner similar to a ring-shaped cutting edge 41.

[0050] FIG. 5 shows a detailed view of the frame interface 2 of the drive configuration 10 according to a third exemplary embodiment of the present invention. This third exemplary embodiment substantially corresponds to the second exemplary embodiment of FIG. 4, having an alternative configuration of indentation 45. In this third exemplary embodiment, the indentation is designed in the form of knurling 45a. FIG. 5(a) shows cross knurling with a diamond pattern. FIG. 5(b) shows another variation of knurling 45a in the form of double cross knurling, wherein the knurling has two additional indentations on each of the diamond regions to produce greater roughness. Knurling 45a produces an effect similar to the pit 45b of FIG. 4.

[0051] Figure 6 shows a simplified schematic diagram of a vehicle 100 that can be operated by muscle force and / or motor force and includes a drive configuration 10 according to one of the exemplary specific examples described. The vehicle 100 is an electric bicycle with an electric motor for assisting the pedaling force of the cyclist. The electric motor is part of the drive unit 1 of the drive configuration 10 and is powered by a rechargeable battery 102. The frame interface 2 of the drive configuration 10 is part of the vehicle frame 105 of the vehicle 100 and / or is connected to or can be connected to the vehicle frame 105. [Simplified Explanation of the Diagram]

[0028] The present invention will now be described with reference to the figures and illustrative examples. Functionally identical components are designated by the same reference numerals in the figures, in which: [Figure 1] shows a cross-sectional view of a drive configuration according to a first illustrative example of the present invention; [Figure 2] shows a cross-sectional view of the component of the drive configuration of Figure 1 during production; [Figure 3] shows a cross-sectional view of the component of the drive configuration of Figure 1 during an alternative production method; [Figure 4] shows a detailed view of the frame interface of a drive configuration according to a second illustrative example of the present invention; [Figure 5] shows a detailed view of the frame interface of a drive configuration according to a third illustrative example of the present invention; and [Figure 6] shows a simplified schematic diagram of a vehicle having a drive configuration according to one of the illustrative examples of the present invention.

Claims

1. A drive configuration for a vehicle (100) operable, particularly by muscle force and / or motor force, comprising: a housing (1), a drive unit within the housing (1), a frame interface (2), and a screw (3), wherein the housing (1) and the frame interface (2) are screwed together along a screw axis (30) by means of the screw (3), wherein the housing (1) is partially coated with a coating (7) such that, in the screwed-together state, at least a portion of the coating (7) is disposed between the housing (1) and the frame interface (2), The frame interface (2) has a predefined surface structure (4) designed to plastically deform a region (6) of the housing (1) by at least one predefined preload force (5) during an initial screwing together, such that the surface structure (4) and the plastically deformed region (6) form a shape fit in a plane (35) perpendicular to the screw axis (30), and wherein the plastically deformed region (6) is formed without a coating.

2. The driving configuration as requested in item 1, wherein the region (6) to be plastically deformed has a lower hardness than the surface structure (4).

3. The drive configuration as requested in item 1 or 2, wherein the screw (3) is screwed into a hole (16) in the housing (1), and wherein a region (6) of the housing (1) surrounding the hole (16) is formed without a coating.

4. The drive configuration as requested in item 1 or 2, wherein the surface structure (4) has an annular cutting edge (41) which is formed concentrically with respect to the screw axis (30).

5. The drive configuration of claim 4, wherein the surface structure (4) has at least one annular groove (42) that is radially disposed inside the annular cutting edge (41) and / or radially disposed outside the annular cutting edge (41).

6. The drive configuration as claimed in claim 1 or 2, wherein the surface structure (4) has at least one indentation (45), particularly in the form of a knurling (45a) and / or a pit (45b) and / or a star-shaped structure.

7. The drive configuration as requested in item 1 or 2, wherein the housing (1) is formed of magnesium, and / or wherein the frame interface (2) is formed of aluminum or steel.

8. The drive configuration of claim 1 or 2, wherein the housing (1) has a sleeve (18) disposed in one of the housing openings (19) of the housing (1), wherein the screw (3) is screwed into the sleeve (18), and wherein the region (6) to be plastically deformed is radially disposed outside the housing opening (19).

9. The drive configuration as requested in item 1 or 2, wherein the coating (7) is a powder coating.

10. A vehicle, particularly a bicycle operable by muscle force and / or motor force, preferably an electric bicycle, comprising a drive configuration as claimed in any one of claims 1 to 9 (10).

11. The vehicle of claim 10, comprising a vehicle frame (105), wherein the frame interface (2) of the drive configuration (10) is an integral part of the vehicle frame (105), or wherein the frame interface (2) of the drive configuration (10) is screwed to the vehicle frame (105).

12. A method for producing a drive configuration (10) of a vehicle (100) operable, particularly by muscle force and / or motor force, comprising the steps of: providing a housing (1) in which a drive unit is located, wherein the housing (1) is partially coated with a coating (7); positioning the housing (1) relative to a frame interface (2) of the vehicle (100) by means of a calibration tool; and initially screwing the housing (1) to the frame interface (2) with a predefined preload force (5) by means of a screw (3) in such a way that a predefined surface structure (4) of the frame interface (2) plastically deforms a region (6) of the housing (1) by means of the preload force (5), wherein the coating (7) is formed on the housing such that, in the screwed-together state, the coating (7) is at least partially located between the housing (1) and the frame interface (2), and the region (6) to be plastically deformed does not have a coating.

13. The method of claim 12, further comprising the steps of: releasing the screw connection, positioning the housing (1) relative to the vehicle frame (105) by means of the surface structure (4) and the plastically deformed region (6), and re-screwing the housing (1) to the frame interface (2) by means of the screw (3).

14. The method of claim 12 or 13, wherein providing the housing (1) includes the step of coating the housing (1), and wherein the area (6) to be plastically deformed is shielded by means of a shielding element (50) during the coating process to avoid coating the area (6) to be plastically deformed.

15. The method of claim 12 or 13, wherein providing the housing (1) comprises the steps of: applying the housing (1) and removing the coating (7) from the area (6) to be plastically deformed.

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