Plug connector component for a drive housing, drive housing, and test method

Abstract

The proposed solution relates in particular to a plug connector component for a drive housing (G) of an electric bicycle (1), having a base (30) that is intended to close off a plug connector opening (O) on the drive housing (G) and, on a first, outer side of the base (30), has at least one plug connector section (3A, 3B) for providing an interface on an outside of the drive housing (G). At least one membrane hole (32) is provided on the base, said membrane hole extending from the first, outer side to a second, inner side of the base (30) and being closed off by a membrane.

Description

[0001] Connector component for a drive housing, drive housing and test method

[0002] Description

[0003] The proposed solution relates in particular to a connector component for a drive housing suitable for use on an electric bicycle.

[0004] Particularly in the case of a drive housing for an electric bicycle, it is difficult to ensure that the drive housing is sealed against the ingress of liquid, while at the same time ensuring pressure equalization between the interior of the drive housing and the exterior space surrounding the drive housing. Appropriate pressure equalization can reduce the load on the seals provided on the drive housing. Furthermore, pressure equalization also allows harmful gases to escape from the interior of the housing to the outside. In this context, it is widely known to provide at least one pressure equalization opening on a drive housing and to close this opening with a membrane. Such a membrane is then permeable to gas to enable pressure equalization, but at the same time prevents liquid or dirt from penetrating the interior of the drive housing.

[0005] However, the permanent fixation of a corresponding membrane to a housing-side pressure equalization opening may not be readily possible. For example, if a metallic drive housing is provided to enable efficient heat dissipation to the outside for electronic components housed in the drive housing and / or at least one motor, in particular an electric motor, housed in the drive housing, a membrane for a pressure equalization opening can typically only be fixed by adhesive. However, it is not uncommon to observe that such a fixation fails at least partially over its service life, and thus the membrane is no longer reliably held to the pressure equalization opening.Against this background, the proposed solution is based on the object of providing an improved possibility of providing pressure equalization between an interior of the drive housing and an exterior space surrounding the drive housing on a drive housing for an electric bicycle.

[0006] This object is achieved in particular with a connector component of claim 1 and a method of claim 13.

[0007] This proposes a connector component for a drive housing of an electric bicycle, which has a base with at least one connector section for providing an interface (e.g. for connecting at least one cable) on an outer side of the drive housing. The base is provided for closing a connector opening on the drive housing, such that the at least one connector section is arranged on a first, outer side of the base when the connector component is provided on the drive housing as intended. Furthermore, at least one membrane hole is provided on the base, which extends from the first, outer side to a second, inner side of the base and is closed by a membrane, in particular on the second, inner side.

[0008] In a proposed connector component, at least one membrane hole closed by a membrane is additionally provided on a base carrying a connector section, which can function as a pressure equalization opening on the drive housing. In other words, a pressure equalization opening is provided via the membrane hole of the connector component closed by the membrane when the connector component is mounted on the drive housing. In this way, a pressure equalization opening does not have to be provided on the drive housing itself. This offers the particular advantage that a connector component can be produced from a plastic material and thus a membrane can also be easily welded onto the membrane hole on the base, e.g. on the second, inner side. This further facilitates the provision of a pressure equalization opening closed by a membrane on a drive housing.

[0009] The base of the connector component is thus used not only to provide a connector section for providing an interface on the outside of the drive housing, but also for integrating a diaphragm hole for pressure equalization on the drive housing. The interface defined by the at least one connector section can be configured and provided, for example, for connecting a cable for supplying electrical energy to at least one motor housed in the drive housing and / or for electronically controlling the at least one motor.

[0010] The membrane hole formed as a through opening at the base can, for example, be designed as a bore.

[0011] In one embodiment, the diaphragm hole connecting the first, outer side and the second, inner side is provided for a flow test on the drive housing. Thus, the diaphragm hole of the connector component can be configured and provided to perform a flow test when the connector component is mounted on the drive housing, which is used to check the reliability of the pressure compensation.

[0012] As already explained above, in order to simplify assembly, particularly with regard to industrial production, it may be advisable for the membrane to be welded to the second, inner side of the base.

[0013] In principle, the base can be made of a plastic material, at least in the area of ​​the at least one membrane hole, or entirely. Manufacturing from a plastic material is advantageous, for example, for cost and weight reasons, but in this case also for easier and more reliable fixation of the membrane to the base, for example, via welding.

[0014] In one embodiment, the base of the connector component additionally has at least one test hole for a leak test on the drive housing. The test hole extends from the first, outer side of the base to the second, inner side of the base. In such an embodiment, the connector component thus integrates an additional function and, when mounted on the drive housing, provides a test hole through which a leak test of the drive housing can be performed. Accordingly, when using the connector component on the drive housing itself, no test hole needs to be provided. Only a connector opening for a variant of a proposed connector component needs to be provided on the drive housing.However, such a connector opening must be present on the drive housing anyway if an interface for connecting at least one cable is to be provided on an outer side, for example to supply an electric motor within the drive housing with electrical energy and / or to transmit control signals to the electric motor.

[0015] In one embodiment, the at least one test hole is provided for the external attachment of a closure element. The connector component can, for example, be provided with a closure element already attached to the test hole to seal the test hole. Alternatively, a corresponding closure element is provided separately and only attached to the test hole during the assembly process of the drive housing, for example, only after the leak test has been performed.

[0016] For example, the at least one test hole is designed and provided for screwing in a sealing screw intended as a closure element from the first, outer side of the base. A corresponding sealing screw is then screwed, for example, from the outside into the at least one test hole of the connector component in order to seal the test hole.

[0017] In principle, it can be provided that a cross-sectional area of ​​the at least one test hole is larger than a cross-sectional area of ​​the at least one membrane hole, or vice versa, in particular, for example, at least 1.2 times or 1.5 times larger. A test hole and / or a membrane hole can generally have a circular cross-section. Accordingly, for example, a diameter of the at least one test hole can also be larger than a diameter of the at least one membrane hole, or vice versa.

[0018] The proposed solution further relates to a drive housing for an electric bicycle, which has a connector opening on an outer side of the drive housing and in which this connector opening is closed by a variant of a proposed connector component. The connector component provided on the drive housing can be manufactured as a separate component and mounted and fixed to the connector opening of the drive housing. Via the membrane hole closed (e.g., on the inside) with a membrane, the connector component on the drive housing provides a pressure equalization opening which, although permeable to gas, prevents the penetration of liquid and dirt into the drive housing via the membrane hole.As already explained above in connection with an embodiment variant of a proposed connector component, it can also be provided in an embodiment variant of a proposed drive housing that the base of the connector component additionally has at least one test hole which extends from the first, outer side to the second, inner side of the base and which is sealed from the outside.The first, outer side of the base faces an exterior space surrounding the drive housing, while the second, inner side of the base faces an interior space of the drive housing in which components of a drive for the electric bicycle are accommodated, such as at least one electric motor and a transmission device for transmitting an assistance or drive torque provided by the at least one electric motor to an output element via which a rear wheel of the electric bicycle can be driven.

[0019] A test hole provided on the connector component can be sealed by a closure element, for example, a sealing screw. In a further development, a sealing element, for example, in the form of an O-ring, can be pressed against an edge surrounding the test hole via the screw head of such a sealing screw. This may allow the test hole to be sealed more reliably.

[0020] In one embodiment, the sealing screw used to seal the test hole has a self-tapping thread. If the base of the connector component is made of a plastic material in the area where the at least one test hole is provided, a thread in the test hole is first cut out of the plastic material via the self-tapping thread of the sealing screw. This facilitates both the production of the test hole and the assembly and sealing of the test hole.

[0021] A further aspect of the proposed solution relates to a method for functional testing of a drive housing for an electric bicycle. Here, the drive housing is provided with a connector opening on an outer side of the drive housing, which is closed by a connector component with a base. The base of the connector component has at least one externally accessible connector section on a first, outer side of the base. At least one membrane hole is provided on the base of the connector section, which extends from the first, outer side to a second, inner side of the base, which faces an interior of the drive housing. The at least one membrane hole is further closed (e.g. on the second, inner side of the base) by a membrane.The proposed method now provides for a flow test to be carried out on the diaphragm hole closed with the diaphragm while the drive housing is assembled.

[0022] The proposed method is therefore based on the basic idea of ​​performing a flow test for pressure equalization on the drive housing via a membrane hole closed by a membrane, which is provided on a connector component of the drive housing. Variants of a proposed method can be implemented in particular using a variant of a proposed connector component and thus also using variants of a proposed drive housing. The features and advantages explained above and below for variants of a proposed connector component and / or for variants of a proposed drive housing therefore also apply to variants of a proposed method, and vice versa.

[0023] In one embodiment of a proposed method, it can be provided, for example, that the base of the connector component additionally has at least one test hole extending from the first, outer side to the second, inner side of the base, and that a leak test is carried out on the assembled drive housing through the open test hole. Such a leak test via a test hole on the connector component side can be provided in particular before a flow test via the at least one diaphragm hole. Thus, a leak test can first be carried out via the at least one test hole of the connector component. Subsequently, the at least one test hole is closed and a flow test is carried out on the at least one diaphragm hole of the connector component.Accordingly, one embodiment of a proposed method can also provide for the test hole to be sealed from the outside after the (successful) leak test. The test hole is therefore sealed on the first, outer side of the base, which faces an external space surrounding the drive housing, in particular before the flow measurement is carried out at the diaphragm hole. The sealing closure of the test hole can be achieved by a closure element, for example a sealing screw. Such a sealing screw can have a self-tapping thread via which the sealing screw is screwed into the test hole and / or which, upon penetrating the test hole, presses a sealing element with a screw head sealingly against an edge of the base surrounding the test hole.

[0024] The attached figures illustrate possible embodiments of the proposed solution.

[0025] Here we show:

[0026] Figure 1A shows an embodiment variant of a proposed drive housing with a view of a (longitudinal) side of the drive housing, on which an interface with two connector sections is provided;

[0027] Figure 1 B shows the drive housing viewed from an opposite side;

[0028] Figure 2 shows an enlarged section of the interface of the drive housing with a variant of a proposed connector component, which has on a base both a membrane hole closed on the inside with a membrane for pressure equalization and a test hole closed with a sealing screw for a leak test of the drive housing;

[0029] Figure 3 shows a flow chart for an embodiment of a proposed method for functional testing of the drive housing;

[0030] Figure 4 shows schematically an electric bicycle in which a drive with a

[0031] Design variant of the proposed drive housing is used.

[0032] Figure 4 shows an electric bicycle 1 with a drive unit A. The electric bicycle 1 has a frame 10 to which the drive unit A is attached. Part of the drive unit AS are control electronics SE and a sensor device 15, for example designed with a torque sensor and a position sensor for sensorically detecting a torque introduced by muscle power onto a drive shaft in the form of a bottom bracket shaft T of the drive unit A. The sensor device 15 can alternatively or additionally comprise a speed sensor via which the speed of the bottom bracket shaft T can be detected. Via a belt or a chain 13 as a power transmission element, an output element of the drive unit A, for example a hollow output shaft mounted coaxially to the bottom bracket shaft T, is connected to a rear wheel 12 of the electric bicycle 1 in order to be able to drive the electric bicycle 1.This rear wheel 12 is assigned, by way of example, a wheel sensor for determining a driving speed of the electric bicycle 1. Of course, the wheel sensor 14 can instead be provided on a front wheel 11 of the electric bicycle 1.

[0033] The drive unit A is part of a drive device of the electric bicycle, which further comprises an operating unit 2. In Figure 4, the operating unit 2 is attached, for example, in the area of ​​a handlebar of the electric bicycle 1 and is coupled to the control electronics SE of the drive unit A. A user input can be detected via the operating unit 2 and used to control the drive unit A. For example, the operating unit 2 further comprises at least one display to inform a user of the electric bicycle 1 about a current operating state of the drive unit A, for example with regard to a currently set assistance class, a charge state of a battery supplying the drive unit A with energy and / or a set gear that specifies the ratio with which a drive torque introduced by muscle power at the bottom bracket shaft T is transmitted to the output shaft.

[0034] Figures 1A and 1B show, with a view of two longitudinal sides facing away from one another, the drive unit A with a drive housing G, via which the drive unit A is attached to the frame 10. The drive housing in the present case consists of two housing parts G1 and G2 fixed to one another, which define an interior of the drive housing G. In this interior, at least one electric motor of the drive unit A and a transmission device are housed in a protected manner, via which a drive torque applied to the bottom bracket shaft T by muscle power and an assistance torque applied by the at least one electric motor by external power are transmitted to an output element, such as the output shaft mentioned above, which is mounted coaxially to the bottom bracket shaft T, for driving the rear wheel 11 of the electric bicycle 1.

[0035] A connector opening O is formed on a housing part G1. An interface for connecting one or more cables protrudes from this connector opening O outward from the interior of the drive housing G. The connector opening O is sealed by a base 30 of a connector component 3, which in this case carries two connector sections 3A and 3B for the interface. These connector sections 3A, 3B protrude on an outer side of the drive housing G. This is illustrated in Figure 2 in a side view and on an enlarged scale.

[0036] The connector sections 3A and 3B protrude on a first, outer side of the base 30 and are designed as sockets for connecting cable-side plugs. Via the interface defined by the sockets 3A and 3B, the at least one electric motor housed in the drive housing G of the drive unit A can be supplied with electrical energy and electronically controlled, for example, by means of the control unit 2 and using the control electronics SE.

[0037] The illustrated connector component 3 further comprises a diaphragm hole 32 and a test hole 33 on the base 30. The diaphragm hole 32 is closed on the inside, i.e., on a second, inner side of the base 30 facing the interior of the drive housing G, by a diaphragm welded to the base 30. Thus, the diaphragm hole 32 is permeable to gas and thus enables pressure equalization in the drive housing G. However, the diaphragm prevents liquid and dirt from penetrating the interior of the drive housing G via the diaphragm hole 32.

[0038] The additional test hole 33 provided on the base 30 serves to perform a leak test on the assembled drive housing G. After the corresponding leak test has been completed, the test hole 33 is sealed using a sealing screw 31. This sealing screw 31 can have a self-tapping thread. Alternatively or additionally, an O-ring is provided, which is pressed against an edge of the test hole 33 via the screw head of the sealing screw 31.

[0039] In this case, the drive housing G is made of metal, while the connector component 3 is made of a plastic material. Due to the metal construction of the drive housing G, a diaphragm typically cannot be welded to any pressure equalization opening formed on the drive housing G. However, by forming the pressure equalization opening via the diaphragm hole 32 on the plastic connector component 3, a diaphragm can be easily welded to the inside of the base 30. Furthermore, no additional pressure equalization opening needs to be provided on one of the housing parts G1 or G2 in addition to the connector opening O.

[0040] The additional integration of the test hole 33 on the base 30 for the leak test of the drive housing G further facilitates a functional test and the assembly of the drive housing G. This means that a corresponding test hole 33 can not only be easily manufactured in the plastic material of the connector component 3. Rather, a leak test of the drive housing G can also be carried out via this test hole 33 in the immediate spatial proximity to the diaphragm hole 32 prior to a flow test of the diaphragm hole 32 closed with the diaphragm. After the test hole 33 has been sealed by screwing in the sealing screw 31, the flow measurement can be carried out at the diaphragm hole 32, which is only slightly spaced from the test hole 33.

[0041] A corresponding procedure within the scope of a functional test of the drive housing G is illustrated in the flow diagram in Figure 3.

[0042] Thus, with the drive housing G mounted with the connector component 3 to the connector opening O, a leak test of the drive housing G is first carried out with the test hole 33 still open. This is provided in a step 40 of Figure 3. Subsequently, in a step 41, the test hole 33 is closed using the sealing screw 31 (or a differently designed closure element) on the outside of the drive housing G. Then, in a step 42, the flow test is carried out at the diaphragm hole 32 of the drive housing G to check whether sufficient pressure equalization is provided via the diaphragm of the diaphragm hole 32, which is welded to the inside of the base 30.

[0043] List of reference symbols

[0044] 1 electric bike

[0045] 10 frames

[0046] 11 Front wheel

[0047] 12 rear wheel

[0048] 13 Chain / belt (power transmission link)

[0049] 14 Wheel sensor

[0050] 15 Sensor device

[0051] 2 Control panel

[0052] 3 Connector component

[0053] 30 Base

[0054] 31 Sealing screw

[0055] 32 membrane holes

[0056] 33 test hole

[0057] 3A, 3B socket (connector section)

[0058] 40, 41 , 42 Process step

[0059] G Drive housing

[0060] G1, G2 housing part

[0061] O Connector opening

[0062] SE control electronics

[0063] T bottom bracket spindle

Claims

Claims 1. A connector component for a drive housing (G) of an electric bicycle (1), comprising a base (30) which is provided for closing a connector opening (O) on the drive housing (G) and has at least one connector section (3A, 3B) on a first, outer side of the base (30) for providing an interface on an outer side of the drive housing (G), characterized in that at least one membrane hole (32) is provided on the base, which extends from the first, outer side to a second, inner side of the base (30) and is closed by a membrane.

2. Connector component according to claim 1, characterized in that the at least one membrane hole (32) is provided for a flow test on the drive housing (A).

3. Connector component according to claim 1 or 2, characterized in that the membrane is arranged on the second inner side of the base, in particular is welded to the second, inner side of the base (30).

4. Connector component according to one of claims 1 to 3, characterized in that the base (30) consists of a plastic material at least in the region of the at least one membrane hole (32) or completely.

5. Connector component according to one of the preceding claims, characterized in that the base (30) of the connector component (3) additionally has at least one test hole (33) for a leak test on the drive housing (G), which extends from the first, outer side to the second, inner side of the base (30).

6. Connector component according to claim 5, characterized in that the at least one test hole (33) is arranged and provided for screwing in a sealing screw (31) from the first, outer side of the base (30).

7. Connector component according to claim 5 or 6, characterized in that a cross-sectional area of the at least one test hole (33) is larger than a cross-sectional area of the at least one membrane hole (32).

8. Drive housing for an electric bicycle (1), with a connector opening (O) on an outer side of the drive housing (G) and a connector component (3) according to one of the preceding claims closing the connector opening (O).

9. Drive housing according to claim 8, characterized in that the base (30) of the connector component (3) additionally has at least one test hole (33) which extends from the first, outer side to the second, inner side of the base (30) and which is sealed from the outside.

10. Drive housing according to claim 9, characterized in that the test hole is sealed by a sealing screw (31) 11. Drive housing according to claim 10, characterized in that a sealing element, in particular an O-ring, is pressed against an edge surrounding the test hole (33) via a screw head of the sealing screw (31).

12. Drive housing according to claim 10 or 11, characterized in that the sealing screw (31) has a self-tapping thread.

13. Method for functional testing of a drive housing (G) for an electric bicycle (1), wherein the drive housing (G) has on an outer side a connector opening (O) which is closed by a connector component (3) with a base (30) which has on a first outer side of the base at least one externally accessible connector section (3A, 3B), characterized in that - at least one membrane hole (32) is provided on the base (30) of the connector component (3), which extends from the first, outer side to a second, inner side of the base (30) facing an interior of the drive housing (G), wherein the at least one membrane hole (32) is closed by a membrane, and - a flow test is carried out on the diaphragm hole (32) closed with the diaphragm when the drive housing (G) is assembled.

14. The method according to claim 13, characterized in that the base (30) of the connector component (3) additionally has at least one test hole (33) extending from the first, outer side to the second, inner side of the base (30), and a leak test of the assembled drive housing (G) is carried out through the open test hole (33).

15. Method according to claim 14, characterized in that the test hole (33) is sealed from the outside after the leak test.

16. Method according to claim 15, characterized in that the test hole (33) is sealed by a sealing screw (31).

17. Method according to claim 16, characterized in that the sealing screw (31) has a self-tapping thread via which the sealing screw (31) is screwed into the test hole.

18. Method according to claim 16 or 17, characterized in that a sealing element is provided which, when the sealing screw (31) is screwed into the test hole (33), is pressed sealingly against an edge surrounding the test hole (33) by a screw head of the sealing screw (31).

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