Mid-drive motor package including a power transmission for an electric bicycle

Abstract

A mid-drive motor package for an electric bicycle includes a power transmission with a crankshaft subassembly, a motor subassembly, a sensor drive subassembly, and a transmission subassembly. The sensor drive subassembly is operable to receive a first power output from the crankshaft subassembly and a second power output from the motor subassembly, and combine the first power output and second power output into a combined power output. The transmission subassembly is operable to modify the combined power output to create a modified power output through a first combination of transmission gears or a second combination of transmission gears. The transmission subassembly is operable to shift between the first combination of transmission gears and the second combination of transmission gears via a countershaft subassembly including a camshaft rotatable within a needle shaft. Rotation of the camshaft within the needle shaft causes different combinations of needles to engage the transmission gears.

Description

[0001] MID-DRIVE MOTOR PACKAGE INCLUDING A POWER TRANSMISSION FOR AN ELECTRIC BICYCLE

[0002] CROSS-REFERENCE TO RELATED APPLICATION

[0003] The present application claims priority to U.S. Provisional Patent Application Serial No. 63 / 585,532, filed September 26, 2023, which is incorporated herein in its entirety by reference.

[0004] FIELD OF THE INVENTION

[0005] The disclosure relates to a mid-drive motor package including a power transmission for an electric bicycle and, in particular, is directed to a mid-drive motor package including a power transmission that is configured to combine a crankshaft output generated from an applied torque with a power output from a mid-drive motor to drive a belt connected to a rear wheel.

[0006] BACKGROUND OF THE INVENTION

[0007] Due to the higher torque outputs of electric bicycles compared to conventional bicycles, the electric bicycle (or e-bike) industry is transitioning to belt drive assemblies rather than traditional chain drivetrains due to their superior durability. The belt drive assemblies also are being increasingly combined with mid-drive motors. The use of the belt drive results in an inability to use known derailleur or rear sprocket transmissions external to the rear hub. One known solution is to place a transmission inside of the rear hub; however, hub transmissions are typically either limited in the number of bicycle “speeds” or combinations of gears (e.g., 3 to 5 speeds), are prohibitively expensive due to high manufacturing costs or whether a large number of gears are provided for a higher number of bicycle speed ratios, and / or are mechanically inefficient.

[0008] Continuously variable transmissions (CVT) may be implemented for electric bicycles, with two known examples being CVT that use toroidal members and epicyclic embodiments that transmit power through friction. However, CVTs are also often mechanically inefficient as compared to geared hubs. Geared hubs offer a transmission solution in the case of a belt drive platform, but have much more costly and expensive gears than traditional freewheel rear hubs while often offering a lower number of speeds than a traditional chain and derailleur system. SUMMARY

[0009] As such, there exists a need for a mechanically efficient power transmission that is not prohibitively expensive, while still including an increased number of gear combinations or bicycle speed ratios. The power transmission should be compatible with belt-driven platforms. The power transmission should include an increased number of gears that are integrated into a mid-drive motor package proximate to a crankshaft, to allow for the combination of a power output from the crankshaft (e.g., caused by a torque applied to the crankshaft by a rider) and a power output from the mid-drive motor. Being integrated within the mid-drive motor package, the power transmission should be couplable to an inexpensive belt-driven rear free hub.

[0010] Embodiments of the present disclosure are directed to a power transmission that addresses these and other shortcomings of known electric bicycle power transmissions and electric motors. The power transmission is combined with a mid-drive motor into a single package proximate to the crankshaft, where the power output from the crankshaft is combined with the power output from the mid-drive motor and passed through the power transmission (e.g., which may modify the combined power outputs) before driving a belt connected to a rear wheel. Mid-drive motors typically require a custom-modified frame to accept a particular motor. As modifications are already necessary to the frame, embodiments of the present disclosure are directed to further modifying the frame to additionally incorporate a power transmission with the mid-drive motor in the form of the combined mid-drive motor package.

[0011] Embodiments of the present disclosure are directed to a power transmission with two sets of transmission gears. For example, the first transmission set of gears may be considered to correspond to a front derailleur or crankshaft chain ring set on a standard bicycle, and the second set of transmission gears may be considered to correspond to a rear derailleur (or internal hub) on a standard bicycle. The power transmission includes a shifter subassembly with a camshaft housed within a needle shaft, which is utilized to manually (e.g., by a rider) or automatically (e.g., via sensors and computer controls) select a combination of gears that represents a bicycle speed ratio from the combinations of gear ratios of the first set of gears and the second set of gears. In some instances, the first set of gears and the second set of gears each include three gears, for a total of nine combinations (e.g., resulting in a nine-speed electric bicycle). In some embodiments, the mid-drive motor package includes a housing subassembly, a crankshaft subassembly, a motor subassembly, a sensor drive subassembly, and a transmission subassembly. The crankshaft subassembly and the motor subassembly are operable to output power to the transmission subassembly, which combines the output power and transfers it to a belt. The sensor drive subassembly monitors power input from the rider, as well as power output from the motor. The sensor drive subassembly also controls the power output (e.g., by controlling the speed of and / or torque supplied by the motor) from the motor for combination with the power output from the crankshaft by the transmission subassembly.

[0012] In additional embodiments, one or more of the housing subassembly, the crankshaft subassembly, the motor subassembly, the sensor drive subassembly, and the transmission subassembly are main subassemblies that include additional subassemblies for select aspects of the main subassemblies. For example, the motor subassembly may include a motor, a motor planetary gearset, and a ring shaft subassembly. The combination of the motor planetary gearset and the ring shaft subassembly converts the high-speed, low-torque motor output to match the low-speed, high-torque input of the power output by the crankshaft prior to the power output by the motor being provided to the transmission subassembly.

[0013] By way of another example, the transmission subassembly may include a shifter subassembly, a gearbox subassembly, and a belt drive subassembly. The shifter subassembly includes the camshaft and the needle shaft that are operable to rotate together or independently of one another. The camshaft causes needles to extend from the needle shaft to engage gears of the gearbox subassembly to create the combination of gears or bicycle speeds. In some instances, power is supplied through the transmission subassembly when the camshaft and the needle shaft are interlocked. In additional instances, the combination of gears may be changed to adjust the bicycle speed ratio when the camshaft is unlocked and configured to rotate independently of the needle shaft.

[0014] An aspect of the present disclosure is to provide a shifter subassembly of a transmission subassembly for a vehicle. The shifter subassembly comprises a countershaft subassembly. The countershaft subassembly comprises a needle shaft with a plurality of needle apertures; a plurality of needles, wherein each needle of the plurality of needles is positioned within a respective needle aperture of the plurality of needle apertures; and a camshaft inserted into a cavity defined within a needle shaft, wherein the camshaft and the needle shaft are coaxial. The camshaft is configured to rotate relative to the needle shaft between a first angular position and a second angular position. The camshaft includes a plurality of camshaft surfaces that selectively engage the plurality of needles to selectively extend the plurality of needles radially outward from the needle shaft. A first combination of needles of the plurality of needles selectively extends radially outward from the needle shaft when the camshaft is in the first angular position relative to the needle shaft to engage a first combination of transmission gears of the transmission subassembly that corresponds to a first speed ratio. A second combination of needles of the plurality of needles selectively extends radially outward from the needle shaft when the camshaft is in the second angular position relative to the needle shaft to engage a second combination of transmission gears of the transmission subassembly that corresponds to a second speed ratio. In some nonlimiting examples, the vehicle is an electric bicycle.

[0015] In embodiments, the shifter subassembly may include, optionally, wherein each needle of the plurality of needles is held within the respective needle aperture of the plurality of needle apertures by a needle spring.

[0016] In embodiments, the shifter subassembly may include one or more of the previous embodiments and, optionally, a detent subassembly. The detent subassembly comprises a plunger positioned within a detent cavity defined within the camshaft, wherein the plunger is operable to engage the needle shaft; and a spring positioned within the detent cavity, wherein the spring is operable to cause the plunger to maintain contact with the needle shaft. Rotation of the camshaft between the first angular position and the second angular position causes the plunger to disengage from a first radial mating hole in the needle shaft and to engage a second radial mating hole in the needle shaft.

[0017] In embodiments, the shifter subassembly may include one or more of the previous embodiments and, optionally, wherein the detent subassembly further comprises a preload screw (or preloaded screw) that sets the plunger at a predetermined depth within the detent cavity to provide a predetermined load for engaging the first radial mating hole with the plunger.

[0018] In embodiments, the shifter subassembly may include one or more of the previous embodiments and, optionally, a shifter planetary gearset. The shifter planetary gearset comprises a needle planetary set including a needle ring, a plurality of needle planet gears, and a needle sun, wherein the needle planetary set engages the needle shaft; a cam planetary set including a cam ring, a plurality of cam planet gears, and a cam sun, wherein the cam planetary set engages the camshaft; and a common carrier, wherein the plurality of cam planet gears and the plurality of needle planet gears are coupled to the common carrier.

[0019] In embodiments, the shifter subassembly may include one or more of the previous embodiments and, optionally, wherein the cam planetary set is actuatable via rotation of the cam ring by a servo via a worm shaft, wherein rotation of the cam ring causes the camshaft to rotate between the first angular position and the second angular position.

[0020] In embodiments, the shifter subassembly may include one or more of the previous embodiments and, optionally, a synchronizer subassembly. The synchronizer subassembly comprises a synchronizer spring shaft positioned in a synchronizer cavity defined within the camshaft, wherein the cam sun is operable to engage the synchronizer spring shaft and provide energy to rotate the camshaft between the first angular position and the second angular position via the synchronizer spring shaft; and a synchronizer spring positioned in the synchronizer cavity, wherein the synchronizer spring is operable to store energy provided to the synchronizer spring shaft.

[0021] Another aspect of the present disclosure is to provide a transmission subassembly for a vehicle. The transmission subassembly comprises a gearbox subassembly. The gearbox subassembly comprises a plurality of multiplier gears that is operable to engage a compound synergy gear and receive a power output from the compound synergy gear. The gearbox subassembly comprises a plurality of index gears that is operable to receive power from the plurality of multiplier gears. The plurality of index gears are operable to engage an output compound gear and provide a modified power output to the output compound gear. A first combination of transmission gears for modifying the power output includes a first multiplier gear of the plurality of multiplier gears and a first index gear of the plurality of index gears that correspond to a first speed ratio. A second combination of transmission gears for modifying the power output includes the first multiplier gear of the plurality of multiplier gears and a second index gear of the plurality of index gears that correspond to a second speed ratio. The transmission subassembly comprises a shifter subassembly including a countershaft subassembly, wherein the plurality of multiplier gears and the plurality of index gears each include apertures operable to receive the countershaft subassembly such that the countershaft subassembly, the plurality of multiplier gears, and the plurality of index gears are coaxial. The countershaft subassembly engages the plurality of multiplier gears and the plurality of index gears to shift the gearbox subassembly between the first combination of transmission gears and the second combination of transmission gears. In some non-limiting examples, the transmission subassembly is for a mid-drive motor package of the vehicle. In additional non-limiting example, the vehicle is an electric bicycle.

[0022] In embodiments, the transmission subassembly may include, optionally, wherein the countershaft subassembly comprises: a needle shaft with a plurality of needle apertures; a plurality of needles, wherein each needle of the plurality of needles is positioned within a respective needle aperture of the plurality of needle apertures; and a camshaft inserted into a cavity defined within a needle shaft, wherein the camshaft and the needle shaft are coaxial. The camshaft is configured to rotate relative to the needle shaft between a first angular position and a second angular position. The camshaft includes a plurality of camshaft surfaces that selectively engage the plurality of needles to selectively extend the plurality of needles radially outward from the needle shaft. A first combination of needles of the plurality of needles selectively extends radially outward from the needle shaft when the camshaft is in a first angular position relative to the needle shaft to engage the first combination of transmission gears. A second combination of needles of the plurality of needles selectively extends radially outward from the needle shaft when the camshaft is in a second angular position relative to the needle shaft to engage the second combination of transmission gears.

[0023] In embodiments, the transmission subassembly may include one or more of the previous embodiments and, optionally, a belt drive subassembly. The belt drive subassembly comprises a spider operable to engage the output compound gear; and a belt drive sprocket coupled to the spider. The spider transfers the modified power output to the belt drive sprocket. In some non-limiting example, the belt drive sprocket drives a belt. In additional non-limiting examples, the belt drive sprocket drives a belt to another belt drive sprocket operable to engage a wheel hub. In further non-limiting examples, the belt drive sprocket drives a belt coupled to a wheel hub.

[0024] In embodiments, the spider is a separately-fabricated component coupled to the belt drive sprocket, such that the belt drive sprocket is interchangeable on the spider.

[0025] Another aspect of the present disclosure is to provide a mid-drive motor package for an electric bicycle. The mid-drive motor package comprises a crankshaft subassembly. The mid-drive motor package comprises a motor subassembly. The mid-drive motor package comprises a sensor drive subassembly operable to receive a first power output from the crankshaft subassembly and receive a second power output from the motor subassembly, the sensor drive subassembly additionally operable to combine the first power output and the second power output into a combined power output. The mid-drive motor package comprises a transmission subassembly operable to receive the combined power output from the sensor drive subassembly, the transmission subassembly additionally operable to modify the combined power output to create a modified combined power output, the transmission subassembly further operable to provide the modified combined power output to a belt of the electric bicycle, to a belt coupled to a belt drive sprocket operable to engage a wheel hub of the electric bicycle, or to a belt coupled to a wheel hub of the electric bicycle. The transmission subassembly comprises a gearbox subassembly including a plurality of transmission gears, wherein a first combination of transmission gears of the plurality of transmission gears corresponds to a first speed ratio of the electric bicycle, and a second combination of transmission gears of the plurality of transmission gears corresponds to a second speed ratio of the electric bicycle. The transmission subassembly comprises a shifter subassembly including a countershaft subassembly inserted within the plurality of transmission gears such that the countershaft subassembly and the plurality of transmission gears are coaxial, wherein the countershaft subassembly selectively engages the plurality of transmission gears to shift the gearbox subassembly between the first combination of transmission gears and the second combination of transmission gears.

[0026] In embodiments, the mid-drive motor package may include, optionally, wherein the crankshaft subassembly comprises a crankshaft including a spline; and a clutch installed on the spline. The clutch transfers power from the crankshaft to the sensor drive subassembly when the crankshaft rotates in the first direction.

[0027] In embodiments, the mid-drive motor package may include one or more of the previous embodiments and, optionally, wherein the motor subassembly comprises a motor including a motor gear; a motor planetary gearset including at least one set of planet gears and a planetary ring gear, wherein the at least one set of planet gears are operable to transfer power from the motor gear to the planetary ring gear; and a ring shaft subassembly including a ratchet gear, wherein the planetary ring gear is coupled to the ring shaft subassembly, and wherein the ratchet gear transfers the power from the planetary ring gear to the sensor drive subassembly when the ratchet gear rotates in a first direction.

[0028] In embodiments, the mid-drive motor package may include one or more of the previous embodiments and, optionally, wherein the sensor drive subassembly comprises a ratchet wheel operable to engage with the crankshaft subassembly and receive the first power output from the crankshaft subassembly; and a compound synergy gear. The compound synergy gear comprises a spur gear operable to engage with the motor subassembly and receive the second power output from the motor subassembly; and a plurality of compound gears operable to engage with the gearbox subassembly, wherein the compound synergy gear is operable to combine the first power output and the second power output into the combined power output and provide the combined power output to the gearbox subassembly.

[0029] In embodiments, the mid-drive motor package may include one or more of the previous embodiments and, optionally, may further comprise a sensor subassembly operable to acquire data for at least one of speed and torque of the ratchet wheel, the sensor subassembly additionally operable to acquire data for at least one of speed and torque of the compound synergy gear. The data acquired by the sensor subassembly is provided to a controller of the mid-drive motor package to adjust the second power output from the motor subassembly.

[0030] In embodiments, the mid-drive motor package may include one or more of the previous embodiments and, optionally, wherein the countershaft subassembly comprises a needle shaft with a plurality of needle apertures; a plurality of needles, wherein each needle of the plurality of needles is positioned within a respective needle aperture of the plurality of needle apertures; and a camshaft inserted into a cavity defined within a needle shaft, wherein the camshaft and the needle shaft are coaxial; wherein the camshaft is configured to rotate relative to the needle shaft between a first angular position and a second angular position, wherein the camshaft includes a plurality of camshaft surfaces that selectively engage the plurality of needles to selectively extend the plurality of needles radially outward from the needle shaft, wherein a first combination of needles of the plurality of needles selectively extends radially outward from the needle shaft when the camshaft is in a first angular position relative to the needle shaft to engage the first combination of transmission gears, and wherein a second combination of needles of the plurality of needles selectively extends radially outward from the needle shaft when the camshaft is in a second angular position relative to the needle shaft to engage the second combination of transmission gears.

[0031] In embodiments, the mid-drive motor package may include one or more of the previous embodiments and, optionally, wherein the plurality of transmission gears comprises a plurality of multiplier gears that is operable to engage a compound synergy gear of the sensor drive subassembly and receive the combined power output from the sensor drive subassembly; and a plurality of index gears that is operable to engage an output compound gear of a belt drive subassembly and operable to provide the modified combined power output to the belt via the output compound gear, wherein the first combination of transmission gears modifies the combined power output and include a first multiplier gear of the plurality of multiplier gears and a first index gear of the plurality of index gears that correspond to the first speed ratio of the electric bicycle. The second combination of transmission gears modifies the combined power output and include the first multiplier gear of the plurality of multiplier gears and a second index gear of the plurality of index gears that correspond to the second speed ratio of the electric bicycle.

[0032] In embodiments, the mid-drive motor package may include one or more of the previous embodiments and, optionally, wherein at least some of the components of the crankshaft subassembly, the motor subassembly, the sensor drive subassembly, and the transmission subassembly are housed within a housing subassembly, and wherein the housing subassembly comprises a motor side housing and a sprocket side housing.

[0033] In embodiments, the housing subassembly comprises a motor side housing and a sprocket side housing.

[0034] Another aspect of the present disclosure is to provide a method for propelling a vehicle. The method may include, but is not limited to, receiving a first power output from a crankshaft subassembly. The method may include, but is not limited to, receiving a second power output from a motor subassembly. The method may include, but is not limited to, combining the first power output and the second power output via a sensor drive subassembly to create a combined power output. The method may include, but is not limited to, receiving the combined power output via a transmission subassembly. The method may include, but is not limited to, modifying the combined power output to create a modified power output via a first combination of transmission gears that corresponds to a first speed ratio, wherein the first combination of transmission gears include a first multiplier gear of a plurality of multiplier gears and a first index gear of the plurality of index gears, and wherein the first combination of transmission gears are selected via a shifter subassembly including a countershaft subassembly inserted within the plurality of multiplier gears and the plurality of index gears such that the countershaft subassembly, the plurality of multiplier gears, and the plurality of index gears are coaxial. The method may include, but is not limited to, providing the modified power output to a belt. The method may include, but is not limited to, providing the modified power output to a belt drive sprocket operable to engage a wheel hub. The method may include, but is not limited to, providing the modified power output to a belt coupled to a wheel hub. In some non-limiting example, the vehicle is an electric bicycle.

[0035] The method may include, optionally, actuating the countershaft subassembly to cause the transmission subassembly to shift between the first combination of transmission gears and a second combination of transmission gears that corresponds to a second speed ratio. The countershaft subassembly comprises a needle shaft with a plurality of needle apertures; a plurality of needles, wherein each needle of the plurality of needles is positioned within a respective needle aperture of the plurality of needle apertures; and a camshaft inserted into a cavity defined within a needle shaft, wherein the camshaft and the needle shaft are coaxial. The camshaft is configured to rotate relative to the needle shaft between a first angular position and a second angular position. The camshaft includes a plurality of camshaft surfaces that selectively engage the plurality of needles to selectively extend the plurality of needles radially outward from the needle shaft. A first combination of needles of the plurality of needles selectively extends radially outward from the needle shaft when the camshaft is in a first angular position relative to the needle shaft to engage the first combination of transmission gears. A second combination of needles of the plurality of needles selectively extends radially outward from the needle shaft when the camshaft is in a second angular position relative to the needle shaft to engage the second combination of transmission gears.

[0036] The phrases “at least one,” “one or more,” and “and / or,” as used herein, are open- ended expressions that are both conjunctive and disjunctive in operation. For example, each of the expressions “at least one of A, B and C,” “at least one of A, B, or C,” “one or more of A, B, and C,” “one or more of A, B, or C” and “A, B, and / or C” means A alone, B alone, C alone, A and B together, A and C together, B and C together, or A, B and C together.

[0037] Unless otherwise indicated, all numbers expressing quantities, dimensions, conditions, and so forth used in the specification and claims are to be understood as being modified in all instances by the term “about.”

[0038] The term “a” or “an” entity, as used herein, refers to one or more of that entity. As such, the terms “a” (or “an”), “one or more” and “at least one” can be used interchangeably herein.

[0039] The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Accordingly, the terms “including,” “comprising,” or “having” and variations thereof can be used interchangeably herein. The use of “engaged with” and variations thereof herein is meant to encompass any direct or indirect connections between components.

[0040] It shall be understood that the term “means” as used herein shall be given its broadest possible interpretation in accordance with 35 U.S.C. § 112(f). Accordingly, a claim incorporating the term “means” shall cover all structures, materials, or acts set forth herein, and all of the equivalents thereof. Further, the structures, materials, or acts and the equivalents thereof shall include all those described in the summary of the invention, brief description of the drawings, detailed description, abstract, and claims themselves.

[0041] These and other advantages will be apparent from the disclosure of the invention(s) contained herein. The above-described embodiments, objectives, and configurations are neither complete nor exhaustive. The Summary is neither intended nor should it be construed as being representative of the full extent and scope of the present disclosure. Moreover, references made herein to "the present disclosure,” or aspects thereof should be understood to mean certain embodiments of the present disclosure and should not necessarily be construed as limiting all embodiments to a particular description. The present disclosure is set forth in various levels of detail in the Summary as well as in the attached drawings and the Detailed Description and no limitation as to the scope of the present disclosure is intended by either the inclusion or non-inclusion of elements, components, etc. in this Summary. Additional aspects of the present disclosure will become more readily apparent from the Detailed Description, particularly when taken together with the drawings.

[0042] It is to be appreciated that any feature or aspect described herein can be claimed in combination with any other feature(s) or aspect(s) as described herein, regardless of whether the features or aspects come from the same described embodiment.

[0043] Any one or more aspects described herein can be combined with any other one or more aspects described herein. Any one or more features described herein can be combined with any other one or more features described herein. Any one or more embodiments described herein can be combined with any other one or more embodiments described herein.

[0044] BRIEF DESCRIPTION OF THE DRAWINGS

[0045] Those of skill in the art will recognize that the following description is merely illustrative of the principles of the disclosure, which may be applied in various ways to provide many different alternative embodiments. This description is made for illustrating the general principles of the teachings of this disclosure and is not meant to limit the inventive concepts disclosed herein.

[0046] The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments and together with the general description of the invention given above and the detailed description of the drawings given below, serve to explain the principles of the invention.

[0047] Fig. 1 A illustrates a first perspective view of a mid-drive motor package including a housing subassembly, a crankshaft subassembly, a motor subassembly, a sensor drive subassembly, and a transmission subassembly, in accordance with one or more embodiments of the present disclosure;

[0048] Fig. IB illustrates a second perspective view of the mid-drive motor package of Fig. 1A;

[0049] Fig. 1C illustrates a third perspective view of the mid-drive motor package of Fig. 1A;

[0050] Fig. ID illustrates a fourth perspective view of the mid-drive motor package of Fig. 1A;

[0051] Fig. 2 illustrates a perspective view of the housing subassembly of the mid-drive motor package of Fig. 1 A, in accordance with one or more embodiments of the present disclosure;

[0052] Fig. 3 A illustrates a perspective view of the crankshaft subassembly of the mid-drive motor package of Fig. 1 A, in accordance with one or more embodiments of the present disclosure;

[0053] Fig. 3B illustrates a cross-section view of the crankshaft subassembly of Fig. 3 A;

[0054] Fig. 4A illustrates a first perspective view of a motor, a motor planetary gearset, and a ring shaft subassembly of the motor subassembly of the mid-drive motor package of Fig. 1 A, in accordance with one or more embodiments of the present disclosure;

[0055] Fig. 4B illustrates a second perspective view of the motor subassembly of Fig. 4A;

[0056] Fig. 4C illustrates a perspective view of the motor of the motor subassembly of Fig. 4A;

[0057] Fig. 4D illustrates a perspective view of a motor side housing of the housing subassembly of Fig. 2 with components of the motor subassembly of Fig. 4A;

[0058] Fig. 4E illustrates a perspective view of the motor planetary gearset of the motor subassembly of Fig. 4D; Fig. 4F illustrates a first perspective view of the ring shaft subassembly of the motor subassembly of Fig. 4A;

[0059] Fig. 4G illustrates a second perspective view of the ring shaft subassembly of Fig. 4F;

[0060] Fig. 4H illustrates a perspective view of the motor planetary gearset and the ring shaft subassembly of the motor subassembly of Fig. 4A;

[0061] Fig. 5A illustrates a perspective view of the sensor drive subassembly of the middrive motor package of Fig. 1 A, in accordance with one or more embodiments of the present disclosure;

[0062] Fig. 5B illustrates a cross-section view of the sensor drive subassembly of Fig. 5 A;

[0063] Fig. 5C illustrates a perspective view of a sensor subassembly of the sensor drive subassembly of Fig. 5 A;

[0064] Fig. 5D illustrates a cross-section view of the sensor subassembly of Fig. 5C;

[0065] Fig. 5E illustrates a perspective view of portions of the sensor drive subassembly of Fig. 5 A and portions of the motor subassembly of Fig. 4A;

[0066] Fig. 5F illustrates a cross-section view of the portions of the sensor drive subassembly and motor subassembly of Fig. 5E;

[0067] Fig. 6A illustrates a cross-sectional view of a package subassembly including the crankshaft subassembly of Fig. 3A and the sensor drive subassembly of Fig. 5A, in accordance with one or more embodiments of the present disclosure;

[0068] Fig. 6B illustrates an enlarged portion of the cross-section view of Fig. 6A;

[0069] Fig. 6C illustrates a perspective view of the package subassembly of Fig. 6A;

[0070] Fig. 6D illustrates a cross-sectional view of the package subassembly of Fig.6C;

[0071] Fig. 7A illustrates a first perspective view of a shifter subassembly, a gearbox subassembly, and a belt drive subassembly of the transmission subassembly of the middrive motor package of Fig. 1 A, in accordance with one or more embodiments of the present disclosure;

[0072] Fig. 7B illustrates a second perspective view of the transmission subassembly of Fig. 7 A;

[0073] Fig. 7C illustrates a cross-section view of the transmission subassembly of Fig. 7A;

[0074] Fig. 7D illustrates a cross-section view of a countershaft subassembly, a detent subassembly, and a synchronizer subassembly of the shifter subassembly of Fig. 7A; Fig. 7E illustrates a perspective view of a shifter planetary gearset of the shifter subassembly of Fig. 7A;

[0075] Fig. 7F illustrates a perspective view of the countershaft subassembly of the transmission subassembly of Fig. 7D;

[0076] Fig. 7G illustrates a first cross-section view of the countershaft subassembly of Fig. 7F;

[0077] Fig. 7H illustrates a second cross-section view of the countershaft subassembly of Fig. 7F;

[0078] Fig. 71 illustrates a cross-section view of the countershaft subassembly and the detent subassembly of Fig. 7D;

[0079] Fig. 7J illustrates a cross-section view of the countershaft subassembly, the detent subassembly, and the synchronizer subassembly of the shifter subassembly of Fig. 7D;

[0080] Fig. 7K illustrates the shifter subassembly of Fig. 7D;

[0081] Fig. 7L illustrates a first cross-section view of the shifter subassembly of Fig. 7K;

[0082] Fig. 7M illustrates a second cross-section view of the shifter subassembly of Fig. 7K;

[0083] Fig. 7N illustrates a third cross-section view of the shifter subassembly of Fig. 7K;

[0084] Fig. 70 illustrates a partial perspective view of a variation of the shifter subassembly of Fig. 7K;

[0085] Fig. 7P illustrates a cross-section view of the shifter subassembly of Fig. 70;

[0086] Fig. 7Q illustrates a cross-section view of the transmission subassembly of Fig. 7A;

[0087] Fig. 7R illustrates a perspective view of a belt drive subassembly of the transmission subassembly of Fig. 7A;

[0088] Fig. 7S illustrates a cross-section view of the belt drive subassembly of Fig. 7R;

[0089] Fig. 8 illustrates a cross-section view of the mid-drive motor package of Fig. 1 A, in accordance with one or more embodiments of the present disclosure;

[0090] Fig. 9 illustrates a flow diagram of a method or process for the operation of the middrive motor package of Fig. 1 A, in accordance with one or more embodiments of the present disclosure;

[0091] Fig. 10 illustrates a cross-section view of the mid-drive motor package of Fig. 1A with arrows representing steps of operation, in accordance with one or more embodiments of the present disclosure; Fig. 11 A illustrates a cross-section view of the shifter subassembly with portions of the gearbox subassembly of the transmission subassembly of Fig. 7A, in accordance with one or more embodiments of the present disclosure;

[0092] Fig. 11B illustrates a cross-section view of the countershaft subassembly of the shifter assembly of Fig. 11 A;

[0093] Fig. 11C illustrates a cross-section view of a first portion of the transmission subassembly of Fig. 11 A;

[0094] Fig. 1 ID illustrates a cross-section view of a second portion of the transmission subassembly of Fig. 11 A;

[0095] Fig. HE illustrates an enlarged segment of the first portion of the transmission subassembly of Fig. 11 A;

[0096] Fig. 1 IF illustrates a different variation of an enlarged segment of the first portion of the transmission subassembly of Fig. 11 A;

[0097] Fig. 11G illustrates a cross-section view of a third portion of the transmission subassembly of Fig. 11 A;

[0098] Fig. 11H illustrates a cross-section view of the shifter subassembly of the transmission assembly of Fig. 11 A;

[0099] Fig. I ll illustrates a cross-section view of a fourth portion of the transmission subassembly of Fig. 11 A;

[0100] Fig. 11 J illustrates a front view of a fifth portion of the transmission subassembly of Fig. 11 A; and

[0101] Fig. UK illustrates the fifth portion of the transmission subassembly of Fig. 11J within the housing subassembly.

[0102] It should be understood that the drawings are not necessarily to scale, and various dimensions may be altered. In certain instances, details that are not necessary for an understanding of the invention or that render other details difficult to perceive may have been omitted. It should be understood, of course, that the invention is not necessarily limited to the particular embodiments illustrated herein.

[0103] Reference Number Component

[0104] 100 Mid-Drive Motor Package

[0105] 102 Housing Subassembly

[0106] 104 Crankshaft Subassembly

[0107] 106 Motor Subassembly 108 Sensor Drive Subassembly

[0108] 110 Transmission Subassembly

[0109] 112 Belt

[0110] 114 Motor Side Housing

[0111] 116 Sprocket Side Housing

[0112] 118 Shifter Planetary Cover

[0113] 120 Drain Plug

[0114] 122 Crankshaft

[0115] 124 Crankshaft Spline

[0116] 126 Crankshaft Clutch

[0117] 128 Crankshaft Clutch Spacer

[0118] 130 Snap Ring

[0119] 132 Crank Arm

[0120] 134 Crank Arm Hardware

[0121] 136 Motor

[0122] 138 Motor Planetary Gear set

[0123] 140 Ring Shaft Subassembly

[0124] 142 Motor Housing

[0125] 144 Motor Hardware

[0126] 146 Power Lines

[0127] 148 Data Lines

[0128] 150 Motor Shaft

[0129] 152 Motor Gear

[0130] 154 First Surface Cavity

[0131] 156 Bearings

[0132] 158 Outer Planet Gear

[0133] 160 Inner Planet Gear

[0134] 162 Motor Shaft Aperture

[0135] 164 Bearing Pins

[0136] 166 Planetary Ring Gear

[0137] 168 Ring Shaft

[0138] 170 Pawls

[0139] 172 Pawl Springs 174 Pawl and Spring Slot

[0140] 176 Ratchet Gear

[0141] 178 Pawl Snap Ring

[0142] 180 Compound Synergy Gear

[0143] 182 Spur Gear

[0144] 184 Compound Spur Gear

[0145] 186 Bearing

[0146] 188 Ratchet Wheel

[0147] 189 Ratchet Wheel T eeth

[0148] 190 Axial Retainer

[0149] 191 Crankshaft Aperture

[0150] 192 Flex Element

[0151] 194 Magnets

[0152] 196 Sensor Subassembly

[0153] 198 Mounting Bracket

[0154] 200 Sensor Printed Circuit Board

[0155] 202 Hall Sensor

[0156] 204 Power and Data Line

[0157] 206 Hardware

[0158] 208 Hardware

[0159] 210 Seal

[0160] 212 Sensor Aperture

[0161] 214 Controller

[0162] 216 Second Surface Cavity

[0163] 218 Crankshaft Aperture

[0164] 220 Crankshaft Aperture

[0165] 222 Radial Shaft Seal

[0166] 224 Snap Ring

[0167] 226 Shifter Subassembly

[0168] 228 Gearbox Subassembly

[0169] 230 Belt Drive Subassembly

[0170] 232 First Set of Transmission Gears

[0171] 234 Second Set of Transmission Gears 236 Countershaft Subassembly

[0172] 238 Detent Subassembly

[0173] 240 Synchronizer Subassembly

[0174] 242 Shifter Planetary Gearset

[0175] 244 Needle Shaft

[0176] 246 Needles

[0177] 248 Needle Aperture

[0178] 250 Needle Spring

[0179] 252 Needle Spring Groove

[0180] 254 Exterior Surface of Needle Shaft

[0181] 256 First Set of Needles

[0182] 258 Second Set of Needles

[0183] 260 Camshaft

[0184] 262 Needle Shaft Cavity

[0185] 263 Camshaft Protrusion

[0186] 264 Bearings

[0187] 266 Plunger

[0188] 268 Detent Spring

[0189] 270 Detent Cavity

[0190] 272 Preload Screw

[0191] 274 Synchronizer Spring Shaft

[0192] 276 Synchronizer Spring

[0193] 278 Synchronizer Cavity

[0194] 280 Pin

[0195] 282 Ball Bearing

[0196] 283 Needle Planetary Set

[0197] 284 Needle Sun

[0198] 286 Needle Planet Gear

[0199] 288 Carrier

[0200] 290 Needle Planet Gear Pin

[0201] 292 Needle Ring

[0202] 294 Carrier Bearing

[0203] 295 Cam Planetary Set 296 Cam Planet Gears

[0204] 298 Cam Planet Gear Pin

[0205] 299 Common Gear Pin

[0206] 300 Cam Ring

[0207] 301 Cam Sun

[0208] 302 Cam Ring Bearing

[0209] 303 Cam Ring Teeth

[0210] 304 Worm Shaft

[0211] 305 Worm Shaft Threading

[0212] 306 Servo

[0213] 307 Cam Sun Teeth

[0214] 308 Servo Bracket

[0215] 310 Worm Gear Bearings

[0216] 312 Seal

[0217] 314 Multiplier Gear

[0218] 315 Multiplier Gear Aperture

[0219] 316 Index Gear

[0220] 317 Index Gear Aperture

[0221] 318 Output Compound Gear

[0222] 320 Compound Spur Gear

[0223] 322 Bearing

[0224] 324 Seal

[0225] 326 Crankshaft Aperture

[0226] 328 Spider

[0227] 330 Lockring

[0228] 332 Belt Drive Sprocket

[0229] 334 Bearing

[0230] 336 Radial Shaft Seal

[0231] 338 Bearing

[0232] 340 Radial Shaft Seal

[0233] 342 Bearing

[0234] 344 Needle Shaft Bracket

[0235] 346 Bearing 350 Process Flow Diagram

[0236] 400, 402, 404 Step

[0237] 406, 408, 410, 412 Step

[0238] 414, 416, 418, 420 Step

[0239] 422, 424, 426, 428 Gear Protrusion

[0240] 430 Groove

[0241] 432 Sloped Surface

[0242] 434 Cam Ring Angle of Rotation

[0243] 435 Exterior Surface of Cam Ring

[0244] 436 Camshaft Angle of Rotation

[0245] 437 Gearing Indicators

[0246] DETAILED DESCRIPTION

[0247] Although the following text sets forth a detailed description of numerous different embodiments, it should be understood that the legal scope of the description is defined by the words of the claims set forth at the end of this disclosure. The Detailed Description is to be construed as exemplary only and does not describe every possible embodiment since describing every possible embodiment of the power transmission (and mid-drive motor, in the combined mid-drive motor package) would be impractical, if not impossible. Numerous alternative embodiments could be implemented, using either current technology or technology developed after the filing date of this patent, which would still fall within the scope of the claims. Additionally, any combination of features shown in the various figures can be used to create additional embodiments of the present disclosure. Thus, dimensions, aspects, and features of one embodiment of the power transmission can be combined with dimensions, aspects, and features of another embodiment of the power transmission to create the claimed embodiment.

[0248] Electric motors are very efficient and capable of quickly outputting high power in a small package, and are a useful addition to a bicycle. Using an electric motor to add power assistance to a bicycle, however, requires the combining of power delivered from the electric motor and the power delivered by a rider (e.g., via legs or arms). Traditional differences between how the two types of power are delivered can create challenges when attempting to add the electric motor to the bicycle. Power, by definition, is the amount of energy transfer over time. In terms of rotational motion, power is the product of angular velocity and torque, as provided in Eq. 1 :

[0249] P = a)T Eq. 1 where P is power, a> is rotational velocity, and T is torque. Using the International System of Units (SI), the unit of rotational velocity is radians per second (rad / s), the unit of torque is Newton-meters (Nm), and the unit of power is the watt (W).

[0250] Electric motors deliver power primarily in the form of rotational velocity rather than torque. Generally speaking, electric motors spin on the order of thousands of rpm, and deliver torque on the order of only a fewNm or less. For example, 10 Nm may be considered a very high torque electric motor. Human legs are the opposite, spinning slowly but delivering high torque. For example, a typical comfortable bicycle cadence (i.e., speed of pedaling) may be between 50-70 rpm with torques that are typically within the 10-40 Nm range, but can reach over 100 Nm at times.

[0251] Thus, to use an electric motor to assist human pedaling, the motor must add torque to the crankshaft rather than speed. For example, if the motor were to spin at thousands of rpm at low torque, it would not assist the low-speed, high-torque propulsion generated by human legs; instead, the pedals would spin too fast for the rider. Therefore, the power of the motor must be converted from being speed dominant to being torque dominant, and speed of the motor must be reduced to the speed of the cadence of the rider.

[0252] In general, embodiments of the present disclosure are directed to a mid-drive motor package including a power transmission for an electric bicycle. In particular, embodiments of the present disclosure are directed to a mid-drive motor package including a power transmission that is configured to combine a crankshaft output generated from an applied torque with a power output from a mid-drive motor to drive a belt connected to a rear wheel. The mid-drive motor package takes power delivered by the motor and converts it from being speed dominant to being torque dominant, such that the speed of the motor is reduced to the speed of the cadence of the rider.

[0253] Embodiments of the present disclosure are also directed to a mid-drive motor package that includes a transmission subassembly that receives the combined power, modifies the combined power based on a gear ratio between a selected combination of transmission gears, and outputs the modified power to a belt drive assembly. Shifting of the transmission subassembly to change the combination of gears includes a set of cams that are manually or automatically controlled by a controller, where the set of cams are inserted within the transmission subassembly such that the transmission gears rotate around the set of cams and are configured to interface with the set of cams.

[0254] Fig. 1 A-1D in general illustrate a mid-drive motor package 100, in accordance with one or more embodiments of the present disclosure. The mid-drive motor package 100 includes a housing subassembly 102, a crankshaft subassembly 104, a motor subassembly 106, a sensor drive subassembly 108, and a transmission subassembly 110. The mid-drive motor package 100 is configured to couple to a belt 112 (or other power transmission device), where the belt 112 is connected to a rear hub of an electric bicycle (not shown). Reference will be made to each of the subassemblies 102, 104, 106, 108, 110 in detail further herein. In addition, any and / or all of the subassemblies 102, 104, 106, 108, 110 may include further subassemblies as described in detail further herein, which are each considered subassemblies of the mid-drive motor package 100.

[0255] In some embodiments, the motor subassembly 106 is positioned within the housing subassembly 102, as generally illustrated by the broken-line box, proximate at least to components of the transmission subassembly 110, as described in detail further herein. In addition, in some embodiments the sensor drive subassembly 108 is positioned within the housing subassembly 102, as generally illustrated by the broken-line box, proximate at least to components of the crankshaft subassembly 104, as described in detail further herein.

[0256] In Figs. 1 A and IB, crank arms 132 of the crankshaft subassembly 104 and a spider sprocket bracket 328 with belt drive sprocket 332 of a belt drive subassembly 230 of the transmission subassembly 110 are illustrated. In Fig. 1C and ID, the belt 112 engaging the belt drive sprocket 332 is illustrated, with the crank arms 132 of the crankshaft subassembly 104 removed to illustrate a crankshaft 122 for purposes of clarity only, and that the removal is not intended on being limiting to the present disclosure.

[0257] Fig. 2 illustrates the housing subassembly 102 of the mid-drive motor package 100, in accordance with one or more embodiments of the present disclosure. In some embodiments, the housing subassembly 102 is constructed of multiple housing sections. For example, the housing subassembly 102 may include, but is not limited to, a motor side housing 114 and a sprocket side housing 116. Components of the subassemblies 104, 106, 108, 110 may be fully positioned within the housings 114, 116, at least partially embedded within or extending outward from the housings 114, 116, or positioned fully exterior to the housings 114, 116.

[0258] It is noted herein, however, that the housing subassembly 102 may be fabricated with a single or one-piece construction, without departing from the scope of the present disclosure. For example, the housing subassembly may be fabricated such that components are insertable from exterior surfaces and provide self-sealing features (e.g., if sealing is necessary for lubrication, prevention of particulate accumulation, or the like) against the housing subassembly 102 (e.g., inset seals, seals positioned between the components and the housing subassembly 102 during installation, or the like). By way of another example, the housing subassembly may not be sealed, such as where the various subassemblies 104, 106, 108, 110 are self-contained and internally sealed (e.g., if sealing is necessary for lubrication, prevention of particulate accumulation, or the like), but may have grooves or channels that lead to cavities into which various components of other subassemblies 104, 106, 108, 110 may be installed during fabrication and assembly.

[0259] In one non-limiting example, the housing subassembly 102 may include, but is not limited to, a shifter planetary cover 118. For instance, the shift planetary cover 118 may be in the sprocket side housing 116. For instance, the shifter planetary cover 118 may provide access to the transmission subassembly 110 without removing the mid-drive motor package 100 from the electric bicycle.

[0260] In another non-limiting example, the housing subassembly 102 may include, but is not limited to, a drain plug 120. For instance, the drain plug 120 may be in the sprocket side housing 116. The drain plug 120 may allow for the changing of gear fluid within the transmission subassembly 110 without removing the mid-drive motor package 100 from the electric bicycle.

[0261] Figs. 3 A and 3B in general illustrate the crankshaft subassembly 104 of the middrive motor package 100, in accordance with one or more embodiments of the present disclosure.

[0262] The crankshaft subassembly 104 includes the crankshaft 122. In some embodiments, at least a portion of the length of the crankshaft 122 is smooth, and at least a portion of the length of the crankshaft 122 includes a crankshaft spline 124. For example, a crankshaft clutch 126 may be positioned on the crankshaft 122 at the crankshaft spline 124, and retained thereon with a crankshaft clutch spacer 128 and a snap ring 130. For instance, the crankshaft clutch 126 may be a one-way clutch, such that the clutch 126 transfers rotational energy from the crankshaft 122 to the transmission subassembly 110 (e.g., via other intermediate- positioned components, as described in detail further herein) only when the crankshaft 122 is rotated in a particular direction. In some embodiments, additional snap rings 130 may be used to retain the sensor drive subassembly 108 (not shown) to the crankshaft subassembly 104.

[0263] The crankshaft subassembly 104 includes the crank arms 132. For example, the crank arms 132 may be secured to the crankshaft 122 via crank arm hardware 134 (e.g., fasteners, interlocking assemblies, and the like). By way of another example, the crank arms 132 may be secured to the crankshaft 122 via complementary components of an interlocking assembly that are integrated with the crankshaft 122 and the crank arms 132, such that additional crank arm hardware 134 is not necessary. It is noted that pedals are couplable to the crank arms 132, but are not shown for purposes of clarity.

[0264] In additional embodiments, one or more of the crank arms 132 may be fabricated with the crankshaft 122 as a single-piece crank unit. For example, the various components of the crankshaft subassembly 104, the motor subassembly 106, the sensor drive subassembly 108, and / or the transmission subassembly 110 may be configured to receive a crankshaft that has casted with one of the crank arms 132. By way of another example, the various components of the crankshaft subassembly 104, the motor subassembly 106, the sensor drive subassembly 108, and / or the transmission subassembly 110 may be configured to receive a crankshaft that has casted with both of the crank arms 132, similar to an American-style or Ashtabula one-piece crank.

[0265] Figs. 4A-4H in general illustrate the motor subassembly 106 of the mid-drive motor package 100, in accordance with one or more embodiments of the present disclosure. As illustrated in at least Figs. 4A and 4B, the motor subassembly 106 includes additional subassemblies of a motor 136, a motor planetary gearset 138, and a ring shaft subassembly 140, which are each additionally considered subassemblies of the mid-drive motor package 100. For example, the subassemblies 136, 138, 140 may be installed within or on the motor side housing 114 of the housing subassembly 102. For instance, the motor planetary gearset 138 and the ring shaft subassembly 140 may be mated (e.g., via meshed teeth, as described in detail further herein) and installed in a cavity on a first side of the motor side housing 114, and the motor 136 may be coupled (e.g., fastened, connected via an interlocking assembly, or the like) to a second side of the motor side housing 114, such that at least a portion of the motor 136 may pass through the motor side housing 114 to engage the motor planetary gearset 138. It is noted that the motor 136 is not shown in Fig. 4B for purposes of clarity only, and that the removal is not intended on being limiting to the present disclosure.

[0266] Referring now to Fig. 4C, the motor 136 includes a motor housing 142 that is couplable to the motor side housing 114 via motor hardware 144. The motor 136 also includes one or more power lines 146 and / or one or more data lines 148. For example, the one or more data lines 148 may be utilized to transmit sensor data from the motor 136 to and / or provide instructions to the motor 136 from a controller of the electric bicycle (e.g., as illustrated in Figs. 5E and 5F).

[0267] In some embodiments, the power lines 146 and / or the data lines 148 may be coupled to the motor 136 via any known electrical connector in the art. For example, the electrical connector may include, but is not limited to, ring connectors, spade connectors, multi-pin connectors, and the like with corresponding components coupled to the motor 136. Although the power lines 146 and the data lines 148 are illustrated as separate lines, it is noted that the power lines 146 and the data lines 148 may be combined lines between the motor 136 and the controller of the electric bicycle (e.g., with a common connector routed from the motor subassembly 106 to a mated connector on a harness in communication with the controller, or alternatively directly to a mated receptacle or port on the controller), without departing from the scope of the present disclosure.

[0268] The motor 136 includes a motor shaft 150 with a motor gear 152. For example, the motor gear 152 may be positioned at a distal end of the motor shaft 150, and is either integrated with or coupled to the motor shaft 150. By way of another example, the motor gear 152 may be integrated into the motor shaft 150, such that the motor shaft 150 includes a spline. It is noted that the motor 136 may be a standard electric bicycle motor, or may be custom modified to a particular usage depending on the build on the mid-drive motor package 100.

[0269] Referring now to Figs. 4D and 4E, the motor planetary gearset 138 is built into a first surface cavity 154 defined within a first side of the motor side housing 114. Bearings 156 are positioned (e.g., pressed or secured via additional bearing brackets) into recesses within the first surface cavity 154. A plurality of outer planet gears 158 and inner planet gears 160 are centered around a motor shaft aperture 162. For example, the bearings 156 may be configured to receive a bearing pin 164 for an outer planet gear 158 or an inner planet gear 160. It is noted that the gears 158, 160 may be pressed onto respective bearing pins 164, or coupled via a snap ring or other hardware, without departing from the scope of the present disclosure.

[0270] Although not shown in Fig. 4E, the motor shaft aperture 162 is operable to receive the motor shaft 150 such that the motor gear 152 is positioned to mate (e.g., mesh teeth with) the plurality of inner planet gears 160. This creates a distribution of load between the motor 136 and the ring shaft subassembly 140 via the plurality of inner planet gears 160 and the plurality of outer planer gears 158 of the motor planetary gearset 138.

[0271] In general, planetary gearsets operate by designating one member (sun, carrier, or ring) as the input, one as the output, and one as the reaction member that facilitates power transfer between input and output. In the present application, the motor gear 152 is the input or sun gear, the planet gears 158, 160 are the reaction members within a stationary carrier, and the ring gear 166 is the output. It is noted that the two sets of planet gears 158, 160 are utilized on the same carrier for packaging reasons. This reduces speed according to the ratio in Eq. 2:

[0272] In Eq. 2, R is the ratio of speed reduction, ZRis the number of teeth on the ring gear, and Zsis the number of teeth on the sun gear. In the configuration of the embodiments of the present disclosure, output direction the speed ratio is positive and a negative sign is not included. It should be noted, however, that if the ring spins the opposite direction as the sun, the negative sign would be included.

[0273] The inclusion of the motor planetary gearset 138 and a ratchet gear 176 (as described in detail further herein) causes the order of the speeds and torques of the motor 136 to be brought into the same orders as that of the rider. In this regard, the motor 136 provides electrical power assistance comfortably and efficiently. While this may be sufficient for an electric motorcycle or electric bicycle with a throttle, a pedal assist bicycle must substantially or completely match the exact speed of the cadence of the rider. To assist in this, a speed sensor and / or controller may be included to cause the motor 136 to spin at the correct speed. In addition, there is the risk of delivering too much torque, when combined with that of the rider that may damage components. To prevent this, a means for sensing rider input torque may be included. It is noted that one way to measure both speed and torque is with magnets, sensors (e.g., hall sensors or another sensor), and / or an elastic element between the input of the crankshaft 122 and the compound spur gears 184.

[0274] Referring now to Figs. 4F-4H, the ring shaft subassembly 140 is illustrated, along with the positioning of the motor planetary gearset 138 relative to the ring shaft subassembly 140. The combination of the motor planetary gearset 138 and the ring shaft subassembly 140 converts the high-speed, low-torque motor output to match the low-speed, high-torque input from the rider through mechanical gearing. In particular, the present disclosure achieves this using the motor planetary gearset 138 coupled to the motor 136, which is passed through the ring shaft subassembly 140.

[0275] The motor planetary gearset 138 includes a planetary ring gear 166. In some embodiments, the planetary ring gear 166 is coupled to a first side of a ring shaft 168 of the ring shaft subassembly 140. For example, the planetary ring gear 166 may be pressed against a lip or into a groove of the ring shaft 168, or coupled via a snap ring or other hardware, without departing from the scope of the present disclosure. By way of another example, the planetary ring gear 166 may be formed with the ring shaft 168. It is noted that the planetary ring gear 166 may additionally or alternatively be considered a component of the ring shaft subassembly 140, for purposes of the present disclosure.

[0276] The ring shaft subassembly 140 includes a plurality of pawls 170 and corresponding pawl springs 172 positioned within respective pawl and spring slots 174. A ratchet gear 176 is positioned proximate to the plurality of pawls 170. The combination of the plurality of pawls 170 and the ratchet gear 176 prevents rotation of the ring shaft subassembly 140 (and the planetary motor gearset 138) in a non-desired direction so as to prevent the rider from driving the motor, making riding the bike more difficult, and to prevent possible damage to the motor 136 and / or electrical components coupled to or in communication with the motor 136. In one non-limiting example, a snap ring 178 is snapped into a groove of the ring shaft 168 to secure the pawls 170 and springs 172.

[0277] In some embodiments, speed matching can be achieved through a one-way clutch (e.g., the ratchet gear 176) between the motor 136 and the crankshaft 122 that prevents power transfer by overrunning if the motor 136 spins too fast. In addition, speed may be controlled by adjustment of voltage supplied to the motor 136. Further, torque control can be achieved by measuring the torque applied by the rider and adjusting the current supplied to the motor 136 accordingly. Figs. 5A-5F in general illustrate the sensor drive subassembly 108, in accordance with one or more embodiments of the present disclosure. The sensor drive subassembly 108 is positioned proximate to and configured to engage with the crankshaft subassembly 104 (not shown).

[0278] Referring now to Figs. 5 A and 5B, the sensor drive subassembly 108 includes a compound synergy gear 180. The compound synergy gear 180 includes a spur gear 182 that is configured to engage (e.g., mate with, via a meshing of teeth) the ratchet gear 176 of the ring shaft subassembly 140 (not shown). The compound synergy gear 180 includes a set of compound spur gears 184. It is noted that the spur gear 182 and the set of compound spur gears 184 may be fixed in relation to other another as a single formed component, or may be separate components that are coupled together during manufacturing and assembly.

[0279] In some embodiments, the number of compound spur gears 184 is equal to the number of gears in a first set of transmission gears of the transmission subassembly 110 (not shown), as described in detail further herein. For example, where the transmission subassembly 110 includes three gears in the first set of transmission gears, the compound synergy gear 180 includes three corresponding compound spur gears 184A, 184B, 184C. In this regard, the rotation of the compound synergy gear 180 is always transferred to the transmission subassembly 110, regardless of which gear of the first set of transmission gears is selected (e.g., manually by a rider, or automatically by a central controller).

[0280] The sensor drive subassembly 108 includes a bearing 186 and a ratchet wheel 188. In some embodiments, both the bearing 186 and the ratchet wheel 188 are configured to engage with the crankshaft 122 of the crankshaft subassembly 104 (not shown). For example, the ratchet wheel 188 may include teeth 189 that engage the crankshaft clutch 126, and a second portion that is inserted through the bearing 186.

[0281] In some embodiments, the ratchet wheel 188 may be retained in place by an axial retainer 190 or other hardware, or may be secured via an interference fit, without departing from the scope of the present disclosure. It is noted that the axial retainer 190 may include a crankshaft aperture 191 to allow the crankshaft 122 (not shown) to pass through the compound synergy gear 180 and the ratchet wheel 188.

[0282] In additional embodiments, a flex element 192 (e.g., a torsion spring, or the like) may be positioned between the compound synergy gear 180 and the ratchet wheel 188 during assembly. The flex element 192 allows relative motion between the spur gear 182 and the ratchet wheel 188 so that the angular displacement can be measured by the sensor subassembly 196. The torque can be known as a function of the spring rate of the flex element 192 and the measured displacement between the spur gear 182 and the ratchet wheel 188.

[0283] In some embodiments, the compound synergy gear 180 and / or the ratchet wheel 188 includes magnets 194. For example, the magnets 194 may be full ring magnets, or may be individual magnets placed in a ring formation, without departing from the scope of the present disclosure. The magnets are configured to rotate with the compound synergy gear 180 and / or the ratchet wheel 188, respectively, and are read by a sensor subassembly 196 of the sensor drive subassembly 108. For example, a magnet (or set of magnets) 194A may correspond to the ratchet wheel 188, and a magnet (or set of magnets) 194B may correspond to the compound synergy gear 180.

[0284] Referring now to Figs. 5C and 5D, the sensor subassembly 196 includes a mounting bracket 198, and a sensor printed circuit board (PCB) 200.

[0285] In some embodiments, the sensor subassembly 196 includes at least one hall sensor 202. The mounting bracket 198 positions the at least one hall sensor 202 within the sensor subassembly 196 to sense the magnets 194 rotating with the compound synergy gear 180 and the ratchet wheel 188. For example, the sensor subassembly 196 may include two hall sensors 202, or a first hall sensor 202 A for the magnet 194 A corresponding to the ratchet wheel 188 and a second hall sensor 202B for the magnet 194B corresponding to the compound synergy gear 180.

[0286] Sensor data from the sensor PCB 200 may be transmitted to a controller of the electric bicycle (as illustrated in Figs 5E and 5F) via a combined power and data line 204. It is noted, however, that separate power lines and data lines may be coupled to the sensor PCB 200, without departing from the scope of the present disclosure.

[0287] In some embodiments, the combined power and data line 204 may be coupled to the controller via any known electrical connector in the art. For example, the electrical connector may include, but is not limited to, ring connectors, spade connectors, multi-pin connectors, and the like with corresponding components coupled to the controller. Although the power and data line 204 is illustrated as a combined line (e.g., with a common connector routed from the motor subassembly 106 to a mated connector on a harness in communication with the controller, or alternatively directly to a mated receptacle or port on the controller), it is noted that the combined power and data line 204 may be separate lines between the sensor subassembly 196 and the controller of the electric bicycle, without departing from the scope of the present disclosure.

[0288] In some embodiments, as illustrated in Figs. 5C and 5D, hardware 206 (e.g., fasteners, brackets, and the like) are used to couple the sensor PCB 200 to the mounting bracket 198. In some embodiments, as illustrated in Figs. 5E and 5F, hardware 208 (e.g., fasteners, brackets, and the like) is used to couple the mounting bracket 198 to the motor side housing 114. It is noted that a seal 210 (e.g., an O-ring, or the like) may be positioned between the mounting bracket 198 and the surface of the motor side housing 114 to prevent gearbox fluid from exiting through a sensor aperture 212 within the motor side housing 114 (e.g., as illustrated in Fig. 4E) through which a portion of the mounting bracket 198 (e.g., including the hall sensors 202 or another sensor) is inserted.

[0289] Although embodiments of the present disclosure are directed to hall sensors 202 and magnets 194, it should be understood that the sensor subassembly 196 (and, in general, the sensor drive subassembly 108) may include different types of sensors and corresponding components to be sensed and / or may be installed in different areas of the mid-drive motor package 100 (and, in general, on the electric bicycle), without departing from the scope of the present disclosure.

[0290] Figs. 5E and 5F illustrate portions of the motor subassembly 106 and portions of the sensor drive subassembly 108 within the motor side housing 114. It is noted that components such as the compound synergy gear 180 and the ratchet wheel 188 of the sensor drive subassembly 108 have been removed for purposes of clarity only, and that the removal is not intended on being limiting to the present disclosure.

[0291] In embodiments, a controller 214 is positioned on the motor side housing 114. For example, the controller 214 may be positioned on the motor side housing 114 proximate to the motor 136, such that the power lines 146 and / or the data lines 148 from the motor 136 (e.g., as illustrated in Fig. 4A) are electrically coupled to the controller 214. By way of another example, the controller 214 may be positioned to communicatively couple to the combined power and data line 204 from the sensor subassembly 196. It should be understood, however, that the power lines 146 and / or the data lines 148 from the motor 136 and / or the combined power and data line 204 from the sensor subassembly 196 may instead be routed from the mid-drive motor package 100 individually, or through a common port or connector, to a harness on the electric bicycle that is in communication with a controller installed elsewhere on the electric bicycle, without departing from the scope of the present disclosure.

[0292] The motor side housing 114 includes a second surface cavity 216 (e.g., as illustrated in Fig. 4E) that is configured to receive the sensor drive subassembly 108, and the sensor aperture 212 through which the portion of the mounting bracket 198 (e.g., including the hall sensors 202 or another sensor) is inserted. It is noted that the first surface cavity 154 and second surface cavity 216 may be a single cavity, overlapping cavities, or separate cavities without departing from the scope of the present disclosure.

[0293] The controller 214 has a crankshaft aperture 218, and the motor side housing 114 similarly includes a crankshaft aperture 220 (e.g., as illustrated in Fig. 4E). It is noted that the either or both of the apertures 218, 220 may include a bearing to facilitate the rotation of the crankshaft 122 (not shown) and / or seals (e.g., an O-ring, or the like) to prevent gearbox fluid from exiting through the apertures 218, 220. For example, a radial shaft seal 222 may be positioned within the aperture 220, which is configured to receive the crankshaft 122 (e.g., as illustrated in Figs. 6B and 6C).

[0294] The controller 214 may include processors and memory (e.g., a memory medium, memory device, or the like). The processors may be configured to execute program instructions maintained on or stored in the memory. The processor of the one or more control units may execute any of the various method or process steps necessary to operate the middrive motor package 100 such as, but not limited to, one or more of those illustrated in Fig. 9 as described in detail further herein.

[0295] The controller 214 may include a user interface. For example, the user interface may be a separate device coupled (e.g., physically coupled, electrically coupled, communicatively coupled, or the like) to another component of the electric bicycle (e.g., the handlebars). By way of another example, the user interface and the controller 214 may be located within a common or shared housing. The user interface may include one or more displays, one or more user input devices, and / or one or more port connectors (e.g., for the transmitting and / or receiving of power and / or data, and the like). For example, the user interface may be operable to communicatively couple to a diagnostic tool.

[0296] The controller 214 may include one or more sensors coupled (e.g., physically coupled, electrically coupled, communicatively coupled, or the like) to or integrated in the controller 214 and / or the mid-drive motor package 100. The one or more sensors may be operable to determine various operational, physical, and / or environmental parameters of the controller 214 and / or the mid-drive motor package 100; the environment surrounding the controller 214 and / or the mid-drive motor package 100; and the like.

[0297] The controller 214 may include one or more transmitters and / or receivers coupled (e.g., physically coupled, electrically coupled, communicatively coupled, or the like) to or integrated in the controller 214 and / or the mid-drive motor package 100. The one or more transmitters and / or receivers may be configured to transmit data to and / or receive data from the controller 214 and / or the mid-drive motor package 100 (e.g., from sensors installed within the controller 214 and / or the mid-drive motor package 100), or from other control units (e.g., additional controllers, or the like) coupled to the electric bicycle and / or external to the electric bicycle (e.g., third-party diagnostic tools) either via wired connections or wireless connections, which may be configured as transmitting (Tx) units, receiving (Rx) units, or combination Tx / Rx units.

[0298] The controller 214 may be configured to monitor the mid-drive motor package 100 via received and / or transmitted data. The controller 214 may be configured to generate control signals to adjust one or more components of the mid-drive motor package 100 via a feedback loop or a feed forward loop based on the received and / or transmitted data. The controller 214 may be configured to receive and / or transmit data in a standardized format and / or a non-standardized format. Where the data is in a non-standardized format, the data may be converted to a standardized format upon receipt and / or prior to transmission to sensors, other control units, or the like.

[0299] The controller 214 may assist in the control of the motor 136. In addition, the controller 214 may assist in the shifting within the transmission subassembly 110, as described in detail further herein.

[0300] Figs. 6A-6D illustrate the assembly of the sensor drive subassembly 108 to the crankshaft subassembly 104. Referring now to Fig. 6A and the enlarged view in Fig. 6B, assembly of the crankshaft subassembly 104, the motor subassembly 106, and the sensor drive subassembly 108 may include one or more of the following steps. First, the sensor drive subassembly 108 is installed onto the crankshaft clutch 126 by sliding a crankshaft aperture 191 of the axial retainer 190 over the crankshaft 122, until teeth 189 of the ratchet wheel 188 engage (e.g., mate) with the pawls of the crankshaft clutch 126. Next, a bore of the bearing 186 is slid onto the crankshaft 122 until the bearing 186 bottoms against the crankshaft spline 124. For example, the bearing 186 may fully seat within the compound synergy gear 180 when the bearing 186 bottoms against the crankshaft spline 124. Further, snap rings 224 are installed on the crankshaft 122 to retain the crankshaft 122 within the compound synergy gear 180 and ratchet wheel 188 (e.g., as also illustrated in Figs. 3 A and 3B).

[0301] Referring now to Figs. 6C and 6D, the crankshaft 122 is passed through the radial shaft seal 222 within the aperture 220 in the motor side housing 114. The crankshaft 122 is additionally passed through the aperture 218 in the controller 214.

[0302] Figs. 7A-7R illustrate the transmission subassembly 110 of the mid-drive motor package 100, in accordance with one or more embodiments of the present disclosure.

[0303] Referring now to Figs. 7A-7C, the motor subassembly 106 includes additional subassemblies of a shifter subassembly 226, gearbox subassembly 228, and a belt drive subassembly 230, which are each considered subassemblies of the mid-drive motor package 100. It is noted that the shifter subassembly 226 may include or be coupled to a servo 306 driving a worm shaft 304, as described in detail further herein and illustrated in Fig. 7 A. In addition, it is noted that the gearbox subassembly 228 may include a plurality of gears separated into a first set 232 of transmission gears that engage the compound synergy gear 180 of the sensor drive subassembly 108 (not shown) and a second set 234 of transmission gears that engage an output compound gear of the belt drive subassembly 230, as described in detail further herein.

[0304] Referring now to Figs. 7D and 7E, the shifter subassembly 226 includes additional subassemblies of a countershaft subassembly 236, a detent subassembly 238, a synchronizer subassembly 240, and a shifter planetary gearset 242, which are each considered subassemblies of transmission subassembly 110 (and the mid-drive motor package 100). It is noted that portions of the shifter subassembly 226 (e.g., components of the countershaft subassembly 236, the detent subassembly 238, the synchronizer subassembly 240, and / or the shifter planetary gearset 242) and / or portions of the gearbox subassembly 228 may be accessible via the shifter planetary cover 118 (e.g., as illustrated in Fig. 1A) without removing the mid-drive motor package 100 from the electric bicycle. It is noted that the countershaft assembly 236 is described further with respect to Figs. 7F-7H. In addition, it is noted that the detent subassembly 238 and the synchronizer subassembly 240 are described further with respect to Figs. 7I-7J and 7K-7M. Further, it is noted that the shifter planetary gearset 242 is described further with respect to Figs. 7K-7M.

[0305] Referring now to Figs. 7F-7H, the countershaft subassembly 236 includes a needle shaft 244. A plurality of needles 246 are installed within the needle shaft 244 into respective needle apertures 248, and may either extend radially outward from or retract radially inward into the needle apertures 248 depending on the selected combination of gears (or bicycle speed ratio), as described in detail further herein. For example, the countershaft subassembly 236 may include a needle 246 for each of the plurality of gears in the gearbox subassembly 228. For instance, the countershaft subassembly 236 may include six needles 246, or one for each of the three gears in the first set 232 of transmission gears of the gearbox subassembly 228, and the three gears in the second set 234 of transmission gears of the gearbox subassembly 228.

[0306] A plurality of needle springs 250 are installed into respective needle spring grooves 252 in the needle shaft 244. The plurality of needle springs 250 are configured to engage a respective needle 246 of the plurality of needles 246. In some embodiments, a needle spring 250 holds (or hooks onto) a corresponding needle 246 below an exterior surface 254 of the needle shaft 244 unless an external force is applied to the needle 246, as described in detail further herein. For example, the needle spring 250 may be an incomplete or broken loop with two ends shaped to stay within the needle spring groove 252, where one end engages the needle 246. It is noted herein, however, that the needle spring 250 may be a complete or unbroken loop that fits within the needle spring groove 252, without departing from the scope of the present disclosure. In some non-limiting examples, the needle spring 250 may be a garter spring, a flat spring, or the like.

[0307] In a non-limiting example as illustrated in Fig. 7G, the needles 246, needle springs 250, and needle spring grooves 252 are separated a first set 256 representing “low (L),” “medium (M),” or “high (H)” respectively, and a second set 258 representing “1,” “2,” and “3” respectively. The “L”,”M”, “H” for the first set 256 corresponds to the first set 232 of transmission gears, and the “1”, “2”, “3” for the second set 258 corresponds to the second set 234 of transmission gears, as described in detail further herein with respect to Figs. 7R, 11 A, and 11B.

[0308] Where the needle springs 250 are an incomplete or broken loop, it is noted that the needle springs 250 may hook onto the needles 246 of the first set 256 in a first direction, and the needle springs 250 may hook onto the needles 246 of the second set 258 in a second, different direction. Alternatively, all needle springs 250 may hook onto the needles 246 in the same direction, without departing from the scope of the present disclosure.

[0309] The countershaft subassembly 236 includes a camshaft 260 inserted in a needle shaft cavity 262 defined within the needle shaft 244, where the camshaft 260 and the needle shaft 244 are coaxial. The camshaft 260 has a plurality of camshaft protrusions 263. For example, each camshaft protrusion 263 causes a respective needle 246 to extend out of the corresponding needle aperture 248 when the camshaft protrusion 263 makes contact with the needle 246. It is noted that the corresponding needle spring 250 also keeps the needle 246 in contact with the respective camshaft protrusion 263. In some embodiments, the camshaft 260 is inserted into one or more bearings 264 and supported within the needle shaft cavity 262 by the one or more bearings 264.

[0310] Referring now to Fig. 71, the detent subassembly 238 includes a plunger 266 and a detent spring 268 positioned in a detent cavity 270 defined within the camshaft 260. The plunger 266 is operable to engage a radial mating hole 271 (or other recess within the needle shaft 244, such as a needle spring groove 252). The detent spring 268 causes the plunger 266 to maintain contact with the radial mating hole 271 (and the needle shaft 244 in general). In some embodiments, the detent subassembly 238 may include a preload screw 272 that sets the plunger 266 at a predetermined depth (or height) within the detent cavity 270, tuning the detent subassembly 238 to a predetermined load necessary for engaging and disengaging the plunger 266 with the radial mating hole 271.

[0311] Referring now to Fig. 7J, the synchronizer subassembly 240 includes a synchronizer spring shaft 274 and a synchronizer spring 276 positioned in a synchronizer cavity 278 defined within the camshaft 260. A pin 280 is positioned within the synchronizer cavity 278 between the synchronizer spring shaft 274 and an interior surface in the synchronizer cavity 278 of the camshaft 260. In one example, the pin 280 may be operable to block the displacement of the synchronizer spring 276 to prevent the synchronizer spring 276 from being overstressed.

[0312] In some embodiments, the synchronizer spring shaft 274 may be positioned within a ball bearing 282. It is noted that the ball bearing 282 may be pressed into the synchronizer cavity 278, or coupled to the camshaft 260 within the synchronizer cavity 278 via hardware, without departing from the scope of the present disclosure.

[0313] In some embodiments, the synchronizer subassembly 240 operates as an energy storage system in the event that a shifting procedure is started while any the needles 246 being engaged are blocked, such that a unique camshaft surface designed into the transmission gears (e.g., as described in detail further herein) fails to rotate the transmission gears into the engaged position. In such an event, the synchronizer spring 276 is loaded by the synchronizer spring shaft 274, storing the shift energy until the transmission gear is rotated into a position to receive the needle 246, and then releasing the energy to cause the camshaft 260 to rotate relative to the needle shaft 244. If no such block occurs, the camshaft 260 should rotate relative to the needle shaft 244 with minimal spring deflection / loading.

[0314] Although shown in Fig. 71, it is noted that the plurality of needle springs 250 are not illustrated in Fig. 7J for purposes of clarity only, and that the removal is not intended on being limiting to the present disclosure.

[0315] Referring now to Figs. 7K-7P, the shifter planetary gearset 242 of the shifter subassembly 226 is a two-sided planetary gearset positioned between the countershaft subassembly 236 and the housing subassembly 102 (e.g., the sprocket side housing 116, where the housing subassembly 102 includes multiple housing sections). For example, the shifter planetary gearset 242 may include a needle planetary set 283 that corresponds to the needle shaft 244 and a cam planetary set 295 that corresponds to the camshaft 260. However, unlike the motor planetary gearset 138, the two planetary sets share a common carrier but have separate sun gears and ring gears. For example, the respective sun gears may rotate together when the needle shaft 244 and the camshaft 260 rotate together (e.g., when the detent subassembly 238 is engaged), but may rotate separately when the cam ring gear is provided power (e.g., when the detent subassembly 238 is disengaged).

[0316] In some embodiments, the needle planetary set 283 includes a needle sun 284 coupled to the needle shaft 244. For example, the needle sun 284 is installed within the needle shaft cavity 262 proximate to the synchronizer subassembly 240. It is noted that the needle sun 284 may be pressed into the needle shaft cavity 262, or coupled to the needle shaft 244 via hardware, without departing from the scope of the present disclosure.

[0317] The needle planetary set 283 includes a plurality of needle planet gears 286 axially coupled to a common carrier 288 via respective needle planet gear pins 290. It is noted that the needle planet gears 286 may be pressed onto the pins 290, or coupled to the pins 290 via hardware, without departing from the scope of the present disclosure. Teeth on the needle planet gears 286 engage (e.g., mesh with) teeth on a needle ring 292 of the needle planetary set 283. In some embodiments, the needle ring 292 is coupled to the sprocket side housing 116, such that it is fixed in position.

[0318] The common carrier 288 rides on a carrier bearing 294 installed on the synchronizer spring shaft 274. It is noted that the carrier bearing 294 may be pressed onto the synchronizer spring shaft 274, or coupled to the synchronizer spring shaft 274 via hardware, without departing from the scope of the present disclosure. The cam planetary set 295 includes a plurality of cam planet gears 296 axially coupled via respective cam planet gear pins 298. It is noted that the cam planet gears 296 may be pressed onto the pins 298, or coupled to the pins 298 via hardware, without departing from the scope of the present disclosure. Teeth on the cam planet gears 296 engage (e.g., mesh with) teeth on a cam ring 300 or worm gear of the cam planetary set 295, and additionally engage (e.g., mesh with) teeth on a cam sun 301 of the cam planetary set 295. In some embodiments, the cam sun 301 interfaces with the synchronizer subassembly 240 (e.g., with the synchronizer spring shaft 274).

[0319] The cam ring 300 engages a cam ring bearing 302 that engages the sprocket side housing 116 (not shown). It is noted that the cam ring bearing 302 may be pressed into the cam ring 300, or the cam ring 300 is coupled to the cam ring bearing 302 via hardware, without departing from the scope of the present disclosure.

[0320] In an alternative embodiment to the arrangement illustrated in Figs. 7K-7N, Figs. 70 and 7P illustrate a configuration where the needle planet gears 286 of the needle planetary set 283 and the cam planer gears 296 of the cam planetary set 295 share common gear pins 299 through the carrier 288. As with the arrangement illustrated in Figs. 7K-7N, the camshaft 260 (not shown) passes through the carrier 288 and engages with the cam sun 301.

[0321] In some embodiments, teeth 303 on the cam ring 300 engage (e.g., mesh with) threading 305 on a worm shaft 304. For example, the worm shaft 304 may be driven by a servo 306 (or stepper motor) that is coupled to a servo bracket 308. The servo bracket 308 may be coupled to the sprocket side housing 116 (not shown). It is noted that the worm shaft 304 may be seated within worm gear bearings 310, to accommodate the torque necessary to overcome friction within the shifter subassembly 226. In addition, it is noted that the worm shaft 304 may pass through a seal 312 (e.g., a radial shaft seal, or the like).

[0322] Although embodiments of the present disclosure are directed to the camshaft 260 being controlled via the servo 306, worm shaft 304, and shifter planetary gearset 242, it is noted that the servo 306, worm shaft 304, and shifter planetary gearset 242 may be replaced with a cable assembly to control the camshaft 260, without departing from the scope of the present disclosure.

[0323] Referring now to Fig. 7Q, the gearbox subassembly 228 is illustrated with the shifter subassembly 226. The gearbox subassembly 228 includes a plurality of multiplier gears 314 (i.e., the first set 232 of transmission gears) and a plurality of index gears 316 (i.e., the second set 234 of transmission gears). The multiplier gears 314 have apertures 315 and the index gears 316 have apertures 317 through which the countershaft subassembly 236 of the shifter subassembly 226 is inserted, such that the countershaft subassembly 236 and the gears 314, 316 of the gearbox subassembly 228 are coaxial. The gearbox subassembly 228 additionally includes an output compound gear 318 with compound spur gears 320. It is noted that the compound spur gears 320 may be fixed in relation to other another as a single formed component, or may be separate components that are coupled together during manufacturing and assembly.

[0324] Although not shown, the crankshaft 122 passes through the compound synergy gear 180, the ratchet wheel 188 and the output compound gear 318. In some embodiments, the gearbox subassembly 228 includes bearings to facilitate the operation of the output compound gear 318 and / or seals to protect various components within the transmission subassembly 110. For example, the gearbox subassembly 228 may include, but is not limited to, a bearing 322 through which the crankshaft 122 (not shown) passes. It is noted that the bearing 322 may be pressed into the output compound gear 318, or coupled to the output compound gear 318 via hardware, without departing from the scope of the present disclosure. In addition, it is noted that the crankshaft 122 may be pressed into the bearing 322, or coupled to the bearing 322 via hardware, without departing from the scope of the present disclosure. By way of another example, the gearbox subassembly 228 may include, but is not limited to, a seal 324 through which the crankshaft 122 passes, that prevents fluid or particulate matter from entering the transmission subassembly 110 via a crankshaft aperture 326.

[0325] In one non-limiting example, the gearbox subassembly 228 includes a multiplier gear 314A that corresponds to the “L” needle 246 of the first set 256, a multiplier gear 314B that corresponds to the “M” needle 246 of the first set 256, and a multiplier gear 314C that corresponds to the “H” needle 246 of the first set 256. The multiplier gears 314 may engage (e.g., mesh with) the compound spur gears 184 of the compound synergy gear 180. In this non-limiting example, the multiplier gears 314A, 314B, 314C may engage with respective compound spur gears 184A, 184B, 184C, to receive inputted power provided by the motor 136 and / or the crankshaft 122 (not shown). It is noted that although the compound synergy gear 180 and the ratchet wheel 188 are described as components of the sensor drive subassembly 108, it should be understood that the compound synergy gear 180 and / or the ratchet wheel 188 may be considered components of the transmission subassembly 110 (and specifically, in some instances, the gearbox subassembly 228), without departing from the scope of the present disclosure.

[0326] In another non-limiting example, the gearbox subassembly 228 includes an index gear 316A that corresponds to the “1” needle 246 of the second set 258, an index gear 316B that corresponds to the “2” needle 246 of the second set 256, and an index gear 316C that corresponds to the “3” needle 246 of the second set 256. The index gears 316 may engage (e.g., mesh with) the compound spur gears 320 of the output compound gear 318. In this non-limiting example, the index gears 316A, 316B, 316C may engage with respective compound spur gears 320A, 320B, 320C, to transfer combined and / or modified power to the belt drive sprocket 332 (not shown).

[0327] Referring now to Figs. 7R and 7S, the belt drive subassembly 230 includes the sprocket bracket or spider 328. For example, the spider 328 may be coupled to the output compound gear 318 of the gearbox subassembly 228. For instance, the spider 328 may be coupled to a lockring 330 with fasteners or other hardware (or pressed into the lockring 330), and the lockring 330 may be coupled to the output compound gear 318 with fasteners or other hardware (or pressed into the crankshaft aperture 326 of the output compound gear 318), without departing from the scope of the present disclosure. It is noted that although the output compound gear 318 are described as components of the gearbox subassembly 228, it should be understood that the output compound gear 318 may be considered components of the belt drive subassembly 230, without departing from the scope of the present disclosure.

[0328] In some embodiments, the belt drive sprocket 332 is coupled to the spider 328 (e.g., via fasteners or other hardware). The belt drive sprocket 332 is configured to engage or interface with the belt 112, to provide power from the transmission subassembly 110 to the rear wheel (not shown). The belt drive sprocket 332 may reduce manufacturing complexity for a particular component (and thus manufacturing costs) and allow a manufacturer or technician to swap the belt drive sprocket 332 (and belt 112) for builds with more or fewer teeth, changing the ride of the electric bicycle. For example, a belt drive sprocket 332 with more teeth may be desirable for racing or enduro usage with higher average speeds, while a belt drive sprocket 332 with fewer teeth may be desirable for hill, off-road, or trail use and / or when the electric bicycle is laden with extra weight in bags, a basket, a trailer, and the like. However, it is noted that the spider 328 and the belt drive sprocket 332 may be fabricated as a single component to reduce manufacturing costs by reducing part count, without departing from the scope of the present disclosure. In addition, although embodiments of the present disclosure are directed to the spider 328 and the belt drive sprocket 332 being components of the belt drive subassembly 230, it should be understood that the spider 328 and the belt drive sprocket 332 may be components coupled to the belt drive subassembly 230, without departing from the scope of the present disclosure.

[0329] In one non-limiting example as illustrated throughout Figs. 7A-7R, power to the belt 112 is provided from the crankshaft subassembly 104 and the motor subassembly 106 via the sensor drive subassembly 108 and the transmission subassembly 110. In particular, the compound synergy gear 180 receives power from both the crankshaft 122 and the motor 136 (not shown), and provides that power to a particular multiplier gear 314 via the corresponding compound spur gear 184.

[0330] The shifter planetary gearset 242 actuates components within the belt drive subassembly 230 by actuating the needle shaft 244 and camshaft 260 to cause needles 246 to engage a multiplier gear 314 and an index gear 316 (with different combinations resulting in different gearing for the electric bicycle). For example, each of the gears 314, 316 correspond to a needle 246 of the first set 256 or second set 258, such that actuation of the camshaft 260 causes a needle 246 of the first set 256 to engage the respective multiplier gear 314 and a needle 246 of the second set 258 to engage the respective index gear 316.

[0331] The power is input into the gearbox subassembly 228 via the selected multiplier gear 314, transferred from the selected multiplier gear 314 to the selected index gear 316 via the engagement of the needles 246 in the needle shaft 244, and provided to the output compound gear 318 via the selected index gear 316. The rotation of the output compound gear 318 is transferred to the belt 112 via rotation of the spider 328 and the belt drive sprocket 332, causing the belt 112 to move.

[0332] Fig. 8 illustrates components of housing subassembly 102 interfacing with components of the subassemblies 104, 106, 108, 110 of the mid-drive motor package 100, according to one or more embodiments of the present disclosure. To accommodate the various components of the subassemblies 104, 106, 108, 110, the housing subassembly 102 includes bearings to facilitate the operation of the various components, and / or includes seals to protect the various components. For example, the housing subassembly 102 may include, but is not limited to, a bearing 334 and a radial shaft seal 336 within the motor side housing 114, which are configured to receive the crankshaft 122. By way of another example, the housing subassembly 102 may include, but is not limited to, a bearing 338 and a radial shaft seal 340 within the sprocket side housing 116, which are configured to receive the compound spur gear 320. Further, the housing subassembly 102 may include, but is not limited to, a bearing 342, a needle shaft bracket 344, and a bearing 346 within the sprocket side housing 116 and components of the transmission subassembly 110.

[0333] Although embodiments of the present disclosure illustrate the gearbox subassembly 228 and the countershaft subassembly 236 of the shifter subassembly 226 having a central axis that is coaxial with a central axis of the motor 136, it is noted that the respective central axes may be offset depending on the configuration of the mid-drive motor package 100, without departing from the scope of the present disclosure.

[0334] Fig. 9 is a method or process flow diagram 350 illustrating the operation of the middrive motor package 100, in accordance with one or more embodiments or the present disclosure. Fig. 10 illustrates arrows that represent an example operation of the mid-drive motor package 100 with subassemblies 102, 104, 106, 108, 110 based on the method or process flow diagram 350. The arrows in Fig. 10 are described in detail further herein, with the operation of the mid-drive motor packet 100 via the process flow diagram 350 in Fig. 9.

[0335] While a general order for the steps of the method or process is shown in Fig. 9, the method or process can include more or fewer steps or can arrange the order of the steps differently (including simultaneously, substantially simultaneously, or sequentially) than those shown in Fig. 9. It is noted that the method or process shall be explained with reference to the components, devices, subassemblies, environments, etc. described in conjunction with Figs. 1A-8, 10, and 11A-11K. For example, it is noted that the embodiments as illustrated in Figs. 1A-8, 10, and 11A-11K should be understood as reading on the embodiments described with respect to Fig. 9, and vice versa, without departing from the scope of the present disclosure.

[0336] In embodiments, a torque is received 400 with the crankshaft 122, applied via pedaling by a user (or a torque is inputted to the crankshaft 122 via pedaling), which is sensed by the controller 214. The controller 214 turns on the motor 136 based on the sensed torque input.

[0337] In embodiments, the inputted torque is transferred 404 into the combined synergy gear 180 (e.g., via the crankshaft clutch 126 and the ratchet wheel 188). Motor output is also passed into the combined synergy gear 180 (e.g., via the ratchet gear 176), with reduced motor speed and increased torque. For example, the ratchet gear 176 may operate as a oneway clutch for speed matching and to prevent back-driving the motor 136. By way of another example, the crankshaft clutch 126 (and the ratchet wheel 188) may operate as a one-way clutch with the sensors for speed and torque (e.g., hall sensors 202).

[0338] In embodiments, power from the motor 136 and the crankshaft 122 is combined 404 at the compound synergy gear 180. Power supplied by the motor 136 and the crankshaft 122 is merged via the ratchet wheel 188 and the compound synergy gear 180, and torque is added.

[0339] It is noted that the operations 400, 402, 404 represent separate inputs from the rider and from the motor, as illustrated by the arrows in Fig. 10.

[0340] In embodiments, the combined power is transferred 406 from the compound synergy gear 180 to the gearbox subassembly 228. For example, the multiplier gears 314 of the first set 232 of transmission gears are engaged with the compound synergy gear 180. Rotation of the compound synergy gear 180 with the combined power is thus ready to be transferred to the multiplier gears 314 of the first set 232 of transmission gears.

[0341] In embodiments, the combined power is transferred 408 from a multiplier gear 314 of the gearbox subassembly 228 to the camshaft 260. For example, the shifter subassembly 226 is actuated to cause the camshaft 260 to extend a first needle 246 of the first set 256 through a first needle shaft 244. The first extended needle 246 engages a particular multiplier gear 314 (e.g., 314B), and power is transferred from the compound synergy gear 180 to the camshaft 260 via the multiplier gear 314 and extended needle 246.

[0342] In embodiments, the combined power is transferred 410 from the camshaft 260 to an index gear 316. For example, the index gears 316 of the second set 234 of transmission gears are engaged with the output compound gear 318. Rotation of the index gear 316 of the second set 234 of transmission gears with the combined power is thus ready to be transferred to the output compound gear 318.

[0343] In embodiments, the combined power is modified 412 by the index gear 316 and the modified power is transferred into the output compound gear 318. For example, the shifter subassembly 226 is actuated to cause the camshaft 260 to extend a second needle 246 of the second set 258 to extend through a second needle shaft 244. The second extended needle 246 engages a particular index gear 316 (e.g., 316B), and power is transferred from the camshaft 260 to the output compound gear 318 via the extended needle 246 and index gear 316.

[0344] It is noted that the operations 406, 408, 410, 412 may be performed simultaneously or substantially simultaneously. For example, the needles 246 may already be extended for engagement with the particular multiplier gear 314 and particular index gear 316 when the combined power is transferred from the compound synergy gear 180 to the output compound gear 318, without departing from the scope of the present disclosure.

[0345] In addition, it is noted that the operations 406, 408, 410, 412 serve to modify the combined power by increasing it or decreasing it prior to the combined power being delivered to the output compound gear 318 through various combinations of the multiplier gears 314 and the index gears 316 that change the power input / output ratio between the compound synergy gear 180 and the output compound gear 318. For example, where there are three multiplier gears 314A-314C and three index gears 316A-316C, a total of nine combinations are possible that each modify the combined power in a different way, prior to the combined power being delivered from the compound synergy gear 180 to the output compound gear 318. In this regard, the combined power may be considered “modified” or a “modified combined power,” for the operations 414, 416, 418 as described further herein. It is noted, however, that the “modified power” may be the same as the “combined power”, such as where a particular combination of multiplier gear 314 and index gear 316 may result in a 1 : 1 ratio for the combined power between the combined synergy gear 180 and the output combined gear 318, without departing from the scope of the present disclosure.

[0346] In embodiments, the modified power is transferred 414 from the output compound gear 318 to a belt drive sprocket 332. For example, the output compound gear 318 may engage a spider 328, which is coupled to the belt drive sprocket 332. Rotation of the output compound gear 318 with the modified combined power is thus transferred to the belt drive sprocket 332 via the spider 328. It is noted, however, that the spider 328 and belt drive sprocket 332 may be fabricated as a single component, without departing from the present disclosure.

[0347] In embodiments, the modified power is transferred 416 from the belt drive sprocket 332 to the belt 112. For example, rotation of the belt drive sprocket 332 causes the belt 112 to translate.

[0348] In embodiments, the modified power is transferred 418 from the belt 112 to a rear hub of a rear wheel (not shown). For example, translation of the belt 112 causes a second belt drive sprocket operable to engage the rear hub to rotate, where rotation of the rear hub causes a rear wheel to rotate.

[0349] Figs. 11 A-l IK further describe the operation (e.g., powering, propelling, providing propulsion to, or the like) of the mid-drive motor package 100, including one or more steps of the process flow diagram 350, in accordance with one or more embodiments of the present disclosure. It is noted that the reference numbers and embodiments provided with respect to Figs. 1 A-8 may be understood as reading on Figs. 11 A-l IK, for purposes of the present disclosure.

[0350] Referring now generally to Figs. 11 A-l IK, in embodiments the multiplier gear and / or the index gear is shifted 420 with the shifter subassembly 226. The shifter subassembly 226 switching between combinations of particular multiplier gears 314 and index gears 316 is further described herein.

[0351] In one example, the shifter subassembly 226 may shift the multiplier gear 314 and / or the index gear 316 in use to a different multiplier gear 314 and / or a different index gear 316, respectively. In some embodiments, a rider may stop pedaling and / or the controller 214 may stop the motor 136 from providing power, prior to the shifting 420 occurring.

[0352] The needle shaft 244 and the camshaft 260 move together when in a selected combination of the multiplier gear 314 and the index gear 316 (i.e., which together represent a selected bicycle speed ratio), being held in place by the detent subassembly 238. In the non-limiting example illustrated throughout the figures, the first set 232 of transmission gears includes the “L” multiplier gear 314A, the “M” multiplier gear 314B, and the “H” multiplier gear 314C, and the second set 234 of transmission gears includes the “1” index gear 316A, the “2” index gear 316B, and the “3” index gear 314C. The shifter countershaft subassembly 236 includes a needle 246 for each of the six gears listed above, and is operable to allow any combination of a multiplier gear 314 and an index gear 316 to be selected for a total of nine combinations. In some embodiments, the nine combinations each create a unique power input / output ratio between the compound synergy gear 180 and the output compound gear 318.

[0353] To change to a different combination of gears or bicycle “speed,” the camshaft 260 is rotated relative to the needle shaft 244. Rotation of the camshaft 260 by the shifter planetary gearset 242 adjusts which of the camshaft protrusions 263 are in contact with a respective needle 246, such that a different multiplier gear 314 and / or a different index gear 316 may be selected through the retraction of currently extended needles 246 and extension of new needles 246. Table 1 provides a non-limiting example of the combinations of gears that result in the nine speeds for the mid-drive motor package 100.

[0354] Table 1 : Gear Combinations

[0355] In the non-limiting example of Table 1, the nine combinations of gears each have a unique ratio. In addition, in the non-limiting example of Table 1, the ratio between the combined multiplier gear 314 and index gear 316 reduces through speeds 1 through 9 from over 2 to less than 0.5, such that the final ratio of speed 1 is over 500% larger than the final ratio of speed 9.

[0356] As illustrated in Figs. 11 A and 1 IB, the camshaft 260 has been actuated so that the combination of the multiplier gear 314A or “L” and the index gear 316A or “1” are selected, representing the first bicycle speed ratio per Table 1. In the shifter subassembly 226, needles 246 that correspond to gears 314A and 316A extend through the needle shaft 244, while the remaining needles 246 are retracted beneath the exterior surface 254 of the needle shaft 244 and do not engage with the respective gears 314, 316. The lack of engagement between the remaining gears 314, 316 and the respective needles 246 allows the remaining gears 314, 316 to rotate freely about the needle shaft 244. In this regard, although rotation of the compound synergy gear 180 may cause all multiplier gears 314 to rotate and / or rotation of the output compound gear 318 may cause all index gears 316 to rotate, only the combination of gears 314, 316 that engage needles 246 extended by the camshaft 260 will engage the countershaft subassembly 236 (and thus the shifter subassembly 226) at any particular time. It is noted that the needle springs 250 are not shown for purposes of clarity only in Fig. 1 IB, which is not intended on being limiting to the present disclosure, and that the needles springs 250 engage the needles 246 such that contact is always maintained between all needles 246 and the camshaft 260.

[0357] As illustrated in Fig. 11C, the camshaft 260 has been actuated so that the multiplier gear 314A or “L” is selected. The multiplier gear 314A includes a gear protrusion 422 that engages a surface of the corresponding extended needle 246, such that the multiplier gear 314A drives the needle shaft 244 when the multiplier gear 314A rotates. In one non-limiting example, the gear protrusion 422 is contoured or shaped to permit torque transmission without slipping and to allow an increased ease of disengagement between the needle shaft 244 and the multiplier gear 314 A. In another non-limiting example, the gear protrusion 422 is contoured or shaped to be one-way, such that the gear protrusion 422 engages the needle 246 when the multiplier gear 314A rotates in a first direction but skips over the needle 246 when the multiplier gear 314A rotates in a second direction. In some embodiments, an adjacent gear protrusion 424 may be provided that rotates the multiplier gear 314A out of the way should a different needle 246 come in to contact with the multiplier gear 314A. This allows the multiplier gear 314A to be radially constrained to the needle shaft 244, without blocking needles 246 from being moved radially out of the needle shaft 244. It is noted that Fig. 11C may also be considered representative of the selection of the multiplier gear 314B or “M” and / or the multiplier gear 314C or “H,” for purposes of the present disclosure.

[0358] As illustrated in Fig. 1 ID, the camshaft 260 has been actuated so that the index gear 316A or “1” is selected. The index gear 316A includes a gear protrusion 426 that engages a surface of the corresponding extended needle 246, such that the needle shaft 244 drives the index gear 316A when the needle shaft 244 rotates. In one non-limiting example, the gear protrusion 426 is contoured or shaped to permit torque transmission without slipping and to allow an increased ease of disengagement between the needle shaft 244 and the index gear 316A. In another non-limiting example, the gear protrusion 426 is contoured or shaped to be one-way, such that the gear protrusion 424 engages the needle 246 when the index gear 316A rotates in a first direction but skips over the needle 246 when the index gear 316A rotates in a second direction. In some embodiments, an adjacent gear protrusion 428 may be provided that rotates the index gear 316A out of the way should the needle 246 come in to contact with the adjacent gear protrusion 428. This allows the index gear 316A to be radially constrained to the needle shaft 244, without blocking needles 246 from being moved radially out of the needle shaft 244. It is noted that Fig. 1 ID may also be considered representative of the selection of the index gear 316B or “2” and / or the index gear 316C or “3,” for purposes of the present disclosure.

[0359] It is contemplated that the camshaft protrusions 263 for the index gears 316 may need to be mirrored relative to the camshaft protrusions 263 for the multiplier gears 314, as the needle shaft 244 drives the index gear 316A versus the multiplier gear 314A driving the needle shaft 244.

[0360] Figs. 1 IE and 1 IF illustrate variations of the gear protrusions 422, 424 of the gears 314, 316. As illustrated in Fig. HE, the needle 246 may be contained within a groove 430 between the gear protrusions 422, 424. As illustrated in Fig. 1 IF, however, the gear protrusions 422, 424 have a sloped surface 432 that allows the needle 246 to more easily and efficiently be shifted into a locked position. It is noted that Figs. 1 IE and 1 IF may also be considered representative of the gear protrusions 426, 428 for purposes of the present disclosure.

[0361] As illustrated in Fig. 11G, during a phase of riding in which the gear combination remains unchanged and power is transferred through the transmission subassembly 110 to the belt 112, the detent subassembly 238 engages the needle shaft 244 to prevent the camshaft 260 from rotating relative to the needle shaft 244, such that the camshaft 260 and the needle shaft 244 rotate together and without relative motion to one another. For example, the plunger 266 may extend outward from the detent cavity 270 to engage one of the radial mating holes 271 within the needle shaft 244.

[0362] In another phase of riding in which the gear combination is changed, however, the detent subassembly 238 is disengaged to uncouple the camshaft 260 from the needle shaft 244, and the camshaft 260 is configured to rotate relative to the needle shaft 244 until the detent subassembly 238 is locked in a new position (which corresponds to a new speed or combination of gears). For example, when the plunger 266 is rotationally forced against the needle shaft 244, the tip of the plunger 266 (e.g., which may be rounded for increased ease of insertion into and withdrawal from the radial mating holes 271) causes the plunger 266 to slide radially inward toward the detent spring 268. The camshaft 260 turns until the plunger 266 reaches the next radial mating hole 271 in the needle shaft 244, such that the plunger 266 engages the next radial mating hole 271 and locks the camshaft 260 and needle shaft 244 together in a new position corresponding to a different combination of needles 246. The needles 246 then extend outward from the needle shaft 244 to engage a new gear 314 and / or 316, resulting in a new bicycle speed ratio being selected. It is noted that motion of the plunger 266 and opposite rotation of the camshaft 260 relative to the needle shaft 244 are illustrated with arrows in Fig. 10G for purposes of clarity. In addition, it is noted that multiplier gears 314A and 314B are shown, but that any of the gears 314, 316 may be similarly represented without departing from the scope of the present disclosure.

[0363] As illustrated in Figs. 11H-11K, the shifter planetary gearset 242 actuates the camshaft 260. Unlike the motor planetary gearset 138 where the motor gear 152 is the sun and the ring gear 166 is the output, the shifter planetary gearset 242 drives the needle ring 292 and the needle sun 284 is the output. This causes the shifter planetary gearset 242 to operate as a speed increaser rather than a speed reducer, in line with Eq. 1 above. As there is only one set of needle planet gears 286, such that the needle sun 284 rotates in an opposite direction as compared to the needle ring 292, the negative sign in Eq. 1 is used to describe the ratio of the shifter planetary gearset 242. It is noted herein, however, that the shifter planetary gearset 242 may be configured as an increaser, but that is not intended to be limiting on the present disclosure. For example, the shifter planetary gearset 242 may function as a reducer without departing from the scope of the present disclosure, as the shifter planetary gearset 242 is operable to create a phase shift or phase change between the concentric camshaft 260 and needle shaft 244 (e.g., which would otherwise move together and at the same speed).

[0364] In some embodiments, when the cam ring 300 is fixed in position, the common carrier 288 freewheels as each planetary set 283, 295 is operating in the same configuration. For example, the needle sun 284 and the cam sun 301 each operate as the respective input, the needle planet gears 286 and the cam planet gears 296 each operate as the respective output through the common carrier 288, and the needle ring 292 and cam ring 300 each operate as reactionary elements.

[0365] However, changing the combination of gears to switch bicycle “speeds” involves turning the worm shaft 304, which turns the cam ring 300. This causes the cam sun 301 to rotate in an opposite direction via the transfer of rotational energy through the cam planet gears 296, such that the configuration of the cam planetary set 295 changes to the cam ring 300 being the input, the cam sun 301 being the output, and the cam planet gears 296 being the reactionary elements.

[0366] As the carrier 288 is common between the needle planet gears 286 and the cam planet gears 296, the carrier 288 similarly becomes a reactionary element for the needle planetary set 283. The needle ring 292 being fixed (e.g., to the sprocket side housing 116) thus causes the needle planetary set 283 to have two reactionary members, resulting in the suns 284, 301 to rotate relative to one another. This relative rotation creates a phase shift or phase change between the needle shaft 244 and the camshaft 260, rotating the camshaft 260 to create a change in gear combination or bicycle speed ratio.

[0367] In one non-limiting example, the camshaft 260 has 9 equally spaced positions, or one for each gear ratio caused by a particular combination of gears that represent a select bicycle speed ratio, such that the camshaft 260 may rotate in 40-degree (°) increments between radial mating holes 271 (e.g., have a change in angular position of 40°). The cam ring 300 turns the camshaft 260 through the cam planet gears 296 at the ratio of the number of teeth 303 on the cam ring 300 to the number of teeth 307 on the cam sun 301, as shown in Eq. 3: es= -0rnr / nsEq. 3 where 0ris the angle of rotation of the cam ring 300, 0Sis the angle of rotation of the cam sun 301, nris the number of teeth of the cam ring 300, and nsis the number of teeth of the cam sun 301. In this non-limiting example, the ratio of teeth is such that a 22.95 degree / shift clockwise (e.g., as represented by angle 434 in Fig. 11 J) at the cam ring 300 (via the worm shaft 304) causes the 40° rotation of the camshaft 260 between radial mating holes 271 (e.g., as represented by angle 436 in Fig. 111). In one instance, the threading 305 on the worm shaft 304 and the teeth 303 of the cam ring 300 may be configured such that one rotation of the worm shaft 304 rotates the cam ring 300 one tooth 303, such that approximately 8.29 revolutions of the worm shaft 304 is necessary to complete the 22.95° rotation of the cam ring 300.

[0368] In embodiments as illustrated in Figs. 11 J and UK, an exterior surface 435 of the cam ring 300 may include gearing indicators 437 that respectively represent a particular gear combination or speed ratio of the transmission subassembly 110. For example, the exterior surface 435 may include one gearing indicator 437 per gear combination or speed ratio. In the exemplary configuration described herein, the exterior surface 435 has nine gearing indicators 437, for the nine different gear combinations or speed ratios. It is noted that the particular gearing indicator 437 representing the particular gear combination or speed ratio of the transmission subassembly 110 may align with the threading 305 on the worm shaft 304. In addition, it is noted that the gearing indicators 437 may be visible within the housing subassembly 102 including, but not limited to, removal of the shifter planetary cover 118 or through a transparent or semi-transparent portion of the housing subassembly 102 (e.g., such as a transparent or semi-transparent shifter planetary cover 118). In this regard, the mid-drive motor package 100 may be monitored for correct alignment within the transmission subassembly 110, without needing to dismantle the entire mid-drive motor package 100.

[0369] It is noted that when the cam ring 300 returns to a stationary reactionary state, the needle shaft 244 and the camshaft 260 return to a 1 : 1 rotary speed.

[0370] In some embodiments, the components of the mid-drive motor package 100 are fabricated from one or more materials including, but not limited to, aluminum or other metal, carbon fiber or another composite material, plastic, rubber, or the like. In additional embodiments, the flex elements or springs 172, 192, 250, 268, 276 may be helical springs, springs that terminate with a ring or loop at either end, incomplete loops, fully complete loops , or the like. It is noted, however, that the flex elements or springs 172, 192, 250, 268, 276 may be more broadly described as bias members that may include, but is not limited to, other solid structures such as air bags, hydraulic systems, pneumatic systems, or the like.

[0371] It should be understood that although the present disclosure illustrates a nine-speed mid-drive motor package 100 with nine combinations of gears 314, 316 within the transmission subassembly 110, the number of gears 314, 316 is not intended to be limiting on the present disclosure. Rather, it is contemplated that the various subassemblies of the mid-drive motor package 100 may be modified to include more or fewer gears 314, 316, resulting in more or fewer combinations of gears (or speeds) for the electric bicycle.

[0372] In this regard, advantages of the present disclosure include, but are not limited to, a mid-drive motor package including a power transmission for an electric bicycle. In particular, advantages of the present disclosure are directed to a mid-drive motor package including a power transmission that is configured to combine a crankshaft output generated from an applied torque with a power output from a mid-drive motor to drive a belt connected to a rear wheel. The mid-drive motor package takes power delivered by the motor and converts it from being speed dominant to being torque dominant, such that the speed of the motor is reduced to the speed of the cadence of the rider.

[0373] Advantages of the present disclosure also include, but are not limited to, a mid-drive motor package that includes a transmission subassembly that receives the combined power, modifies it based on a gear ratio between a selected combination of transmission gears, and outputs the modified combined power to a belt drive assembly. Shifting of the transmission subassembly to change the combination of gears includes a set of cams that are manually or automatically controlled by a controller, where the set of cams are inserted within the transmission subassembly such that the transmission gears rotate around the set of cams and are configured to interface with the set of cams.

[0374] While various embodiments of the present disclosure have been described in detail, it is apparent that modifications and alterations of those embodiments will occur to those skilled in the art. However, it is to be understood that such modifications and alterations are within the scope and spirit of the present disclosure, as set forth in the following claims.

[0375] Further, the invention(s) described herein is capable of other embodiments and of being practiced or of being carried out in various ways. It is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.

Claims

CLAIMSWhat is claimed is:

1. A shifter subassembly of a transmission subassembly for a vehicle, comprising: a countershaft subassembly, comprising: a needle shaft with a plurality of needle apertures; a plurality of needles, wherein each needle of the plurality of needles is positioned within a respective needle aperture of the plurality of needle apertures; and a camshaft inserted into a cavity defined within a needle shaft, wherein the camshaft and the needle shaft are coaxial; wherein the camshaft is configured to rotate relative to the needle shaft between a first angular position and a second angular position, wherein the camshaft includes a plurality of camshaft surfaces that selectively engage the plurality of needles to selectively extend the plurality of needles radially outward from the needle shaft, wherein, when a first combination of needles of the plurality of needles extends radially outward from the needle shaft when the camshaft is in the first angular position relative to the needle shaft, the first combination of needles engages a first combination of transmission gears of the transmission subassembly that corresponds to a first speed ratio, and wherein, when a second combination of needles of the plurality of needles extends radially outward from the needle shaft when the camshaft is in the second angular position relative to the needle shaft, the second combination of needles engages a second combination of transmission gears of the transmission subassembly that corresponds to a second speed ratio.

2. The shifter subassembly of claim 1, wherein each needle of the plurality of needles is held within the respective needle aperture of the plurality of needle apertures by a needle spring.

3. The shifter subassembly of claim 1, further comprising: a detent subassembly, comprising: a plunger positioned within a detent cavity defined within the camshaft, wherein the plunger is operable to engage the needle shaft; and a spring positioned within the detent cavity, wherein the spring is operable to cause the plunger to maintain contact with the needle shaft, wherein rotation of the camshaft between the first angular position and the second angular position causes the plunger to disengage from a first radial mating hole in the needle shaft and to engage a second radial mating hole in the needle shaft.

4. The shifter subassembly of claim 3, wherein the detent subassembly further comprises a preload screw that sets the plunger at a predetermined depth within the detent cavity to provide a predetermined load for engaging the first radial mating hole with the plunger.

5. The shifter subassembly of claim 1, further comprising: a shifter planetary gearset, comprising: a needle planetary set including a needle ring, a plurality of needle planet gears, and a needle sun, wherein the needle planetary set engages the needle shaft; a cam planetary set including a cam ring, a plurality of cam planet gears, and a cam sun, wherein the cam planetary set engages the camshaft; and a common carrier, wherein the plurality of cam planet gears and the plurality of needle planet gears are coupled to the common carrier.

6. The shifter subassembly of claim 5, wherein the cam planetary set is actuatable via rotation of the cam ring by a servo via a worm shaft, wherein rotation of the cam ring causes the camshaft to rotate between the first angular position and the second angular position.

7. The shifter subassembly of claim 5, further comprising: a synchronizer subassembly, comprising: a synchronizer spring shaft positioned in a synchronizer cavity defined within the camshaft, wherein the cam sun is operable to engage the synchronizer spring shaft and provide energy to rotate the camshaft between the first angular position and the second angular position via the synchronizer spring shaft; and a synchronizer spring positioned in the synchronizer cavity, wherein the synchronizer spring is operable to store energy provided to the synchronizer spring shaft.

8. A transmission subassembly for a vehicle, comprising: a gearbox subassembly, comprising: a plurality of multiplier gears that is operable to engage a compound synergy gear and receive a power output from the compound synergy gear; and a plurality of index gears that is operable to receive power from the plurality of multiplier gears, the plurality of index gears being operable to engage an output compound gear and provide a modified power output to the output compound gear, wherein a first combination of transmission gears for modifying the power output includes a first multiplier gear of the plurality of multiplier gears and a first index gear of the plurality of index gears that correspond to a first speed ratio, wherein a second combination of transmission gears for modifying the power output includes the first multiplier gear of the plurality of multiplier gears and a second index gear of the plurality of index gears that correspond to a second speed ratio; and a shifter subassembly including a countershaft subassembly, wherein the plurality of multiplier gears and the plurality of index gears each include apertures operable to receive the countershaft subassembly such that the countershaft subassembly, the plurality of multiplier gears, and the plurality of index gears are coaxial, and wherein the countershaft subassembly engages the plurality of multiplier gears and the plurality of index gears to shift the gearbox subassembly between the first combination of transmission gears and the second combination of transmission gears.

9. The transmission subassembly of claim 8, wherein the countershaft subassembly comprises: a needle shaft with a plurality of needle apertures; a plurality of needles, wherein each needle of the plurality of needles is positioned within a respective needle aperture of the plurality of needle apertures; and a camshaft inserted into a cavity defined within a needle shaft, wherein the camshaft and the needle shaft are coaxial; wherein the camshaft is configured to rotate relative to the needle shaft between a first angular position and a second angular position, wherein the camshaft includes a plurality of camshaft surfaces that selectively engage the plurality of needles to selectively extend the plurality of needles radially outward from the needle shaft, wherein, when a first combination of needles of the plurality of needles extends radially outward from the needle shaft when the camshaft is in the first angular position relative to the needle shaft, the first combination of needles engages the first combination of transmission gears, and wherein, when a second combination of needles of the plurality of needles extends radially outward from the needle shaft when the camshaft is in the second angular position relative to the needle shaft, the second combination of needles engages the second combination of transmission gears.

10. The transmission subassembly of claim 8, further comprising: a belt drive subassembly, comprising: a spider operable to engage the output compound gear; and a belt drive sprocket coupled to the spider, wherein the spider transfers the modified power output to the belt drive sprocket, and wherein the belt drive sprocket drives a belt.

11. The transmission subassembly of claim 10, wherein the spider is a separately-fabricated component coupled to the belt drive sprocket, such that the belt drive sprocket is interchangeable on the spider.

12. A mid-drive motor package for an electric bicycle, comprising: a crankshaft subassembly; a motor subassembly;a sensor drive subassembly operable to receive a first power output from the crankshaft subassembly and receive a second power output from the motor subassembly, the sensor drive subassembly additionally operable to combine the first power output and the second power output into a combined power output; and a transmission subassembly operable to receive the combined power output from the sensor drive subassembly, the transmission subassembly additionally operable to modify the combined power output to create a modified combined power output, the transmission subassembly further operable to provide the modified combined power output to a belt of the electric bicycle, wherein the transmission subassembly comprises: a gearbox subassembly including a plurality of transmission gears, wherein a first combination of transmission gears of the plurality of transmission gears corresponds to a first speed ratio of the electric bicycle, and a second combination of transmission gears of the plurality of transmission gears corresponds to a second speed ratio of the electric bicycle; and a shifter subassembly including a countershaft subassembly inserted within the plurality of transmission gears such that the countershaft subassembly and the plurality of transmission gears are coaxial, wherein the countershaft subassembly selectively engages the plurality of transmission gears to shift the gearbox subassembly between the first combination of transmission gears and the second combination of transmission gears.

13. The mid-drive motor package of claim 12, wherein the crankshaft subassembly comprises: a crankshaft including a spline; and a clutch installed on the spline, wherein the clutch transfers power from the crankshaft to the sensor drive subassembly when the crankshaft rotates in a first direction.

14. The mid-drive motor package of claim 12, wherein the motor subassembly comprises: a motor including a motor gear; a motor planetary gearset including at least one set of planet gears and a planetary ring gear, wherein the at least one set of planet gears are operable to transfer power from the motor gear to the planetary ring gear; anda ring shaft subassembly including a ratchet gear, wherein the planetary ring gear is coupled to the ring shaft subassembly, and wherein the ratchet gear transfers the power from the planetary ring gear to the sensor drive subassembly when the ratchet gear rotates in a first direction.

15. The mid-drive motor package of claim 12, wherein the sensor drive subassembly comprises: a ratchet wheel operable to engage with the crankshaft subassembly and receive the first power output from the crankshaft subassembly; and a compound synergy gear, comprising: a spur gear operable to engage with the motor subassembly and receive the second power output from the motor subassembly; and a plurality of compound spur gears operable to engage with the transmission subassembly, wherein the compound synergy gear is operable to combine the first power output and the second power output into the combined power output and provide the combined power output to the gearbox subassembly.

16. The mid-drive motor package of claim 15, further comprising: a sensor subassembly operable to acquire data for at least one of speed and torque of the ratchet wheel, the sensor subassembly additionally operable to acquire data for at least one of speed and torque of the compound synergy gear, wherein the data acquired by the sensor subassembly is provided to a controller of the mid-drive motor package to adjust the second power output from the motor subassembly.

17. The mid-drive motor package of claim 12, wherein the countershaft subassembly comprises: a needle shaft with a plurality of needle apertures; a plurality of needles, wherein each needle of the plurality of needles is positioned within a respective needle aperture of the plurality of needle apertures; and a camshaft inserted into a cavity defined within a needle shaft, wherein the camshaft and the needle shaft are coaxial; wherein the camshaft is configured to rotate relative to the needle shaft between a first angular position and a second angular position,wherein the camshaft includes a plurality of camshaft surfaces that selectively engage the plurality of needles to selectively extend the plurality of needles radially outward from the needle shaft, wherein, when a first combination of needles of the plurality of needles extends radially outward from the needle shaft when the camshaft is in the first angular position relative to the needle shaft, the first combination of needles engages the first combination of transmission gears, and wherein, when a second combination of needles of the plurality of needles extends radially outward from the needle shaft when the camshaft is in the second angular position relative to the needle shaft, the second combination of needles engage the second combination of transmission gears.

18. The mid-drive motor package of claim 12, wherein the plurality of transmission gears comprises: a plurality of multiplier gears that is operable to engage a compound synergy gear of the sensor drive subassembly and receive the combined power output from the sensor drive subassembly; and a plurality of index gears that is operable to engage an output compound gear of a belt drive subassembly and operable to provide the modified combined power output to the belt via the output compound gear, wherein the first combination of transmission gears modifies the combined power output and include a first multiplier gear of the plurality of multiplier gears and a first index gear of the plurality of index gears that correspond to the first speed ratio of the electric bicycle, wherein the second combination of transmission gears modifies the combined power output and include the first multiplier gear of the plurality of multiplier gears and a second index gear of the plurality of index gears that correspond to the second speed ratio of the electric bicycle.

19. A method for propelling a vehicle, comprising: receiving a first power output from a crankshaft subassembly; receiving a second power output from a motor subassembly; combining the first power output and the second power output via a sensor drive subassembly to create a combined power output; receiving the combined power output via a transmission subassembly;modifying the combined power output to create a modified power output via a first combination of transmission gears that corresponds to a first speed ratio, wherein the first combination of transmission gears includes a first multiplier gear of a plurality of multiplier gears and a first index gear of a plurality of index gears, and wherein the first combination of transmission gears are selected via a shifter subassembly including a countershaft subassembly inserted within the plurality of multiplier gears and the plurality of index gears such that the countershaft subassembly, the plurality of multiplier gears, and the plurality of index gears are coaxial; and providing the modified power output to a belt of the vehicle.

20. The method of claim 19, further comprising: actuating the countershaft subassembly to cause the transmission subassembly to shift between the first combination of transmission gears and a second combination of transmission gears that corresponds to a second speed ratio, wherein the countershaft subassembly comprises: a needle shaft with a plurality of needle apertures; a plurality of needles, wherein each needle of the plurality of needles is positioned within a respective needle aperture of the plurality of needle apertures; and a camshaft inserted into a cavity defined within a needle shaft, wherein the camshaft and the needle shaft are coaxial; wherein the camshaft is configured to rotate relative to the needle shaft between a first angular position and a second angular position, wherein the camshaft includes a plurality of camshaft surfaces that selectively engage the plurality of needles to selectively extend the plurality of needles radially outward from the needle shaft, wherein, when a first combination of needles of the plurality of needles extends radially outward from the needle shaft when the camshaft is in the first angular position relative to the needle shaft, the first combination of needles engages the first combination of transmission gears, and wherein, when a second combination of needles of the plurality of needles extends radially outward from the needle shaft when the camshaft is in a second angular position relative to the needle shaft, the second combination of needles engages the second combination of transmission gears.

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