Continuously variable transmission for an electric bicycle

Abstract

A compact-size CVT in a mid-drive motor package for an electric bicycle includes planetary gear systems coupled to motors, which are each coaxial along a longitudinal axis through a crankshaft insertable through the planetary gear system and motors. A two-gearbox CVT includes an assistant subassembly with an assistant motor and an assistant gearbox, and a shifting subassembly with a shifting motor and a shifting gearbox, for providing the power output of the assistant subassembly and the shifting subassembly, along with an optional user input from a crankshaft. A three-gearbox CVT includes an assistant subassembly with an assistant motor and an assistant gearbox, a shifting subassembly with shifting motor and shifting gearbox, and a planetary gear system for providing the power outputs of the assistant subassembly and the shifting subassembly, along with an optional user input from a crankshaft. Controlled power output by the shifting and assistant motors promotes CVT functionality.

Description

[0001] CONTINUOUSLY VARIABLE 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 / 605,350, filed December 1, 2023, which is incorporated herein in its entirety by reference.

[0004] FIELD

[0005] The disclosure relates to a transmission for an electric bicycle and, in particular, is directed to a continuously variable transmission for an electric bicycle in a compact middrive motor package.

[0006] BACKGROUND

[0007] In the electric bicycle (or E-bike) industry, continuously variable transmission (CVT) technology presents challenges due to the unique constraints of electric bicycles. Typically, achieving a desired reducer ratio in a transmission for an electric bicycle requires multiple gear systems, each including shaft spur gear systems and / or planetary gear systems, resulting in larger packaging sizes. This increases the cost and complexity of the transmission, and increases the weight of the electric bicycle to which the electric transmission is coupled.

[0008] Previous attempts to adapt the automatic CVT mechanism from cars to electric bicycles have faced several disadvantages. For example, one major drawback is that CVT technology is traditionally designed to operate most efficiently at high speeds, while bikes typically operate at lower speeds. This requires a CVT installed on an electric bicycle to increase speed first to reach optimal efficiency, before decreasing the speed for the electric bicycle to achieve the desired continuous shifting operation. One method to offset this requirement is the incorporation of numerous gear sets within the CVT, which results in a larger overall size. In addition, when considering the desired speed ratio for the electric bicycle, a typical CVT may require multiple shafts of spur gear systems or multiple levels of planetary gear systems to output the necessary ratio if a motor were used to drive the electric bicycle, similarly increasing the packaging size of the CVT.

[0009] As such, known CVT technology in electric bicycles involves complex arrangements of gear sets and a large packaging size. In addition, known CVT technology in electric bicycles requires additional shafts or gear systems to achieve the desired speed ratio, further increasing the packaging size. SUMMARY

[0010] As such, there exists a need for a CVT for an e-bike that is compact in size and that can shift while in pedal assist mode. Embodiments of the present disclosure are directed to a compact-size CVT for an electric bicycle in a mid-drive motor package. The present disclosure addresses the above issues by employing a planetary gear system that takes input power from multiple motors. An output power is obtained from a planet carrier of the planetary gear system, which is a combination of the power received from one or multiple motors, and optionally the input from the crankshaft, resulting in continuous speed variation to provide electric bicycles with CVT technology. Embodiments of the present disclosure are also directed to the use of a harmonic gear system, which offers advantages through easily achieved larger gear ratios. The implementation of the harmonic gear system significantly reduces the overall package size of the mid-drive motor package, addressing packaging constraints in electric bicycle designs. Embodiments of the present disclosure are further directed to incorporating the use of an axial flux motor within the mid-drive motor package. Use of an axial flux motor allows for a feasible and efficient packaging solution, enabling the successful implementation of CVT technology in electric bicycles.

[0011] It is one aspect of embodiments of the present disclosure to provide planetary gear systems in the CVT. In some embodiments, a ring gear or a sun gear of the planetary gear system inputs a speed, and the carrier speed in the planetary gear system is variable. The carrier speed may be controlled by the input speed of the ring gear. As a result, the speed ratio is not fixed but instead is continuously variable. Embodiments of the present disclosure are also directed to axial flux motors in the CVT. In some embodiments, the axial flux motors include a center hollow design, allowing for placement directly on an axle or crankshaft without the need for multiple shafts, creating compact packaging and making the mid-drive motor package more space-efficient. Embodiments of the present disclosure are also directed to a planetary gear system that uses multiple gears to transfer power, enabling a CVT shifting function that smoothly changes gear ratios while maintaining a less complex structure and a more compact packaging. Embodiments of the present disclosure are also directed to a harmonic gear system that allows for a large speed ratio while maintaining a compact size to achieve a wide range of speed adjustments efficiently. In this regard, compact packaging is enabled while offering CVT operation and a large speed ratio, due to the single-axis build of the planetary gear systems and the motors (i.e., about a longitudinal axis defined by a crankshaft inserted or located through the planetary gear systems and the motors, such that the planetary gear systems and the motors are co-axial).

[0012] It is another aspect of embodiments of the present disclosure to provide a three- gearbox CVT. The three-gearbox CVT includes an assistant subassembly with an assistant motor for providing assistant power and an assistant gearbox for the assistant motor, which is responsible for transferring the assistant power from the assistant motor. The three- gearbox CVT additionally includes a shifting subassembly with a shifting motor that provides shifting power used for shifting gears in the CVT and a shifting gearbox for the shifting motor that facilitates gear shifting operations. The three-gearbox CVT further includes a planetary gear system that receives inputs from both the assistant subassembly and the shifting subassembly, and produces a power as a variable speed output through an output sprocket. The planetary gear system, driven by the assistant subassembly and / or the shifting subassembly, enables continuous variation of the speed output. In this regard, the three-gearbox CVT of the present disclosure offers versatility and control over the reducer speed ratio, enhancing the overall performance and efficiency of the electric bicycle.

[0013] It is a further aspect of embodiments of the present disclosure to provide a two- gearbox CVT. The two-gearbox CVT includes an assistant subassembly with an assistant motor for providing assistant power to the CVT, and an assistant gearbox for the assistant motor that is responsible for transferring the assistant power from the assistant motor. The two-gearbox CVT additionally includes a shifting subassembly with a shifting motor that provides shifting power used for shifting gears in the CVT, and a shifting gearbox for the shifting motor that facilitates gear shifting operations. The shifting subassembly produces a power from the assistant power and / or the shifting power as a variable speed output through an output sprocket, where the power enables continuous variation of the speed output. In this regard, the two-gearbox CVT of the present disclosure offers versatility and control over the reducer speed ratio, enhancing the overall performance and efficiency of the electric bicycle.

[0014] It is a further aspect of embodiments of the present disclosure to provide an electric bicycle. The electric bicycle includes a mid-drive motor package with an assistant subassembly and a shifting subassembly. Optionally, the mid-drive motor package includes a planetary gear system in addition to the assistant subassembly and the shifting subassembly. The mid-drive motor package is in communication with a hub of a wheel via a belt or chain. The electric bicycle includes a battery pack for powering the mid-drive motor package. The electric bicycle includes a control system operable to monitor and / or control one or more aspects of the electric bicycle, including battery pack input / output, assistant motor input / output, and / or shifting motor input / output.

[0015] It is a further aspect of embodiments of the present disclosure to provide an assistant subassembly and a shifting subassembly within a CVT of a mid-drive motor package that contributes to the continuous variability of the speed ratio or mechanical advantage of the mid-drive motor package. In a three-gearbox CVT, the combination of the assistant subassembly and the shifting subassembly continuously varies the speed ratio of a planetary gear system by rotating the output of the planetary gear system (i.e., which is in communication with an output sprocket of the mid-drive motor package) with variable speeds. Thus, even with a fixed number of teeth and gears, the speed ratio of the planetary gear system is continuously variable. Similarly, in a two-gearbox CVT, the combination of the assistant subassembly and the shifting subassembly continuously varies the speed ratio between a user input and a modified shifting power that is transmitted to an output of the CVT.

[0016] A first aspect of embodiments of the present disclosure is to provide a CVT of a middrive motor package for an electric bicycle. The CVT includes an assistant subassembly with an assistant motor operable to produce assistant power; and an assistant gearbox operable to receive the assistant power via a first set of assistant planet gears and convert the assistant power via a second set of assistant planet gears to produce a modified assistant power. The CVT includes a shifting subassembly with a shifting motor operable to produce shifting power; and a shifting gearbox operable to receive the shifting power via a first set of shifting planet gears and convert the shifting power via a second set of shifting planet gears to produce a modified shifting power. The CVT includes a planetary gear system operable to receive the modified assistant power from the assistant subassembly and provide the modified assistant power to an output of the mid-drive motor package, the planetary gear system further operable to receive the modified shifting power from the shifting subassembly and provide the modified shifting power to the output of the mid-drive motor package. The assistant motor, the assistant gearbox, the shifting motor, the shifting gearbox, and the planetary gear system are coaxial along a longitudinal axis through the assistant subassembly, the shifting subassembly, and the planetary gear system.

[0017] The CVT of the first aspect may include, optionally, a clutch operable to transfer the modified assistant power from the assistant gearbox to the planetary gear system. The CVT of the first aspect may include one or more of the previous embodiments and, optionally, wherein the assistant gearbox includes a first assistant ring gear operable to engage with the first set of assistant planet gears, wherein the first assistant ring gear is fixed in place within the continuously variable transmission; a second assistant ring gear operable to engage with the second set of assistant planet gears; and an assistant planet carrier to which the first set of assistant planet gears and the second set of assistant planet gears are coupled. The assistant gearbox receives the assistant power from the assistant motor via the assistant planet carrier. The assistant gearbox provides the modified assistant power via the second assistant ring gear.

[0018] The CVT of the first aspect may include one or more of the previous embodiments and, optionally, wherein the shifting gearbox includes a first shifting ring gear operable to engage with the first set of shifting planet gears, wherein the first shifting ring gear is fixed in place within the continuously variable transmission; a second shifting ring gear operable to engage with the second set of shifting planet gears; and a shifting planet carrier to which the first set of shifting planet gears and the second set of shifting planet gears are coupled. The shifting gearbox receives the shifting power from the shifting motor via the shifting planet carrier. The shifting gearbox provides the modified shifting power via the second shifting ring gear.

[0019] The CVT of the first aspect may include one or more of the previous embodiments and, optionally, wherein the planetary gear system includes a sun gear operable to receive the modified assistant power provided by the assistant gearbox; a ring gear operable to receive the modified shifting power provided by the shifting gearbox; and a planet carrier to which a set of planet gears are coupled. The set of planet gears are operable to engage the sun gear and transfer the modified assistant power via the planet carrier to the output of the mid-drive motor package. The set of planet gears are operable to engage the ring gear and transfer the modified shifting power via the planet carrier to the output of the mid-drive motor package.

[0020] The CVT of the first aspect may include one or more of the previous embodiments and, optionally, wherein the longitudinal axis is defined along a length of a crankshaft of the mid-drive motor package, wherein the crankshaft is inserted or located through the assistant motor and the assistant gearbox of the assistant subassembly, the shifting motor and the shifting gearbox of the shifting subassembly, and the planetary gear system, wherein the sun gear is operable to receive crankshaft power generated in the crankshaft, and wherein the sun gear is operable to combine the received crankshaft power and the received modified assistant power prior to engagement with the set of planet gears.

[0021] The CVT of the first aspect may include one or more of the previous embodiments and, optionally, a clutch operable to transfer the crankshaft power from the crankshaft to the sun gear of the planetary gear system.

[0022] The CVT of the first aspect may include one or more of the previous embodiments and, optionally, wherein a reference plane is definable between the assistant subassembly and the shifting subassembly, wherein, within the assistant subassembly, the assistant motor is positioned lateral relative to the reference plane and the assistant gearbox is positioned medial relative to the reference plane, wherein, within the shifting subassembly, the shifting gearbox is positioned lateral relative to the reference plane and the shifting motor is positioned medial relative to the reference plane, and wherein the planetary gear system is positioned lateral to the shifting subassembly relative to the reference plane.

[0023] The CVT of the first aspect may include one or more of the previous embodiments and, optionally, wherein the assistant motor and the shifting motor are axial flux motors, and wherein the output of the mid-drive motor package is an output sprocket.

[0024] A second aspect of embodiments of the present disclosure is to provide a CVT of a mid-drive motor package for an electric bicycle. The CVT includes an assistant subassembly with an assistant motor operable to produce assistant power; and an assistant gearbox operable to receive the assistant power via a first set of assistant planet gears and convert the assistant power via a second set of assistant planet gears to produce a modified assistant power. The CVT includes a shifting subassembly with a shifting motor operable to produce shifting power; and a shifting gearbox operable to receive the shifting power via a first set of shifting planet gears and convert the shifting power via a second set of shifting planet gears to produce a modified shifting power. The shifting subassembly is operable to provide the modified shifting power to an output of the mid-drive motor package. The shifting subassembly is further operable to receive the modified assistant power and provide the modified assistant power to the output of the mid-drive motor package. The assistant motor, the assistant gearbox, the shifting motor, the shifting gearbox are coaxial along a longitudinal axis through the assistant subassembly and the shifting subassembly.

[0025] The CVT of the second aspect may include, optionally, wherein the assistant gearbox includes a first assistant ring gear operable to engage with the first set of assistant planet gears, wherein the first assistant ring gear is fixed in place within the continuously variable transmission; a second assistant ring gear operable to engage with the second set of assistant planet gears; and an assistant planet carrier to which the first set of assistant planet gears and the second set of assistant planet gears are coupled. The assistant gearbox receives the assistant power from the assistant motor via the assistant planet carrier. The assistant gearbox provides the modified assistant power via the second assistant ring gear.

[0026] The C VT of the second aspect may include one or more of the previous embodiments and, optionally, wherein the shifting gearbox includes a first shifting ring gear operable to engage with the first set of shifting planet gears; a second shifting ring gear operable to engage with the second set of shifting planet gears; and a shifting planet carrier to which the first set of shifting planet gears and the second set of shifting planet gears are coupled. The shifting gearbox receives the shifting power from the shifting motor via the shifting planet carrier. The shifting gearbox provides the modified shifting power via the second shifting ring gear. The second shifting ring gear is operable to provide the modified assistant power and the modified shifting power to the output of the mid-drive motor package.

[0027] The C VT of the second aspect may include one or more of the previous embodiments and, optionally, a clutch operable to transfer the modified assistant power from the assistant gearbox to the second shifting ring gear.

[0028] The C VT of the second aspect may include one or more of the previous embodiments and, optionally, wherein the longitudinal axis is defined along a length of a crankshaft of the mid-drive motor package, wherein the crankshaft is inserted or located through the assistant motor and the assistant gearbox of the assistant subassembly and the shifting motor and the shifting gearbox of the shifting subassembly. The first shifting ring gear is operable to receive crankshaft power generated in the crankshaft. The shifting planet carrier is operable to combine the received crankshaft power and the shifting power.

[0029] The C VT of the second aspect may include one or more of the previous embodiments and, optionally, a clutch operable to transfer the crankshaft power from the crankshaft to the first shifting ring gear.

[0030] The C VT of the second aspect may include one or more of the previous embodiments and, optionally, wherein a reference plane is definable between the assistant subassembly and the shifting subassembly, wherein, within the assistant subassembly, the assistant motor is positioned lateral relative to the reference plane and the assistant gearbox is positioned medial relative to the reference plane within the assistant subassembly, and wherein, within the shifting subassembly, the shifting motor is positioned lateral relative to the reference plane and the shifting gearbox is positioned medial relative to the reference plane.

[0031] The C VT of the second aspect may include one or more of the previous embodiments and, optionally, wherein the assistant motor and the shifting motor are axial flux motors, and wherein the output of the mid-drive motor package is an output sprocket.

[0032] A third aspect of embodiments of the present disclosure is to provide a mid-drive motor package for an electric bicycle. The mid-drive motor package includes a CVT. The CVT includes an assistant subassembly with an assistant motor operable to produce assistant power; and an assistant gearbox operable to receive the assistant power via a first set of assistant planet gears and convert the assistant power via a second set of assistant planet gears to produce a modified assistant power. The CVT includes a shifting subassembly with a shifting motor operable to produce shifting power; and a shifting gearbox operable to receive the shifting power via a first set of shifting planet gears and convert the shifting power via a second set of shifting planet gears to produce a modified shifting power. The mid-drive motor package includes a crankshaft inserted or located through the assistant motor, the assistant gearbox, the shifting motor, and the shifting gearbox, wherein the assistant subassembly and the shifting subassembly are coaxial along a longitudinal axis through the assistant motor, the assistant gearbox, the shifting motor, and the shifting gearbox, and wherein the longitudinal axis is defined along a length of the crankshaft. The mid-drive motor package includes an output sprocket operable to receive the modified assistant power and the modified shifting power.

[0033] The mid-drive motor package of the third aspect may include, optionally, a planetary gear system operable to receive the modified assistant power from the assistant subassembly and provide the modified assistant power to the output sprocket, the planetary gear system further operable to receive the modified shifting power from the shifting subassembly and provide the modified shifting power to the output sprocket. The assistant motor and the assistant gearbox of the assistant subassembly, the shifting motor and the shifting gearbox of the shifting subassembly, and the planetary gear system are coaxial along the longitudinal axis through the assistant subassembly, the shifting subassembly, and the planetary gear system.

[0034] The mid-drive motor package of the third aspect may include one or more of the previous embodiments and, optionally, wherein the shifting subassembly is operable to provide the modified shifting power to the output sprocket, and wherein the shifting subassembly is operable to receive the modified assistant power and provide the modified assistant power to the output sprocket.

[0035] A fourth aspect of embodiments of the present disclosure is to provide a CVT of a mid-drive motor package. The CVT includes an assistant subassembly and a shifting subassembly. The assistant subassembly includes an assistant motor operable to produce an assistant power, and an assistant gearbox operable to receive the assistant power via a first set of assistant planet gears and convert the assistant power via a second set of assistant planet gears to produce a modified assistant power. The shifting subassembly includes a shifting motor operable to produce a shifting power, and a shifting gearbox operable to receive the shifting power via a first set of shifting planet gears and convert the shifting power via a second set of shifting planet gears to produce a modified shifting power. The modified assistant power and the modified shifting power are provided to an output sprocket of the mid-drive motor package. The assistant motor, the assistant gearbox, the shifting motor, and the shifting gearbox are coaxial along a longitudinal axis through the assistant subassembly and the shifting subassembly.

[0036] The CVT of the fourth aspect may include, optionally, wherein the shifting subassembly is operable to provide the modified shifting power to the output sprocket, and wherein the shifting subassembly is operable to receive the modified assistant power and provide the modified assistant power to the output sprocket.

[0037] The CVT of the fourth aspect may include one or more of the previous embodiments and, optionally, wherein the assistant gearbox includes a first assistant ring gear operable to engage with the first set of assistant planet gears, wherein the first assistant ring gear is fixed in place within the CVT; a second assistant ring gear operable to engage with the second set of assistant planet gears; and an assistant planet carrier to which the first set of assistant planet gears and the second set of assistant planet gears are coupled, wherein the assistant gearbox receives the assistant power from the assistant motor via the assistant planet carrier, and wherein the assistant gearbox provides the modified assistant power via the second assistant ring gear.

[0038] The CVT of the fourth aspect may include one or more of the previous embodiments and, optionally, wherein the shifting gearbox includes a first shifting ring gear operable to engage with the first set of shifting planet gears; a second shifting ring gear operable to engage with the second set of shifting planet gears; and a shifting planet carrier to which the first set of shifting planet gears and the second set of shifting planet gears are coupled, wherein the shifting gearbox receives the shifting power from the shifting motor via the shifting planet carrier, wherein the shifting gearbox provides the modified shifting power via the second shifting ring gear, and wherein the second shifting ring gear is operable to provide the modified assistant power and the modified shifting power to the output sprocket.

[0039] The CVT of the fourth aspect may include one or more of the previous embodiments and, optionally, a clutch operable to transfer the modified assistant power from the assistant gearbox to the second shifting ring gear.

[0040] The CVT of the fourth aspect may include one or more of the previous embodiments and, optionally, wherein the longitudinal axis is defined along a length of a crankshaft of the mid-drive motor package, wherein the crankshaft is located through the assistant motor and the assistant gearbox of the assistant subassembly and the shifting motor and the shifting gearbox of the shifting subassembly, wherein the first shifting ring gear is operable to receive a user input from the crankshaft, and wherein the shifting planet carrier is operable to combine the received user input and the shifting power.

[0041] The CVT of the fourth aspect may include one or more of the previous embodiments and, optionally, a clutch operable to transfer the user input from the crankshaft to the first shifting ring gear.

[0042] The CVT of the fourth aspect may include one or more of the previous embodiments and, optionally, a planetary gear system coupled to the output sprocket, wherein the planetary gear system is operable to receive the modified assistant power from the assistant subassembly and provide the modified assistant power to the output sprocket of the middrive motor package, wherein the planetary gear system is operable to receive the modified shifting power from the shifting subassembly and provide the modified shifting power to the output sprocket of the mid-drive motor package, and wherein the assistant motor, the assistant gearbox, the shifting motor, the shifting gearbox, and the planetary gear system are coaxial along the longitudinal axis.

[0043] The CVT of the fourth aspect may include one or more of the previous embodiments and, optionally, a clutch operable to transfer the modified assistant power from the assistant gearbox to the planetary gear system.

[0044] The CVT of the fourth aspect may include one or more of the previous embodiments and, optionally, wherein the assistant gearbox includes a first assistant ring gear operable to engage with the first set of assistant planet gears, wherein the first assistant ring gear is fixed in place within the CVT; a second assistant ring gear operable to engage with the second set of assistant planet gears; and an assistant planet carrier to which the first set of assistant planet gears and the second set of assistant planet gears are coupled, wherein the assistant gearbox receives the assistant power from the assistant motor via the assistant planet carrier, and wherein the assistant gearbox provides the modified assistant power via the second assistant ring gear.

[0045] The CVT of the fourth aspect may include one or more of the previous embodiments and, optionally, wherein the shifting gearbox includes a first shifting ring gear operable to engage with the first set of shifting planet gears, wherein the first shifting ring gear is fixed in place within the CVT; a second shifting ring gear operable to engage with the second set of shifting planet gears; and a shifting planet carrier to which the first set of shifting planet gears and the second set of shifting planet gears are coupled, wherein the shifting gearbox receives the shifting power from the shifting motor via the shifting planet carrier, and wherein the shifting gearbox provides the modified shifting power via the second shifting ring gear.

[0046] The CVT of the fourth aspect may include one or more of the previous embodiments and, optionally, wherein the planetary gear system includes a sun gear operable to receive the modified assistant power provided by the assistant gearbox; a ring gear operable to receive the modified shifting power provided by the shifting gearbox; and a planet carrier to which a set of planet gears are coupled, wherein the set of planet gears are operable to engage the sun gear and transfer the modified assistant power via the planet carrier to the output of the mid-drive motor package, and wherein the set of planet gears are operable to engage the ring gear and transfer the modified shifting power via the planet carrier to the output of the mid-drive motor package.

[0047] The CVT of the fourth aspect may include one or more of the previous embodiments and, optionally, wherein the longitudinal axis is defined along a length of a crankshaft of the mid-drive motor package, wherein the crankshaft is located through the assistant motor and the assistant gearbox of the assistant subassembly, the shifting motor and the shifting gearbox of the shifting subassembly, and the planetary gear system, wherein the sun gear is operable to receive a user input from the crankshaft, and wherein the sun gear is operable to combine the received user input and the received modified assistant power prior to engagement with the set of planet gears. The CVT of the fourth aspect may include one or more of the previous embodiments and, optionally, a clutch operable to transfer the user input from the crankshaft to the sun gear of the planetary gear system.

[0048] A fifth aspect of embodiments of the present disclosure is to provide a mid-drive motor package. The mid-drive motor package includes a CVT with an assistant subassembly and a shifting subassembly. The assistant subassembly includes an assistant motor operable to produce an assistant power; and an assistant gearbox operable to receive the assistant power via a first set of assistant planet gears and convert the assistant power via a second set of assistant planet gears to produce a modified assistant power. The shifting subassembly includes a shifting motor operable to produce a shifting power; and a shifting gearbox operable to receive the shifting power via a first set of shifting planet gears and convert the shifting power via a second set of shifting planet gears to produce a modified shifting power. The mid-drive motor package includes a crankshaft located through the assistant motor, the assistant gearbox, the shifting motor, the shifting gearbox, wherein the assistant subassembly and the shifting subassembly are coaxial along a longitudinal axis through the assistant motor, the assistant gearbox, the shifting motor, the shifting gearbox, and wherein the longitudinal axis is defined along a length of the crankshaft. The mid-drive motor package includes an output sprocket operable to receive the modified assistant power and the modified shifting power.

[0049] The mid-drive motor package of the fifth aspect may include, optionally, wherein the shifting subassembly is operable to provide the modified shifting power to the output sprocket, and wherein the shifting subassembly is further operable to receive the modified assistant power and provide the modified assistant power to the output sprocket.

[0050] The mid-drive motor package of the fifth aspect may include one or more of the previous embodiments and, optionally, wherein the CVT includes a planetary gear system operable to receive the modified assistant power from the assistant subassembly and provide the modified assistant power to the output sprocket, the planetary gear system further operable to receive the modified shifting power from the shifting subassembly and provide the modified shifting power to the output sprocket, wherein the assistant motor and the assistant gearbox of the assistant subassembly, the shifting motor and the shifting gearbox of the shifting subassembly, and the planetary gear system are coaxial along the longitudinal axis through the assistant subassembly, the shifting subassembly, and the planetary gear system. A sixth aspect of embodiments of the present disclosure is to provide an electric bicycle. The electric bicycle includes a mid-drive motor package. The mid-drive motor package includes a CVT with an assistant subassembly and a shifting subassembly. The assistant subassembly includes an assistant motor operable to produce assistant power; and an assistant gearbox operable to receive the assistant power and to produce a modified assistant power. The shifting subassembly includes a shifting motor operable to produce shifting power; and a shifting gearbox operable to receive the shifting power and to produce a modified shifting power. The mid-drive motor package includes a crankshaft located through the assistant motor, the assistant gearbox, the shifting motor, the shifting gearbox, wherein the assistant subassembly and the shifting subassembly are coaxial along a longitudinal axis through the assistant motor, the assistant gearbox, the shifting motor, the shifting gearbox, and wherein the longitudinal axis is defined along a length of the crankshaft. The mid-drive motor package includes an output sprocket operable to receive the modified assistant power and the modified shifting power.

[0051] The electric bicycle of the sixth aspect may include, optionally, wherein the shifting subassembly is operable to provide the modified shifting power to the output sprocket, and wherein the shifting subassembly is further operable to receive the modified assistant power and provide the modified assistant power to the output sprocket.

[0052] The electric bicycle of the sixth aspect may include one or more of the previous embodiments and, optionally, wherein the CVT of the mid-drive motor package includes a planetary gear system operable to receive the modified assistant power from the assistant subassembly and provide the modified assistant power to the output sprocket, the planetary gear system further operable to receive the modified shifting power from the shifting subassembly and provide the modified shifting power to the output sprocket, wherein the assistant motor and the assistant gearbox of the assistant subassembly, the shifting motor and the shifting gearbox of the shifting subassembly, and the planetary gear system are coaxial along the longitudinal axis through the assistant subassembly, the shifting subassembly, and the planetary gear system.

[0053] 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. 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” or “approximately”. As used herein, unless otherwise specified, the terms “about,” “approximately,” etc., when used in relation to numerical limitations or ranges, mean that the recited limitation or range may vary by up to 10%. By way of non-limiting example, “about 750” can mean as little as 675 or as much as 825, or any value therebetween. When used in relation to ratios or relationships between two or more numerical limitations or ranges, the terms “about,” “approximately,” etc. mean that each of the limitations or ranges may vary by up to 10%; by way of non-limiting example, a statement that two quantities are “approximately equal” can mean that a ratio between the two quantities is as little as 0.9: 1.1 or as much as 1.1 :0.9 (or any value therebetween), and a statement that a four-way ratio is “about 5:3: 1 : 1” can mean that the first number in the ratio can be any value of at least 4.5 and no more than 5.5, the second number in the ratio can be any value of at least 2.7 and no more than 3.3, and so on.

[0054] The use of “substantially” in the present disclosure, when referring to a measurable quantity (e.g., a diameter or other distance) and used for purposes of comparison, is intended to mean within 5% of the comparative quantity. The terms “substantially similar to,” “substantially the same as,” and “substantially equal to,” as used herein, should be interpreted as if explicitly reciting and encompassing the special case in which the items of comparison are “similar to,” “the same as” and “equal to,” respectively.

[0055] 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.

[0056] 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.

[0057] 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.

[0058] 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 of the Invention 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 invention,” or aspects thereof should be understood to mean certain embodiments of the present invention / disclosure and should not necessarily be construed as limiting all embodiments to a particular description. The present invention is set forth in various levels of detail in the Summary of the Invention as well as in the attached drawings and the Detailed Description and no limitation as to the scope of the present invention is intended by either the inclusion or non-inclusion of elements, components, etc. in this Summary of the Invention. Additional aspects of the present invention will become more readily apparent from the Detailed Description, particularly when taken together with the drawings.

[0059] 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.

[0060] 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.

[0061] BRIEF DESCRIPTION OF THE DRAWINGS

[0062] 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.

[0063] 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. Fig. 1A illustrates a perspective view of a mid-drive motor package including a continuously variable transmission within a housing, a crankshaft, and an output sprocket, in accordance with one or more embodiments of the present disclosure;

[0064] Fig. IB illustrates a top plan view of the continuously variable transmission and the crankshaft of Fig. 1A, where the continuously variable transmission is removed from the housing;

[0065] Fig. 1C illustrates a schematic view of the continuously variable transmission and the crankshaft of Fig. 1A;

[0066] Fig. ID illustrates a cross-section of the top plan view of the continuously variable transmission and the crankshaft of Fig. 1A;

[0067] Fig. IE illustrates a cross-section of the top plan view of a variation of the continuously variable transmission and the crankshaft of Fig. IB;

[0068] Fig. 2 illustrates a flow diagram of a method or process for the operation and use of the mid-drive motor package of Fig. 1A, in accordance with one or more embodiments of the present disclosure;

[0069] Fig. 3A illustrates a perspective view of a mid-drive motor package including a continuously variable transmission within a housing, a crankshaft, and an output sprocket, in accordance with one or more embodiments of the present disclosure;

[0070] Fig. 3B illustrates a top plan view of the continuously variable transmission and the crankshaft of Fig. 3 A, where the continuously variable transmission is removed from the housing;

[0071] Fig. 3C illustrates a schematic view of the continuously variable transmission and the crankshaft of Fig. 3 A;

[0072] Fig. 3D illustrates a cross-section of the top plan view of the continuously variable transmission and the crankshaft of Fig. 3B;

[0073] Fig. 3E illustrates a cross-section of the top plan view of the continuously variable transmission and the crankshaft of Fig. 3B;

[0074] Fig. 4 illustrates a flow diagram of a method or process for the operation and use of the mid-drive motor package of Fig. 3 A, in accordance with one or more embodiments of the present disclosure;

[0075] Fig. 5 A illustrates an electric bicycle including the mid-drive motor package of Fig. 1 A, in accordance with one or more embodiments of the present disclosure; and Fig. 5B illustrates an electric bicycle including the mid-drive motor package of Fig.

[0076] 3 A, in accordance with one or more embodiments of the present disclosure.

[0077] 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.

[0078] Reference Number Component

[0079] 100 Mid-Drive Motor Package

[0080] 102 Continuously Variable Transmission

[0081] 104 Crankshaft

[0082] 105 Splines

[0083] 106 Output Sprocket

[0084] 108 Housing

[0085] 110 Assistant Subassembly

[0086] 112 Assistant Motor

[0087] 114 Assistant Gearbox

[0088] 116 Shifting Subassembly

[0089] 118 Shifting Motor

[0090] 120 Shifting Gearbox

[0091] 122 Planetary Gear System

[0092] 124 Ring Gear

[0093] 126 Set of Planet Gears

[0094] 128 Set of Planet Gears

[0095] 130 Planet Carrier

[0096] 132 Ring Gear

[0097] 134 Ring Gear

[0098] 136 Set of Planet Gears

[0099] 138 Set of Planet Gears

[0100] 140 Planet Carrier

[0101] 142 Ring Gear

[0102] 144 Ring Gear

[0103] 146 Set of Planet Gears 148 Sun Gear

[0104] 150 Planet Carrier

[0105] 152 Clutch

[0106] 154 Clutch

[0107] 156 Shaft

[0108] 158 Opening

[0109] 160 Flange

[0110] 162 Axle

[0111] 164, 164 A, 164B Shaft

[0112] 166 Shaft

[0113] 168 Opening

[0114] 170 Flange

[0115] 172 Axle

[0116] 174 Flange

[0117] 176 Flange

[0118] 178 Axle

[0119] 180 Shaft

[0120] 182 Bearing

[0121] 184 Seal

[0122] 186 Assistant Torque Pathway

[0123] 188 Shifting Torque Pathway

[0124] 190 Pedal Torque Pathway

[0125] 200 Process Flow Diagram

[0126] 202 Provide Assistant Power with Assistant Subassembly

[0127] 204 Receive User Input from Crankshaft

[0128] 206 Provide Shifting Power with Shifting Subassembly

[0129] 208 Generate Output Power for Output Sprocket

[0130] 300 Mid-Drive Motor Package

[0131] 302 Continuously Variable Transmission

[0132] 304 Crankshaft

[0133] 305 Splines

[0134] 306 Output Sprocket

[0135] 308 Housing 310 Assistant Subassembly

[0136] 312 Assistant Motor

[0137] 314 Assistant Gearbox

[0138] 316 Shifting Subassembly

[0139] 318 Shifting Motor

[0140] 320 Shifting Gearbox

[0141] 324 Ring Gear

[0142] 326 Set of Planet Gears

[0143] 328 Set of Planet Gears

[0144] 330 Planet Carrier

[0145] 332 Ring Gear

[0146] 334 Ring Gear

[0147] 336 Set of Planet Gears

[0148] 338 Set of Planet Gears

[0149] 340 Planet Carrier

[0150] 342 Ring Gear

[0151] 344 Clutch

[0152] 346 Clutch

[0153] 348 Shaft

[0154] 350 Flange

[0155] 352 Axle

[0156] 354 Shaft

[0157] 356 Shaft

[0158] 358 Flange

[0159] 360 Axle

[0160] 362 Bearing

[0161] 364 Seal

[0162] 366 Assistant Torque Pathway

[0163] 368 Shifting Torque Pathway

[0164] 370 Pedal Torque Pathway

[0165] 400 Process Flow Diagram

[0166] 402 Provide Assistant Power with Assistant Subassembly

[0167] 404 Provide Shifting Power with Shifting Subassembly 406 Receive User Input from Crankshaft

[0168] 408 Generate Output Power for Output Sprocket

[0169] 500A, 500B Electric Bicycle

[0170] 501 Assistant Subassembly Power

[0171] 502 Belt or Chain

[0172] 503 Shifting Subassembly Power

[0173] 504 Hub

[0174] 505 User Input

[0175] 506 Wheel

[0176] 507 Electrical Power

[0177] 508 Battery Pack

[0178] 509 Output Power

[0179] 510 Control System

[0180] 511 Data

[0181] Pl Reference Plane

[0182] P2 Reference Plane

[0183] P3 Reference Plane

[0184] DETAILED DESCRIPTION

[0185] 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 a continuously variable transmission (CVT) for an electric bicycle 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 CVT can be combined with dimensions, aspects, and features of another embodiment of the CVT to create the claimed embodiment.

[0186] In general, embodiments of the present disclosure are directed to a compact-size CVT in a mid-drive motor package for an electric bicycle. Embodiments of the present disclosure are directed to planetary gear systems in the CVT. Embodiments of the present disclosure are also directed to axial flux motors in the CVT. Embodiments of the present disclosure include gear systems and motors that are each coaxial along a longitudinal axis through a crankshaft that is insertable through the planetary gear system and motors. Embodiments of the present disclosure are directed to a three-gearbox CVT that includes an assistant subassembly, a shifting subassembly, and a planetary gear system for providing the power outputs of the assistant subassembly and the shifting subassembly (and optionally a user input from a crankshaft). Embodiments of the present disclosure are directed to a two- gearbox CVT that includes an assistant subassembly and a shifting subassembly for providing the power output of the assistant subassembly and the shifting subassembly (and optionally a user input from a crankshaft).

[0187] Fig. 1A-1E in general illustrate a mid-drive motor package 100, in accordance with one or more embodiments of the present disclosure.

[0188] The mid-drive motor package 100 includes a continuously variable transmission 102 (“CVT”). The mid-drive motor package 100 also includes a crankshaft 104 with splines 105 that passes through and is in communication with the CVT 102. For example, the splines

[0189] 105 may be configured to receive and / or otherwise engage with pedals installed on the crankshaft 104 (pedals not shown). It is noted, however, that the pedals may include a male coupler that inserts into an opening at each respective end of the crankshaft 104, which may be held in place via a fastener through the male coupler and into the opening, via an interference fit, via an interlocking assembly, via an adhesive, or some combination thereof without departing from the scope of the present disclosure.

[0190] The mid-drive motor package 100 further includes an output sprocket 106 (or other ring output) in communication with the CVT 102 (e.g., as illustrated in Fig. ID). In some embodiments, the output sprocket 106 is a belt-drive sprocket that is operable to receive and power a belt coupled to a hub of a wheel of an electric bicycle (not shown). In other embodiments, the output sprocket 106 is a chain-drive sprocket that is operable to receive and power a chain coupled to a hub of a wheel of an electric bicycle (not shown).

[0191] At least a portion of the CVT 102, the crankshaft 104, and / or the output sprocket

[0192] 106 may be positioned within a housing 108 of the mid-drive motor package 100. For example, the CVT 102 may be substantially positioned within the housing 108, the crankshaft 104 may pass through the housing 108, and the output sprocket 106 may be fully positioned external to, or have at least a portion positioned external to, the housing 108. It is noted that the housing 108 may be of a single-piece or integrated construction, or alternatively be of a multi-piece construction with separate and joined components, without departing from the scope of the present disclosure.

[0193] In some embodiments, one or more electrical connectors may be positioned within (or extend outward from) an exterior surface of the housing 108. For example, the one or more electrical connectors may provide power to an assistant motor 112 and / or a shifting motor 118, as described in detail further herein. By way of another example, the one or more electrical connectors may receive data from one or more sensors (e.g., operational data, environmental data, and the like) within the mid-drive motor package 100 and / or transmit data or other instructions to components within the mid-drive motor package 100. The one or more electrical connectors may be individual connectors and / or may be leads grouped into one or more plugs or receptacles that are configured to engage with corresponding components on a harness coupled to the mid-drive motor package 100, without departing from the scope of the present disclosure.

[0194] Reference will be made to the CVT 102 in detail further herein. It is noted that any and / or all of the subassemblies of the CVT 102 may include further subassemblies as described in detail further herein, which are each considered subassemblies of the mid-drive motor package 100.

[0195] Fig. IB illustrates the CVT 102 of the mid-drive motor package 100, in accordance with one or more embodiments of the present disclosure. The CVT 102 includes a three- gearbox configuration, where the crankshaft 104 is not mechanically integrated into the shifting operation of the CVT 102 but the cadence is instead by wire.

[0196] The CVT 102 includes an assistant subassembly 110 with an assistant motor 112 and an assistant gearbox 114 to facilitate assistance to the pedaling by the user. The CVT 102 also includes a shifting subassembly 116 with a shifting motor 118 and a shifting gearbox 120 to facilitate a shifting operation. The CVT 102 further includes a planetary gear system 122.

[0197] In the three-gearbox configuration of the CVT 102, the assistant subassembly 110 and the shifting subassembly 116 are separated by a reference plane Pl (e.g., as illustrated in Fig. IE). Within the assistant subassembly 110, the assistant motor 112 is positioned lateral relative to the reference plane Pl and the assistant gearbox 114 is positioned medial relative to the reference plane Pl . Within the shifting subassembly 116, the shifting gearbox 120 is positioned lateral relative to the reference plane Pl and the shifting motor 118 is positioned medial relative to the reference plane Pl. Further, the planetary gear system 122 is positioned lateral to the shifting subassembly 116 relative to the reference plane Pl. It is noted that “lateral” means to be positioned or distanced further from the reference plane Pl, and “medial” means to be positioned or distanced closer to the reference plane Pl, for purposes of the present disclosure.

[0198] However, it is contemplated that the assistant motor 112 may be positioned medial relative to the reference plane Pl and the assistant gearbox 114 may be positioned lateral relative to the reference plane Pl within the assistant subassembly 110, without departing from the scope of the present disclosure. In addition, it is contemplated that the shifting gearbox 120 may be positioned medial relative to the reference plane Pl and the shifting motor 118 may be positioned lateral relative to the reference plane Pl within the shifting subassembly 116, without departing from the scope of the present disclosure.

[0199] Also in the three-gearbox configuration of the CVT 102, the shifting subassembly 116 and the planetary gear system 122 are separated by a reference plate P2 (e.g., as illustrated in Fig. IE). In some embodiments, the shifting gearbox 120 and the planetary gear system 122 are combined within a single gearbox housing. For example, gear oil may be localized to only the single gearbox housing for both the shifting gearbox 120 and the planetary gear system 122. In other embodiments, the shifting gearbox 120 and the planetary gear system 122 are in separate gearbox housings that are coupled together.

[0200] In embodiments, the assistant motor 112 and / or the shifting motor 118 are axial flux motors capable of receiving the crankshaft 104 as it passes through the CVT 102. This allows for a configuration along a single longitudinal axis through the crankshaft 104, as opposed to a multi-axis build with separate parallel (or substantially parallel) axes for the assistant motor 112, the assistant gearbox 114, the shifting motor 118, the shifting gearbox 120, and / or the planetary gear system 122. It is noted herein that the longitudinal axis may be considered a “cadence point,” for purposes of the present disclosure.

[0201] It is noted that embodiments of the CVT 102 have the shifting subassembly 116 positioned between the assistant subassembly 110 and the planetary gear system 122. It is contemplated, however, that the assistant subassembly 110 may be positioned between the shifting subassembly 116 and the planetary gear system 122, without departing from the scope of the present disclosure.

[0202] Fig. 1C illustrates a schematic flow of power through the CVT 102 of the mid-drive motor package 100. It should be understood that Fig. 1C represents a schematic of a crosssection view of the CVT 102. The assistant gearbox 114 includes a first ring gear 124, a first set of planet gears 126 in communication with a second set of planet gears 128 via a planet carrier 130, and a second ring gear 132. In some embodiments, the first set of planet gears 126 and the second set of planet gears 128 have a different count of teeth, effecting a power transfer ratio as power is transferred from the first set of planet gears 126 to the second set of planet gears 128 via the planet carrier 130. For example, the ratio may be 39: 1, 40: 1, 49: 1, or other ratio that effects a power transfer.

[0203] It is noted that components of the assistant gearbox 114 may be considered “assistant” components, for purposes of the present disclosure (i.e., assistant ring gears, sets of assistant planet gears on an assistant planet carrier, and the like). In addition, it is noted that the assistant gearbox 114 may be considered a harmonic gear system capable of power conversion from a high speed / low torque input to a low speed / high torque output to facilitate CVT functionality, for purposes of the present disclosure.

[0204] The shifting gearbox 120 includes a first ring gear 134, a first set of planet gears 136 in communication with a second set of planet gears 138 via a planet carrier 140, and a second ring gear 142. In some embodiments, the first set of planet gears 136 and the second set of planet gears 138 have a different count of teeth, effecting a power transfer ratio as power is transferred from the first set of planet gears 136 to the second set of planet gears 138 via the planet carrier 140. For example, the ratio may be 39: 1, 40: 1, 49: 1, or other ratio that effects a power transfer.

[0205] It is noted that components of the shifting gearbox 120 may be considered “shifting” or “shift” components, for purposes of the present disclosure (i.e., shifting ring gears or shift ring gears, sets of shifting planet gears on a shifting planet carrier or sets of shift planet gears on a shift planet carrier, and the like). In addition, it is noted that the shifting gearbox 120 may be considered a harmonic gear system capable of power conversion from a high speed / low torque input to a low speed / high torque output to facilitate CVT functionality, for purposes of the present disclosure.

[0206] The planetary gear system 122 includes a ring gear 144, a set of planet gears 146, and a sun gear 148. The set of planet gears 146 are coupled to a planet carrier 150, which is in communication with the output sprocket 106 (not shown). In some embodiments, the planetary gear system 122 may provide a gearing ratio between the ring gear 144 and the sun gear 148. For example, the gearing ratio may be a 3: 1 ratio, or another ratio. Power in the assistant subassembly 110 is generated by the assistant motor 112, and is transferred to the planet carrier 130. The first ring gear 124 is fixed in place within the assistant gearbox 114, and the second ring gear 132 is able to rotate when acted upon by the second set of planet gears 128. The rotation of the second ring gear 132 via the engagement of the second set of planet gears 128 transfers power from the second ring gear 132 of the assistant gearbox 114 to the sun gear 148 of the planetary gear system 122 via a clutch 152. For example, the clutch 152 may be a one-way clutch that allows for the transfer of power from the second ring gear 132 of the assistant gearbox 114 to the sun gear 148 of the planetary gear system 122, but that prevents power from being transferred from the sun gear 148 of the planetary gear system 122 to the second ring gear 132 of the assistant gearbox 114.

[0207] Power in the shifting subassembly 116 is generated by the shifting motor 118, and is transferred to the planet carrier 140. The first ring gear 134 is fixed in place within the shifting gearbox 120, and the second ring gear 142 is able to rotate when acted upon by the second set of planet gears 138. The rotation of the second ring gear 142 via the engagement of the second set of planet gears 138 transfers power from second ring gear 142 of the shifting gearbox 120 to the ring gear 144 of the planetary gear system 122. It is noted that the second ring gear 142 and the ring gear 144 may be separate components that are coupled together, or may alternatively be a single integrated component, without departing from the scope of the present disclosure.

[0208] In embodiments, power applied to the crankshaft 104 by a rider is input into the sun gear 148 via a clutch 154. For example, the clutch 154 may be a one-way clutch that allows for the transfer of power from the crankshaft 104 to the sun gear 148 of the planetary gear system 122, but that prevents power from being transferred from the sun gear 148 of the planetary gear system 122 to the crankshaft 104.

[0209] Rotation of the ring gear 144 with the shifting power from the shifting subassembly 116 and / or rotation of the sun gear 148 with the assisting power from the assistant subassembly 110 (and / or with the user input from the crankshaft) causes the planet carrier 150 to rotate. The planet carrier 150 is in communication with the output sprocket 106 (not shown), such that power is transferred from the planet carrier 150 to the output sprocket 106. In this regard, rotation of the planet carrier 150 causes the output sprocket 106 to rotate, thus providing power to a hub of a wheel (e.g., via a belt or chain connecting the output sprocket 106 to the hub, although not shown). Figs. ID and IE illustrate cross-section views of the assistant subassembly 110 and the shifting subassembly 116 of the CVT 102, and the crankshaft 104, of the mid-drive motor package 100.

[0210] In the CVT 102, the planet carrier 130 of the assistant gearbox 114 includes a shaft 156 to which the assistant motor 112 engages. For example, such as where the assistant motor 112 is an axial flux motor, an outer diameter of the shaft 156 may be dimensioned to receive an inner diameter of an opening 158 of the assistant motor 112. A flange 160 of the planet carrier 130 includes one or more axles 162 to which the first set of planet gears 126 and the second set of planet gears 128 of the assistant gearbox 114 are coupled.

[0211] Power transferred through the planet carrier 130 to the second ring gear 132 of the assistant gearbox 114 engages the clutch 152, which in turn engages the sun gear 148 of the planetary gear system 122. For example, the power may be transferred through a shaft 164 of the sun gear 148. As illustrated in Fig. ID, the shaft 164 may be a single-piece component. As illustrated in Fig. IE, however, the shaft 164 may be a multi-piece component (164A, 164B), without departing from the scope of the present disclosure. It is noted herein that portions of the shaft 164 may be formed or coupled to the second ring gear 132, without departing from the scope of the present disclosure.

[0212] The planet carrier 140 of the shifting gearbox 120 includes a shaft 166 to which the shifting motor 118 engages. For example, such as where the shifting motor 118 is an axial flux motor, an outer diameter of the shaft 166 may be dimensioned to receive an inner diameter of an opening 168 of the shifting motor 118. A flange 170 includes one or more axles 172 to which the first set of planet gears 136 and the second set of planet gears 138 of the shifting gearbox 120 are coupled.

[0213] The clutch 154 engages a flange 174 of the sun gear 148 of the planetary gear system 122, to transfer power from the crankshaft 104 to the sun gear 148. Thus, the planetary gear system 122 can receive the power from the crankshaft 104 and / or the assistant power supplied from the assistant subassembly 110 via the sun gear 148, and additionally receive the power supplied from the shifting subassembly 116 via the ring gear 144.

[0214] The planet carrier 150 of the planetary gear system 122 includes a flange 176 with one or more axles 178 to which the set of planet gears 146 are coupled. The planet carrier 150 also includes a shaft 180 that is coupled to (or integrated with) the output sprocket 106, to provide power from the CVT 102 to the output sprocket 106 (and thus to a hub of a wheel via a belt or chain driven by the output sprocket 106). In some examples, the shaft 180 includes splines for the output sprocket 106. For instance, the splines may be on an exterior surface of the shaft 180, such that the output sprocket 106 slides over and engages with the shaft 180 via the splines. In addition, the splines may be on an interior surface of the shaft 180, such that a portion of the output sprocket 106 is inserted into and engages with the shaft 180 via the splines. In other examples, the output sprocket 106 is press-fit onto (or into) the shaft 180.

[0215] It is noted that one or more bearings 182 may be positioned along the longitudinal axis through the crankshaft 104 to improve the rotation of the components of the assistant gearbox 114 and / or the shifting gearbox 120. In addition, it is noted that one or more seals 184 (e.g., O-rings, gaskets, rope seals, or the like) may be positioned along the longitudinal axis through the crankshaft 104. For example, the seals may be utilized to prevent gear oil from escaping the CVT 102. By way of another example, the seals may be utilized to prevent fluid or particulates from entering the CVT 102.

[0216] As illustrated in Fig. IE, the CVT 102 includes an assistant torque pathway 186, a shifting torque pathway 188, and a pedal torque pathway 190. In the assistant torque pathway 186, power is generated by the assistant motor 112 and transferred through the planet carrier 130 of the assistant gearbox 114 to the sun gear 148 of the planetary gear system 122, before being transferred by the planet carrier 150 of the planetary gear system 122 to the output sprocket 106. In the shifting torque pathway 188, power is generated by the shifting motor 118 and transferred the planet carrier 140 through the shifting gearbox 120 to the ring gear 144 of the planetary gear system 122, before being transferred by the planet carrier 150 of the planetary gear system 122 to the output sprocket 106. In the pedal torque pathway 190, power applied to the crankshaft 104 by a rider is provided to the sun gear 148 of the planetary gear system 122, before being transferred by the planet carrier 150 of the planetary gear system 122 to the output sprocket 106.

[0217] The providing of power to the planetary gear system 122 from one or more of the three sources (e.g., the crankshaft 104, the assistant subassembly 110, and / or the shifting subassembly 116) to the output sprocket 106 allows for the operation of a continuously variable transmission with smooth, efficient shifting. In particular, the compact CVT 102 outputs the required torque and speed from the assistant motor 112, the shifting motor 118, and the crankshaft 104 to the output sprocket 106, which drives the hub and wheel of the electric bicycle (not shown). Fig. 2 is a method or process flow diagram 200 illustrating the operation of the middrive motor package 100, in accordance with one or more embodiments of the present disclosure. While a general order for the steps of the method or process 200 is shown in Fig. 2, the method or process 200 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. 2. It is noted that the method or process 200 shall be explained with reference to the components, devices, subassemblies, environments, etc. described in conjunction with Figs. 1 A-1E. For example, it is noted that the embodiments as illustrated in Figs. 1 A-1E should be understood as reading on the embodiments described with respect to Fig. 2, and vice versa, without departing from the scope of the present disclosure.

[0218] In embodiments, assistant power is provided 202 with an assistant subassembly of a mid-drive motor package. The assistant subassembly 110 may be a component of the CVT 102 of the mid-drive motor package 100. Assistant power is generated by the assistant motor 112 of the assistant subassembly 110 and transferred to the planet carrier 130 of the assistant gearbox 114 of the assistant subassembly 110. The assistant power is converted by the two sets of planet gears 126, 128 coupled to the planet carrier 130, and outputted from the assistant gearbox 114 via the second ring gear 132. The outputted assistant power is transferred via the clutch 152 to the sun gear 148 of the planetary gear system 122.

[0219] In embodiments, a user input is received 204 from a crankshaft of the mid-drive motor package. Where a rider supplies a torque to the crankshaft 104, the user input is provided as crankshaft power via the clutch 154 to the sun gear 148 of the planetary gear system 122. It is noted that this may be in addition to or instead of the assistant power. It is noted that the receiving of the user input may be considered optional, for purposes of the present disclosure. For example, the assistant power and the crankshaft power may be provided the sun gear 148, such that both are provided to the planet carrier 150 via the sun gear 148. By way of another example, only assistant power may be provided to the planet carrier 150 via the sun gear 148 (i.e., where the rider is not pedaling). Further, only crankshaft power may be input to the planet carrier 150 via the sun gear 148 (i.e., where the assistant motor 112 is not providing assistant power).

[0220] In embodiments, shifting power is provided 206 with a shifting subassembly of the mid-drive motor package. The shifting subassembly 116 may be a component of the CVT 102 of the mid-drive motor package 100. For example, shifting power is generated by the shifting motor 118 of the shifting subassembly 316 and transferred to the planet carrier 140 of the shifting gearbox 120 of the shifting subassembly 116. The shifting power is converted by the two sets of planet gears 136, 138 coupled to the planet carrier 140, and outputted from the shifting gearbox 120 via the second ring gear 142. The outputted shifting power is transferred to the ring gear 144 of the planetary gear system 122.

[0221] In embodiments, output power is generated 208 for an output sprocket of the middrive motor package. The planetary gear system 122 provides the assistant power (optionally with the user input as crankshaft power) from the sun gear 148 and / or the shifting power from the ring gear 144 as an output power via the set of planet gears 146 on the planet carrier 150. The planet carrier 150 is in communication with the output sprocket 106, such that rotation of the planet carrier 150 causes the rotation of the output sprocket 106 (and thus the rotation of a hub of a wheel via a belt or a chain coupling the output sprocket 106 to the hub, although not shown). In this regard, by properly controlling the assistant motor 112 and the shifting motor 118, in combination with torque from the pedal input via the crankshaft 104 when applied, the CVT 102 achieves variable transmission functionality.

[0222] Figs. 3 A-3E in general illustrate a mid-drive motor package 300, in accordance with one or more embodiments of the present disclosure. It should be understood that assemblies, subassemblies, and / or components of the mid-drive motor package 300 may be similar or identical to assemblies, subassemblies, and / or components of the mid-drive motor package 100, unless otherwise noted. In addition, it should be understood that assemblies, subassemblies, and / or components of the mid-drive motor package 300 may be combinable and / or interchangeable with assemblies, subassemblies, and / or components of the mid-drive motor package 100, unless otherwise noted.

[0223] The mid-drive motor package 300 includes a continuously variable transmission 302 (“CVT”). The mid-drive motor package 300 also includes a crankshaft 304 with splines 305 that passes through and is in communication with the CVT 302. For example, the splines 305 may be configured to receive and / or otherwise engage with pedals installed on the crankshaft 104 (pedals not shown). It is noted, however, that the pedals may include a male coupler that inserts into an opening at each respective end of the crankshaft 104, which may be held in place via a fastener through the male coupler and into the opening, via an interference fit, via an interlocking assembly, via an adhesive, or some combination thereof without departing from the scope of the present disclosure.

[0224] The mid-drive motor package 300 further includes an output sprocket 306 (or other ring output) in communication with the CVT 302. In some embodiments, the output sprocket 306 is a belt-drive sprocket that is operable to receive and power a belt coupled to a hub of a wheel of an electric bicycle (not shown). In some embodiments, the output sprocket 306 is a chain-drive sprocket that is operable to receive and power a chain coupled to a hub of a wheel of an electric bicycle (not shown).

[0225] At least a portion of the CVT 302, the crankshaft 304, and / or the output sprocket 306 may be positioned within a housing 308 of the mid-drive motor package 300. For example, the CVT 302 may be substantially positioned within the housing 308, the crankshaft 304 may pass through the housing 308, and the output sprocket 306 may be fully positioned external to, or have at least a portion positioned external to, the housing 308. It is noted that the housing 308 may be of a single-piece or integrated construction, or alternatively be of a multi-piece construction with separate and joined components, without departing from the scope of the present disclosure.

[0226] In some embodiments, one or more electrical connectors may be positioned within (or extend outward from) an exterior surface of the housing 308. For example, the one or more electrical connectors may provide power to an assistant motor 312 and / or a shifting motor 318, as described in detail further herein. By way of another example, the one or more electrical connectors may receive data from one or more sensors (e.g., operational data, environmental data, and the like) within the mid-drive motor package 300 and / or transmit data or other instructions to components within the mid-drive motor package 300. The one or more electrical connectors may be individual connectors and / or may be leads grouped into one or more plugs or receptacles that are configured to engage with corresponding components on a harness coupled to the mid-drive motor package 300, without departing from the scope of the present disclosure.

[0227] Reference will be made to the CVT 302 in detail further herein. It is noted that any and / or all of the subassemblies of the CVT 302 may include further subassemblies as described in detail further herein, which are each considered subassemblies of the mid-drive motor package 300.

[0228] Fig. 3B illustrates the CVT 302 of the mid-drive motor package 300, in accordance with one or more embodiments of the present disclosure. The CVT 302 includes a two- gearbox configuration, where the crankshaft 304 is mechanically integrated into the shifting operation of the CVT 302.

[0229] The CVT 302 includes an assistant subassembly 310 with an assistant motor 312 and an assistant gearbox 314 to facilitate assistance to the pedaling by the user. The CVT 302 also includes a shifting subassembly 316 with a shifting motor 318 and a shifting gearbox 320 to facilitate a shifting operation.

[0230] In the two-gearbox configuration of the CVT 302, the assistant subassembly 310 and the shifting subassembly 316 are separated by a reference plane P3 (e.g., as illustrated in Fig. 3E). Within the assistant subassembly 310, the assistant motor 312 is positioned lateral relative to the reference plane P3 and the assistant gearbox 314 is positioned medial relative to the reference plane P3. Within the shifting subassembly 316, the shifting motor 318 is positioned lateral relative to the reference plane P3 and the shifting gearbox 320 is positioned medial relative to the reference plane P3. It is noted that “lateral” means to be positioned or distanced further from the reference plane P3, and “medial” means to be positioned or distanced closer to the reference plane P3, for purposes of the present disclosure.

[0231] However, it is contemplated that the assistant motor 312 may be positioned medial relative to the reference plane P3 and the assistant gearbox 314 may be positioned lateral relative to the reference plane P3 within the assistant subassembly 310, without departing from the scope of the present disclosure. In addition, it is contemplated that the shifting motor 318 may be positioned medial relative to the reference plane P3 and the shifting gearbox 320 may be positioned lateral relative to the reference plane P3 within the shifting subassembly 316, without departing from the scope of the present disclosure.

[0232] In some embodiments, the assistant gearbox 314 and the shifting gearbox 320 are combined within a single gearbox housing. For example, gear oil may be localized to only the single gearbox housing for both the assistant gearbox 314 and the shifting gearbox 320, as opposed to where the gearboxes 314, 320 are separate. In other embodiments, the assistant gearbox 314 and the shifting gearbox 320 are in separate gearbox housings that are coupled together.

[0233] In embodiments, the assistant motor 312 and / or the shifting motor 318 are axial flux motors capable of receiving the crankshaft 304 as it passes through the CVT 302. This allows for a configuration along a single longitudinal axis through the crankshaft 304, as opposed to a multi-axis build with separate parallel (or substantially parallel) axes for the assistant motor 312, the assistant gearbox 314, the shifting motor 318, and / or the shifting gearbox 320. It is noted herein that the longitudinal axis may be considered a “cadence point,” for purposes of the present disclosure. It is noted that embodiments of the CVT 302 has the assistant subassembly 310 positioned between the shifting subassembly 316 and the output sprocket 306, in contrast to the CVT 102 having the shifting subassembly 116 positioned between the assistant subassembly 110 and the planetary gear system 122 / output sprocket 106, as described previously herein. In addition, it is noted that the two-gearbox configuration of the CVT 302 does not include the planetary gear system 122, as described previously herein. It is contemplated that shifting may require adjustment of an orientation of components within the shifting gearbox 320 (e.g., orientation of the first ring gear 334, the second ring gear 342, and / or the planet carrier 340 with sets of planet gears 336, 338) relative to the longitudinal axis through the crankshaft 304. For example, the orientation may need to be adjusted in a clockwise direction about the longitudinal axis or cadence point, or alternatively may need to be adjust in a counterclockwise direction about the longitudinal axis or cadence point. It is also contemplated that the shifting subassembly 316 may be positioned between the assistant subassembly 310 and the output sprocket 306, without departing from the scope of the present disclosure.

[0234] Fig. 3C illustrates a schematic flow of power through the CVT 302 within the middrive motor package 300. It should be understood that Fig. 3C represents a cross-section view of the CVT 302.

[0235] The assistant gearbox 314 includes a first ring gear 324, a first set of planet gears 326 in communication with a second set of planet gears 328 via a planet carrier 330, and a second ring gear 332. In some embodiments, the first set of planet gears 326 and the second set of planet gears 328 have a different count of teeth, effecting a power transfer ratio as power is transferred from the first set of planet gears 326 to the second set of planet gears 328 via the planet carrier 330. For example, the ratio may be 39: 1, 40: 1, 49: 1, or other ratio that effects a power transfer. It is noted that the ratio based on the second ring gear 342 is dependent at least in part on an input received from the crankshaft 304 via the first ring gear 334, being driven by the crankshaft 304 as described in detail further herein.

[0236] It is noted that components of the assistant gearbox 314 may be considered “assistant” components, for purposes of the present disclosure (i.e., assistant ring gears, sets of assistant planet gears on an assistant planet carrier, and the like). In addition, it is noted that the assistant gearbox 314 may be considered a harmonic gear system capable of power conversion from a high speed / low torque input to a low speed / high torque output to facilitate CVT functionality, for purposes of the present disclosure. The shifting gearbox 320 includes a first ring gear 334, a first set of planet gears 336 in communication with a second set of planet gears 338 via a planet carrier 340, and a second ring gear 342. In some embodiments, the first set of planet gears 336 and the second set of planet gears 338 have a different count of teeth, effecting a power transfer ratio as power is transferred from the first set of planet gears 336 to the second set of planet gears 338 via the planet carrier 340. For example, the ratio may be 39: 1, 40: 1, 49: 1, or other ratio that effects a power transfer.

[0237] It is noted that components of the shifting gearbox 320 may be considered “shifting” components, for purposes of the present disclosure (i.e., shifting ring gears or shift ring gears, sets of shifting planet gears on a shifting planet carrier or sets of shift planet gears on a shift planet carrier, and the like). In addition, it is noted that the shifting gearbox 320 may be considered a harmonic gear system capable of power conversion from a high speed / low torque input to a low speed / high torque output to facilitate CVT functionality, for purposes of the present disclosure.

[0238] Power in the assistant subassembly 310 is generated by the assistant motor 312, and is transferred to the planet carrier 330. The first ring gear 324 is fixed in place within the assistant gearbox 314, and the second ring gear 332 is able to rotate when acted upon by the second set of planet gears 328. The rotation of the second ring gear 332 via the engagement of the second set of planet gears 328 transfers power from the second ring gear 332 of the assistant gearbox 314 to the output sprocket 306 (not shown) via a clutch 344. For example, the clutch 344 may be a one-way clutch that allows for the transfer of power from the second ring gear 332 of the assistant gearbox 314 to the output sprocket 306, but that prevents power from being transferred from the output sprocket 306 to the second ring gear 332 of the assistant gearbox 314.

[0239] Power in the shifting subassembly 316 is generated by the shifting motor 318, and is transferred to the planet carrier 340. The second ring gear 342 is able to rotate when acted upon by the second set of planet gears 338. The rotation of the second ring gear 342 via the engagement of the second set of planet gears 338 transfers power from the shifting gearbox 320 to the output sprocket 306 (not shown).

[0240] In embodiments, power applied to the crankshaft 304 by a rider is input into the first ring gear 334 of the shifting gearbox 320 via a clutch 346. For example, the clutch 346 may be a one-way clutch that allows for the transfer of power from the crankshaft 304 to the first ring gear 334 of the shifting gearbox 320, but that prevents power from being transferred from the first ring gear 334 of the shifting gearbox 320 to the crankshaft 304.

[0241] In this regard, power from the crankshaft 304 and / or the shifting motor 318 may be provided to the output sprocket 306 via the shifting gearbox 320. In addition, power from the assistant subassembly 310 and the shifting subassembly 316 may be provided to the output sprocket 306. The power from the assistant subassembly 310 and the shifting subassembly 316, either singular or combined, causes the output sprocket 306 to rotate, thus providing power to a hub of a wheel (e.g., via a belt or chain connecting the output sprocket 306 to the hub, although not shown).

[0242] Figs. 3D and 3E illustrate cross-section views of the assistant subassembly 310 and the shifting subassembly 316 of the CVT 302, and the crankshaft 304, of the mid-drive motor package 300.

[0243] In the CVT 302, the planet carrier 330 of the assistant gearbox 314 includes a shaft 348 to which the assistant motor 312 engages. A flange 350 of the planet carrier 330 includes one or more axles 352 to which the first set of planet gears 326 and the second set of planet gears 328 of the assistant gearbox 314 are coupled. Power transferred through the planet carrier 330 to the second ring gear 332 of the assistant gearbox 314 engages the clutch 346, to drive a shaft 354 of the second ring gear 342 in communication with the output sprocket 306 (and thus to a hub of a wheel via a belt or chain driven by the output sprocket 306). In some examples, the shaft 354 includes splines for the output sprocket 306. For instance, the splines may be on an exterior surface of the shaft 354, such that the output sprocket 106 slides over and engages with the shaft 354 via the splines. In addition, the splines may be on an interior surface of the shaft 354, such that a portion of the output sprocket 106 is inserted into and engages with the shaft 354 via the splines. In other examples, the output sprocket 106 is press-fit onto (or into) the shaft 354.

[0244] The clutch 346 engages the first ring gear 334 of the shifting gearbox 320 to transfer power from the crankshaft 304 to the first ring gear 334. Thus, the shifting gearbox 320 can combine the power from the crankshaft 304 with the power supplied via the shifting motor 318.

[0245] The planet carrier 340 of the shifting gearbox 320 includes a shaft 356 to which the shifting motor 318 engages. A flange 358 of the planet carrier 340 includes one or more axles 360 to which the first set of planet gears 336 and the second set of planet gears 338 of the shifting gearbox 320 are coupled. Power transferred through the planet carrier 340 to the second ring gear 342 of the shifting gearbox 320 drives the shaft 354 of the second ring gear 342 in communication with the output sprocket 306. Thus, the shaft 354 of the second ring gear 342 can combine the power from the assistant subassembly 310 and the shifting subassembly 316.

[0246] It is noted that one or more bearings 362 may be positioned along the longitudinal axis through the crankshaft 304 to improve the rotation of the components of the assistant gearbox 314 and / or the shifting gearbox 320. In addition, it is noted that one or more seals 364 (e.g., O-rings, gaskets, rope seals, or the like) may be positioned along the longitudinal axis through the crankshaft 304. For example, the seals may be utilized to prevent gear oil from escaping the CVT 302. By way of another example, the seals may be utilized to prevent fluid or particulates from entering the CVT 302.

[0247] As illustrated in Fig. 3E, the CVT 302 includes an assistant torque pathway 366, a shifting torque pathway 368, and a pedal torque pathway 370. In the assistant torque pathway 366, power is generated by the assistant motor 312 and transferred through the planet carrier 330 of the assistant gearbox 314, before being transferred from the second ring gear 332 via the clutch 344 to the shaft 354 of the second ring gear 332 in communication with the output sprocket 306. In the shifting torque pathway 368, power is generated by the shifting motor 318 and transferred through the planet carrier 340 of the shifting gearbox 320 to the shaft 354 of the second ring gear 342 in communication with the output sprocket 306. In the pedal torque pathway 370, power applied to the crankshaft 304 by a rider is provided via the clutch 346 to the first ring gear 334, before being transferred by the planet carrier 340 to the second ring gear 342 and the shaft 354 in communication with the output sprocket 306.

[0248] The providing of power from one or more of the three sources (e.g., the crankshaft 304, the assistant subassembly 310, and / or the shifting subassembly 316) to the output sprocket 306 allows for the operation of a continuously variable transmission with smooth, efficient shifting. In particular, the compact CVT 302 outputs the required torque and speed from the assistant motor 312, the shifting motor 318, and the crankshaft 304 to the output sprocket 306, which drives the hub and wheel of the electric bicycle (not shown).

[0249] Fig. 4 is a method or process flow diagram 400 illustrating the operation of the middrive motor package 300, in accordance with one or more embodiments of the present disclosure. While a general order for the steps of the method or process 400 is shown in Fig. 4, the method or process 400 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. 4. It is noted that the method or process 400 shall be explained with reference to the components, devices, subassemblies, environments, etc. described in conjunction with Figs. 3A-3E. For example, it is noted that the embodiments as illustrated in Figs. 3 A-3E should be understood as reading on the embodiments described with respect to Fig. 4, and vice versa, without departing from the scope of the present disclosure. In addition, it should be understood that various steps of the method or process 400 may be interchangeable with the various steps of the method or process 200, without departing from the scope of the present disclosure.

[0250] In embodiments, assistant power is provided 402 with an assistant subassembly of a mid-drive motor package. The assistant subassembly 310 may be a component of the CVT 302 of the mid-drive motor package 300. Assistant power is generated by the assistant motor 312 of the assistant subassembly 310 and transferred to the planet carrier 330 of the assistant gearbox 314 of the assistant subassembly 310. The assistant power is converted by the two sets of planet gears 326, 328 coupled to the planet carrier 330, and outputted from the assistant gearbox 314 via the second ring gear 332. The outputted assistant power is transferred via the clutch 344 to the output sprocket 306.

[0251] In embodiments, shifting power is provided 404 with a shifting subassembly of the mid-drive motor package. The shifting subassembly 316 may be a component of the CVT 302 of the mid-drive motor package 300. Shifting power is generated by the shifting motor 318 of the shifting subassembly 316 and transferred to the planet carrier 340 of the shifting gearbox 320 of the shifting subassembly 316. The shifting power is converted by the two sets of planet gears 336, 338 coupled to the planet carrier 340, and outputted from the shifting gearbox 320 via the second ring gear 342.

[0252] In embodiments, a user input is received 406 from a crankshaft of the mid-drive motor package. Where a rider supplies a torque to the crankshaft 304, the user input is provided as crankshaft power via the clutch 346 to the first ring gear 334 of the shifting gearbox 320. It is noted that this may be in addition to or instead of the shifting power. It is noted that the receiving of the user input may be considered optional, for purposes of the present disclosure. For example, the shifting power and the crankshaft power may be provided via the planet carrier 340 prior to being output via the second ring gear 342, such that both are provided to the output sprocket 306 via the second ring gear 342. By way of another example, only crankshaft power may be input to the second ring gear 342 from the first ring gear 334 via the planet carrier 340 (i.e., where the shifting motor 318 is not providing assistant power).

[0253] In embodiments, output power is generated 408 for an output sprocket of the middrive motor package. The assistant power from the assistant subassembly 310 and / or the shifting power (optionally with the user input as crankshaft power) from the shifting subassembly 316 are provided as an output power via the shaft 354 of the second ring gear 342 that is in communication with the output sprocket 306. Rotation of the shaft 354 causes the rotation of the output sprocket 306 (and thus the rotation of a hub of a wheel via a belt or a chain coupling the output sprocket 306 to the hub, although not shown). In this regard, by properly controlling the assistant motor 312 and the shifting motor 318, in combination with torque from the pedal input via the crankshaft 304 when applied, the CVT 302 achieves variable transmission functionality.

[0254] Figs. 5A and 5B illustrates a schematic of an electric bicycle, in accordance with one or more embodiments of the present disclosure. In particular, Fig. 5A illustrates an electric bicycle 500A with the mid-drive motor package 100, as described throughout the present disclosure. In addition, Fig. 5B illustrates an electric bicycle 500B with the mid-drive motor package 300, as described throughout the present disclosure. It should be understood that assemblies, subassemblies, and / or components of the electric bicycle 500A (e.g., including the mid-drive motor package 100 and its subassemblies and / or components) may be similar or identical to assemblies, subassemblies, and / or components of the electric bicycle 500B (e.g., including the mid-drive motor package 300 and its subassemblies and / or components), unless otherwise noted. In addition, it should be understood that assemblies, subassemblies, and / or components of the electric bicycle 500A (e.g., including the mid-drive motor package 100 and its subassemblies and / or components) may be combinable and / or interchangeable with assemblies, subassemblies, and / or components of the electric bicycle 500B (e.g., including the mid-drive motor package 300 and its subassemblies and / or components), unless otherwise noted.

[0255] Referring now to Fig. 5A, the electric bicycle 500A includes the mid-drive motor package 100 with the CVT 102 including the assistant subassembly 110, the shifting subassembly 116, and the planetary gear system 122; the crankshaft 104; and the output sprocket 106. The electric bicycle 500A has a belt or chain 502 that couples to the output sprocket 106 of the mid-drive motor package 100. The belt or chain 502 is coupled to a hub 504 of a wheel 506, such rotation of the output sprocket 106 causes actuation of the belt or chain 504 and subsequent rotation of the hub 504 and the wheel 506.

[0256] Assistant subassembly power 501 is provided by the assistant subassembly 110 to the planetary gear system 122. Shifting subassembly power 503 is additionally provided by the shifting subassembly 116 to the planetary gear system 122. User input 505 from the crankshaft 104 is optionally received by the planetary gear system 122.

[0257] Electrical power 507 is provided to the assistant subassembly 110 and the shifting subassembly 116 to generate the assistant subassembly power 501 and the shifting subassembly power 503, respectively. For example, the electric bicycle 500A includes a battery pack 508, which powers the assistant motor 112 of the assistant subassembly 110 and the shifting motor 118 of the shifting subassembly 116.

[0258] Power from the planetary gear system 122 is provided as generated output power 509 to the output sprocket 106. For example, the output power 509 may be generated from a combination of one or more of the assistant subassembly power 501, shifting subassembly power 503, and the user input 505.

[0259] The electric bicycle 500A includes a control system 510 that controls power input and / or power output of the battery pack 508, power input and / or power output of the assistant motor 112, and / or power input and / or power output of the shifting motor 118. The control system 510 may be coupled to the battery pack 508 and / or the mid-drive motor package 100 via wired connections and / or via wireless connections.

[0260] Although the components of the CVT 102 are illustrated as stacked blocks within the schematic diagram of Fig. 5 A, it should be understood that the arrangement of the blocks within the CVT 102 is not indicative of the actual arrangement within the CVT 102. Rather, the arrangement of the components within the CVT 102 may be similar to that illustrated in Figs. 1A-1E and as described in the corresponding disclosure, in one exemplary embodiment of the mid-drive motor package 100.

[0261] Referring now to Fig. 5B, the electric bicycle 500B includes the mid-drive motor package 300 with the CVT 302 including the assistant subassembly 310 and the shifting subassembly 316, the crankshaft 304, and the output sprocket 306. The electric bicycle 500B has a belt or chain 502 that couples to the output sprocket 306 of the mid-drive motor package 300. The belt or chain 502 is coupled to a hub 504 of a wheel 506, such rotation of the output sprocket 306 causes actuation of the belt or chain 504 and subsequent rotation of the hub 504 and the wheel 506. Assistant subassembly power 501 is provided by the assistant subassembly 310. In addition, shifting subassembly power 503 is provided by the shifting subassembly 316. User input 505 from the crankshaft 304 is optionally received by the shifting subassembly 316.Electrical power 507 is provided to the assistant subassembly 110 and the shifting subassembly 116 to generate the assistant subassembly power 501 and the shifting subassembly power 503, respectively. For example, the electric bicycle 500B includes a battery pack 508, which powers the assistant motor 312 of the assistant subassembly 310 and the shifting motor 318 of the shifting subassembly 316.

[0262] Power from the assistant subassembly 310 and the shifting subassembly 316 is provided as generated output power 509 to the output sprocket 106. For example, the output power 509 may be generated from a combination of one or more of the assistant subassembly power 501 and / or the shifting subassembly power 503, where the shifting subassembly power 503 may optionally include the user input 505.

[0263] The electric bicycle 500B includes a control system 510 that controls power input and / or power output of the battery pack 508, power input and / or power output of the assistant motor 312, and / or power input and / or power output of the shifting motors 318. The control system 510 may be coupled to the battery pack 508 and / or the mid-drive motor package 300 via wired connections and / or via wireless connections.

[0264] In general, the control system 510 of the electric bicycles 500A, 500B may include one or more control units (e.g., a controller, server, or the like). The one or more control units 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 electric bicycles 500A, 500B, and / or the subassemblies and / or components of the electric bicycles 500A, 500B.

[0265] The control system 510 may include a user interface coupled (e.g., physically coupled, electrically coupled, communicatively coupled, or the like) to the one or more control units. For example, the user interface may be a separate device coupled to the one or more control units. By way of another example, the user interface and the one or more control units 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). The control system 510 may include one or more sensors coupled (e.g., physically coupled, electrically coupled, communicatively coupled, or the like) to or integrated in the one or more control units, the electric bicycles 500A, 500B, and / or the subassemblies and / or components of the electric bicycles 500A, 500B. The one or more sensors may be operable to determine various operational, physical, and / or environmental parameters of the electric bicycles 500A, 500B, the subassemblies and / or components of the electric bicycles 500A, 500B, and / or the control system 510; the environment surrounding the electric bicycles 500A, 500B, the subassemblies and / or components of the electric bicycles 500A, 500B, and / or the control system 510, and the like. For instance, the sensors may be operable to determine the power input and / or power output of the electric bicycles 500A, 500B, the subassemblies and / or components of the electric bicycles 500A, 500B, and / or the control system 510.

[0266] The control system 510 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 one or more control units, the electric bicycles 500A, 500B, and / or the subassemblies and / or components of the electric bicycles 500A, 500B. The one or more transmitters and / or receivers may be configured to transmit data 511 and / or receive data 511 for the electric bicycles 500A, 500B and / or the subassemblies and / or components of the electric bicycles 500A, 500B (e.g., from sensors installed within the electric bicycles 500A, 500B and / or the subassemblies and / or components of the electric bicycles 500A, 500B) or from external third-party control units (e.g., controllers, servers, or the like) either via wired connections or wireless connections, which may be configured as transmitting (Tx) units, receiving (Rx) units, or combination Tx / Rx units.

[0267] The control system 510 may be configured to monitor the electric bicycles 500A, 500B and / or the subassemblies and / or components of the electric bicycles 500A, 500B via received and / or transmitted data. The control system 510 may be configured to generate control signals to adjust one or more components of the electric bicycles 500A, 500B and / or the subassemblies and / or components of the electric bicycles 500A, 500B via a feedback loop or a feed forward loop based on the received and / or transmitted data. The control system 510 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, third-party control units, or the like. In this regard, advantages of the present disclosure include a compact-size CVT in a mid-drive motor package for an electric bicycle. Advantages of the present disclosure include planetary gear systems in the CVT. Advantages of the present disclosure are also directed to axial flux motors in the CVT. Advantages of the present disclosure include gear systems and motors that are each coaxial along a longitudinal axis through a crankshaft insertable through the planetary gear system and motors. Advantages of the present disclosure include a three-gearbox CVT that includes an assistant subassembly, a shifting subassembly, and a planetary gear system for providing the power outputs of the assistant subassembly and the shifting subassembly (and optionally a user input from a crankshaft). Advantages of the present disclosure include a two-gearbox CVT that includes an assistant subassembly, and a shifting subassembly for providing the power output of the assistant subassembly and the shifting subassembly (and optionally a user input from a crankshaft).

[0268] Although embodiments of the present disclosure are directed to the use of the described mid-drive motor packages with an electric bicycle, it should be understood that this should not be interpreted as limiting on the present disclosure. For example, the middrive motor packages (and / or components thereof) may be installed on other wheeled devices including, but not limited to, scooters, wheelchairs, unicycles, tricycles, small rover vehicles, all terrain vehicles, utility terrain vehicles, motorcycles, automobiles, recreation vehicles, construction vehicles, warehouse and freight transportation vehicles, lawn and farm implement machinery, or any wheeled device that may benefit from the application of power (i.e., through a CVT) to assist in propulsion of the wheeled device.

[0269] 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. 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 continuously variable transmission of a mid-drive motor package, comprising: an assistant subassembly, comprising: an assistant motor operable to produce an assistant power; and an assistant gearbox operable to receive the assistant power via a first set of assistant planet gears and convert the assistant power via a second set of assistant planet gears to produce a modified assistant power; and a shifting subassembly, comprising: a shifting motor operable to produce a shifting power; and a shifting gearbox operable to receive the shifting power via a first set of shifting planet gears and convert the shifting power via a second set of shifting planet gears to produce a modified shifting power, wherein the modified assistant power and the modified shifting power are provided to an output sprocket of the mid-drive motor package, and wherein the assistant motor, the assistant gearbox, the shifting motor, and the shifting gearbox are coaxial along a longitudinal axis through the assistant subassembly and the shifting subassembly.

2. The continuously variable transmission of claim 1, wherein the shifting subassembly is operable to provide the modified shifting power to the output sprocket, and wherein the shifting subassembly is operable to receive the modified assistant power and provide the modified assistant power to the output sprocket.

3. The continuously variable transmission of claim 1, wherein the assistant gearbox comprises: a first assistant ring gear operable to engage with the first set of assistant planet gears, wherein the first assistant ring gear is fixed in place within the continuously variable transmission; a second assistant ring gear operable to engage with the second set of assistant planet gears; and an assistant planet carrier to which the first set of assistant planet gears and the second set of assistant planet gears are coupled,wherein the assistant gearbox receives the assistant power from the assistant motor via the assistant planet carrier, and wherein the assistant gearbox provides the modified assistant power via the second assistant ring gear.

4. The continuously variable transmission of claim 1, wherein the shifting gearbox comprises: a first shifting ring gear operable to engage with the first set of shifting planet gears; a second shifting ring gear operable to engage with the second set of shifting planet gears; and a shifting planet carrier to which the first set of shifting planet gears and the second set of shifting planet gears are coupled, wherein the shifting gearbox receives the shifting power from the shifting motor via the shifting planet carrier, wherein the shifting gearbox provides the modified shifting power via the second shifting ring gear, and wherein the second shifting ring gear is operable to provide the modified assistant power and the modified shifting power to the output sprocket.

5. The continuously variable transmission of claim 4, further comprising: a clutch operable to transfer the modified assistant power from the assistant gearbox to the second shifting ring gear.

6. The continuously variable transmission of claim 4, wherein the longitudinal axis is defined along a length of a crankshaft of the mid-drive motor package, wherein the crankshaft is located through the assistant motor and the assistant gearbox of the assistant subassembly and the shifting motor and the shifting gearbox of the shifting subassembly, wherein the first shifting ring gear is operable to receive a user input from the crankshaft, and wherein the shifting planet carrier is operable to combine the received user input and the shifting power.

7. The continuously variable transmission of claim 6, further comprising: a clutch operable to transfer the user input from the crankshaft to the first shifting ring gear.

8. The continuously variable transmission of claim 1, further comprising: a planetary gear system coupled to the output sprocket, wherein the planetary gear system is operable to receive the modified assistant power from the assistant subassembly and provide the modified assistant power to the output sprocket of the mid-drive motor package, wherein the planetary gear system is operable to receive the modified shifting power from the shifting subassembly and provide the modified shifting power to the output sprocket of the mid-drive motor package, and wherein the assistant motor, the assistant gearbox, the shifting motor, the shifting gearbox, and the planetary gear system are coaxial along the longitudinal axis.

9. The continuously variable transmission of claim 8, further comprising: a clutch operable to transfer the modified assistant power from the assistant gearbox to the planetary gear system.

10. The continuously variable transmission of claim 8, wherein the assistant gearbox comprises: a first assistant ring gear operable to engage with the first set of assistant planet gears, wherein the first assistant ring gear is fixed in place within the continuously variable transmission; a second assistant ring gear operable to engage with the second set of assistant planet gears; and an assistant planet carrier to which the first set of assistant planet gears and the second set of assistant planet gears are coupled, wherein the assistant gearbox receives the assistant power from the assistant motor via the assistant planet carrier, and wherein the assistant gearbox provides the modified assistant power via the second assistant ring gear.

11. The continuously variable transmission of claim 8, wherein the shifting gearbox comprises: a first shifting ring gear operable to engage with the first set of shifting planet gears, wherein the first shifting ring gear is fixed in place within the continuously variable transmission; a second shifting ring gear operable to engage with the second set of shifting planet gears; anda shifting planet carrier to which the first set of shifting planet gears and the second set of shifting planet gears are coupled, wherein the shifting gearbox receives the shifting power from the shifting motor via the shifting planet carrier, and wherein the shifting gearbox provides the modified shifting power via the second shifting ring gear.

12. The continuously variable transmission of claim 8, wherein the planetary gear system comprises: a sun gear operable to receive the modified assistant power provided by the assistant gearbox; a ring gear operable to receive the modified shifting power provided by the shifting gearbox; and a planet carrier to which a set of planet gears are coupled, wherein the set of planet gears are operable to engage the sun gear and transfer the modified assistant power via the planet carrier to the output of the mid-drive motor package, and wherein the set of planet gears are operable to engage the ring gear and transfer the modified shifting power via the planet carrier to the output of the mid-drive motor package.

13. The continuously variable transmission of claim 12, wherein the longitudinal axis is defined along a length of a crankshaft of the mid-drive motor package, wherein the crankshaft is located through the assistant motor and the assistant gearbox of the assistant subassembly, the shifting motor and the shifting gearbox of the shifting subassembly, and the planetary gear system, wherein the sun gear is operable to receive a user input from the crankshaft, and wherein the sun gear is operable to combine the received user input and the received modified assistant power prior to engagement with the set of planet gears.

14. The continuously variable transmission of claim 13, further comprising: a clutch operable to transfer the user input from the crankshaft to the sun gear of the planetary gear system.

15. A mid-drive motor package, comprising: a continuously variable transmission, comprising: an assistant subassembly, comprising: an assistant motor operable to produce assistant power; andan assistant gearbox operable to receive the assistant power via a first set of assistant planet gears and convert the assistant power via a second set of assistant planet gears to produce a modified assistant power; and a shifting subassembly, comprising: a shifting motor operable to produce shifting power; and a shifting gearbox operable to receive the shifting power via a first set of shifting planet gears and convert the shifting power via a second set of shifting planet gears to produce a modified shifting power; a crankshaft located through the assistant motor, the assistant gearbox, the shifting motor, the shifting gearbox, wherein the assistant subassembly and the shifting subassembly are coaxial along a longitudinal axis through the assistant motor, the assistant gearbox, the shifting motor, the shifting gearbox, and wherein the longitudinal axis is defined along a length of the crankshaft; and an output sprocket operable to receive the modified assistant power and the modified shifting power.

16. The mid-drive motor package of claim 15, wherein the shifting subassembly is operable to provide the modified shifting power to the output sprocket, and wherein the shifting subassembly is further operable to receive the modified assistant power and provide the modified assistant power to the output sprocket.

17. The mid-drive motor package of claim 15, wherein the continuously variable transmission further comprises: a planetary gear system operable to receive the modified assistant power from the assistant subassembly and provide the modified assistant power to the output sprocket, the planetary gear system further operable to receive the modified shifting power from the shifting subassembly and provide the modified shifting power to the output sprocket, wherein the assistant motor and the assistant gearbox of the assistant subassembly, the shifting motor and the shifting gearbox of the shifting subassembly, and the planetary gear system are coaxial along the longitudinal axis through the assistant subassembly, the shifting subassembly, and the planetary gear system.

18. An electric bicycle, comprising: a mid-drive motor package, comprising: a continuously variable transmission, comprising: an assistant subassembly, comprising:an assistant motor operable to produce an assistant power; and an assistant gearbox operable to receive the assistant power and to produce a modified assistant power; and a shifting subassembly, comprising: a shifting motor operable to produce a shifting power; and a shifting gearbox operable to receive the shifting power and to produce a modified shifting power; a crankshaft located through the assistant motor, the assistant gearbox, the shifting motor, the shifting gearbox, wherein the assistant subassembly and the shifting subassembly are coaxial along a longitudinal axis through the assistant motor, the assistant gearbox, the shifting motor, the shifting gearbox, and wherein the longitudinal axis is defined along a length of the crankshaft; and an output sprocket operable to receive the modified assistant power and the modified shifting power.

19. The electric bicycle of claim 18, wherein the shifting subassembly is operable to provide the modified shifting power to the output sprocket, and wherein the shifting subassembly is further operable to receive the modified assistant power and provide the modified assistant power to the output sprocket.

20. The electric bicycle of claim 18, wherein the continuously variable transmission of the mid-drive motor package further comprises: a planetary gear system operable to receive the modified assistant power from the assistant subassembly and provide the modified assistant power to the output sprocket, the planetary gear system further operable to receive the modified shifting power from the shifting subassembly and provide the modified shifting power to the output sprocket, wherein the assistant motor and the assistant gearbox of the assistant subassembly, the shifting motor and the shifting gearbox of the shifting subassembly, and the planetary gear system are coaxial along the longitudinal axis through the assistant subassembly, the shifting subassembly, and the planetary gear system.

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