Bicycle Frame Motor Mount Prestructure for Multi-Motor Compatibility

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Solution Overview

Problem

Conventional e-bike bicycle frames are costly and inefficient due to the need for custom motor mounts for different motor systems, leading to high mold development and storage costs, and existing adaptors often do not optimize the motor placement for the center of gravity.

Innovation Solution

A manufacturing method involving pressing, abutting, connecting, and forming metal sheets to create a prestructure with a motor mount adaptable to various motor systems, using CNC or laser cutting to customize the motor mount for specific systems, reducing material consumption and inventory costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a custom motor mount is designed for each motor system, then the motor placement can be optimized for the center of gravity, but the mold development cost and storage cost increase significantly

Engineering Contradiction:

Improvemotor system compatibilityVSAvoidmold development cost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The patent applies universality by designing a standardized motor mount structure that can accommodate multiple different motor systems through a common interface. The motor mount includes a standardized receiving space and mounting structure that works with various motor types, eliminating the need for custom molds for each motor system while maintaining optimized motor placement for center of gravity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent segments the motor mount into standardized components including a receiving space, mounting structure, and interface elements. This segmentation allows the motor mount to be designed once as a modular unit that can be adapted to different motor systems through configuration rather than requiring entirely custom designs, reducing mold development costs.

Inventive Principle:

Principle #1Segmentation

2Adaptability or versatility

If different types of adaptors are made to adapt the bicycle frame for different motor systems, then the frame can accommodate various motors, but the storage cost and mold cost increase

Engineering Contradiction:

Improvemotor system adaptabilityVSAvoidinventory cost

Core Design Contradiction:

Adaptability or versatilityVSQuantity of substance

Solution Approach 1:

The patent eliminates the need for multiple adaptors by designing the motor mount with universal compatibility. The standardized receiving space and mounting structure directly accommodate various motor systems without requiring separate adaptor components, reducing inventory complexity and storage costs while maintaining adaptability.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The standardized motor mount interface acts as an intermediary between the bicycle frame and various motor systems. This universal interface mediates the connection between different motor types and the frame, eliminating the need for multiple specialized adaptors while maintaining compatibility across different motor systems.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Ease of manufacture

If conventional motor mounts are made independently or along with other frame components, then the manufacturing process is simplified, but the motor placement cannot be optimized for center of gravity

Engineering Contradiction:

Improvemanufacturing process simplicityVSAvoidcenter of gravity optimization

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The patent applies preliminary action by pre-designing the motor mount with optimized geometry and positioning for center of gravity placement. The receiving space and mounting structure are configured in advance to position the motor at the optimal location, and this optimized design is then manufactured using standard processes, achieving both optimization and manufacturing simplicity.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentEP4219280A1Manufacturing method, product of bicycle frame unit and prestructure of bicycle frame adaptable for different motor systems

Publication Date: 2023.08.02 ASTRO ENG

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AI summary

A manufacturing method of a bicycle unit has the following steps. In a pressing step (S1): press metal sheets to form casing parts (100) being overlappable. In an abutting step (S21): abut the casing parts (100) to form an abutting line (103'). In a connecting step (S3): connecting the two casing parts (100) along the abutting line (103') to form a motor mount prestructure (10) having side plates (12) and a motor-installation space (16) formed therebetween. A prestructure of a bicycle frame is thereby made. In a motor mount forming step (S41): cut the two side plates (12) of the motor mount prestructure (10) in compliance with a pre-determined motor system (30', 30", 30‴) so as to form a bicycle frame unit with a motor mount (10', 10", 10‴).