Bicycle Frame Segmentation for Motor Mounting Flexibility
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Solution Overview
Problem
The conventional method of manufacturing bicycle frames with motor mounting parts is inefficient and costly, as it requires frequent changes to stamping molds when motor specifications and shapes change, hindering automation and increasing production costs.
Innovation Solution
A bicycle frame manufacturing method that uses a single stamping mold to form a main frame and a sub-frame, where the sub-frame, comprising a support bracket and a motor mounting bracket, is bonded to the main frame, allowing for various motor specifications and shapes to be accommodated without needing new molds, improving productivity and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a new stamping mold is manufactured for each motor specification and shape, then the motor mounting portion can be precisely adapted to the motor, but the manufacturing cost increases and productivity deteriorates
Solution Approach 1:
The frame is divided into a main body portion and a separate motor mounting portion. The motor mounting portion can be independently manufactured and then attached to the main body, allowing different motor mounting portions to be produced using the same base mold structure. This segmentation enables flexibility in adapting to different motor specifications without requiring complete remanufacturing of the entire frame mold.
Solution Approach 2:
A universal base mold structure is designed for the main body portion that can accommodate multiple motor specifications. The motor mounting portion serves as an adaptable interface that can be configured for different motor shapes and sizes while using the same fundamental manufacturing process and mold structure, thereby improving productivity while maintaining precision.
2Manufacturing precision
If a new stamping mold is manufactured for each motor specification and shape, then the motor mounting portion can be precisely adapted to the motor, but the manufacturing cost increases
Solution Approach 1:
By segmenting the frame into a main body and a separate motor mounting portion, the expensive mold investment is concentrated in the standardized main body, while the motor mounting portion can be produced more economically through alternative methods or simpler molds, reducing overall manufacturing cost.
Solution Approach 2:
The universal base mold for the main body portion eliminates the need to invest in multiple expensive molds for different motor specifications. A single mold structure serves multiple functions across different product variants, significantly reducing tooling costs while maintaining manufacturing precision through the standardized interface design.
3Adaptability or versatility
If the frame is manufactured by welding the motor mounting part and tube after cutting, then the motor mounting portion can be customized, but automation is hindered and production cost increases
Solution Approach 1:
The frame is segmented into a main body portion that can be manufactured using automated stamping processes, and a separate motor mounting portion that provides customization capability. This segmentation allows the majority of production to be automated while still enabling customization through the separate mounting component.
Solution Approach 2:
The main body portion is designed with a universal interface that can accommodate different motor specifications. This universal design enables automated production of the main body using a single mold structure, while the motor mounting portion provides the necessary adaptability for different motor types without compromising automation levels.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables the production of bicycle frames with improved rigidity and reduced manufacturing costs by allowing the use of a single stamping mold for different motor specifications and shapes, enhancing productivity and simplifying the manufacturing process.
Implementation Method 1
a support bracket formed separately from the main frame and bonded to a lower end portion of the main frame, and a motor mounting bracket having a motor mounting portion configured to mount a motor therein
Data Source
AI summary
The present disclosure provides a bicycle frame including: a main frame; a support bracket formed separately from the main frame and bonded to a lower end portion of the main frame, and a motor mounting having a motor mounting portion configured to mount a motor therein, wherein the motor mounting bracket is formed separately from the support bracket, and is bonded to the support bracket.