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 each motor system, 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, and connecting metal sheets to form a prestructure with a motor mount adaptable to different motor systems, allowing for cost-efficient production and flexible motor system compatibility, including CNC cutting or laser cutting to customize the motor mount for specific systems.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a motor mount is designed and manufactured according to a predetermined motor system, then the motor mount can be specifically created for each individual motor system, but the costs for developing molds and storage increase significantly

Engineering Contradiction:

Improvemotor system compatibilityVSAvoidmold development cost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The motor mount is divided into a standard base structure and variable mounting points. The base structure uses a universal design that can accommodate different motor systems, while only the mounting points need to be customized through CNC or laser cutting. This segmentation allows the majority of the motor mount to be produced using a single mold, significantly reducing mold development costs while maintaining adaptability to various motor systems.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent creates a universal motor mount base structure that can serve multiple motor systems through standardized geometry and positioning features. By designing the base to be motor-system-agnostic and only customizing the mounting attachment points, a single mold can produce motor mounts that are adaptable to different motor manufacturers and models, eliminating the need for separate molds for each motor system.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If different types of adaptors are made to adapt the bicycle frame for different motor systems, then the bicycle frame can be adapted for different motor systems, but the costs for molds and storage increase

Engineering Contradiction:

Improvemotor system adaptabilityVSAvoidadaptor variety

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent extracts the customization requirement from the entire motor mount structure and isolates it to only the mounting points where motors attach to the frame. By removing the need for customized adaptors and instead providing a universal base with customizable attachment points, the system eliminates the complexity of managing multiple adaptor types while maintaining full adaptability to different motor systems.

Inventive Principle:

Principle #2Taking out (Extraction)

3Productivity

If metal sheets are pressed and connected to form a prestructure, then material consumption and production time are reduced, but the precision of motor mount formation must be maintained

Engineering Contradiction:

Improveproduction timeVSAvoidmotor mount precision

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent forms the motor mount geometry as a prestructure during the metal sheet pressing stage, establishing the base structure, positioning features, and mounting point locations before final customization. This preliminary formation of the motor mount geometry through pressing reduces production time compared to forming the entire structure after assembly, while subsequent precise cutting operations maintain the required manufacturing precision for the final motor mount.

Inventive Principle:

Principle #10Preliminary action

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 method reduces material consumption and production time, enabling the creation of lightweight, precise bicycle frames that can be easily adapted to various motor systems, minimizing inventory and manufacturing costs while optimizing motor placement for improved e-bike performance.

Implementation Method 1

press one or more metal sheets to form two casing parts that are overlappable

Methodology Applied

Scientific EffectPlastic deformation: Plasticity

Implementation Method 2

cut the two side plates of the motor mount prestructure in compliance with a pre-determined motor system

Methodology Applied

Scientific EffectLaser ablation: Laser Ablation

Data Source

PatentUS20230242205A1Manufacturing method, product of bicycle frame unit and prestructure of bicycle frame adaptable for different motor systems

Publication Date: 2023.08.03 ASTRO ENG

AI summary

A manufacturing method of a bicycle unit has the following steps. In a pressing step: press metal sheets to form casing parts being overlappable. In an abutting step: abut the casing parts to form an abutting line. In a connecting step: connecting the two casing parts along the abutting line to form a motor mount prestructure having side plates and a motor-installation space formed therebetween. A prestructure of a bicycle frame is thereby made. In a motor mount forming step: cut the two side plates of the motor mount prestructure in compliance with a pre-determined motor system so as to form a bicycle frame unit with a motor mount.