Detent Freewheel Torque Sensing for Bicycle Drive Accuracy

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Solution Overview

Problem

Existing drive arrangements for bicycles, particularly in Pedelecs, face challenges in accurately detecting the transmitted drive force due to disturbance variables such as radial forces and production tolerances, which can lead to imprecise torque determination.

Innovation Solution

A drive arrangement featuring a detent freewheel mechanism with a sensor apparatus that includes deformation sensors for each detent, allowing for precise detection of deformations and thus the applied drive force, while compensating for tolerance deviations and load variations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If a freewheel mechanism is used to decouple the drive motor from the foot pedal shaft, then the bicycle can travel without pedals rotating and the drive motor can be decoupled, but disturbance variables such as radial forces and production tolerances cause imprecise torque detection

Engineering Contradiction:
Improvefreewheel mechanism operationVSAvoidtorque detection precision
Core Design Contradiction:
Ease of operationVSMeasurement precision

Solution Approach 1:

The patent divides the torque detection function into multiple independent detent elements (at least two detents) that engage with tooth arrangements on separate rings. Each detent independently detects torque through its own deformation, allowing the system to segment the measurement function and compensate for individual detent variations and disturbance forces by combining readings from multiple detents.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The patent implements individual deformation sensors for each detent element, allowing local measurement of torque at each detent position. This local quality approach enables the system to detect and compensate for position-specific disturbance variables and production tolerances by treating each detent's measurement independently rather than using a single centralized sensor.

Inventive Principle:
Principle #3Local quality

2Measurement precision

If deformation sensors are installed to detect torque transmitted through the freewheel mechanism, then torque measurement is enabled, but radial forces and production tolerances create disturbance variables that reduce measurement accuracy

Engineering Contradiction:
Improvedrive force detectionVSAvoiddisturbance variables from radial forces and tolerances
Core Design Contradiction:
Measurement precisionVSObject-affected harmful factors

Solution Approach 1:

The patent employs feedback by continuously monitoring the engagement state and deformation of multiple detents with individual sensors. The system uses this feedback information to distinguish between deformation caused by actual torque transmission and deformation caused by disturbance variables such as radial forces and production tolerances, enabling compensation and improved measurement accuracy.

Inventive Principle:
Principle #23Feedback

Solution Approach 2:

The patent changes the measurement parameter from a single aggregate deformation measurement to multiple independent deformation measurements from individual detents. By measuring deformation at multiple locations and comparing these parameters, the system can identify and compensate for disturbance variables that affect individual detents differently, thereby improving overall measurement precision.

Inventive Principle:
Principle #35Parameter changes

3Reliability

If multiple detents are used in the freewheel mechanism, then the torque transmission is more reliable, but the complexity of the sensor apparatus and evaluation increases

Engineering Contradiction:
Improvetorque transmission reliabilityVSAvoidsensor apparatus complexity
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The patent makes each detent element a multi-functional component that simultaneously serves mechanical torque transmission and individual torque measurement functions. Each detent with its associated sensor acts as a self-contained measurement unit, eliminating the need for separate sensing mechanisms and reducing overall system complexity despite having multiple detents.

Inventive Principle:
Principle #6Universality (Multi-functionality)

Solution Approach 2:

The detent elements are designed to be self-measuring components where the deformation of each detent directly indicates the torque it is transmitting. This self-service approach eliminates the need for complex external measurement systems, as each detent inherently provides its own measurement data through its deformation, which is then captured by simple deformation sensors.

Inventive Principle:
Principle #25Self-service

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

The solution enables precise measurement of the drive force and torque transmitted through the detent freewheel mechanism, improving control over the drive motor and gear shifts, and allowing for predictive maintenance and quality control.

Implementation Method 1

The sensor apparatus has one associated deformation sensor per detent in each case, wherein the deformation sensor is configured to detect the deformation in a measurement region, for example, beside or on the associated detent

Methodology Applied
Scientific EffectDeformation detection: Deformation

Data Source

PatentUS20250128785A1Drive Arrangement for a Bicycle
Publication Date: 2025.04.24 ZF FRIEDRICHSHAFEN AG
  • US20250128785A1 patent drawing
  • US20250128785A1 patent drawing

AI summary

A drive arrangement for a bicycle includes a detent freewheel mechanism (14). The detent freewheel mechanism (14) has a first ring (20) with detents (24), which are movably supported thereon, and a second ring (22) having a tooth arrangement (26). In addition, the drive arrangement has at least one sensor apparatus, which is configured to detect a deformation of the first ring (20) of the detent freewheel mechanism (14) on the basis of a drive force which is applied. The sensor apparatus (24) has one associated deformation sensor (28) in each case per detent (24).