Electric Bicycle Battery Mount with Detachable Alignment Jig
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Solution Overview
Problem
Existing battery holders for electric bicycles, comprising two separate holding elements, face challenges in alignment and assembly due to warped bicycle frames and assembly jig tolerances, leading to potential failure and suboptimal performance.
Innovation Solution
A battery holder design featuring a detachable assembly jig connected to both holding elements, allowing precise alignment and distance specification, which can be removed after secure mounting and is optionally flexible and material-saving, utilizing a wire or strip with predetermined breaking points for easy removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If two separate holding elements are used for battery mounting, then the battery holder can be attached to the bicycle frame, but alignment errors occur due to frame warping and assembly jig tolerances
Solution Approach 1:
The mounting system is divided into three segments: first holding element, second holding element, and mounting jig. The mounting jig acts as an intermediary that connects both holding elements with a predetermined distance, allowing each component to be manufactured separately while ensuring precise alignment during assembly.
Solution Approach 2:
The mounting jig serves as a mediator between the first and second holding elements. It establishes a fixed geometric relationship between the two holding elements, compensating for frame warping and assembly tolerances by providing a reference framework that ensures correct positioning.
2Manufacturing precision
If a rigid connection between holding elements is used, then alignment is maintained, but the mounting jig cannot be removed after assembly
Solution Approach 1:
The connection between the mounting jig and holding elements transitions from a temporary rigid state during assembly to a removable state after assembly. The mounting jig provides rigid alignment guidance during mounting, then can be detached to allow battery insertion and removal operations.
Solution Approach 2:
The mounting jig performs its alignment function preliminarily during the assembly process. Once the holding elements are securely mounted to the frame with correct positioning, the mounting jig has fulfilled its purpose and can be removed, allowing the battery to be freely inserted and removed.
3Manufacturing precision
If a non-detachable mounting jig is used, then alignment is ensured, but material is wasted and the system becomes more complex
Solution Approach 1:
The mounting jig is designed as a temporary component that is discarded after serving its alignment purpose. It is removed after the holding elements are securely mounted, allowing material to be recovered or reused for other purposes rather than being permanently integrated into the battery holder system.
4Manufacturing precision
If the mounting jig remains connected after battery insertion, then alignment is maintained, but the system complexity increases
Solution Approach 1:
The system is segmented into permanent components (holding elements attached to frame) and temporary components (mounting jig). This segmentation allows the mounting jig to be removed after assembly, simplifying the final system structure while maintaining alignment precision during the critical assembly phase.
Data Source
Figure 1~2
Figure 3a~3b
AI summary
The invention relates to a battery holder for an electric bicycle with a first holding element (10) and a second holding element (20) for holding a battery arranged between them, wherein the first holding element (10) has first fastening means (15) for attachment to a bicycle frame, and wherein the second holding element (20) has second fastening means (25) for attachment to the bicycle frame. The core of the invention consists in the fact that the battery holder has a mounting jig (30) which is connected to the first holding element (10) and the second holding element (20) in such a way that a distance and/or an orientation of the first holding element (10) and the second holding element (20) relative to each other are predetermined.