Ebike Wire Routing in Diagonal Tube
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Solution Overview
Problem
Existing ebike designs face challenges in efficiently routing cables and wires within the frame, leading to potential damage and aesthetic issues, while also limiting battery and motor placement options which affect handling and maneuverability.
Innovation Solution
The ebike design incorporates a frame structure with a diagonal tube that houses electrical cables, allowing the battery assembly to be positioned lower for improved handling and maneuverability, and uses an internal routing tube to guide actuator housings, avoiding the down tube to maximize battery capacity and reduce frame size, while protecting components with impact-absorbing materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cables and wires are housed within the hollow chamber of the ebike frame, then cable protection is improved, but cable routing efficiency and aesthetics deteriorate
Solution Approach 1:
The frame is divided into separate routing channels: a first routing channel in the down tube for cables, and a second routing channel in the seat tube for wires. This segmentation allows organized routing of different cable types while maintaining protection within the frame structure.
Solution Approach 2:
A cable routing tube acts as an intermediary component that guides cables from the handlebar assembly through the down tube to the motor assembly. This intermediary structure simplifies cable routing by providing a dedicated pathway that protects cables while enabling efficient routing.
2Device complexity
If battery assembly is positioned in the down tube, then cable routing is simplified, but battery capacity and handling deteriorate
Solution Approach 1:
The battery assembly is repositioned from the down tube to the triangle formed by the top tube, seat tube, and diagonal tube. This spatial relocation in a different dimensional space of the frame allows for increased battery capacity while maintaining cable routing efficiency through the dedicated down tube pathway.
Solution Approach 2:
The frame's hollow chamber is segmented into distinct routing zones: the down tube contains cable routing, while the triangle formed by the top tube, seat tube, and diagonal tube houses the battery assembly. This segmentation allows both cable management and battery capacity optimization to coexist.
3Ease of operation
If frame size is reduced to improve maneuverability, then handling is improved, but cable routing space deteriorates
Solution Approach 1:
The cable routing utilizes the existing hollow chamber walls of the frame tubes as protective enclosures. By routing cables along the interior surfaces of the down tube and seat tube, the design protects cables without requiring additional space, thereby maintaining a compact frame size for improved maneuverability.
4Adaptability or versatility
If diagonal tube is used for cable routing instead of down tube, then battery placement flexibility is improved, but cable protection deteriorates
Solution Approach 1:
The frame routing system is segmented into functionally dedicated channels: the down tube serves as the primary protective conduit for cables due to its structural robustness, while the diagonal tube and triangle formation provide flexible mounting options for the battery assembly. This segmentation ensures cable protection is maintained in the down tube while battery placement flexibility is achieved through alternative mounting locations.
Data Source
AI summary
An ebike comprises a front wheel, a rear wheel, a frame structure supported on the front wheel and the rear wheel, a motor assembly coupled to the frame structure, and a battery assembly configured to be coupled to the frame structure. The frame structure includes a head tube, a down tube, a top tube, a seat tube, and a diagonal tube coupling the top tube with the seat tube. The battery assembly is configured to be at least partially positioned in the down tube. The ebike further includes a user interface configured to be supported by the frame structure, and further includes an electrical cable coupling the user interface with the motor assembly, the electrical cable being positioned at least partially in the diagonal tube.