eBike Battery and Motor Mount Layout With Hidden Wire Routing
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Solution Overview
Problem
Existing electric bicycles (ebikes) face limitations in power usage, battery and motor placement, wire routing, and speed sensing, which affect their functionality and aesthetics.
Innovation Solution
The ebike design incorporates a motor and battery assembly positioned below the frame, with a unique routing system for cables and wires, and a low-profile speed sensor mount, enhancing maneuverability, weight reduction, and aesthetic appeal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the battery and motor are secured to the ebike frame using conventional mounting methods, then the components can be easily installed and removed, but the structural stability and rigidity of the assembly are compromised
Solution Approach 1:
The patent combines the battery mounting and motor mounting functions into a single integrated bracket assembly. The bracket includes a battery mounting portion with fasteners and a motor mounting portion with suspension bosses, allowing both components to be secured simultaneously to the frame. This merging of mounting functions maintains ease of installation while improving structural stability through a unified mounting system.
Solution Approach 2:
The bracket is pre-configured with suspension bosses and fasteners during manufacturing, so that when the battery and motor are installed, the mounting structure is already optimized for stability. The suspension bosses are positioned and sized in advance to provide rigid support, eliminating the need for additional stabilization measures during assembly.
2Strength
If the bracket has high stiffness to ensure stable attachment, then the battery and motor are securely mounted, but the bracket becomes difficult to integrate with the frame and increases overall weight
Solution Approach 1:
The bracket is segmented into distinct functional portions: a battery mounting portion with specific fasteners and a motor mounting portion with suspension bosses. This segmentation allows each portion to be optimized for its specific function - the battery portion for secure attachment and the motor portion for rigid support - while using thin-walled construction to minimize weight. The segmented design enables high stiffness where needed without requiring the entire bracket to be heavy.
3Ease of repair
If cables and wires are routed externally for easy access and maintenance, then the ebike is easier to service, but the aesthetic appearance and aerodynamic performance are degraded
Solution Approach 1:
The patent routes cables and wires through hollow chambers within the frame structure, nesting the wiring system inside the frame's internal volume. This nesting approach hides the cables from external view, improving aesthetics and aerodynamics, while the cables remain accessible through designated access points and connection interfaces that allow for maintenance and repair without disassembling the entire frame.
4Ease of manufacture
If the speed sensor uses a conventional mounting method, then the sensor is easy to install, but the sensor profile increases and interferes with the aerodynamic flow
Solution Approach 1:
The speed sensor is mounted in a low-profile configuration that utilizes the depth dimension of the frame rather than protruding outward. The sensor is positioned within or close to the frame's aerodynamic surface, changing the mounting approach from a protruding external mount to a recessed or integrated mount that maintains the frame's streamlined shape and reduces interference with airflow.
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 configuration improves handling, reduces weight, and enhances the ebike's overall performance and appearance by optimizing battery and motor placement, streamlining cable routing, and providing efficient speed sensing.
Implementation Method 1
an inductive sensor may be attached to the ebike frame, and one of the wheels may be provided with a magnet that rotates with the wheel. As the magnet rotates with the wheel, the sensor detects the magnet passing by and counts the number of revolutions of the wheel.
Data Source
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AI summary
An ebike comprises a front wheel, a rear wheel, a frame structure supported on the front wheel and the rear wheel, a crank assembly, and a battery assembly. The frame structure can include a front fork supported on the front wheel, a head tube coupled to the front fork, and a down tube extending downward and rearward from the head tube, the down tube defining a down tube axis and being open at its lower end. The crank assembly can be supported by the frame structure and can be rotatable about a crank axis that is spaced rearward from the down tube axis. The battery assembly can be at least partially secured in the down tube in an installed position and can be slidable into the down tube from the lower end of the down tube along the down tube axis.