Integrated Electric Bicycle Drive System Nesting
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Solution Overview
Problem
Conventional electric bicycles often have heavy batteries and drive components mounted outside the frame, leading to increased weight, raised center of gravity, poor handling, and a non-integrated, bulky appearance, exposing expensive components to damage and theft.
Innovation Solution
An integrated electric drive system that fits within the bicycle frame, comprising a unitary motor-controller-drive system and a longitudinally-extending battery pack, which can be slid into and removed from the frame through an open bottom bracket shell, allowing for automatic power application based on pedal force without external controls, maintaining a slim and lightweight design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If heavy batteries and drive components are mounted outside the frame, then power and energy capacity are improved, but weight distribution and center of gravity deteriorate
Solution Approach 1:
The electric motor, controller, and drive system are nested within the hollow frame tubes of the bicycle, specifically utilizing the bottom bracket shell and seat tube. This nesting approach allows the heavy components to be positioned low and centrally within the frame structure, improving weight distribution and lowering the center of gravity while maintaining full power capacity.
2Ease of operation
If batteries and drive components are mounted outside the frame, then accessibility and installation ease are improved, but security and aesthetic appearance deteriorate
Solution Approach 1:
By nesting the batteries and drive components within the frame tubes, the system provides inherent security and protection from theft and damage. The components are concealed within the frame structure, eliminating exposure to external harm while maintaining accessibility through strategic access points.
Solution Approach 2:
The drive system is segmented into modular components (motor, controller, batteries) that can be independently installed and removed through the open bottom bracket shell. This segmentation maintains ease of operation and accessibility while keeping each component secure within the frame structure.
3Object-affected harmful factors
If electric components are integrated within the frame, then security and aesthetic appearance are improved, but installation complexity and manufacturing precision requirements increase
Solution Approach 1:
The drive system is divided into separate modular components that can be installed independently through the open bottom bracket shell. This segmentation reduces manufacturing precision requirements by allowing components to be assembled separately and then integrated into the frame without requiring complex precision machining of the frame itself.
Solution Approach 2:
Instead of integrating components into a closed frame structure, the design utilizes the open bottom bracket shell as an access point for installation. This inverted approach allows components to be inserted from the bottom rather than requiring frame disassembly or complex integration procedures.
4Ease of manufacture
If components are positioned toward the rear or upper part of the bicycle, then ease of installation is improved, but handling and balance deteriorate
Solution Approach 1:
Rather than positioning components at the rear or upper part of the bicycle for ease of installation, the system inverts this approach by utilizing the bottom bracket shell as the access point. This allows components to be installed easily at the bottom center while simultaneously achieving optimal weight distribution and handling characteristics.
Solution Approach 2:
The components are positioned at the bottom bracket shell, which is the lowest and most central point of the bicycle frame. This creates an equipotential position for the heavy components, balancing the weight distribution and lowering the center of gravity to improve handling and stability.
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 provides a high-performance, lightweight electric bicycle with improved handling and balance, concealing the electric components within the frame, reducing the risk of damage and theft while maintaining a conventional appearance.
Implementation Method 1
an electric motor; a controller configured to electronically control the electric motor
Implementation Method 2
a longitudinally-extending battery pack configured to be electrically connected with and to provide electrical power to the electric motor and the controller
Data Source
AI summary
An integrated high-performance and light-weight electric drive system for a bicycle is disclosed comprising an integrated unitary motor-controller-drive system that can be inserted into and removed from a first tube portion of a bicycle frame through an open bottom bracket shell portion of the bicycle frame. A longitudinally-extending battery pack configured to be electrically connected with and to provide electrical power to the electric motor and the controller may be configured to be inserted into and removed from a second tube portion of the bicycle frame through the open bottom bracket shell portion of the bicycle frame. Some or all of the electrical components may not be visible from the exterior of the bicycle. A unique digital torque sensing and control system is described along with regenerative braking and other unique features.