Motor Housing Integrated Spoke for Electric Bicycle
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Solution Overview
Problem
Existing electric bicycle wheel assemblies face challenges in easy motor installation, increased weight, and higher costs due to the need for additional installation components and metal components, which complicate the assembly process and manufacturing.
Innovation Solution
A motor housing integrated-type spoke structure is developed, where the motor housing and spokes are formed as an integral body through injection molding, using materials with varying rigidity, such as aluminum alloy, to reduce weight and cost, and simplify assembly by eliminating the need for additional installation components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional installation members are used to install the motor on the wheel, then the motor can be securely installed, but the assembly process becomes more complicated and time-consuming
Solution Approach 1:
The motor housing is merged with the spoke structure into a single integrated component. The motor housing forms part of the wheel assembly structure itself, eliminating the need for separate installation members. This integration secures the motor directly within the wheel while simplifying the assembly process, as the motor housing and spokes are formed as one piece through injection molding.
2Strength
If metal components are used to support the motor weight, then the structural strength is sufficient, but the weight and cost of the wheel increase
Solution Approach 1:
The wheel assembly uses a composite structure where the motor housing and spokes are formed from a single material through injection molding, creating an integrated component that optimizes the strength-to-weight ratio. The design distributes the motor weight across the integrated spoke structure, providing sufficient support while avoiding the need for additional heavy metal components.
3Reliability
If additional installation components are used, then the motor can be firmly fixed, but the manufacturing cost increases
Solution Approach 1:
The motor housing is combined with the spoke structure into a single integrated component manufactured through injection molding. This eliminates the need for separate installation members and reduces the total number of parts, thereby lowering manufacturing costs while maintaining firm motor fixation within the integrated housing structure.
4Adaptability or versatility
If multiple separate components are used for the wheel assembly, then each component can be optimized independently, but the overall assembly process becomes more complex
Solution Approach 1:
The motor housing and spokes are merged into a single integrated component manufactured through injection molding. This reduces the number of separate parts that need to be assembled, thereby improving assembly efficiency and productivity. The integrated design maintains the ability to optimize the overall structure while eliminating complex assembly operations.
Data Source
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AI summary
A motor housing integrated type spoke for an electric bicycle and a manufacturing method thereof, a wheel assembly having the same, and a manufacturing method thereof, the motor housing integrated type spoke coupled to a rim and including a motor housing, which is provided at a center of the motor housing integrated-type spoke to accommodate a motor, the motor housing integrally formed with the motor housing integrated-type spoke through an injection molding.