Mid drive electric bicycle powerflow with planetary gear overdrive and stepped pinion planetary

A product may include a gear set that may have a first gear, a second gear that may be engaged with the first gear and a third gear. The third gear may be held from rotation and may be engaged with the second gear. A carrier may carry the second gear for rotation. A crank may be continuously connected with the carrier to provide input thereto. A torque measurement device may be connected to the third gear.

TECHNICAL FIELD

The field to which the disclosure generally relates includes electric cycles, and more particularly, electric cycles with planetary drive mechanisms.

BACKGROUND

An electric cycle may have various wheel arrangements and may include an on-board electric motor that can be used for propulsion through one or more gears.

SUMMARY OF ILLUSTRATIVE VARIATIONS

A number of variations may involve a product that may include a gear set that may have a first gear, a second gear that may be engaged with the first gear, and a third gear. The third gear may be held from rotation and may be engaged with the second gear. A carrier may carry the second gear for rotation. A crank may be continuously connected with the carrier to provide input thereto. A torque measurement device may be connected to the third gear.

DETAILED DESCRIPTION OF ILLUSTRATIVE VARIATIONS

FIG. 1illustrates a number of variations which may include an electric cycle40. In any of a number of variations, the electric cycle40may include a frame42which may include a top tube44connected to a seat tube46. A steering tube45may extend from the top tube44. The steering tube45may be operatively connected to a front fork56which may be attached to a front wheel54. Handlebars48may be attached to the steering tube45and may be used to control the direction of the front wheel54by way of the front fork56. Control levers50may be provided on the handlebars48and may be constructed and arranged to communicate with one or more electronic control devices58, one or more mechanical mechanisms that will be described later, and/or a motor60. The one or more electronic control devices58may include electronic processing components to receive input signals and to send out signals to control various components of the electric cycle40, which may include sending output signals to control operation of the electric motor60. In a number of variations the one or more electronic control devices58may include memory, a processor and software and/or hardware to process input signals and generate output signals, and may include formulas, lookup tables or other means for comparing and processing data. A brake lever52may also be provided on the handlebars48, if desired.

The electric cycle40may also include a crank assembly62which may include a crankshaft64having a first pedal assembly66and a second pedal assembly70connected thereto. The first pedal assembly66may include a first foot pedal68, and the second pedal assembly70may include a second foot pedal72. A linked element71, which may be a sprocket or a pulley or another device, may be operatively connected to the crankshaft64for driving a linking member76. The linking member76may be a chain or belt or another link suitable for engaging the linked element71and may be operatively connected to a rear linked element78which may be operatively connected to a hub80of a rear wheel82. The linked element78may be a sprocket or pulley or another device suitable for engaging with the linking member76.

The electric cycle40may be constructed and arranged to allow a rider to rotate a first and second pedal assembly66,70in a full clockwise or counter clockwise rotation to power the electric cycle40or may allow a rider to use a pedal force-based propulsion system wherein the first and second pedal assemblies66,70may be fixed in an approximately horizontal position so that a rider may provide intuitive input commands by applying a force to a first foot pedal68attached to the first pedal assembly66or a second foot pedal72attached to the second pedal assembly70in the clockwise or counter clockwise direction. The input commands may be intuitive to the rider and may be similar to riding a non-motorize cycle wherein the rider applies a clockwise force to a cycle crank by applying force to a forward positioned foot pedal to move the cycle in a forward direction, and the rider applies a counter clockwise force to the cycle crank by applying force to a rearward positioned foot pedal to slow the cycle. Reference herein as to clockwise or counterclockwise is made with respect to the right hand side of the cycle with an operator facing the forward direction of movement of the electric cycle40. The electric cycle40may be a bicycle, tricycle, or four-wheel electric cycle having a crank assembly62constructed and arranged to allow a rider to provide input thereto using the first pedal assembly66and the second pedal assembly70.

Referring toFIGS. 2 and 3along withFIG. 1, in a number of variations, the electric cycle40may include a product100that may include the electric motor/generator60which may be used to propel the electric cycle40and to generate electricity from motor/generator regenerative braking. The motor/generator60may be attached to the electric cycle40at the frame42and may be adjacent the pedal assemblies66,70, linked element71and/or crankshaft64. The motor/generator60may include any of a number of types of motor/generators including, but not limited to, a brushless ring motor. The motor/generator60may include a stator101and a rotor102. The rotor102may rotate within the stator101which may be held or grounded to a case103. The motor/generator60may be powered by a battery or any number of batteries or battery assemblies. In a number of variations, one or more gear sets may be located within the motor60. In one variation, a first gear set104, which may be a planetary gear set, may be operatively connected with the motor60and may be included therewith as part of a common assembly, and may be used to provide additional gear ratios to the motor60.

In a number of variations, the first gear set104may include a gear105that may be a sun gear, and which may be operatively engaged with one or more gears106, which may be planetary gears so that when the gear105is rotated, it may cause the one or more gears106to rotate within a ring gear107, which may be held or grounded. In a number of variations, the one or more gears106may be operatively connected to a carrier108and may cause the carrier108to rotate when the one or more gears106may be rotated. The one or more gears106may be stepped pinion gears with a larger diameter pinion109engaged with the gear107, and a smaller diameter pinion110engaged with the linked element71through a torque transfer element112, the selectively engaged mechanical mechanism57, and a torque transfer element116. The torque transfer element112may be a part of the mechanical mechanism57or may be connected thereto. The torque transfer element112may include, or may be, a ring gear that may have internal teeth meshing with the pinion110. The gear set104may be operatively connected to the linking member76through the linked element71. The linking member76may drive the rear linked element78.

In a number of variations the gear105may rotate the one or more gears106and the carrier108when driven by the motor60through a torque transfer element111. With gear107held or grounded, which may prevent its rotation, the one or more gears106may travel around the inside of the gear107and the carrier108may rotate in the same direction as the rotor102and at a slower speed. This may allow for high speed input from the motor60to the linked element71, reduced through the gear set104.

In a number of variations output from the gear set104may be provided through the pinion110. The pinion110may be connected with the pinion109and may rotate in the same direction but due to its smaller diameter may provide a slower relative output. From the pinion110, torque may be transferred through a torque transfer element112and the mechanical mechanism57to the torque transfer element116that may be connected with the linked element71. The torque transfer element112may include a gear for engagement with the pinion110. The torque transfer element116may be a tube or other structural element for engagement between the mechanical mechanism57, the linked element71, and for providing additional functions described below.

In a number of variations, the mechanical mechanism57may be operatively connected between the torque transfer element112and the torque transfer element116. The mechanical mechanism57may be constructed and arranged so that when closed, torque to the linked element78may be generated by rotation of the rotor102, and recovery torque may be passed from the rear linked element78to the motor60which may also operate as a generator. In a number of variations, the mechanical mechanism57may be a clutch and/or may include a selectively operated clutch mechanism as known in the art to provide open and closed states between the torque transfer elements112,116. The mechanical mechanism57may be mechanically, electrically or otherwise actuated, or by a combination thereof.

In a number of variations a second gear set114may be operatively connectable with, and driven by, the rotor102of the motor60through the torque transfer element116and/or by the crank assembly62through the crankshaft64. The second gear set114may include a carrier118which may be operatively connected with one or more gears120, which may be planet gears. The crank assembly62may be connected with the carrier118through the crankshaft64and a torque transfer element122, so that when the pedals68,72may rotate the crank, the carrier118may be rotated through the crankshaft64and the torque transfer element122. The crankshaft64may extend through the torque transfer element116. In a number of variations, rotation of the carrier118may cause the one or more gears120to rotate and to travel around the inside of a gear124, which may be a ring gear with internal teeth, and may be held or grounded. As such, the gear124may be a nonrotating element. In a number of variations the one or more gears120may be operatively connected with a mechanical mechanism55through a torque transfer element which may be or may include a gear126, and which may be the gear126. The gear126may be a sun gear and may include teeth that may mesh with and may be engaged with the one or more gears120. The mechanical mechanism55may be operatively engaged with the torque transfer element116so that when closed, rotation of the crank assembly62may result in rotation of the linked element71through the crankshaft64, the torque transfer element122, the carrier118, the one or more gears120, the gear126, the mechanical mechanism55and the torque transfer element116. The mechanical mechanism55may be of any type suitable to provide at least one of the following: (1) allowing for the free rotation of the first and second pedal assemblies66,70in both the clockwise and counterclockwise directions; (2) locking the first and second pedal assemblies66,70and preventing rotation in both the clockwise and counterclockwise directions; (3) locking the first and second pedal assemblies66,70preventing movement in the clockwise direction and allowing rotation in the counterclockwise direction; or (4) locking the first and second pedal assemblies66,70preventing rotation in the counterclockwise direction but allowing rotation in the clockwise direction. In addition, the mechanical mechanism55may allow for rotation of the torque transfer element116faster than rotation of the crank assembly62such as in an overrunning state. The mechanical mechanisms55,57may be of the type disclosed in U.S. patent application Ser. No. 14/714,495 titled Electric Bike Powertrain with Dual Planetary Gear Sets and Ring Gear Pedal Reaction Torque Measurement, filed May 18, 2015, which is specifically incorporated herein by reference. In a number of other variations the mechanical mechanisms55,57may be a clutch as known in the art.

In a number of variations, a torque measurement device130that may be constructed and arranged to measure torque and that may include, but not be limited to, a strain gauge as known in the art. The torque measurement device130may also be operatively connected to the gear set114and may be used to measure the reaction torque from the pedal input on crank assembly62. The torque measurement device130may be operatively connected between the gear124and ground at the case103, and may measure reaction torque of the gear124which may be proportional to the rider input torque through the crank assembly62. The torque measurement device130may be used to control the operation of at least one of the electric motor60or a regenerative braking system in the electric motor60.

The electric cycle40may be constructed and arranged to selectively provide for at least one of the following functions or modes: (A) Pedal assist, wherein the torque (and optionally the speed, position, and direction of the crank) is detected and assistance in rotating the crankshaft64is provided by the electric motor60in response to the detected torque, (and optionally the speed and direction of the crankshaft64); (B) Coast with spinning motor60synchronized with the road, wherein the crankshaft64is de-coupled to the electric motor and the rider is not rotating the pedal assemblies66,70of the electric cycle40, but the wheels54,82and motor60are spinning; (C) Coast without spinning motor synchronized with the road, wherein the crankshaft64is not coupled to the motor60and the motor60is not coupled to the linked element71; (D) Electronic coaster with regenerative braking mode, wherein the first and second pedals assemblies66,70may not be rotating and the crankshaft64is de-coupled from the electric motor60, and the rider may apply a backward force to the first or second foot pedal68,72so that the torque measurement device130may measure the reaction torque and may cause a regenerative braking command to be sent to the motor60to generate energy which may be delivered into the battery; (E) Regenerative braking mode, wherein the motor60slows down the electric cycle40while a regenerative braking command may be sent to the motor60to generate energy which may be delivered into the battery; (F) Pedal force throttle mode, wherein a clockwise torque/force of the crankshaft64may be measured when the mechanical mechanism55is closed and wherein the force applied on a pedal by the rider may be detected and used as a throttle input to the motor60; (G) Pedal mode without back drive lockup, wherein the rider may rotate the crankshaft64in a clockwise direction to move the electric cycle40forward, and the rider may rotate the crankshaft64in a counter clockwise direction in a free spinning mode without back drive lockup or locking the rear wheel82when moving backwards; or (H) Security lock mode, wherein the first and second pedal assemblies66,70may not be rotated clockwise or counterclockwise but the electric cycle40may be rolled.

FIG. 3illustrates the product100in a lever diagram form. Torque measurement may be obtained from the grounded gear124in a simplified form since the torque measurement device130need not rotate. Driving torque for the hub80may be provided by the crank assembly64and/or the motor60. An overdrive ratio that may be applicable over a wide range and may be provided through the held or grounded gear124, with input to the carrier118and output through the gear126. A maximum of speed increase may be obtained through this arrangement of the gear set114.

Variation 1 may involve a product that may include a gear set that may have a first gear, a second gear that may be engaged with the first gear and a third gear. The third gear may be held from rotation and may be engaged with the second gear. A carrier may carry the second gear for rotation. A crank may be continuously connected with the carrier to provide input thereto. A torque measurement device may be connected to the third gear.

Variation 2 may include the product according to variation 1 and may include a linking member and a linked element that engaged with the linking member. The linked element may be connected to the third gear through a mechanical mechanism that may be constructed and arranged to selectively transfer torque between the third gear and the linked element.

Variation 3 may include the product according to variation 2 wherein the mechanical mechanism may be a clutch.

Variation 4 may include the product according to any of variations 1 through 3 and may include a second gear set that may have a fourth gear that may be shaped like a ring, a fifth gear that may be engaged with the fourth gear and a sixth gear that may be engaged with the fifth gear. A second carrier may carry the fifth gear for rotation. A motor may be included and may have a rotor that may be directly engaged with the sixth gear. A mechanical mechanism may be connected between the fifth gear and a linked element that may be selectively driven by the second gear set.

Variation 5 may include the product according to variation 4 wherein the mechanical mechanism may be connected to the linked element through a torque transfer element that may be tubular.

Variation 6 may include the product according to variation 4 or 5 wherein the mechanical mechanism may be constructed and arranged to selectively transfer torque between the fifth gear and the linked element.

Variation 7 may include the product according to any of variations 4 through 6 wherein the fifth gear may include a first pinion and a second pinion that may be smaller than the first pinion. The first pinion may be directly engaged with the fourth gear and the second pinion may be engaged with the linked element through a ring gear and the mechanical mechanism.

Variation 8 may include the product according to variation 7 and may include a torque transfer element connected between the ring gear and the mechanical mechanism.

Variation 9 may include the product according to any of variations 1 through 8 and may include a torque transfer element that may be tubular. The third gear may be connected to the torque transfer element and may provide output from the gear set. The crank may include a shaft that may extend through the torque transfer element.

Variation 10 may include the product according to variation 9 and may include a linked element connected to the torque transfer element. A linking member may be engaged with the linked element. A rear hub may be engaged with the linking member.

Variation 11 may involve a product that may include a first gear set that may have a first gear, a second gear that may mesh with the first gear, and a third gear that may mesh with the second gear. A first carrier may carrying the second gear. A second gear set may have a fourth gear, a fifth gear that may mesh with the fourth gear, and a sixth gear that may mesh with the fifth gear. A second carrier may carry the fifth gear. A crank assembly may be engaged with the first carrier and may provide input to the first gear set. A first mechanical mechanism may be connected between the third gear and a torque transfer element and may provide output from the first gear set. A motor may be engaged with the sixth gear and may provide input to the second gear set. The fifth gear may be connected to the torque transfer element through a second mechanical mechanism and may provide output from the second gear set.

Variation 12 may include the product according to variation 11 wherein the first gear may be held from rotating.

Variation 13 may include the product according to variation 12 and may include a torque device that may be connected to the first gear and may measure torque applied to the first gear.

Variation 14 may include the product according to variation 13 and may include a case that may house the first and second gear sets. The torque device may be connected between the first gear and the case.

Variation 15 may include the product according to any of variations 11 through 14 wherein the fifth gear may include a first pinion and a second pinion that may be smaller than the first pinion. The first pinion may be directly engaged with the fourth gear. The second pinion may be engaged with the mechanical mechanism.

Variation 16 may include the product according to any of variations 11 through 15 wherein the fourth gear may be held from rotating.

Variation 17 may include the product according to any of variations 11 through 15 and may include a linking member and a sprocket that may be drivingly engaged with the linking member. The sprocket may be fixed to the torque transfer element.

Variation 18 may involve an electric cycle powertrain that may include a wheel that may have a hub. A torque transfer element may be connected with the hub. First and second gear sets may be connected with the torque transfer element. The first gear set may have a first gear that may be held from rotation. A second gear may be engaged with the first gear and a third gear may be engaged with the second gear. The third gear may provide output from the first gear set to the torque transfer element. The second gear set may have a fourth gear, a fifth gear that may be engaged with the fourth gear, and a sixth gear that may be engaged with the fifth gear. The fifth gear may be connected with the torque transfer element and may provide output from the second gear set.

Variation 19 may include the product according to variation 18 and may include a torque measurement device that may be engaged with the first gear.

Variation 20 may include the product according to variation 18 or 19 and may include a motor that may have a rotor that may be engaged with the sixth gear.

The above description of select variations within the scope of the invention is merely illustrative in nature and, thus, variations or variants thereof are not to be regarded as a departure from the spirit and scope of the invention.