Abstract:
A dual power electric assist hub wheel wherein two power source outputs are combined into a compact planetary gear set with precisely located one-way bearings in a specific configuration which provides:
       A first mode, direct drive pedaling   A second mode, motor powered alone with throttle activation   A third mode, dual power drive with variable speed output hub wheel and hand throttle control   A fourth mode, motor and/or pedaling regenerative braking manually activated.

Description:
RELATED APPLICATION 
       [0001]    This application claims the benefit of the U.S. Provisional Application Ser. No. 62/070,299, filed on Aug. 20, 2014, which is herein incorporated by reference in its entirety. 
     
    
     TECHNICAL FIELD 
       [0002]    This relates to an electric assist rear hub whose planetary gearing allows the combination of electric motor power and pedaling speed in three power modes: direct drive, motor alone, and variable output speed for the hub wheel; Regenerative braking and complete freewheeling are two more features of this invention. 
       BACKGROUND 
       [0003]    This field is represented in part in literature and by nearly 100 patents which mostly lack the features needed to provide a complete hybrid drive; many of them are so complex or are built with many highly costly custom parts that any production cost would be prohibitive; several have from three to five sets of gears side by side, making them have a width which could not fit in a normal bike frame. 
         [0004]    The prior art in this field showed the following patents:
       U.S. Pat. No. 5,242,335 by Michael Kutter, Sep. 7, 1993   U.S. Pat. No. 6,276,475 by Haruhiko Nakansono, Aug. 21, 2001   U.S. Pat. No. 6,974,399 by Chin-Hsiang Lo, Dec. 13, 2005   Pub. US 2006/0037796 A1 by Hans Peter Naegeli, Feb. 23, 2006   Application WO 2011/US 28686 by Jordan Brian, Mar. 16, 2011   Patent CN 102111034A, Jun. 29, 2011   Patent WO 2011162200 A1 by Kiyohiro Ito, Dec. 29, 2011   Pub. NO. 2012/0149517 A1 by Jeong Han Ko and Kyung Phil Kang, Jun. 14, 2012   Application NO. WO 2012/132927 A1 by Kiyohiro Ito, Oct. 4, 2012   Pub. NO. US 2014/008964 A1 by Adriano Zanfei and Fabio Giorgi, Jan. 9, 2014   U.S. Pat. No. 8,536,095 B2 by Kiyohiro Ito, Jan. 28, 2014       
 
       Background of Current E-Bike Drive 
       [0016]    The always present goal of cycle and assist e-bike is to permit acceptable pedaling rotational speed under a wide variety of riding conditions; even now most rear hub wheel still use from 5 to 10 ratio at the hub requiring an expensive derailleur and a near 2″ wide cassette or freewheel with 5 to 10 sprockets. 
         [0017]    Most e-bike rear hubs are Direct Drive from the motor with the drawback of non-negligible drag from the magnetic and electric interference with when riding without electric assist. 
         [0018]    A second group is the geared rear hub motor wheel which is lacking any regenerative capability and still requires the full capability of shifting one or two derailleurs plus controlling the e-bike functions. 
         [0019]    A new group is rear hub wheel with wireless control and batteries and controller located inside the wheel hub; here many manufacturers use a single chain or timing belt which limits the bike to mostly flat or urban applications, a few others still carry the multiple sprockets and derailleurs. 
       SUMMARY OF THE INVENTION 
       [0020]    The present invention is an e-bike rear hub built with mass produced components following a precise configuration allowing several components to be located concentric to each other permitting the use of Direct Drive or Geared Motor combined with one extra planetary set and several one-way bearings, in order to produce a Multi Mode E-BIKE Hub Wheel giving four distinct modes of operation:
       Direct Drive in Pedaling   Motor Drive Alone   Variable Speed Overdrive (Both Power)   Regenerative Braking on Demand       
 
         [0025]    This is accomplished with the pedaling power driving a single sprocket or timing pulley at the rear hub; the non-rotating hub shaft is supporting a sleeve where the cyclist rotates the power drive sleeve while a first one-way bearing drives the hub casing providing Direct Drive; on this sleeve, a second one-way bearing drives a sun gear which meshes with the planets whose carrier is fastened to the hub casing in order to propel the rear wheel when the power is provided to the ring gear by the e-bike motor, for either motor drive alone or under Assist Drive and Variable Speed Overdrive; Regenerative Braking is provided by locking the planetary set as a single unit similarly to the Electric Direct Drive rear wheel hub. 
       OBJECTS AND ADVANTAGES 
       [0026]    It is a foremost object of this invention to provide a rear e-bike wheel hub which is highly efficient and performs similarly to a hybrid car powertrain; either using one of two power sources, human power or electric power, or using the two powers combined together for hill climbing or higher speed riding. 
         [0027]    A second object is to permit the user to control the level of power ( 1 - 2 - 3 ) with one hand at the handle bar near one brake lever and the other hand near the other brake lever to activate the throttle without having to touch the usual console located at the center of the handlebar; the only other control is a push button which activates regenerative braking. 
         [0028]    A third object and advantage of this invention is the combination of the current e-bike hub with an extra low cost bicycle planetary and basic small size industrial, or bicycle one-way clutch in a specific configuration to allow the manufacturing of a better highly advanced and competitive e-bike rear hub. 
         [0029]    A fourth object and advantage is to allow the use of a cleaner timing belt instead of a chain with the single ratio crank to rear wheel for urban and other uses; a crankset with two gears and front derailleur will provide the necessary low ratio for a cyclist riding in a very hilly area. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS AND PICTURES 
         [0030]    This invention&#39;s objects, features and advantages will be better understood in consideration of the detailed description of several embodiments illustrated in the drawings and pictures, in which: 
           [0031]      FIG. 1  Illustrates a cross-sectional view of a first embodiment of the invention. 
           [0032]      FIG. 2  Illustrates a cross-sectional view of a second embodiment of the invention. 
           [0033]      FIG. 3  Illustrates a cross-sectional view of a third embodiment of the invention. 
           [0034]      FIG. 4-5-6  Show four pictures of the third embodiment as a fabricated prototype. Note:  FIG. 4  has anti-rotation clutch. 
           [0035]      FIG. 7  Illustrates a cross-sectional view of the first embodiment modified to develop regenerative braking. 
           [0036]      FIG. 8-9-10  Show (Prior Art) level  1 ,  2 , and  3  of current control system. 
           [0037]      FIG. 11-12  Show prototype of the second embodiment of the invention. Note:  FIG. 11  has anti-rotation on the pedal crank 
           [0038]      FIG. 13  Illustrates a novel speed pedal assist system (PAS). 
           [0039]      FIG. 14-15-16  Show 3 levels of PAS including level  2  and  3  including the  FIG. 13  system. 
           [0040]      FIG. 17  Shows a 2 or 3 speed crank set which could be used with any of the previous embodiments 
       
    
    
     LIST OF NUMERAL REFERENCE 
       [0000]    
       
           10  electric e-bike rear hub 
           12  supporting shaft 
           14  sleeve 
           16  motor disc 
           18  electric coils 
           20  magnetic ring 
           21  magnetic ring casing 
           22  supporting flange 
           24  set of bearings 
           26  ring gear fastened by press fit 
           28  sprocket 
           30  power hub 
           32  bearing 
           34  one-way clutch 
           36  hub casing 
           38  second one-way clutch 
           40  sun gear 
           42  set of planet gears 
           44  planet holder 
           46  bearing 
           48  series of bolts 
           50  sleeve 
           52  locking ring 
           56  keyway 
           60  feeding cord 
           62  solenoids 
           64  set of bolts 
           66  square edge teeth engaging surface 
           68  set of plungers 
           70  set of solenoids 
           72  set of brushes 
           74  spring loaded ring 
           76  group of insulated buttons 
           110  e-bike rear hub 
           112  supporting shaft 
           114  sleeve 
           118  electric coils 
           121  ring and supporting flange 
           122  group of magnets 
           124  set of bearings 
           126  second ring gear 
           128  sprocket 
           130  power hub 
           132  set of bearings 
           134  one-way clutch 
           136  hub casing 
           138  one-way clutch 
           140  sun gear 
           142  planets 
           144  planet holder 
           146  bearing 
           158  sun gear 
           160  power cord 
           164  planetary holder flange 
           166  one-way clutch 
           168  set of planet axles 
           170  set of planets 
           172  ring gear 
           174  spacer flange 
           176  large diameter bearing 
           178  numerous bolts 
           180  circle ring 
           182  second circle ring 
           210  hybrid rear hub 
           212  supporting shaft 
           221  large sprocket 
           223  sleeve hub 
           224  set of bearings 
           226  ring gear 
           228  sprocket 
           230  power hub 
           232  set of bearings 
           234  one-way clutch 
           236  hub casing 
           239  one-way bearing 
           240  sun gear 
           242  planet gears 
           244  planetary holder 
           246  bearings 
           262  group of bolt-axles 
           270  second one-way clutch 
       
     
       DETAILED DESCRIPTION OF THE INVENTION 
       [0122]    Referring to  FIG. 1  which shows a cross-sectional view of an electric e-bike rear hub  10 , which includes the first power input, a high torque brush or brushless direct drive motor  20  &amp;  18  fastened around a supporting shaft  12  including a sleeve  14 , a motor disc  16  an electric coils  18  which power a magnetic ring  20 - 21  fastened to a supporting flange  22 , which rotates on a set of bearings  24  and transfers its power through a ring gear fastened by press fit  26 ; the second power input is a sprocket  28  which is directly fastened to a power hub  30 , which rotates a bearing  32 , which also drives a first one-way clutch  34  which is fastened to and drives a hub casing  36  toward forward motion at a 1:1 ratio when the bicycle is driven in pedaling mode by a set of fastening axle bolts  62 ; the power hub  30  drives a second one-way clutch  38 , linked directly to a sun gear  40  which is free to rotate faster than the power hub sprocket member  28 , the main power driving the hub casing  36  is a set of planet gear  42 , and a planet holder  44 ; fastened go the hub casing  36  by the axle bolts  62 ; a bearing  46  is also supporting the casing on the other side. The hub sleeve  14  is fastened on the supporting shaft  12  by slight press fit and a keyway  56 , also the electric power and feedback control wires by a feeding cord  60 . 
         [0123]    According to the aforementioned structural combination, the novel electric hybrid rear hub allows the cyclist to choose a preferred rotating speed: 
         [0124]    1st scenario: one direct drive gear which is comfortable to pedal, example: 60-80 rpm which translates to 15-20 miles per hour. This translates to around 120-200 watts, which an average cyclist can produce via the one-way clutch  32  which drives the hub casing  36  and bicycle wheel. Under pedaling alone the direct drive motor is allowed to rest still because the ring  26  fastened to the motor does not rotate and is compensated by the sun gear  38  which turns freely at 3 times the speed of the wheel for a sun-to-ring ratio of 1:2, at 15 miles per hour or 3 rotations per second, 180 rotations per minute, this is 540 rpm which is much more efficient than rotating the motor at 180 rpm and resulting magnetic interaction. 
         [0125]    2nd scenario: when the motor helps the propulsion but the motor speed is equal to the sprocket speed and therefore can assist as low as no power or as high as twice the cyclist power, example: climbing a hill at 15-20 miles per hour with the total power ranging from 300 watts to 900 watts; the motor power load would be 200 to 600 watts, respectively and human pedaling power would be 100 and 300 watts respectively which is under the US Federal limit of 750 for motor power. 
         [0126]    3rd scenario: when the motor rotates faster than the pedaling sprocket. Extreme condition is no pedaling and the hub wheel rotates at ⅔ the speed of the motor (this means more torque than a similar motor directly driving the hub wheel combination). Also, this means the electric motor can provide up to 100% of the power or as little as none. The speed relationship of the wheel is a combination of the sun gear and ring gear speed. As example, if on electric alone, 20 miles per hour is the maximum cruising speed, adding pedaling will bring that speed to 30 miles per hour. Again this follows the Federal limit of 20 miles per hour for no pedaling. In summary the motor assist can be from 0% to 100% and the direct speed of 15 miles per hour can be maintained in any situation; then variation from 15 to 30 miles per hour can be achieved by simple motor speed variation. 
         [0127]    Under load sharing, with the ring gear turning faster than the human power sprocket, the cyclist power is carried by the sun gear  40  while the motor power is applied to the ring gear  26  and the speed of the output planetary drives the wheel hub at a higher speed than the human sprocket  28  and slower than the motor ring gears; during that time the one-way clutch  34  is running freely. 
         [0128]    The hub casing  36  is fastened together by a series of bolts  48 , similarly, the ring  21  is fastened to the flange  22  by a set of bolts  64 ; the axle  12  is completed by a sleeve  50  and on the other end a locking ring  52 . 
         [0129]    Referring to  FIG. 2  which shows a cross-sectional view of a second embodiment of an e-bike rear hub  110  for bicycle which includes a high speed brush or brushless gear motor fastened around a supporting shaft  112  including a sleeve  114 , an electric coils  118  which rotate a group of magnets  122  fastened to a ring and supporting flange  121  which rotates on a set of bearings  124  and transfers its power to a sun gear  158 ; the second power input a sprocket  128  which is directly threaded or fastened to a power hub  130  which rotates on a set of bearings  132 , which also drives a first one-way clutch  134  which is fastened to and drives a hub casing  136  toward forward motion at a 1:1 ratio; the power hub  130  also drives a second one-way clutch  138 , linked directly to a sun gear  140  which is free to rotate faster than the sprocket member  128 , the hub casing  136  is powered with a set of planets  142  planet holder  144  when the bike is driven in electric assist mode; a bearing  146  is also supporting the casing on the other side. 
         [0130]    Different than the embodiment is the high speed motor output which is the sun-gear  158  driven directly by a flange disc  121 ; receiving that power is a planetary holder flange  164  where a one-way clutch  166  is fastened and holds solidly a set of planet axles  168 , a set of planets  170  which transmit their rotational torque and speed to a ring gear  171  which is fastened to a large spacer flange  174  which is free rotating on a thin large bearing  176 . 
         [0131]    The speed and power of the ring gear  172  via the spacer flange  174  to a second ring gear  126  which plays the same role as the ring gear  26  of  FIG. 1 ., first embodiment. Therefore, every component of the output planetary fastened to the hub casing  136  is playing the same role as in  FIG. 1 . 
         [0132]    It is to be noted that the ring gears  172  and  126  are fastened to the spacer flange  174  by numerous bolts  178 , also the large diameter bearing  176  is fastened at its inside diameter by a circle ring  180  and at its outer diameter by a second circle ring  182 . 
         [0133]    It should be noted that the gear motor hub sun gear rotation is always reversed in relation to the bicycle wheel since the planetary and the planets reverse the rotation to the ring gear. 
         [0134]    Referring to  FIG. 3 . which shows a cross-sectional view of a hybrid rear hub  210  which is fastened around a supporting shaft  212  including a large sprocket  221  fastened to a sleeve hub  223  and a ring gear  226 ; the second power input, a sprocket  228  which is directly fastened to a power hub  230  which rotates on a set of bearings  232  which also drive a first one-way clutch  234  which is fastened to and drives a hub casing  236  at a 1:1 ratio only in forward motion. The power hub  230  also drives a sun gear  240  which is engaged with a group of planet gears  242  which are fastened to the wheel hub casing  236  via a planetary holder  244  and a group of bolt-axles  262 . 
         [0135]    A one-way bearing  239  allows the power and rotation of an external source via the sprocket  221  to be transferred to the sleeve hub  223  and in a single forward motion to the ring gear  226 . 
         [0136]    This one-way bearing  239  becomes the key component permitting: either a first scenario propulsion of the hub wheel by only the sprocket  228 ; or in a second scenario by only the sprocket  221 ; or in a third scenario by both the sprocket  228  &amp;  221 ; or in a fourth scenario it permits the hub wheel to freewheel without any motion of any of the two sprockets, in such case the sun gear would not rotate, the planetary holder rotates at the same speed as the wheel and the ring gear would rotate at 1.5 times the speed of the wheel for a ratio of 1:2 between the sun gear/ring gear diameter. 
         [0137]    On the power hub  230  is a second one-way clutch  270  which prevents backward rotation of the sprocket  228  when the only power source is the ring gear  226  powered by the large sprockets  221  and permit electric mode without negative torque to the bike user. 
         [0138]    Referring to  FIGS. 4,5 and 6  which show a PROTOTYPE following the third embodiment  FIG. 3 . 
         [0139]    Referring to  FIG. 7  is a central section of  FIG. 1  which illustrates the novel system allowing to lock the planetary ring gear supporting flange  22  shown with a square edge teeth engaging surface  66  which allows a set of plungers  68  to engage with. 
         [0140]    A set of solenoids  70  are fastened to the flange  22  permitting energization when needed via a group of insulated buttons  76  and a spring loaded ring  74  and a set of brushes  72 . 
         [0141]    The buttons  76  are fastened to the disc  16  and hub  14  which permit electrical connection with the controller via wire tube  60 . 
         [0142]    Referring to  FIGS. 8, 9 and 10  which show Prior Art of e-bike Pedal Assist System (PAS). 
         [0143]    Referring to  FIGS. 11 and 12  which show an E-BIKE REAR HUB PROTOTYPE following the second embodiment  FIG. 2 . On  FIG. 11  it is to be noted that a one-way clutch located on the crank arm axle when fastened to the crank arm would prevent reverse rotation of the pedaling allowing the bike to be powered in electric mode alone without requiring the user to counteract the torque transmit by the sun gear  140  and the sprocket  128  and therefore to the crank set via the bike chain shown in the photograph. 
         [0144]    Referring to  FIG. 13  which shows the novel PAS preferred for the present invention in a manner to improve the pedaling motion where the magnets which are normally equidistant from each other in order for the controller to feel an change of speed in the pedaling motion. Therefore in current e-bike the goal of the magnetic disc and sensor is to keep or to reach the steady speed that the cyclist wants. 
         [0145]    In the new sensor shown in  FIG. 13 , the goal is to have the assist motor to provide more torque during the push down motion of each pedal, and lower torque when the pedaling goes through the over-center or what is called the dead center where the pedaling motion of each leg goes in a more horizontal plane; where in a current assist e-bicycle the pedaling motion is related to the inertia of the bicycle which varies only slightly during the pedaling motion (depending on the speed of the bicycle). 
         [0146]    With the new invention when running with the output ring gear rotating faster than the sun gear, the variation of speed of pedaling is competing with the torque of the electric motor, therefore it is necessary to lower the power of the motor during the weak dead center portion of the pedaling. This problem is solved by the new magnet sensor with variation of position of the magnets which instruct the controller to vary its power in relation to the pedaling position. 
         [0147]    Even more, if adjusted properly the new speed sensor disc could allow the PAS to permit what is called the dead center pedaling portion to be done faster than the push down section which provides the large portion of the pedaling energy and this gives a more dynamic pedaling motion. 
         [0148]    Advanced controller as seen on  FIG. 10  (third generation can compensate for as little as 1% inequality between pedaling strength of one leg to the other). Therefore even with a simple magnet sensor speed system it is readily possible to vary the motor output in order to combine harmoniously the cyclist&#39;s variation of pedaling torque and the electric motor assist power. 
         [0149]    Referring to  FIG. 14  which shows a level  1  of control of the new invention and would work with low power hub of around 250-350 watts. 
         [0150]    Referring to  FIG. 15  which shows the new concept of  FIG. 13 . PAS speed control which will be advantageous with any power level and permit precise control of power and speed. 
         [0151]    Referring to  FIG. 16  which shows the same concept as  FIG. 15  combined with a V2 CA control box which gives extra information and data during or after the ride. 
         [0152]    Referring to  FIG. 17  which shows a two speed front derailleur which provides extra variation of speed for riding on hilly roads. Therefore the rear derailleur is not needed and a single tensioner  311  is used to keep the chain taut and allowing the shifting from larger sprocket  315  to a smaller sprocket  314 . At the rear wheel a single small sprocket  312  is transferring the pedaling power to a rear hub wheel  313 . 
         [0153]    It is to be understood that many mechanical fastenings of the component are done following general mechanical and machinist procedure and therefore it is to be understood that many fastenings which were not shown in the description are either press fit or threaded, and sometimes with lock tight. Sometimes two of the components could be welded together when permitted. 
       U.S. Provisional Application Ser. No. 62/070,299 Aug. 20, 2014 
       [0154]    From the previous description it is readily apparent that a low cost and compact planetary transmission mechanism can be incorporated into a rear e-bike hub wheel which could be built and appreciated by those skilled in the art. It is to be understood that various changes and modifications may be made without departing from the spirit and scope of the invention.