Patent Description:
Bicycle derailleurs are commonly incorporated into a drivetrain of a bicycle. The typical drivetrain also includes a crank assembly that is coupled to one or more drive sprockets. The crank assembly is operable to drive a chain that is routed or wrapped around one of the drive sprockets. The chain may also be routed to one of wheels of the bicycle, for example a rear wheel, wherein the chain may engage one or more driven sprockets. Derailleurs are provided as a part of the drivetrain. For example, one derailleur (e.g., front) may be located adjacent the one or more drive sprockets, while another derailleur (e.g., rear) may be located adjacent the driven sprockets, for example adjacent the rear wheel. The derailleur(s) may be actuated to selectively shift the chain of the drivetrain between the drive sprockets, and/or to selectively shift the chain between the one or more of the driven sprockets. Shifting of the bicycle chain from one drive sprocket to another, or from one driven sprocket to another, is done in order to change the gear ratio of the drivetrain. The rear derailleur may also apply a tension to the chain to take-up slack, as well as to maintain the desired tension, in the chain on the non-drive-side of the drivetrain.

In some embodiments, the rear derailleur may be a wireless, electrically actuated rear derailleur, which relies on a battery to supply power to a motor. The battery may need to be periodically charged or replaced, which may be an inconvenience if the battery is discharged during use of the bicycle, or at a remote location not conveniently located to a charging station or providing access to replacement batteries.

<CIT>, <CIT> and <CIT> disclose bicycle derailleurs, in which a motor for moving components of the derailleur is placed on one of the base member, the moveable member and the linkage between the base member and the movable member of the derailleur. <CIT> discloses a solution, in which the motor for moving components of the derailleur is placed on the base member Document <CIT> shows the preamble of claim <NUM>.

The invention relates to a bicycle derailleur according to claim <NUM>. The dependent claims relate to further embodiments of the invention.

According to the invention, a bicycle derailleur includes a base member mountable to a bicycle frame and a cage assembly moveably coupled to the base member. The cage assembly is moveable in opposite first and second directions relative to the base member. A motor is coupled to and moveable with the cage assembly in the opposite first and second directions. The motor is operable to move the cage assembly in the opposite first and second directions, wherein the motor is mounted on the cage assembly. In one embodiment, the cage assembly may include a chain pulley rotatably coupled to the cage assembly about a first rotation axis.

In another not claimed aspect, one embodiment of a bicycle derailleur may include a base member mountable to a bicycle frame and a cage assembly moveably coupled to the base member. An electrical generator system may be coupled to and moveable with the cage assembly. The electrical generator system may include a generator and a generator drive system. The generator drive system may include a chain pulley rotatably coupled to the cage assembly about a first rotation axis and a generator transmission operably coupled between the chain pulley and the generator.

In another not claimed aspect, one embodiment of a bicycle derailleur may include a base member mountable to a bicycle frame and a cage assembly moveably coupled to the base member. An electrical generator system may be coupled to and moveable with the cage assembly. The electrical generator system may include a generator and a generator drive system. The generator drive system may include a chain pulley rotatable about a first rotation axis in opposite first and second rotational directions and a clutch. The clutch may driveably connect the chain pulley and the generator when the chain pulley is rotated in the first rotational direction such that the generator is activated. The clutch disconnects the chain pulley and the generator when the chain pulley is rotated in the second rotational direction such that the generator is deactivated.

In another not claimed aspect, a bicycle derailleur may include a base member mountable to a bicycle frame and a cage assembly moveably coupled to the base member. An electrical generator system may be coupled to and moveable with the cage assembly. The electrical generator system may include a generator and a generator drive system. The generator drive system may include a chain pulley rotatable about a first rotation axis, at least first and second pulleys rotatable about second and third rotation axes respectively, and a belt engaged with the first and second pulleys. In one embodiment, the first and second pulleys may have a pulley ratio greater than <NUM>.

The various aspects and embodiments of the derailleur, and the methods for the use and assembly thereof, may provide significant advantages over other derailleurs and methods. For example and without limitation, the motor and/or the electrical generator system may be mounted on and moveable with the cage. If damaged, the cage, including the motor and electrical generator system, may be quickly and easily replaced without having to replace the other components of the derailleur. In addition, the cage, which may include a chain pulley engageable by a chain, provides an input to the generator system and motor, with the components being positionally fixed relative to each other and moveable with the cage as the cage is: (<NUM>) moved laterally during a gear changing sequence, and/or (<NUM>) rotated to maintain a tension in the chain. In this way, the assembly avoids the need for couplings, whether electrical or mechanical, between any components located on the cage and components located on other parts of the derailleur, which may be moveable relative to each other. In addition, the electrical generator system ensures that power is always available to power the motor, for example during shifting, and/or for other activities and accessories requiring electrical power.

The foregoing paragraphs have been provided by way of general introduction and are not intended to limit the scope of the claims presented below. The various preferred embodiments, together with further advantages, will be best understood by reference to the following detailed description taken in conjunction with the accompanying drawings.

Objects, features, and advantages of the present invention will become apparent upon reading the following description in conjunction with the drawing figures, in which:.

It should be understood that the term "plurality," as used herein, means two or more. The term "longitudinal," as used herein means of or relating to a length or lengthwise direction. The term "lateral," as used herein, means situated on, directed toward or running in a side-to-side direction. The term "coupled" means connected to or engaged with, whether directly or indirectly, for example with an intervening member, and does not require the engagement to be fixed or permanent, although it may be fixed or permanent. The terms "first," "second," and so on, as used herein are not meant to be assigned to a particular component so designated, but rather are simply referring to such components in the numerical order as addressed, meaning that a component designated as "first" may later be a "second" such component, depending on the order in which it is referred. It should also be understood that designation of "first" and "second" does not necessarily mean that the two components or values so designated are different, meaning for example a first direction may be the same as a second direction, with each simply being applicable to different components. The terms "upper," "lower," "rear," "front," "fore," "aft," "vertical," "horizontal," "right," "left," "inboard," "outboard" and variations or derivatives thereof, refer to the orientations of an exemplary bicycle <NUM>, shown in <FIG>, from the perspective of a user seated thereon, for example with an "inboard" component or feature being closer to a vertical mid-plane of the bicycle extending in a direction <NUM>. The term "transverse" means non-parallel. The terms "outer" and "outwardly" refers to a direction or feature facing away from a centralized location, for example the phrases "radially outwardly," "radial direction" and/or derivatives thereof, refer to a feature diverging away from a centralized location, for example a rotation axis <NUM> of the cassette <NUM> as shown in <FIG>. Conversely, the terms "inward" and "inwardly" refers to a direction facing toward the centralized or interior location. The term "subassembly" refers to an assembly of a plurality of components, with subassemblies capable of being further assembled into other subassemblies and/or a final assembly, such as the bicycle <NUM>.

<FIG> illustrates one example of a human powered vehicle. In this example, the vehicle is one possible type of bicycle <NUM>, such as a road bicycle. The bicycle <NUM> has a frame <NUM>, handlebars <NUM> near a front end of the frame, and a seat or saddle <NUM> for supporting a rider over a top of the frame. The bicycle <NUM> has a first or front wheel <NUM> carried by a front fork subassembly <NUM> supporting the front end of the frame. The bicycle <NUM> also has a second or rear wheel <NUM> supporting a rear end of the frame <NUM>, which includes a pair of chain stays <NUM> connected to a pair of seat stays <NUM> (see also <FIG>). The rear end of the frame <NUM> may be supported by a rear suspension component, such as a rear shock <NUM>. The bicycle <NUM> also has a drive train <NUM> with a crank assembly <NUM> that is operatively coupled via a bicycle chain <NUM> to a rear cassette <NUM>, otherwise referred to as a driven sprocket assembly, near the hub providing a rotation axis of the rear wheel <NUM>. The crank assembly <NUM> includes at least one, and typically two, crank arms <NUM> and pedals <NUM>, along with a front chainring assembly <NUM>, or drive sprocket assembly. A crank spindle or shaft may connect the two crank arms. The crank shaft defines a center rotational axis <NUM> of the chainring assembly <NUM>. The crank assembly may also include other components.

A rear gear change device, such as a rear derailleur <NUM>, is disposed at the rear wheel <NUM> to move the bicycle chain <NUM> to different sprockets of the cassette <NUM>. In one embodiment, a front gear changer device, or front derailleur, may be provided to move the chain <NUM> to different sprockets of the chainring assembly. In the illustrated example, the saddle <NUM> is supported on a seat post <NUM> having an end portion received in a top of a frame seat tube of the frame <NUM>.

In <FIG>, a normal riding or forward moving direction <NUM> of the bicycle <NUM> is shown. While the bicycle <NUM> depicted in <FIG> is a mountain bicycle, the rear gear change device, or rear derailleur <NUM>, including the specific embodiments and examples disclosed herein as well as alternative embodiments and examples, may be implemented on other types of bicycles. For example and without limitation, the disclosed rear derailleur <NUM> may be used on road bicycles, and any other type of bicycle incorporating a derailleur. It should be understood that the various energy harvesting systems and embodiments disclosed herein may also be incorporated into derailleurs, at any location (e.g., front), having a cage assembly with a rotatable wheel.

Referring to <FIG> and <FIG>, the rear derailleur <NUM> includes a base member <NUM>, otherwise referred to as b-knuckle, which may be attached to the bicycle frame <NUM> with a fastener <NUM>, for example a b-bolt. The frame <NUM> may include a hanger <NUM> connected to the frame <NUM> at a junction between the seat stay <NUM> and the chain stay <NUM>. The base member <NUM> may be connected to the hanger frame <NUM>, or directly to the frame <NUM>. The base member <NUM> is removeably coupled to the frame <NUM> with the fastener <NUM>, and may be free to pivot around an axis (A) of the fastener <NUM>. An adjustment member <NUM>, which may be configured as a screw, is threadably engaged with the base member, and may be actuated so as to adjust the rotational position of the base member <NUM> with respect to frame <NUM>.

A linkage <NUM> includes an inner link <NUM> and an outer link <NUM> having first ends <NUM>, <NUM> that are rotatably connected to the base member <NUM>, for example with a first axle or pin <NUM> and a second axle or pin <NUM>, respectively. A moveable member <NUM>, otherwise referred to as a p-knuckle, is rotatably connected to opposite second ends <NUM>, <NUM> of the inner link <NUM> and the outer link <NUM> with a third axle or pin <NUM> and a fourth axle or pin <NUM>, respectively, such that the links <NUM>, <NUM> extend between the base member <NUM> and moveable member <NUM>. The pin <NUM> may be supported by a pair of bushings <NUM> in the moveable member <NUM> as shown in <FIG>. The base member <NUM>, moveable member <NUM>, inner link <NUM>, and outer link <NUM> form a four-bar linkage, and in particular a parallelogram linkage <NUM>. In this way, the moveable member <NUM> may be moveably coupled to the base member <NUM>. In one embodiment, the moveable member <NUM> is moveable relative to the base member <NUM>, and the frame <NUM>, in opposite inboard and outboard directions. It should be understood that the moveable member <NUM> may be moveably connected to the base member <NUM> with other components and/or linkages other than the disclosed linkage, which may or may not include one or more links.

A biasing member <NUM>, which may be configured as a torsion spring, biases the linkage <NUM> to rotate clockwise, or outboard, as shown in <FIG>, for example about the first and second pins <NUM>, <NUM>. In one embodiment, the biasing member <NUM> may be arranged co-axially with second pin <NUM> and have a first end engaging the base member and a second end engaging the linkage <NUM>, for example the outer link <NUM>. The derailleur may include a rotational limit, including for example an upper limit screw <NUM> and a lower limit screw <NUM>, which are threadably engaged with base member <NUM> and limit the movements of the inner link <NUM> and the outer link <NUM>, respectively.

In an alternative embodiment, the biasing force of the biasing member <NUM> may be reversed, such that the biasing member <NUM> bias the linkage <NUM> to rotate counterclockwise, or inboard, with reference to <FIG>. In operation, the chain <NUM> may apply a drag force to a pulley wheel <NUM>, which may cause the linkage <NUM> to want to rotate counterclockwise as shown in <FIG>. In this embodiment, the biasing member <NUM> and pulley wheel <NUM> work together in tandem to bias the linkage <NUM> in the same direction. As such, the parallelogram linkage is biased in the same rotational direction by the biasing force applied by the biasing member <NUM> and the drag force applied by the chain to the pulley wheel <NUM>.

Referring to <FIG>, the derailleur <NUM> may include a cage assembly <NUM> moveably coupled to the base member <NUM>. The cage assembly <NUM> is moveable in opposite first and second translation directions (e.g., inboard and outboard) relative to the base member <NUM>. The cage assembly <NUM> may also be moveable in opposite first and second rotational directions (e.g., clockwise and counterclockwise rotation) about a laterally extending axis B relative to the moveable member <NUM> and the base member <NUM>, or moveable relative to the base member <NUM> with a combination of translation and rotation. In particular, the cage assembly <NUM> is rotatably connected to the moveable member with a fastener extending in a lateral direction and defining the rotation axis B. The cage assembly may rotate clockwise around the axis B of the fastener to take up slack in the chain <NUM>, which is engaged with the cassette <NUM>, an upper chain pulley <NUM> and a lower chain pulley <NUM>. The upper and lower chain pulleys <NUM>, <NUM> are rotatably connected to the cage assembly <NUM>.

Referring to <FIG>, <FIG> and <FIG>, the cage assembly <NUM> may include one or both of an outer cage <NUM> secured to an inner cage <NUM>, for example with fasteners <NUM>, <NUM>, configured as screws, a snap-fit, and/or other know suitable securing devices. The lower chain pulley <NUM> rotates on a ball bearing having an inner race clamped between the inner cage <NUM> and the outer cage <NUM> with the fasteners, configured as a screw <NUM>, threaded into the inner cage <NUM>. This connection also serves to fix the inner cage <NUM> to the outer cage <NUM>. A cover <NUM> is fixed to the outer cage <NUM> with a plurality of fasteners <NUM>, shown as nine screws, spaced apart around the perimeter of the cover <NUM>, with the cover and outer cage defining a housing <NUM>. It should be understood that the term "housing" refers to a component capable of supporting or holding other components, and may be enclosed or open. As such, the outer cage and/or cover may each individually define a housing, or may in combination define the housing <NUM>, which is enclosed and sealed to prevent the intrusion of fluid into an interior of the housing in one embodiment. Referring to <FIG> and <FIG>, an elastomeric sealing element <NUM> may be disposed in a groove <NUM> formed in the outer cage <NUM>. It should be understood that the groove may alternatively be formed in the cover. The groove <NUM> may define a closed loop that follows the contour of the perimeter of the cover <NUM>, with the sealing element <NUM> forming a fluid-tight seal between the outer cage <NUM> and cover <NUM>, or housing <NUM>. In one embodiment, the fastener <NUM> is threadably engaged with outer cage <NUM>, and fixes the inner cage <NUM> to the outer cage <NUM>.

As shown in <FIG>, one embodiment of the upper wheel pulley assembly include a sealed ball bearing assembly <NUM> received in a recess <NUM> formed in the outer cage <NUM> and engaged by the shoulder of an annular flange <NUM>. A ball bearing assembly <NUM> is received in a recess <NUM> formed in the cover <NUM>, and is supported on an outer side surface <NUM> of the housing. A pulley shaft <NUM> is disposed inside, and supported by, the inner races of ball bearing assemblies <NUM> and <NUM>. The pulley shaft <NUM> has an end <NUM> rotatably supported by the ball bearing assembly <NUM>, with an annular shoulder <NUM> engaging the inner race and trapping the bearing assembly <NUM> between the shoulder <NUM> and the surface <NUM>. The pulley shaft <NUM> includes an annular flange <NUM> spaced laterally from the annular shoulder <NUM>, with the annular flange <NUM> defining a second annular shoulder <NUM> engaging the inner race of the ball bearing <NUM> and trapping the bearing assembly <NUM> between the shoulder <NUM> and the annular flange <NUM>. The annular shoulders <NUM>, <NUM> face in opposite directions such that the annular shoulders limit the axial movement of the shaft <NUM> in both lateral directions (inboard and outboard). The ball bearing assembly <NUM> is captured between the outer cage <NUM>, or an annular shoulder defined thereby, and the annular shoulder <NUM> of the shaft <NUM>. A sealing element <NUM>, configured in one embodiment as an O-ring, is located in a circumferential groove <NUM> formed in the shaft <NUM> inboard and spaced apart from the annular flange <NUM>. The groove may alternatively be formed in the ball bearing assembly. The sealing element <NUM> forms a fluid-tight seal between the pulley shaft <NUM> and the inner race of the ball bearing assembly <NUM>, such that fluid is prevented from entering the interior space of the housing <NUM> defined between the cover <NUM> and the outer cage <NUM>. The pulley shaft <NUM> may include an axially extending hole <NUM>. The hole <NUM> may be threaded and threadably engaged by a fastener <NUM>, shown as a screw.

Referring to <FIG>, the upper chain pulley <NUM> may include a key hole 21b, having a cross-shaped recess <NUM> in one embodiment. The pulley shaft <NUM> may be configured with a corresponding key <NUM>, or insert portion configured with mating corresponding cross-shaped protrusions 35b. When the upper chain pulley <NUM> is assembled as shown in <FIG>, the key <NUM> interfaces and ensures a non-rotatable engagement or coupling with the key hole 21b, for example by way of the engagement of the recesses <NUM> by the protrusions 35b. The chain pulley <NUM> includes a hub <NUM> having an inner surface <NUM> that abuts an end surface 35a of the pulley shaft <NUM> defined between the protrusions 35b. By way of the interface between the key <NUM> and key hole 21b, the upper chain pulley <NUM> is non-rotatably and axially secured to the pulley shaft <NUM>, such that torsion may be transmitted between the upper chain pulley <NUM> and the pulley shaft <NUM> via the key <NUM> and key hole 21b, i.e., between the protrusions 35b and recesses <NUM>. As shown in <FIG>, the pulley shaft <NUM> is captured between the cover <NUM> and the outer cage <NUM>, with the chain pulley <NUM> secured to the shaft <NUM>. As such, the chain pulley <NUM> is not captured or clamped between the inner and outer cages <NUM>, <NUM>. Rather, the chain pulley <NUM> is supported in a cantilevered fashion on an end of the shaft <NUM>, which is supported by the housing <NUM> outboard of the chain pulley <NUM>. As such, the inner cage <NUM> may not overlie the chain pulley <NUM>, and in particular the pulley shaft <NUM>, but rather may be configured to provide clearance between the inner cage <NUM> and the upper pulley system as shown in <FIG>. To replace the chain pulley, the inner cage <NUM>, therefore, does not need to be removed from the outer cage <NUM>. Of course, in other embodiments, the inner cage may overlie the chain pulley.

Referring to <FIG>, <FIG>, <FIG> and <FIG>, an electrical generator system <NUM> is coupled to and moveable with the cage assembly <NUM>, meaning the electrical generator system <NUM> translates and rotates with the cage assembly <NUM> as the cage assembly moves relative to the moving member <NUM>, base <NUM> and bicycle frame <NUM>. Put another way, the electrical generator system is fixed to the cage assembly and follows the movement path of the cage assembly. In one embodiment, the electrical generator system <NUM> is disposed in the housing <NUM>, defined by the cover <NUM> and outer cage <NUM>, and may be entirely enclosed within a sealed interior cavity <NUM> defined between the cover <NUM> and outer cage <NUM>. The electrical generator system <NUM> includes a generator <NUM> and a generator drive system <NUM>, with the generator drive system <NUM> including an input. The input may be configured in one embodiment as the chain pulley <NUM> rotatably coupled to the housing <NUM>, and the outer cage <NUM> and cover <NUM> in particular. The chain pulley <NUM> is rotatable about a rotation axis <NUM>. The generator drive system may further include a generator transmission <NUM> operably coupled between the input, e.g., chain pulley <NUM>, an output, e.g., the generator <NUM>. The generator transmission <NUM> includes a first generator spur gear <NUM>, which is non-rotatably and axially fixed to the pulley shaft <NUM>, such that the spur gear <NUM> rotates with the chain pulley <NUM> about the rotation axis <NUM>. For example and without limitation, the spur gear <NUM> may be fixed to the pulley shaft with a friction fit, and/or with a spline interface. The spur gear <NUM> is disposed in a space, or interior cavity <NUM>, defined between the cover and outer cage. The first generator spur gear <NUM> has a plurality of teeth <NUM> spaced circumferentially around the perimeter of the spur gear, with the teeth <NUM> engaged with teeth <NUM> spaced circumferentially around the perimeter of a pinion gear <NUM>. The pinion gear <NUM> is rotatable about an axle <NUM> supported by and between the outer cage <NUM> and cover <NUM>. In one embodiment, the spur gear <NUM> has thirty (<NUM>) teeth <NUM>, while the pinion gear <NUM> has ten (<NUM>) teeth <NUM>, providing a gear ratio of <NUM>:<NUM>, meaning that one rotation of the spur gear <NUM> results in three (<NUM>) rotations of the pinion gear <NUM>. In one embodiment, the chain pulley <NUM> has a plurality of teeth, for example <NUM>. In one embodiment, the axle <NUM> has a first end engaged with the outer cage <NUM>, for example a non-rotatable engagement, e.g., threaded, such that the axle <NUM> is non-rotatable, with an opposite second end engaged with the cover <NUM>. Alternatively, the axle <NUM> may be allowed to rotate relative to the outer cage <NUM>. The pinion gear <NUM> includes a hub <NUM> that rotates on the axle <NUM> about a rotation axis <NUM>. A second generator spur gear <NUM> is co-axially and non-rotatably fixed to first generator pinion gear <NUM>, <NUM>, and to the hub <NUM> in particular, and rotates with and is driven by the pinion gear <NUM>, <NUM>. The spur gear <NUM>, <NUM> has thirty-six (<NUM>) teeth <NUM> spaced circumferentially around a perimeter thereof in one embodiment. The teeth <NUM> of the spur gear engage teeth <NUM> spaced circumferentially around the perimeter of a pinion gear <NUM>, which is supported by and rotatable about an axle <NUM> rotatably or non-rotatably supported by and between the outer cage <NUM> and cover <NUM>. In one embodiment, the axle <NUM> has a first end engaged with the outer cage <NUM>, for example a threadable engagement such that the axle is non-rotatable, with an opposite second end engaged with the housing <NUM>. In another embodiment, the axle is rotatably supported by and between the outer cage <NUM> and cover <NUM>. The pinion gear <NUM> includes a hub <NUM> that rotates on the axle about a rotation axis <NUM>. The pinion gear may have for example twelve (<NUM>) teeth <NUM>, providing a gear ratio of <NUM>:<NUM> between the spur gear <NUM> and pinion gear <NUM>, meaning that one rotation of the spur gear <NUM> results in three (<NUM>) rotations of the pinion gear <NUM>.

The generator transmission <NUM> also includes at least first and second pulleys <NUM>, <NUM> rotatably coupled to the housing <NUM> about rotation axes <NUM>, <NUM> respectively, and a belt <NUM> engaged with the first and second pulleys. In one embodiment, a first generator pulley <NUM> preferably has a plurality of teeth <NUM>, for example <NUM> teeth <NUM>, and is co-axially and non-rotatably fixed to the hub <NUM> of the pinion gear <NUM>, with the pulley <NUM> and pinion gear <NUM> being rotatable about the rotation axis <NUM>. The second pulley <NUM> has a plurality of teeth <NUM>, for example <NUM> teeth, and is co-axially and non-rotatably fixed to a rotor <NUM> of the generator <NUM>, with the pulley <NUM> and rotor <NUM> being rotatable about the rotation axis <NUM>. A belt <NUM> forms a continuous or endless loop. In one embodiment, the belt <NUM> may be a toothed belt having a plurality of teeth <NUM> formed around an inner surface of the loop. In one embodiment, the belt <NUM> may include for example and without limitation <NUM> teeth <NUM>. The belt <NUM>, and the teeth <NUM> in particular, are engaged with the first and second pulleys <NUM>, <NUM> and the teeth <NUM>, <NUM> thereof. The pulleys <NUM>, <NUM> have a pulley ratio of greater than <NUM>, and in one embodiment a ratio of <NUM>:<NUM>. It should be understood that in other embodiments, the belt <NUM> and pulleys <NUM>, <NUM> may be configured without teeth, with the belt <NUM> engaging the pulleys <NUM>, <NUM> by way of friction. The rotor <NUM> is rotatably received in a bore <NUM> defined by a generator base <NUM>. The generator <NUM> includes a stator <NUM> disposed inside an outer periphery, or annular wall <NUM>, of the rotor <NUM>. The stator may be non-rotatably fixed to the generator base <NUM>, with the rotor <NUM> being rotatable relative to the stator <NUM> about the rotation axis <NUM>. In one embodiment, the chain pulley <NUM>, or input, has a first rotational speed and the generator <NUM>, e. g, the rotor <NUM> or output, has a second rotational speed, wherein the generator transmission provides a ratio between the first and second rotation speeds of between and including <NUM>:<NUM> and <NUM>:<NUM>. In one embodiment, the overall gear ratio of the transmission between the upper pulley <NUM> and the rotor <NUM> of the generator <NUM> is preferably <NUM>:<NUM> (e.g., overall gear ratio = (gear ratio <NUM>)*(gear ratio <NUM>)*(pulley ratio <NUM>) = <NUM>*<NUM>*<NUM>=<NUM>:<NUM>, meaning the rotational speed of rotor <NUM> will be <NUM> times greater than the rotational speed of upper pulley <NUM>. It should be understood that this ratio may be varied by changing any of the gear ratios between the spur gear <NUM> and the pinion gear <NUM>, <NUM>, the spur gear <NUM>, <NUM> and the pinion gear <NUM>, and the first pulley <NUM> and the second pulley <NUM>.

In one embodiment, shown in <FIG>, the generator transmission <NUM> includes a clutch <NUM>, which driveably connects the chain pulley <NUM> and the generator <NUM>, and the rotor <NUM> in particular, when the chain pulley <NUM> is rotated in the first rotational direction such that the generator <NUM> is activated, meaning the rotor <NUM> is being rotated relative to the stator <NUM>. The clutch <NUM> disconnects the chain pulley <NUM> and the generator <NUM> when the chain pulley <NUM> is rotated in the second rotational direction such that the generator <NUM> is deactivated, meaning the rotor <NUM> is not being rotated relative to the stator <NUM>. In one embodiment, the clutch <NUM> is disposed between the spur gear <NUM> and the pinion gear <NUM>. It should be understood that the clutch <NUM> may also be disposed between any coaxially mounted components, including for example between the chain pulley <NUM> and the spur gear <NUM>, or the pinion gear <NUM> and the pulley <NUM>. In other embodiments, the clutch may be disposed between non-coaxially mounted components, for example a slip interface between the adjacent pulleys. In one embodiment of the clutch, the pinion gear <NUM> defines a drive member, which is rotatably supported by the axle <NUM>. It should be understood that the drive member may be a spur gear. In either case, the clutch <NUM> is disposed or mounted between the drive member, i.e., pinion gear <NUM>, and a driven member, i.e., the spur gear <NUM>. In this way, the clutch <NUM> provides for one-way rotational engagement between the drive member and the driven member. In one embodiment, the clutch <NUM> includes at least one spring finger <NUM>, and preferably a plurality of spring fingers (shown as two). The driven member, or gear or pulley, may include in one embodiment a hub <NUM> having at least one indentation <NUM>, and preferably a number of indentations <NUM> (e.g., <NUM>) corresponding to the number of spring fingers <NUM>, although the numbers may be different. The spring fingers <NUM>, which are in-molded with the spur gear <NUM> in one embodiment, may be configured as cantilever leaf springs having a curved arm <NUM> extending from web of the spur gear <NUM> and terminating at an engagement end <NUM>. The engagement end <NUM> is positioned radially inwardly from an inner bearing surface <NUM> of the driven gear, or spur gear <NUM>, when the arm <NUM> is in a non-biased position, i.e., is not pre-loaded. The arm <NUM> is preloaded by moving the end <NUM> radially outwardly until it engages an outer bearing surface <NUM> of the hub <NUM>, or shaft, of the pinion gear <NUM>. The indentations <NUM> are formed and extend radially inwardly form the bearing surface <NUM>. In one embodiment, the indentations include a ramped surface <NUM> tapering inwardly from and intersecting the bearing surface <NUM> and a stop surface <NUM> extending from and intersecting the ramped surface <NUM> toward and intersecting the bearing surface <NUM>. The stop surface <NUM> is substantially orthogonal to a tangent of the bearing surface <NUM>, and the intersection thereof, in one embodiment, although other angles may be suitable. The arm <NUM> biases the engagement end <NUM> into engagement with the indentation <NUM>, and the surfaces <NUM> and <NUM> in particular, due to the preload. When the pinion gear <NUM> is rotated relative to the spur gear <NUM> in one direction, the arms <NUM>, and the ends <NUM> thereof, will eventually engaged the stop surface <NUM> as the arm is biased radially inwardly and thereafter drive the driven gear, or spur gear <NUM> with the drive gear <NUM> as the chain wheel <NUM> is rotated in one rotation direction, i.e., a pedaling direction. When the user backpedals, the chain <NUM> and chain pulley <NUM> are rotated in an opposite rotational direction, with the ends of the arms <NUM> successively and intermittently sliding outwardly along the ramp <NUM> as the arms <NUM> are biased out of engagement and thereafter along the bearing surface <NUM>, such that the drive gear, or pinion gear <NUM>, does not rotate the driven gear, or spur gear <NUM>. In this way, the spring fingers <NUM>, or curved arm <NUM>, is biased into engagement with the indentation <NUM>, and the stop surface <NUM>, when the chain pulley <NUM> is rotated in the first rotational direction, and wherein the spring fingers <NUM>, or curved arm <NUM>, is biased out of engagement with the indentation <NUM> by the ramped surface <NUM> and bearing surface <NUM> when the chain pulley <NUM> is rotated in the second rotational direction such that the generator <NUM> is deactivated, or not rotated.

Referring to <FIG>, <FIG> and <FIG>, a belt tensioner <NUM> may be coupled to the cage assembly and is operable to adjust a tension of the belt <NUM>. The belt tensioner <NUM> includes a first fastener <NUM>, or first generator screw, which is threadably engaged with a first boss 24a formed on the outer cage <NUM>, and a second fastener <NUM>, or second generator screw, which is threadably engaged with a second boss 24b formed on the outer cage <NUM>. The first fastener <NUM> passes through an opening in the generator base <NUM>, and the second fastener <NUM> passes through a washer <NUM> overlapping an edge of the generator base <NUM>. The belt tensioner <NUM> further includes a belt tension adjustment member <NUM> that acts between the outer cage <NUM> and the generator <NUM>, and the base <NUM> in particular. In one embodiment, the adjustment member <NUM> may be configured as a set screw, which is threadably received in a boss 24b formed in the outer cage <NUM>. An end <NUM> of the adjustment member <NUM> abuts the generator base <NUM>, for example an edge thereof. In operation, and in order to adjust the tension of the belt <NUM>, the fasteners <NUM>, <NUM> are left slightly loose. The adjustment member <NUM> may then be actuated, for example by threadably engaging the upper boss 24b, such that the adjustment member <NUM> pushes on the edge of generator base <NUM> against a biasing force or tension of the belt <NUM>. The base <NUM> may rotate slightly around the fastener <NUM>, creating more tension in the belt <NUM>. When the desired belt tension has been reached, the fasteners <NUM>, <NUM> may be tightened, thus fixing the belt tension at the desired level. The adjustment member <NUM> may be provided with an anti-loosening device, for example a nylon patch to prevent loosening of the adjustment member <NUM> over time.

Referring to <FIG> and <FIG>, a plurality of generator wires <NUM>, shown as three, extend from the stator <NUM> of the generator. The generator wires <NUM> are electrically connected to a generator printed circuit board (generator PCB) <NUM>, which is mounted to the housing <NUM>. In one embodiment, the generator PCB <NUM> is secured to the outer cage <NUM> with a screw <NUM>, although the PCB <NUM> may be secured with adhesives, a snap fit or other suitable fasteners. The PCB <NUM> may alternatively be secured to the cover <NUM>.

Referring to <FIG>, <FIG>, and <FIG>, a main printed circuit board (main PCB) <NUM> is fixed relative to housing <NUM>, for example the cover <NUM>, by a first mounting screw <NUM> and a second motor holder mounting screw <NUM>. Referring to <FIG>, the main PCB <NUM> includes various electronic components, including but not limited to a power storage device 57d, configured in one embodiment as supercapacitors, a motor driver 57f, an encoder 57e, a switch 57b, an LED 57c, a plurality of pogo pins 57a, and a microcontroller <NUM>. Referring to <FIG>, the pogo pins 57a of the main PCB <NUM> are in electrical contact with the generator PCB <NUM>. The energy storage device 57d, e.g., supercapacitors, also is coupled to and moveable with the cage assembly <NUM>, and in particular is secured to the main PCB <NUM>. The generator <NUM> generates energy which is transmitted to and stored in the energy storage device 57d. In one embodiment, the energy storage device 57d includes at least one capacitor, shown as two supercapacitors. In other embodiments, the energy storage device may include one or more batteries, for example rechargeable batteries.

Referring to <FIG>, <FIG> and <FIG>, a function button <NUM> is coupled to the housing <NUM>, and cover <NUM> in particular, by a button retainer <NUM>. An elastomeric seal <NUM> is disposed between the button retainer <NUM> and a surface of the cover <NUM>, or housing <NUM>. When the function button <NUM> is pressed by the user, the button <NUM> actuates the switch 57b of the main PCB <NUM>. Among other functions, the function button <NUM> may be used to wirelessly pair the derailleur <NUM> with other system components, such as shifters that may located remotely on the handle bars, for example. A LED lens <NUM> may be a clear lens that is fixed in a hole in the cover <NUM> or cage <NUM>, i.e. housing <NUM>. The LED lens <NUM> is positioned such that LED 57c of the main PCB <NUM> shines through the lens <NUM> and is visible to the user. The LED 57c may be used to indicate a state of the system. For example and without limitation, the LED 57c is used when wirelessly pairing derailleur <NUM> with other system components, such as the shifters. The LED 57c also may also be used to indicate other system states, such as battery life, for example.

<FIG> and <FIG> depict a motor holder assembly <NUM>, including a motor <NUM>, which is coupled to and moveable with the cage assembly <NUM> in the opposite first and second directions. The motor <NUM> is operable to move the cage assembly <NUM> in the opposite first and second directions relative to the base member <NUM> and frame <NUM>, for example inboard and outboard lateral directions. A shifting drive system <NUM> is coupled between the motor <NUM> and the linkage <NUM>, wherein the shifting drive system includes an input from the motor <NUM> and an output coupled to the linkage <NUM>.

The motor <NUM>, for example a DC motor, includes a first drive pinion gear <NUM> fixed to an output shaft <NUM>, which defines the input for the shifting drive system. The motor <NUM> is fixed to the motor holder <NUM> by at least one fastener <NUM>, for example a pair of screws. One end of a first drive axle <NUM> is received in a hole in motor holder <NUM>. A first drive spur gear <NUM> is coaxially fixed to a second drive pinion gear <NUM>, having a plurality of teeth (e.g., twenty (<NUM>)), and together the first drive spur gear <NUM> and the second drive pinion gear <NUM> rotate around the first drive axle <NUM>. The first drive pinion gear <NUM> has a plurality of teeth, e.g., twelve (<NUM>), spaced circumferentially around a periphery of the pinion gear that are engaged with a plurality of teeth (e.g., forth-eight (<NUM>)) spaced circumferentially around a periphery of a first drive spur gear <NUM>, providing a gear ratio of <NUM>:<NUM>. An encoder gear <NUM>, having a plurality of teeth (e.g., thirty eight (<NUM>), has a cylindrical recess in which an encoder magnet <NUM> is received. The encoder magnet <NUM> is fixed relative to encoder gear <NUM>. The encoder gear <NUM> has a long, cylindrical end portion that is rotatably received in a hole in motor holder <NUM>. The encoder gear <NUM> is engaged with the first drive spur gear <NUM>, and is axially retained by a retaining clip <NUM>. Referring to <FIG>, the motor holder assembly <NUM> is fixed to the cover <NUM> or outer cage <NUM>, i.e., housing <NUM>, with one or more fasteners, for example a first motor holder mounting screw <NUM> and a second motor holder mounting screw <NUM>. The encoder magnet <NUM> is positioned adjacent to encoder 57e of the main PCB <NUM>. Electrical wires electrically connect the motor <NUM> to the main PCB <NUM>.

Referring to <FIG>, the shifting drive system <NUM> includes a gear support plate <NUM> positioned relative to housing <NUM> by two positioning pins <NUM> that protrude from the cover <NUM>, and are retained by a screw <NUM>. The gear support plate <NUM> supports an end of the previously described first drive axle <NUM>. A second drive axle <NUM> has a first end that is received in an opening in the cover <NUM>, and a second end that is supported by the gear support plate <NUM>. A second drive spur gear <NUM> is coaxially fixed to a third drive pinion gear, with these two gears rotating together as a unit around the second drive axle <NUM>. The second drive spur gear <NUM> has a plurality of teeth (e.g., <NUM>) that are engaged with a plurality of teeth (e.g., <NUM>) on the second drive pinion gear <NUM>, providing a gear ratio of <NUM>:<NUM>. A third spur gear <NUM>, having a plurality of teeth (e.g., <NUM>), is engaged with the third drive pinion gear, having a plurality of teeth (e.g., <NUM>), providing a gear ratio of <NUM>:<NUM>. The shifting drive system has an overall gear ratio of <NUM>*<NUM>*<NUM>=<NUM>:<NUM> in one embodiment, although other gear ratios may be suitable.

Referring to <FIG>, <FIG> and <FIG>, the shifting drive system <NUM> has an output with a second rotational speed that is less than the first rotational speed of an input, or the motor <NUM> and the shaft <NUM>, as determined by the overall gear ratio. In one embodiment, the output is configured as a lead screw <NUM>, which is coaxially fixed to the third spur gear <NUM>. The lead screw <NUM> is rotatable in first and second opposite rotation directions, and is threadably engaged with a crank arm <NUM>. The crank arm <NUM> is moveable in opposite first and second axial directions in response to the rotation of the lead screw <NUM> in the opposite first and second rotation directions. As further explained below, the crank arm <NUM> is coupled to the linkage <NUM>. In one embodiment, the lead screw <NUM> is partially threaded along its length. A lead screw bearing <NUM> is received in a recess formed in the cover <NUM>, or housing <NUM>. An adjustable bearing <NUM> is threadably received in the moveable member cover <NUM>, which is fixed to the moveable member <NUM> with fasteners, shown as three screws <NUM>. The lead screw <NUM> is radially supported by a lead screw bearing <NUM> near a first end and is radially supported by an adjustable bearing <NUM> at a second end. Axial thrust loads of the lead screw <NUM> are reacted in a first direction by a thrust element <NUM> that is received in a recess in the outer cage <NUM>, and are reacted in a second direction by a surface of the adjustable bearing <NUM>. The adjustable bearing <NUM> may be threaded into the moveable member cover <NUM> to substantially eliminate any axial "play" of the lead screw <NUM>. Preferably, the adjustable bearing <NUM> includes a nylon locking element on its threaded portion to prevent it from moving after it has been set in the desired position.

Referring to <FIG> and <FIG>, a cage shaft <NUM> is fixed to the cover <NUM> and housing <NUM> with fasteners, for example six screws <NUM>. Alternatively, the cage shaft <NUM> may be fixed to the cover <NUM> by an over-molding process or by other means. Referring to <FIG>, the cage shaft <NUM> has two keying features 85a that protrude radially inward from an inner diameter of cage shaft <NUM>. The cage shaft <NUM> is rotatably received in a hole in the moveable member <NUM> coaxial with the axis B and is axially retained to the moveable member <NUM> by a retaining ring <NUM>. A thrust washer <NUM> is disposed between the retaining ring <NUM> and a surface of the moveable member <NUM>. Alternatively, the thrust washer <NUM> may be replaced by shims of variable thickness that can be used to substantially eliminate any axial play between the cage shaft <NUM> and the moveable member <NUM>.

Referring to <FIG>, <FIG>, and <FIG>, a lead nut <NUM> has a threaded internal diameter and a first end 91b having a spherical shape. Keyways 91a are formed as grooves along the length of an outer diameter of lead nut <NUM>. Threads of the lead nut <NUM> are threadably engaged with threads of the lead screw <NUM>, and keying features 85a of the cage shaft <NUM> are slidably received in keyways 91a of the lead nut <NUM>. Rotation of the lead nut <NUM> relative to the cage shaft <NUM> is prevented by the key and keyway arrangement. Therefore, rotation of lead screw <NUM> causes translation of the lead nut <NUM> along axis B.

Referring to <FIG>, <FIG>, <FIG>, the crank arm <NUM> has a cylindrical recess 92a, a first hole 92b and a second hole 92c. The crank arm <NUM> is rotatably connected to a fourth pin <NUM> at the second hole 92c. The spherical end 91b of lead nut <NUM> is engaged with the cylindrical recess 92a of the crank arm <NUM>. The crank arm <NUM> includes a slot 92d, which cuts through cylindrical recess 92a and provides clearance for the elongated cylindrical portion of the lead nut <NUM> and lead screw <NUM>. Thus, contact between the lead nut <NUM> and crank arm <NUM> is maintained between the spherical portion 91b of the lead nut <NUM> and the cylindrical recess 92a of the crank arm <NUM>, which is preferably the only contact between those components in one embodiment.

Referring to <FIG>, a fourth pin <NUM> passes through a hole 99d of a drive element <NUM>. In one embodiment, the drive element <NUM> may be fixed to the fourth pin <NUM> by a set screw <NUM> that is threadably engaged with a threaded hole 99e of the drive element <NUM> and engages a flat surface 18a formed on the fourth pin <NUM>. A drive pin <NUM> is received in the hole 92b of the crank arm <NUM> and is fixed to the crank arm <NUM> by a set screw <NUM>. The drive pin <NUM> extends into a recess 99a of the drive element <NUM>. A saver spring sleeve <NUM> is a cylindrical sleeve co-axially located relative to the fourth pin <NUM>. A saver spring <NUM> is a torsion spring that is located co-axially with the saver spring sleeve <NUM>. A first end of the saver spring <NUM> engages the crank arm <NUM>, and a second end of the saver spring <NUM> engages the surface 99c of the drive element <NUM>. The saver spring <NUM> biases a surface 99b of the drive element <NUM> against the drive pin <NUM> in the clockwise direction around an axis (C) shown in <FIG>.

Referring to <FIG>, the outer link <NUM> is fixed to the fourth pin <NUM> with a fastener, for example a set screw <NUM>, which engages a flat 18b formed on the fourth pin <NUM>.

Referring to <FIG>, a fastener <NUM>, for example a screw, is threadably engaged with an end of the fourth pin <NUM>. Prior to engaging the drive element <NUM> with the drive pin <NUM> disposed in the recess 99a of drive element <NUM>, the saver spring <NUM> is in a "free," or relaxed state. A tool, such as a screwdriver bit, may be engaged with the fastener <NUM>, e.g., by inserting the tool into a screw, and thereafter actuated to rotate the fourth pin <NUM> counterclockwise as shown in FIG. around the axis (C). Since the fourth pin <NUM> is fixed to the drive element <NUM>, the drive element (<NUM>) is rotated with the pin <NUM>. The surface 99c of the drive element <NUM> biases or pushes an end of the saver spring <NUM>, so as to load or wind up the saver spring <NUM> from a "free", or relaxed, state to a preloaded state. The drive pin <NUM> may thereafter be slid into engagement with the recess 99a of the drive element <NUM>. The tool may be removed, with the biasing force of the saver spring <NUM> biasing the surface 99b of the drive element <NUM> clockwise around the axis (C) against the drive pin <NUM>.

Referring to <FIG>, a cage spring <NUM> is formed as a torsion spring, a first end of which is disposed in a recess formed in the moveable member <NUM> and is engaged therewith. A second end of the spring <NUM> is engaged with the cover <NUM>, and is disposed in a recess in the cover <NUM>. The cage spring <NUM> is arranged to rotationally bias the cage assembly <NUM> in the clockwise direction around axis (B) as shown in <FIG> to take up any slack in the chain <NUM>.

Again referring to <FIG>, a clutch spring <NUM> is shown as having a plurality of coils, for example in one embodiment with seven coils. The inner diameter of the a first plurality of coils, e.g., approximately the first five coils, is wrapped around a cylindrical surface of the moveable member <NUM>. The inner diameter of a second plurality of coils, or a single auxiliary coil, is wrapped around a cylindrical surface of the cage shaft <NUM>, with the first plurality of coils being greater than the second plurality (or auxiliary) coils. Because a greater number of coils is wrapped around the moveable member <NUM>, any relative rotation between the cage shaft <NUM> and the moveable member <NUM> may cause slippage between the clutch spring <NUM> and the cage shaft <NUM>, while the moveable member <NUM> and the clutch spring <NUM> remain fixed to each other. The clutch spring <NUM> is wound such that when the cage shaft <NUM>, together with the cage assembly <NUM>, rotates in the counterclockwise direction around axis (B), the resulting drag of the cage shaft <NUM> slipping against the clutch spring <NUM> causes the coils of the clutch spring <NUM> to tighten against the cylindrical surface of cage shaft <NUM>, which acts to increase friction and dampen the rotation of cage assembly <NUM>. When the cage shaft <NUM>, along with the cage assembly <NUM>, rotates in the clockwise direction around axis (B), the resulting drag of the cage shaft <NUM> against the clutch spring <NUM> causes the coils of the clutch spring <NUM> to loosen against the cylindrical surface of cage shaft <NUM>, which acts to reduce friction and allow the cage assembly <NUM> to rotate more easily. The function of the clutch spring <NUM> is to resist undesired (counterclockwise around axis (B) rotation of the cage assembly <NUM>, which may allow the chain <NUM> to become slack, for example when the bicycle is traveling over rough terrain.

Referring to <FIG>, <FIG>, and <FIG>, when the rider pedals the bicycle, the chain <NUM> drives the cassette <NUM> clockwise, referring to <FIG>, and causes the rear wheel to rotate. Because the chain <NUM> is also engaged with upper chain pulley <NUM>, the upper chain pulley <NUM> is driven counterclockwise, referring to <FIG>. Referring to <FIG>, rotation of upper chain pulley <NUM> causes the pulley shaft <NUM> to rotate. The first generator spur gear <NUM>, which is non-rotationally fixed to the pulley shaft <NUM>, is therefore also rotated. Referring to <FIG>, the transmission <NUM> provides for rotational power to flow from the first generator spur gear <NUM> to the first generator pinion gear <NUM> to the second generator spur gear <NUM> to the second generator pinion gear <NUM> to the first generator pulley <NUM> through the belt <NUM> to the second generator pulley <NUM> to the rotor <NUM> of the generator <NUM>. Rotation of the rotor <NUM> relative to the stator <NUM> generates electrical power. Referring to <FIG> and <FIG>, the generated electrical power flows through the wires <NUM> of the generator <NUM> to the generator PCB <NUM>, and thereafter through the pogo pins 57a into the main PCB <NUM>, where it is stored in an storage device 57d, for example the supercapacitors or a battery. The storage device may thereafter supply power to the motor <NUM> to effect various shifting actions. It should be understood that the storage device 57d may supply power to other electrical devices and accessories, including those located remote to the derailleur, for example and without limitation a wheel speed sensor, a cassette speed sensor, a power meter, lights, the front derailleur, an adjustable seat post, and/or other types of bicycle accessories, or may supply power to the motor and to such auxiliary devices. In embodiments where the electrical devices and accessories are located remote to the storage device, power may be transmitted by various electrical connectors, e.g., wires. In other embodiments, the energy storage device also may be located remote to the derailleur, for example with the energy storage device mounted on another part of the frame <NUM> or bicycle component, and joined to the generator with electrical connectors, e.g., wires.

It should be noted that the interface of the pulleys <NUM>, <NUM> and the belt <NUM> results in less noise than an equivalent spur and pinion gear interface. Typically, gears that rotate relatively slowly do not create as much noise that may be objectionable to the rider, whereas gears that rotate at a high revolution per minute (RPM) may create a highpitched noise that may be objectionable to the rider. Therefore, in one embodiment, the transmission may use gear interfaces when the angular velocities are relatively low, (i.e. close to the angular velocity of the upper pulley <NUM>), and a pulley belt interface may be used when the angular velocity of the pulleys are relatively high (i.e. close to the angular velocity of the rotor <NUM>).

In order to request a gear shift, the rider operates a switch of a shifter on the handlebar. A wireless signal may be emitted from the shifter. The wireless signal is received by the antenna and radio on the main PCB <NUM>. The signal is processed by the main PCB <NUM>, and a controller provides for power to be transmitted from the power storage device 57d, e.g., the supercapacitors, to the motor <NUM>. Referring to <FIG> and <FIG>, mechanical power from the motor <NUM>, or a shifting drive system input, is transmitted from the first drive pinion <NUM> to the first drive spur <NUM> to the second drive pinion <NUM> to the second drive spur <NUM> to the third drive pinion to the third drive spur <NUM> to the lead screw <NUM>, or output.

In the case that the rider requests a shift to a larger sprocket or cog of the cassette <NUM>, power supply provides power to the motor <NUM>, which rotates in the direction that, through the shifting drive system, including the drive pinion gears and spur gears <NUM>-<NUM>, drives the third drive spur gear <NUM> and the lead screw <NUM> in a first rotational direction. The lead nut <NUM> is threadably engaged with the lead screw, but the lead nut <NUM> is unable to rotate relative to the cage shaft <NUM>. Accordingly, the lead nut <NUM> moves axially along the axis (B) in the upwards direction, with reference to the orientation of <FIG>. The spherical end 91b of the lead nut <NUM> drives the crank arm <NUM> counterclockwise around the axis (C) of the fourth pin <NUM>. Referring to <FIG> and <FIG>, the drive pin <NUM> engages the surface 99b of the drive element <NUM>, thereby rotating the drive element <NUM> counterclockwise around the axis (C) of the fourth pin <NUM>. Since the drive element <NUM> is fixed to the fourth pin <NUM>, the fourth pin <NUM> also rotates counterclockwise. Since the fourth pin <NUM> also is fixed to the outer link <NUM>, the outer link <NUM> also rotates counterclockwise around the axis (C), driving the linkage <NUM> in the inboard direction of the bicycle, which drives the moveable member <NUM> and the cage assembly <NUM> in the inboard direction. Since the chain <NUM> is engaged with upper chain pulley <NUM> of the cage assembly <NUM>, the chain <NUM> also is driven in the inboard direction, causing the chain <NUM> to shift to the next larger sprocket or cog of the cassette <NUM>.

In the case that the rider requests a shift to a smaller sprocket or cog of the cassette <NUM>, the power supply supplies power to the motor <NUM>, which rotates in the direction that, through the shifting drive system, including the drive pinion gears and spur gears <NUM>-<NUM>, drives the third drive spur gear <NUM> and the lead screw <NUM> in a second rotational direction, driving lead nut <NUM> to move axially along axis (B) in the downwards direction. The spherical end 91b of the lead nut <NUM> drives the crank arm <NUM> clockwise in <FIG> around the axis (C) of the fourth pin <NUM>. The crank arm <NUM> drives the saver spring <NUM> clockwise around axis (C) of the fourth pin <NUM>. The saver spring <NUM> drives the drive element <NUM> clockwise around axis (C) of the fourth pin <NUM>. Since the drive element <NUM> is fixed to the fourth pin <NUM>, the fourth pin <NUM> also rotates clockwise. Since the fourth pin <NUM> is fixed to the outer link <NUM>, the outer link <NUM> also rotates clockwise around axis (C), driving the parallelogram linkage <NUM> in the outboard direction of the bicycle, which drives the moveable member <NUM> and the cage assembly <NUM> in the outboard direction. Since the chain <NUM> is engaged with upper chain pulley <NUM> of the cage assembly <NUM>, the chain <NUM> is also driven in the outboard direction, causing the chain <NUM> to shift into the next smaller sprocket or cog of the cassette <NUM>.

Referring to <FIG>, <FIG>, and <FIG>, the encoder 57e on the main PCB <NUM>, together with encoder magnet (<NUM>), are used to provide positional feedback of the moveable member <NUM>, the cage assembly <NUM> and the chain pulley <NUM>. The encoder gear <NUM> is engaged with first drive spur gear <NUM>. As first drive spur gear <NUM> rotates, the gear <NUM> causes the encoder gear <NUM>, along with encoder magnet <NUM> to rotate about the axis of encoder gear <NUM>. Thus, the encoder magnet <NUM> rotates relative to the encoder 57e. The encoder 57e outputs a signal that indicates the angular position of encoder magnet <NUM> relative to the encoder 57e. During a shifting operation, the encoder magnet <NUM> makes multiple complete revolutions. A controller on the main PCB <NUM> counts the number of times that encoder magnet <NUM> makes a complete revolution. Knowing the number of times that encoder magnet <NUM> has rotated, along with its current angular position relative to encoder 57e, the controller can calculate the current position of the moveable member <NUM> relative to the bicycle frame <NUM>, and by extension the cassette <NUM>. A predetermined shift table has multiple values, each of which corresponds to a shift position of derailleur <NUM>. As the encoder magnet <NUM> rotates during a shifting operation, a value corresponding to the current position of the moveable member <NUM> is compared to a target value in the table, with the controller capable or operable to determine when the moveable member <NUM> has reached its target position (i.e. the gear selected by the rider).

In order for the system to establish a known relationship between the values of angular position output by the encoder 57e and the physical location of the moveable member <NUM>, a homing routine may be performed. In this routine, the derailleur <NUM> positions the crank arm <NUM> at a reference position, and sets the corresponding angular position indicated by encoder 57e as a reference value. Referring to <FIG>, the lead nut <NUM> is driven downwards, driving the crank arm <NUM> clockwise around axis (C) until contact between the crank arm <NUM> and a moveable member cover <NUM> prevents further clockwise rotation of the crank arm <NUM>. This is the reference position, which represents the farthest outboard position to which the derailleur can move. The corresponding positional value output by the encoder 57e is established as a reference value. In one embodiment, this homing routine is performed at the factory when the derailleur <NUM> is assembled, but the routine may also be performed after derailleur <NUM> is installed on a bicycle. The homing routine may be performed even when the moveable member <NUM> is physically prevented from moving (i.e. when the rider isn't pedaling and the presence of the chain <NUM> prevents movement of the moveable member <NUM>). For example, in the event that the moveable member <NUM> is physically prevented from moving, the outer link <NUM>, fourth pin <NUM> and drive element <NUM> will also be prevented from moving. However, the crank arm <NUM> can still rotate clockwise to the position shown in <FIG> by winding up the saver spring <NUM>. Thus, the crank arm <NUM> may be driven to its reference position and the homing operation can be performed, even if movement of the moveable member <NUM> is blocked.

The saver spring <NUM>, along with its associated parts, also acts as a safety clutch during impacts. In the event that the moveable member <NUM> or outer link <NUM> is acted upon by an external force that pushes the moveable member <NUM> in the inboard direction, the drive element <NUM> will be driven in the counterclockwise direction around axis (C). If the external force exceeds the preload of the saver spring <NUM>, the drive element <NUM> will wind up the saver spring <NUM>, preventing excessive force from being transmitted to the lead nut <NUM>. When the external force is removed, the saver spring <NUM> will unwind to its previous position.

Referring to <FIG>, a schematic shows one embodiment of a control system for the generator <NUM>, motor <NUM> and shifting drive system <NUM>. As noted above, the chain pulley <NUM> rotates the generator <NUM> which creates an alternating current (AC) voltage across each set of coils within the generator <NUM>. The coils are connected to a rectification circuit <NUM> formed by diodes D1, D2, D3, D4, D5 and D6, which rectify the voltage to direct current (DC). The generator <NUM> may be configured as a permanent magnet brushless type generator having a plurality of (e.g., three) sets of coils internally connected preferably in a star configuration, although a delta configuration may also be suitable. The generator <NUM> may also be constructed from any number of coils so long as the coils are connected to the rectification circuit <NUM> that creates a DC voltage. The generator <NUM> may also be of a brushed type which creates DC voltage mechanically. Capacitors C3 and C4 are incorporated into the circuit to create a better impedance match to the energy storage device 57d, e.g., storage capacitors C1 and C2.

Diodes D7, D8 and resistors R9, R10 are used to sense the speed and direction of the generator <NUM> which may be used to determine the speed and rotational direction of the chain pulley <NUM> and therefore the speed and rotational direction of the chain <NUM>. A memory contains information about the number of teeth of each sprocket or cog of the cassette <NUM>. As explained above, the encoder 57e provide a signal such that the controller, e.g., microcontroller <NUM>, knows what gear is currently indexed. The microcontroller <NUM> is programmed with information about the number of teeth on chainring(s). If the bicycle has more than one chainring installed, the front chainring shifting system communicates the currently selected chainring to the rear derailleur <NUM> when the front chain ring is changed. With all this information, the controller <NUM> on the rear derailleur <NUM> knows how fast the bicycle is travelling and how fast the rider is turning the cranks. The bicycle speed and cadence information may be used to perform an automatic shifting algorithm which keeps the gear ratio at a preferable ratio for the rider. The diode anode of each diode-resistor pair is connected to a signal input on the microcontroller <NUM> as well as to the digital voltage supply Vdd through a pull up resistor. When the individual phase voltages of the diodes D7 or D8 drop below the VDD, the diode will conduct to ground and register a low signal to the microcontroller <NUM>. When the phase voltage exceeds VDD the diode will not conduct and the signal to the microcontroller <NUM> will be clamped to VDD through R9 or R10. The sequence of pulses from each phase are different if the generator <NUM> is spinning clockwise or counter clockwise, as shown in <FIG>, and any change in frequency is based on how fast the generator <NUM> is turning and therefore how fast the rider is pedaling. These sequences can be recognized by timing order by the microcontroller <NUM>. The microcontroller <NUM> may modify the charging behavior if the pulse train corresponds to forward or reverse pedaling, for instance it may be desirable to disable charging, or deactivate the generator, while backpedaling, for example with the clutch, to reduce slack in the chain <NUM>, which may cause the chain to disengage from the sprockets. It may be desirable to only allow charging above a certain rider cadence, and/or it may be desirable to always have charging enabled while not pedaling to reduce chain slap, etc. One way to determine rotational direction is to look at the pulses read by the microcontroller <NUM> for two adjacent generator coils. The phase of the L2 and L3 signals are separated by <NUM> degrees (of time) followed by <NUM> degrees and the sequence repeats when the generator <NUM> is spinning at a constant speed. The order of pulses indicates direction. For instance, an L2 signal followed by <NUM> degrees, then an L3 signal followed by <NUM> degrees and another L2 signal might indicate forward pedaling (<FIG>), where an L3 signal followed by <NUM> degrees then an L2 signal followed by <NUM> degrees followed by another L3 signal would indicate reverse pedaling (<FIG>). The actual generator speed is not likely to be perfectly constant in reality, but, because the generator <NUM> rotates many times for each turn of the cranks, analyzing the relative spacing of the L2, L3 sequence will be valid.

Referring to <FIG>, a P-channel mosfet Q2 connects and disconnects the rectified voltage from the generator <NUM> to the storage device 57d (e.g., capacitors C1 and C2) for charging. Resistors R6, R7, R8 and n-channel mosfets Q3 and Q4 allow the microcontroller <NUM> to control the Q2 on/off state with a digital output while also setting Q2 to a state by default if the voltage on C1, C2 is too low to power the microcontroller <NUM>. Microcontroller <NUM> senses the state of charge of the capacitors (C1, C2) as a voltage through a voltage divider formed by R11 and R12. The microcontroller <NUM> turns Q2 off when maximum capacitor state of charge is reached and turns on Q2 when capacitor state of charge falls below some threshold. The microcontroller <NUM> may switch Q2 on and off rapidly with pulse width modulation or another variable duty cycle modulation scheme in order to regulate the effective rate of charge to reduce torque at the chain pulley. A proportional control of the Q2 switching modulation may be implemented by the microcontroller such that a low state of charge of the storage capacitors (C1, C2) would cause Q2 to be on at or nearly <NUM> percent charge rate but a state of charge close to maximum capacitor change may be at a very low charge rate. Modulation of the charge signal allows smooth transitions between not charging to charging, thereby preventing the user from feeling abrupt torque changes. As a redundancy to the microcontroller <NUM> turning off Q2 at full charge a voltage sensing integrated circuit (IC) <NUM> may also disable Q2 if the capacitor state of charge exceeds some threshold voltage. The threshold voltage that the voltage supervisor disables Q2 is preferably higher than the voltage the microcontroller <NUM> would stop charging at by some small margin. If either the IC or the microcontroller <NUM> signals for charging to be disabled, Q2 will turn off regardless of state of other control signal. Redundant charge control is useful for situations where the microcontroller <NUM> is unable to perform charge control function, for instance during a firmware update of the microcontroller. An additional redundant overvoltage protection of the capacitors is optionally provided by an integrated circuit (IC) U4, which may be of type LM317 shunt regulator. This IC senses capacitor voltage and turns on Q1 shorting the capacitors to ground if a safe voltage threshold is exceeded, which will discharge capacitors until capacitor voltage is below safe threshold. Capacitors (C1, C2) are preferably of electrochemical double-layer (ELDC) type also known as super capacitors. The schematic shows two capacitors (C1, C2) in series but any number of series capacitors may be used. The number of capacitors in series should be matched to the preferred operating voltage of the motor <NUM> and open circuit voltage of the generator <NUM>. The capacitors 57d may also be arranged in a multiple parallel-series arrangement to achieve different voltage and capacitance values. The capacitors (C1, C2) may be of other types such as ceramic, electrolytic, tantalum or a future capacitor technology. The capacitors (C1, C2) function may also be performed by a rechargeable battery such as a lithium ion battery or lithium polymer battery or some future battery technology. Resistors R1 and R2 function to balance the charge between the two capacitors over time so that one capacitor does not develop an excess of charge compared to the other capacitor.

In one embodiment of the derailleur <NUM>, configured with the linkage <NUM> actuated by lead screw <NUM>, the encoder 57e may be required to count multiple turns of sensing element (such as a diametrically magnetized magnet). This turn counting can be performed by the encoder 57e or by the microcontroller <NUM> noting when the encoder wraps over its max value. The absolute position of the linkage <NUM> is determined by moving the derailleur to one end of possible travel and detecting a stall condition on the motor <NUM>. Ideally this motion limit detection is performed only once during manufacturing, therefore the encoder system must store the number of full rotational wraps between power cycles of the device. In one embodiment, the derailleur <NUM> has the characteristic of having a non-removable power supply 57d (capacitors (C1, C2)), meaning the power source cannot be suddenly disconnected.

Referring to <FIG>, when the bicycle is not being ridden, the capacitor voltage may slowly fall due to internal leakage, the balancing resistors and the small power requirements of the microcontroller <NUM>, and may drop to <NUM>. When the voltage of the capacitor 57d approaches a threshold voltage (e.g., <NUM>. 5V), or a voltage slightly above the minimum voltage required to power the encoder 57e, (e.g., <NUM>. 3V), the microcontroller <NUM> may save the current wrap count to the memory. As shown in <FIG>, when the voltage of the capacitors 57d starts increasing again due to the bike being pedaled, the microcontroller will turn on when the voltage reaches a first threshold voltage (e.g., <NUM>. 8V), the encoder will turn on when the voltage reaches a second threshold voltage <NUM>. 3V), and at some voltage threshold (e.g., <NUM>. 7V), higher than the voltage at which the derailleur saved the last wrap count, but lower than a threshold voltage (e.g., <NUM>. 2V) at which the microcontroller <NUM> allows shifting to occur, the microcontroller <NUM> will read the current encoder position and add the last known wrap count to restore a knowledge of the absolute position of the derailleur. Above the shifting threshold voltage (e.g., <NUM>. 2V), shifting may occur.

Referring to <FIG>, a voltage regulator <NUM> may be included to provide a voltage source lower than the voltage of the capacitor 57d to supply the microcontroller <NUM>, encoder 57e, motor controller and other ICs in the circuit. The voltage regulator <NUM> may be integral to the microcontroller <NUM>, or one of the other ICs, which in turn supplies a lower voltage to other components in the circuit. The voltage regulator <NUM> is preferably a switching buck type, but may also be a linear type or buck boost type. The voltage regulator <NUM> may be omitted if the capacitor voltage does not exceed the maximum ratings for the microcontroller or other ICs.

A switch SW1 is connected to a digital input of the microcontroller <NUM> to provide user input to system such as wireless pairing function. More or fewer switches may be used for various user input.

Optional LEDs D9, D10 and D11 may be provided to indicate to the user about the derailleur <NUM> such as pairing state or state of capacitor charge. These may be omitted. The LEDs may be configured to illuminate in various colors.

Motor driver 57f is operatively connected to the microcontroller <NUM> by an appropriate control signal or set of control signals such as an analog control signal, a digital control signal such as I2C, SPI, UART, etc., or may be control by pulse width modulated digital signals.

The microcontroller <NUM> may include a general processor, digital signal processor, an application specific integrated circuit (ASIC), field programmable gate array (FPGA), analog circuit, digital circuit, combinations thereof, or other now known or later developed processor. The processor may be a single device or combinations of devices, such as through shared or parallel processing.

The memory may be a volatile memory or a non-volatile memory. The memory may include one or more of a read only memory (ROM), random access memory (RAM), a flash memory, an electronic erasable program read only memory (EEPROM), or other type of memory. The memory may be removable from the derailleur <NUM>, such as a secure digital (SD) memory card. In a particular non-limiting, exemplary embodiment, a computer-readable medium can include a solid-state memory such as a memory card or other package that houses one or more non-volatile read-only memories. Further, the computer-readable medium can be a random-access memory or other volatile re-writable memory. Additionally, the computer-readable medium can include a magneto-optical or optical medium, such as a disk or tapes or other storage device. Accordingly, the disclosure is considered to include any one or more of a computer-readable medium and other equivalents and successor media, in which data or instructions may be stored.

The memory may be a non-transitory computer-readable medium and may be described as a single medium. However, the term "computer-readable medium" includes a single medium or multiple media, such as a centralized or distributed memory structure, and/or associated caches that are operable to store one or more sets of instructions and other data. The term "computer-readable medium" shall also include any medium that is capable of storing, encoding or carrying a set of instructions for execution by a processor or that cause a computer system to perform any one or more of the methods or operations disclosed herein.

A communication interface provides for data and/or signal communication from and between the derailleur to another component of the bicycle, or an external device such as a mobile phone or other computing device. The communication interface communicates the data using any operable connection. An operable connection may be one in which signals, physical communications, and/or logical communications may be sent and/or received. An operable connection may include a physical interface, an electrical interface, and/or a data interface. The communication interface may be configured to communicate wirelessly, and as such include one or more antennae. The communication interface provides for wireless communications in any now known or later developed format. Bluetooth® and or ANT+™ standards may also, or alternatively, be used.

The communication interface is configured to send and/or receive data such as control signals and/or commands to and/or from bicycle components such as the front gear changer and/or the derailleurs <NUM>. The component communication interface communicates the data using any operable connection. An operable connection may be one in which signals, physical communications, and/or logical communications may be sent and/or received. An operable connection may include a physical interface, an electrical interface, and/or a data interface. The communication interface provides for wireless communications in any now known or later developed format.

In accordance with various embodiments of the present disclosure, methods described herein may be implemented with software programs executable by a computer system, such as the microcontroller and circuitry.

As used in this application, the term 'circuitry' or 'circuit' refers to all of the following: (a) hardware-only circuit implementations (such as implementations in only analog and/or digital circuitry) and (b) to combinations of circuits and software (and/or firmware), such as (as applicable): (i) to a combination of processor(s) or (ii) to portions of processor(s)/software (including digital signal processor(s)), software, and memory(ies) that work together to cause an apparatus, such as a mobile phone or server, to perform various functions) and (c) to circuits, such as a microprocessor(s) or a portion of a microprocessor(s), that require software or firmware for operation, even if the software or firmware is not physically present.

Claim 1:
A bicycle derailleur (<NUM>) comprising:
a base member (<NUM>) mountable to a bicycle frame (<NUM>); and
a cage assembly (<NUM>) moveably coupled to the base member (<NUM>), wherein the cage assembly (<NUM>) is moveable in opposite first and second directions relative to the base member (<NUM>);
characterized in that the bicycle derailleur (<NUM>) further comprises a motor (<NUM>) coupled to and moveable with the cage assembly (<NUM>) in the opposite first and second directions, wherein the motor (<NUM>) is operable to move the cage assembly (<NUM>) in the opposite first and second directions, wherein the motor (<NUM>) is mounted on the cage assembly (<NUM>).