Electric motor device for pedal assist bicycles

Abstract

An electric motor device for pedal assist bicycles may include an electric motor connectable to a rear wheel rim of a bicycle, a pedaling sensor connectable to a hanger of a frame of the bicycle, a charging outlet, a control unit, and a block insertable into an oblique main tube of the frame. The electric motor may include at least one free wheel rigidly connectable to transmission gear wheels of the bicycle. The block may include a battery configured to actuate the electric motor, a motor controller configured to control a plurality of operating parameters of the electric motor, a battery manager configured to manage the battery connected in parallel to the battery and to the motor controller, a plurality of first cables connecting the block to the electric motor, the charging outlet, and the pedaling sensor, and a plurality of second cables connecting the block to the control unit.

The invention claimed is: 
     
         1 . An electric motor device for pedal assist bicycles, comprising:
 an electric motor having a hub shape, the electric motor connectable to a rim of a rear wheel of a bicycle, the electric motor including at least one free wheel rigidly connectable to at least one transmission gear wheel of the bicycle;   a pedaling sensor connectable to a hanger of a frame of the bicycle, the hanger disposed in an anchoring zone of a rear hub of the frame of the bicycle;   a charging outlet;   a control unitconnectable to the frame of the bicycle and operable via a user for actuation and control;   a block insertable into an oblique main tube ofthe a frame of the bicycle;   wherein the block includes:
 a battery operatively connected to the charging outlet such that the battery is rechargeable via the charging outlet, the battery configured to actuate the electric motor; 
 a motor controller connectedin parallel to the battery, the motor controller configured to control a plurality of operating parameters of the electric motor; 
 a battery manager connectedin parallel to the battery and to the motor controller, the battery manager configured to manage the battery; 
 a plurality of first cables connecting the block to the electric motor, the charging outlet, and the pedaling sensor; 
 a plurality of second cables connecting the block to at least the control unit; 
 a first cover closing a first axial end of the block, the plurality of first cables extending out of the block through the first cover; and 
 a second cover closing a second axial end of the block, the plurality of second cables extending out of the block through the second cover; 
   wherein the battery manager and the motor controller are directly connected to one another in parallel.   
     
     
         2 . The electric motor device as claimed in  claim 1 , wherein the pedaling sensor includes:
 a disk rigidly connectable to the at least one free wheel of the electric motor; and   a plurality of magnets arranged on the disk configured to activate the pedaling sensor.   
     
     
         3 . The electric motor device as claimed in  claim 1 , wherein the control unit includes:
 a pushbutton with at least one button actuatable via the user;   a lighting mechanism configured to transmit information via emitting light; and   a vibration motor connected to the pushbutton configured to transmit information via providing vibrations.   
     
     
         4 . The electric motor device as claimed in  claim 3 , wherein the vibration motor includes a variable-frequency drive configured to transmit information via providing a plurality of different vibrations. 
     
     
         5 . The electric motor device as claimed in  claim 1 , wherein:
 the battery includes a block of cells; and   the block of cells includes a group of ten cells and an auxiliary cell structured and arranged in an 11S2P layout.   
     
     
         6 . The electric motor device as claimed in  claim 1 , wherein:
 the battery includes a block of cells; and   the block of cells includes a group of thirteen cells and an auxiliary cell structured and arranged in a 14S2P layout.   
     
     
         7 . The electric motor device as claimed in  claim 1 , wherein:
 the battery includes a block of cells;   the block of cells includes eleven cells connected to one another in series; and   the eleven cells includes two groups of cells connected in parallel such that the eleven cells are arranged in an 11S2P layout.   
     
     
         8 . The electric motor device as claimed in  claim 1 , wherein:
 the battery includes a block of cells;   the block of cells includes fourteen cells connected to one another in series; and   the fourteen cells includes two groups of cells connected in parallel such that the fourteen cells are arranged in an 14S2P layout.   
     
     
         9 . The electric motor device as claimed in  claim 1 , wherein:
 the battery includes a block of cells;   the block of cells includes a plurality of groups of cells;   each of the plurality of groups of cells includes at least one of ten cells and thirteen cells; and   the block of cells further includes one auxiliary cell for each group of the plurality of groups of cells.   
     
     
         10 . The electric motor device as claimed in  claim 1 , wherein:
 the battery, the battery manager, and the motor controller are directly connected to one another in parallel; and   a circuit board of the battery manager is connected directly to a circuit board of the motor controller.   
     
     
         11 . The electric motor device as claimed in  claim 1 , wherein a direct connection between the battery manager and the motor controller is free of cables. 
     
     
         12 . The electric motor device as claimed in  claim 1 , further comprising an auxiliary battery that is operatively connectable to the battery and is releasably connectable to the bicycle. 
     
     
         13 . The electric motor device as claimed in  claim 1 , wherein the battery manager and the motor controller are directly connected to one another physically and electrically such that the battery manager and the motor controller are configured as a single unit. 
     
     
         14 . An electric motor device for pedal assist bicycles, comprising:
 an electric motor having a hub shape, the electric motor connectable to a rim of a rear wheel of a bicycle, the electric motor including at least one free wheel rigidly connectable to at least one transmission gear wheel of the bicycle;   a pedaling sensorconnectable to a hanger of a frame of the bicycle, the hanger disposed in an anchoring zone of a rear hub of the frame of the bicycle;   a charging outlet;   a control unitconnectable to the frame of the bicycle and operable via a user for actuation and control;   a block insertable into an oblique main tube ofthe a frame of the bicycle;   wherein the block includes:
 a battery operatively connected to the charging outlet such that the battery is rechargeable via the charging outlet, the battery configured to actuate the electric motor; 
 a motor controller configured to control a plurality of operating parameters of the electric motor; 
 a battery manager configured to manage the battery; 
 the battery manager, the battery, and the motor controller connected directly togetherin parallel; 
 a plurality of first cables connecting the block to the electric motor, the charging outlet, and the pedaling sensor; 
 a plurality of second cables connecting the block to at least the control unit; 
 a first cover closing a first axial end of the block, the plurality of first cables extending out of the block through the first cover; and 
 a second cover closing a second axial end of the block, the plurality of second cables extending out of the block through the second cover. 
   
     
     
         15 . The electric motor device as claimed in  claim 14 , wherein:
 the block further includes a rubber insulator and a rubber O-ring seal; and   the O-ring seal and the insulator are coupled to the block via the first cover and seal the block.   
     
     
         16 . The electric motor device as claimed in  claim 15 , wherein the insulator is overmolded onto the plurality of first cables sealingly connecting the plurality of first cables together. 
     
     
         17 . An electric motor device for pedal assist bicycles, comprising:
 an electric motor having a hub shape, the electric motor connectable to a rim of a rear wheel of a bicycle, the electric motor including at least one free wheel rigidly connectable to at least one transmission gear wheel of the bicycle;   a pedaling sensorconnectable to a hanger of a frame of the bicycle, the hanger disposed in an anchoring zone of a rear hub of the frame of the bicycle;   a charging outlet;   a control unitconnectable to the frame of the bicycle and operable via a user for actuation and control;   a block insertable into an oblique main tube ofthe a frame of the bicycle;   wherein the block includes:
 an outer protective coveringincluding an upper casing and a lower casing; 
 a first cover closing a first axial end of the block; 
 a second cover closing a second axial end of the block; 
 a battery operatively connected to the charging outlet such that the battery is rechargeable via the charging outlet, the battery configured to actuate the electric motor; 
 a motor controller connectedin parallel to the battery, the motor controller configured to control a plurality of operating parameters of the electric motor; 
 a battery manager connected in parallel to the battery and to the motor controller, the battery manager configured to manage the battery; 
 a plurality of first cables connecting the block to the electric motor, the charging outlet, and the pedaling sensor, the plurality of first cables extending out of the block through the first cover; and 
 a plurality ofat least one second cables connecting the block to the control unit, theplurality of at least one second cables extending out of the block through the second cover. 
   
     
     
       18. An electric motor device for pedal assist bicycles, comprising:
 an electric motor connectable to a rim of a rear wheel of a bicycle, the electric motor including at least one free wheel rigidly connectable to at least one transmission gear wheel of the bicycle;   a pedaling sensor;   a charging outlet;   a user actuatable control unit connectable to a handlebar of the bicycle;   a block insertable into a tube of a frame of the bicycle;   wherein the block includes:
 a battery operatively connected to the charging outlet such that the battery is rechargeable via the charging outlet, the battery configured to actuate the electric motor; 
 a motor controller configured to control a plurality of operating parameters of the electric motor; 
 a battery manager configured to manage the battery; 
 the battery manager, the battery, and the motor controller connected directly together; 
 a plurality of first cables connecting the block to the electric motor, the charging outlet, and the pedaling sensor; 
 at least one second cable connecting the block to at least the control unit; 
 a first cover closing a first axial end of the block, the plurality of first cables extending out of the block through the first cover; and 
 a second cover closing a second axial end of the block, the at least one second cable extending out of the block through the second cover. 
   
     
     
       19. The electric motor device as claimed in  claim 18 , further comprising an auxiliary component, wherein the at least one second cable connects the block to the control unit and to the auxiliary component. 
     
     
       20. The electric motor device as claimed in  claim 19 , wherein the auxiliary component is a light. 
     
     
       21. The electric motor device as claimed in  claim 19 , wherein:
 the at least one second cable includes a plurality of second cables; and   the plurality of second cables includes a cable connecting the block to the control unit and another cable connecting the block to the auxiliary component.