Electric bicycle transmission systems, methods, and devices

• US 9,656,672 B2
• Filed: 02/11/2016
• Issued: 05/23/2017
• Est. Priority Date: 02/13/2015
• Status: Active Grant

• Current Assignee: Civilized Cycles Incorporated
• Original Assignee: Civilized Cycles Incorporated
• Inventors: Schieffelin, Zachary
• Primary Examiner(s): PANG, ROGER L
• Application Number:
  US15/109,105
• Publication Number:
  US 20170106866A1
• Time in Patent Office: 467 Days
• Field of Search: 701 51
• CPC Class Codes: B60W 10/08 including control of electric propulsion units, e.g. motors or generators
• CPC Class Codes: B60W 10/11 Stepped gearings
• CPC Class Codes: B60W 2510/104 Output speed
• CPC Class Codes: B60W 2520/28 Wheel speed
• CPC Class Codes: B60W 2710/081 Speed
• CPC Class Codes: B60W 2710/1005 Transmission ratio engaged
• CPC Class Codes: B60W 2710/1038 Output speed
• CPC Class Codes: B60W 30/181 Preparing for stopping
• CPC Class Codes: B62J 43/13 on rider-propelled cycles with additional electric propulsion
• CPC Class Codes: B62J 45/20 Cycle computers as cycle accessories
• CPC Class Codes: B62J 50/22 electronic, e.g. displays
• CPC Class Codes: B62M 25/08 with electrical or fluid transmitting systems
• CPC Class Codes: B62M 6/45 Control or actuating devices therefor
• CPC Class Codes: B62M 9/04 of changeable ratio
• CPC Class Codes: B62M 9/122 electrically or fluid actuated; Controls thereof
• CPC Class Codes: B62M 9/132 electrically or fluid actuated; Controls thereof
• CPC Class Codes: F16D 41/24 specially adapted for cycles
• CPC Class Codes: F16H 7/06 with chains
• CPC Class Codes: Y02T 10/72 Electric energy management in electromobility

Abstract

A derailleur-based electronic transmission system for an electric bicycle comprises a wheel; a driven sprocket set coupled to the wheel via at least a first one-way clutch, the driven sprocket set comprising two or more concentric sprockets of different effective diameters; a drive chain configured to engage the driven sprocket set; an electronically controllable derailleur configured to move the drive chain among the two or more sprockets; a pedal crank configured to cause rotation of the driven sprocket set by providing a user pedal force to the driven sprocket set through at least a second one-way clutch and the drive chain; a motor configured to cause rotation of the driven sprocket set by providing an electromechanical force to the driven sprocket set through at least a the drive chain; and an electronic controller configured to, responsive to a determination that a shift should occur at a time when neither the pedal crank nor the motor is causing rotation of the driven sprocket: operate the motor to rotate the driven sprocket at a rotational speed less than or equal to a current rotational speed of the wheel; and operate the derailleur to cause the shift to occur while the driven sprocket is being rotated by the motor.

Claims

1. A derailleur-based electronic transmission system for an electric bicycle, the system comprising:

a wheel;

a driven sprocket set coupled to the wheel via at least a first one-way clutch, the driven sprocket set comprising two or more concentric sprockets of different effective diameters;

a drive chain configured to engage the driven sprocket set;

an electronically controllable derailleur configured to move the drive chain among the two or more sprockets;

a pedal crank configured to cause rotation of the driven sprocket set by providing a user pedal force to the driven sprocket set through at least a second one-way clutch and the drive chain;

a motor configured to cause rotation of the driven sprocket set by providing an electromechanical force to the driven sprocket set through at least a the drive chain; and

an electronic controller configured to, responsive to a determination that a shift should occur at a time when neither the pedal crank nor the motor is causing rotation of the driven sprocket;

operate the motor to rotate the driven sprocket at a rotational speed less than or equal to a current rotational speed of the wheel; and

operate the derailleur to cause the shift to occur while the driven sprocket is being rotated by the motor.

2. The derailleur-based electronic transmission system of claim 1, wherein the motor is further configured to provide the electromechanical force to the driven sprocket set through at least a third one-way clutch and the drive chain.

3. The derailleur-based electronic transmission system of claim 1, wherein the electronic controller is configured to determine that the shift should occur by determining that a stop event is occurring.

4. The derailleur-based electronic transmission system of claim 3, wherein determining that the stop event is occurring comprises monitoring, directly and/or indirectly, one or more of the following:

a rotational speed of the wheel, a rotational speed of the pedal crank, a rate of deceleration of the rotational speed of the wheel, a braking force, a rate of translational deceleration, a pedal cadence.

5. The derailleur-based electronic transmission system of claim 3, wherein the electronic controller is further configured to:

estimate a remaining amount of revolutions of the wheel before the stop event completes; and

operate the motor to rotate the driven sprocket at a rotational speed less than or equal to the current rotational speed of the wheel, but sufficiently fast to complete the shift within the estimated remaining amount of revolutions of the wheel.

6. The derailleur-based electronic transmission system of claim 1, further comprising:

a jackshaft configured to transfer the user pedal force and electromechanical force to the driven sprocket through at least the drive chain,

wherein the pedal crank and motor are each connected to the jackshaft through a separate chain or belt different than the drive chain.

7. The derailleur-based electronic transmission system of claim 6, wherein the second one-way clutch is located functionally between the pedal crank and the jackshaft.

8. The derailleur-based electronic transmission system of claim 6, wherein the third one-way clutch is located functionally between the motor and the jackshaft.

9. The derailleur-based electronic transmission system of claim 1, wherein the motor, pedal crank, and driven sprocket are arranged in a mid-drive arrangement.

10. The derailleur-based electronic transmission system of claim 1, wherein the electronic controller is further configured to:

monitor the rotational speed of the wheel as the shift is occurring; and

adjust the operation of the motor, responsive to a determination that the rotational speed of the wheel has changed, to increase or decrease the rotational speed of the driven sprocket to maintain the rotational speed of the driven sprocket at a speed less than or equal to the rotational speed of the wheel.

11. The derailleur-based electronic transmission system of claim 10, wherein the electronic controller is configured to maintain the rotational speed of the driven sprocket to within 5% of the monitored rotational speed of the wheel as the shift is occurring.

12. A method of automatically operating a derailleur-based transmission of an electric bicycle, the method comprising:

determining, by an electric bicycle controller, that a stop event is occurring;

determining, by the electric bicycle controller, that a downshift is desirable before the stop event completes;

measuring, directly or indirectly, a rotational sprocket set speed and determining that the rotational sprocket set speed is below a threshold speed for effecting the downshift before the stop event completes, the sprocket set comprising two or more concentric sprockets;

operating, by the electric bicycle controller, a motor to cause rotation of the sprocket set at a speed equal to or greater than the threshold speed, but equal to or less than a rotational speed of a wheel coupled to the sprocket set; and

operating, by the electric bicycle controller, an electronic derailleur to cause the electronic derailleur to shift a chain from a first sprocket of the two or more concentric sprockets to a different sprocket of the two or more concentric sprockets while the motor is causing the sprocket set to rotate.

13. The method of claim 12, wherein determining that the stop event is occurring comprises monitoring, directly or indirectly, by one or more sensors, one or more of the following bicycle conditions:

a rotational speed of the wheel, a rotational speed of a pedal crank, a rate of deceleration of the rotational speed of the wheel, a braking force, a rate of translational deceleration, a pedal cadence.

14. The method of claim 12, wherein determining that the stop event is occurring further comprises determining that the rate of deceleration of the rotational speed of the wheel is equal to or greater than a threshold rate of deceleration.

15. The method of claim 14, wherein the threshold rate of deceleration is at least 0.5 meters/sec/sec.

16. The method of claim 12, further comprising:

calculating the threshold speed for effecting the downshift before the stop event completes, the calculating comprising;

detecting a current gear status;

determining an amount of sprocket set rotation required to effect a shift from the current gear to an optimum starting gear; and

calculating a minimum sprocket set rotational speed required to effect the required amount of sprocket set rotation before the stop event completes.

17. The method of claim 16, wherein the calculating the threshold speed further comprises:

determining an optimum gear change sprocket set speed range; and

responsive to determining that the minimum sprocket set rotational speed required to effect the required amount of sprocket set rotation before the stop event completes is below the optimum gear change sprocket set speed range, setting the threshold speed to be at least as fast as a bottom end of the optimum gear change sprocket set speed range.

18. The method of claim 12, further comprising:

continually monitoring, directly and/or indirectly, the rotational speed of the wheel during the shift of the chain; and

reducing the rotational speed of the sprocket set as needed, during the shift of the chain, to maintain the rotational speed of the sprocket set equal to or less than the rotational speed of the wheel.

19. The method of claim 18, further comprising increasing the rotational speed of the sprocket set, during the shift of the chain, in response to a determination that the rotational speed of the wheel has increased during the shift of the chain.

20. A computer-readable, non-transitory storage medium having a computer program stored thereon for causing a suitably programmed computer system to process by one or more processors computer-program code by performing a method for automatically operating a derailleur-based transmission of an electric bicycle when the computer program is executed on the suitably programmed computer system, the method comprising:

determining, using a computer system, that a stop event is occurring;

determining, by the computer system, that a downshift is desirable before the stop event completes;

measuring, directly or indirectly, a rotational sprocket set speed and determining that the rotational sprocket set speed is below a threshold speed for effecting the downshift before the stop event completes, the sprocket set comprising two or more concentric sprockets;

operating, using the computer system, a motor to cause rotation of the sprocket set at a speed equal to or greater than the threshold speed, but equal to or less than a rotational speed of a wheel coupled to the sprocket set; and

operating, using the computer system, an electronic derailleur to cause the electronic derailleur to shift a chain from a first sprocket of the two or more concentric sprockets to a different sprocket of the two or more concentric sprockets while the motor is causing the sprocket set to rotate;

wherein the computer system comprises a computer processor and electronic memory.