Drive unit
A drive unit ( 10 ) for a manually driven vehicle, in particular a bicycle or an EPAC, includes a housing ( 12 ), an electric motor ( 18 ) with a stator ( 44 ) and a rotor ( 46 ), a stator support ( 48 ), and an electronic unit ( 50 ). The stator support ( 48 ), the stator ( 44 ), the rotor ( 46 ), and the electronic unit ( 50 ) are designed in the form of one unit ( 56 ), which can be preassembled so that the preassembled unit ( 56 ) is installable into the housing ( 12 ).
1. A drive unit ( 10 ) for a manually driven vehicle, namely a bicycle or an EPAC, comprising:
a housing ( 12 );
an electric motor ( 18 ) with a stator ( 44 ) and a rotor ( 46 );
a stator carrier ( 48 ); and
electronics ( 50 ),
wherein the stator carrier ( 48 ), the stator ( 44 ), the rotor ( 46 ), and the electronics ( 50 ) are formed as a premountable unit ( 56 ) such that the premounted unit ( 56 ) is mountable in the housing ( 12 )
wherein one or more ducts ( 60 , 62 ) for electrical signal lines and electrical power lines are formed on the stator carrier ( 48 ); and
wherein the stator ( 44 ), the electronics ( 50 ), and the rotor ( 46 ) are fastened on the stator carrier ( 48 ); and
wherein the rotor ( 46 ) is mounted on the stator carrier ( 48 ) by a rolling bearing ( 58 ).
2. The drive unit ( 10 ) of claim 1 , wherein the stator carrier ( 48 ) has a radially outward projecting fastening section ( 54 ) by which the stator carrier ( 48 ) is mountable or fixable in the housing ( 12 ) of the drive unit ( 10 ) by a press fit between the stator carrier ( 48 ) and the housing ( 12 ).
3. The drive unit ( 10 ) of claim 1 , wherein the electric motor ( 18 ) is an external rotor motor.
4. The drive unit ( 10 ) of claim 1 , wherein the rotor ( 46 ) comprises a sleeve-shaped coupling section ( 64 ) for coupling to a harmonic drive ( 20 ) arranged in the housing ( 12 ), and the sleeve-shaped coupling section ( 64 ) has an elliptical outer contour ( 65 ).
5. The drive unit ( 10 ) of claim 1 , wherein the stator ( 44 ) of the electric motor ( 18 ) is potted to the stator carrier ( 48 ).
6. The drive unit ( 10 ) of claim 1 , wherein the rotor ( 46 ) is mounted on the stator carrier ( 48 ) only by the rolling bearing ( 58 ), the rolling bearing ( 58 ) being a single rolling bearing.
7. The drive unit ( 10 ) of claim 1 , further comprising a flex conductor ( 72 ) with two layers ( 74 , 76 ), wherein the flex conductor ( 72 ) is connected at one end to the electronics ( 50 ) and at the other end comprises an electrical interface ( 78 ) with a plurality of contact surfaces ( 79 ) for connection to a vehicle-side plug ( 204 ).
8. The drive unit ( 10 ) of claim 7 , wherein a groove ( 82 ) is formed on an outer side ( 80 ) of the housing ( 12 ), the flex conductor ( 72 ) and the electrical interface ( 78 ) are arranged in the groove ( 82 ), the layers ( 74 , 76 ) of the flex conductor ( 72 ) are covered by a potting compound or a covering ( 88 ), and a through-opening ( 89 ) is formed at the electrical interface ( 78 ).
9. The drive unit ( 10 ) of claim 1 , wherein the electronics ( 50 ) comprises a position sensor system ( 90 ) for detecting a rotational position of a bottom bracket shaft ( 14 ) of the drive unit ( 10 ), the position sensor system ( 90 ) comprises an eccentric ring ( 94 ) and one or more proximity sensors ( 92 ), the eccentric ring ( 94 ) fastened non-rotatably to the bottom bracket shaft ( 14 ) and interacting with the one or more proximity sensors ( 92 ).
10. An assembly ( 200 ), comprising
a wiring loom ( 202 ) of a manually driven vehicle, namely a bicycle or an EPAC; and
the drive unit ( 10 ) of claim 7 ,
wherein the wiring loom ( 202 ) comprises a connector plug ( 204 ) for connection to the electrical interface ( 78 ) of the flex conductor ( 72 ), the connector plug ( 204 ) comprises spring-loaded contact pins ( 206 ) for contacting the contact surfaces ( 79 ), and/or the connector plug ( 204 ) is secured to the drive unit ( 10 ) by a retaining clamp ( 208 ), the retaining clamp ( 208 ) gripping the connector plug ( 204 ) and latchable into recesses ( 91 ) formed on an outer side ( 80 ) of the housing ( 12 ) of the drive unit ( 10 ).
11. A drive unit ( 10 ) for a manually driven vehicle, namely a bicycle or an EPAC, comprising:
a housing ( 12 );
an electric motor ( 18 ) with a stator ( 44 ) and a rotor ( 46 );
a stator carrier ( 48 );
electronics ( 50 ); and
a flex conductor ( 72 ) with two layers ( 74 , 76 ), wherein the flex conductor ( 72 ) is connected at one end to the electronics ( 50 ) and at the other end comprises an electrical interface ( 78 ) with a plurality of contact surfaces ( 79 ) for connection to a vehicle-side plug ( 204 ),
wherein the stator carrier ( 48 ), the stator ( 44 ), the rotor ( 46 ), and the electronics ( 50 ) are formed as a premountable unit ( 56 ) such that the premounted unit ( 56 ) is mountable in the housing ( 12 ).
12. A drive unit ( 10 ) for a manually driven vehicle, namely a bicycle or an EPAC, comprising:
a housing ( 12 );
an electric motor ( 18 ) with a stator ( 44 ) and a rotor ( 46 );
a stator carrier ( 48 ); and
electronics ( 50 ), the electronics ( 50 ) comprising a position sensor system ( 90 ) for detecting a rotational position of a bottom bracket shaft ( 14 ) of the drive unit ( 10 ), the position sensor system ( 90 ) comprising an eccentric ring ( 94 ) and one or more proximity sensors ( 92 ), the eccentric ring ( 94 ) being fastened non-rotatably to the bottom bracket shaft ( 14 ) and interacting with the one or more proximity sensors ( 92 )
wherein the stator carrier ( 48 ), the stator ( 44 ), the rotor ( 46 ), and the electronics ( 50 ) are formed as a premountable unit ( 56 ) such that the premounted unit ( 56 ) is mountable in the housing ( 12 ).