TWM680077U - Motor integration device - Google Patents

Abstract

A motor integration device adapted to be connected among a vehicle frame, a shock absorber, and a wheel is provided, and the motor integration device includes a swing arm housing, an electric motor, a controller, and a gear module. One of two ends of the swing arm housing is pivotally connected to the vehicle frame, and the other end of the swing arm housing is pivotally connected to the shock absorber, wherein the swing arm housing has a first accommodation area and a second accommodation area. The electric motor is disposed in the first accommodation area and configured to drive the wheel. The controller is disposed in the second accommodation area and configured to drive the electric motor. The gear module is disposed on an exterior of the swing arm housing, and the gear module is connected between the electric motor and the wheel. The motor integration device integrates the electric motor and the controller together within the swing arm housing, while combining the gear module on the exterior of the swing arm housing, whereby this structural configuration facilitates maintenance or replacement operations.

Description

Motor integration device

An integrated device, particularly a motor integrated device that integrates an electric motor and a controller within a rocker arm housing.

According to the existing electric motorcycles known to the new creators, the frame mainly supports the battery and controller and fixes the shock absorber, rear control arm (rocker arm), rear wheel, and motor (including gearbox). The front end of the rear control arm is hinged to the frame, and the rear end supports the rear wheel and shock absorber to absorb vibrations, keep the wheel in contact with the ground, and allow it to swing up and down with road conditions. The motor is powered by the battery and is divided into hub type and mid-mounted type. Hub type means that the motor is directly integrated into the rear wheel, while mid-mounted type means that the motor is fixed to the frame and drives the rear wheel through the transmission device. There are many components and they are installed in various parts of the frame.

In view of this, according to some embodiments, a motor integration device is proposed suitable for connection between a vehicle frame, shock absorber, and wheel. The motor integration device includes a rocker arm housing, an electric motor, a controller, and a gear module. One end of the rocker arm housing is hinged to the vehicle frame, and the other end is hinged to the shock absorber. The rocker arm housing has a first receiving area and a second receiving area. The electric motor is disposed in the first receiving area and is used to drive the wheel. The controller is disposed in the second receiving area and is used to drive the electric motor. The gear module is disposed on the outside of the rocker arm housing and is connected between the electric motor and the wheel.

In some embodiments, the rocker arm housing includes a partition located between the first receiving area and the second receiving area.

In some embodiments, the controller includes a first substrate and a second substrate. The first substrate has multiple power posts, and the second substrate has multiple through holes, with each power post passing through a through hole.

In some embodiments, the electric motor has multiple power lines, each power line extending from a first receiving area to a second receiving area and connecting to a power column.

In some embodiments, the motor integration device further includes an end cap that fits into the first receiving area and covers the electric motor, the end cap having a row of holes for the various power lines to pass through.

In some embodiments, the controller includes a substrate having multiple power posts and an electric motor having multiple power lines, each power line extending from a first accommodating region to a second accommodating region and connecting to a power post.

In some embodiments, the sides of the rocker arm housing include side openings and an outer cover that covers the side openings.

In some embodiments, the outer surface of the cover has multiple heat dissipation sections corresponding to the controller area.

In some embodiments, the gear module includes a cover and a gear assembly located within the cover, the rocker arm housing has a shaft hole communicating with a first receiving area, the electric motor has a drive rod passing through the shaft hole, and the gear assembly is sleeved on the drive rod and connected to the wheel.

In some embodiments, the gear assembly includes a first gear, a second gear, a third gear, and multiple bearings. A drive rod is sleeved on the first gear and multiple bearings. The second gear has a shaft portion that is sleeved on multiple bearings. The first gear meshes with the second gear, and the second gear meshes with the third gear. The cover has a recess. The third gear has a driven rod. Multiple bearings are sleeved on both ends of the driven rod. The driven rod passes through the recess and connects to the wheel. The first gear, the third gear, and one end of the rocker arm housing are arranged along a horizontal axis.

In summary, according to some embodiments, by installing an electric motor and controller inside the rocker arm housing and a gear module on the outside of the rocker arm housing, the various components of the motor integration device between the frame, shock absorber and wheel are integrated together, which facilitates the maintenance or replacement of the entire motor integration device.

Unless otherwise specified as electrical connection, the terminology used in the following embodiments regarding connections may refer to physical connections, or direct or indirect connections between physical components.

Please refer to Figures 1 to 3. Figure 1 is a schematic diagram of the appearance of the motor integration device 100, Figure 2 is an exploded front view of the motor integration device 100, and Figure 3 is an exploded rear view of the motor integration device 100. Figures 1 to 3 illustrate a first embodiment of the motor integration device 100, which is applied to an electric motorcycle or electric bicycle. The electric motorcycle includes a frame 200 (body frame), a shock absorber 300, and a wheel 400 (rear wheel). The motor integration device 100 is adapted to connect between the frame 200, the shock absorber 300, and the wheel 400. The motor integration device 100 includes a rocker arm housing 1, an electric motor 2, a controller 3, and a gear module 4 (reduction mechanism). The wheel 400 is supported by the motor integration device 100 and connected to the frame 200 through the shock absorber 300. The electric motor 2, controller 3 and gear module 4 (reduction mechanism) are integrated on the rocker arm housing 1 to form a structure suspended from the frame 200.

The swing arm housing 1 is a cantilever arm located on the left side of the vehicle, responsible for supporting the weight of the vehicle and transmitting force during acceleration and deceleration. In this embodiment, the swing arm housing 1 is a generally elongated elliptical shell. One end of the swing arm housing 1 is hinged to the frame 200, and the other end is hinged to the shock absorber 300 (rear suspension system). Here, both ends of the swing arm housing 1 have pivot portions 19, which are hinged to the pivot portion 209 of the frame 200 and the pivot portion 309 of the shock absorber 300 by fasteners (bolts). The rocker arm housing 1 can swing freely between the connected shock absorber 300 and the frame 200 as the wheel 400 vibrates. Here, the rocker arm housing 1 is used with a single shock absorber 300 on one side of the vehicle, but is not limited to this. In some embodiments, the rocker arm housing 1 can be used with dual shock absorbers 300 on both sides of the vehicle.

The rocker arm housing 1 is a hollow housing made of metal (such as aluminum or aluminum alloy). The rocker arm housing 1 has a first accommodating area 11 and a second accommodating area 12. The first accommodating area 11 is a circular groove, and the second accommodating area 12 is generally a rectangular groove. In this embodiment, the rocker arm housing 1 has a side opening 15 and an outer cover 16 covering the side opening 15. The side opening 15 connects the first accommodating area 11 and the second accommodating area 12. The periphery of the outer cover 16 is locked to the rocker arm housing 1 at the periphery of the side opening 15 by fasteners, so that the rocker arm housing 1 becomes a sealed space to prevent external moisture or dust from entering. The outer cover 16 has multiple heat dissipation sections 161 corresponding to the area of the controller 3, thereby dissipating the heat generated by the controller 3 and the electric motor 2 when the vehicle is in motion, which may cause the temperature of the interior space of the rocker arm housing 1 to rise, and the heat is dissipated by the airflow on the surface of the multiple heat dissipation sections 161.

In this embodiment, the rocker arm housing 1 includes a partition 13 located between the first receiving area 11 and the second receiving area 12. The controller 3 includes a first substrate 31A and a second substrate 31B. The first substrate 31A (power board) includes power transistors (MOSFETs, IGBTs) and provides power conversion and motor driving functions. The second substrate 31B (control board) provides signal processing and motor actuation logic control functions. The second substrate 31B has multiple power posts 311, and the first substrate 31A has multiple through holes 312, with each power post 311 passing through each through hole 312. The electric motor 2 has multiple power lines 21, each power line 21 extending from the first receiving area 11 to the second receiving area 12 and connecting to each power post 311.

An electric motor 2 is disposed in the first receiving area 11 and is used to drive the wheel 400. The electric motor 2 includes a stator and a rotor located within the stator. In this embodiment, the motor integration device 100 further includes an end cover 25, which is fitted into the first receiving area 11 and covers the electric motor 2. The periphery of the end cover 25 is locked to the periphery of the rocker arm housing 1 at the side opening 15 by fasteners. The end cover 25 has a row of holes 251 through which the power lines 21 pass.

The controller 3 is equipped with a drive circuit and is located in the second accommodating area 12 for driving the electric motor 2. The controller 3 is positioned to the side of the electric motor 2 and connected to it. The controller 3 is externally connected to a battery and can convert the DC power from the battery into an electric current suitable for the electric motor 2. The electric motor 2 receives power from the controller 3, generates a magnetic field, and thus drives the wheel 400 to rotate. When the controller 3 sends current into the stator windings of the electric motor 2 and forms a rotating magnetic field, the rotor is connected to the gear module 4. Therefore, the rotating magnetic field generated by the stator drives the rotor to rotate, thereby pushing the wheel 400.

Please refer to Figures 2 to 4. Figure 4 is a schematic diagram of the appearance of the gear module 4 when assembled. Figure 4 also shows a first embodiment of the motor integration device 100. The gear module 4 (reduction mechanism) is disposed on the outside of the rocker arm housing 1 and is connected between the electric motor 2 and the wheel 400. The gear module 4 is separated from the electric motor 2 and the wheel 400. The gear module 4 is connected to the rotor of the electric motor 2, converting the high-speed motor output into low-speed, high-torque output, making it easier for the vehicle to start, climb hills, and carry loads, thereby adjusting the speed and torque to meet the vehicle's needs.

In this embodiment, the gear module 4 includes a cover 41 and a gear assembly 42 located inside the cover 41. The periphery of the cover 41 is locked to the outer wall of the rocker arm housing 1 by fasteners, so that the inside of the cover 41 becomes a sealed space to prevent external moisture or dust from entering.

Please refer to Figures 2, 5, and 6. Figure 5 is a side view of the motor integration device 100, and Figure 6 is a side cross-sectional view of the position marked A-A in Figure 5. Figures 5 and 6 also show a first embodiment of the motor integration device 100. The rocker arm housing 1 has a shaft hole 17 connecting to the first receiving area 11, and the electric motor 2 has a transmission rod 27 passing through the shaft hole 17. The gear assembly 42 is sleeved on the transmission rod 27 and connected to the wheel 400. Specifically, the gear assembly 42 includes a first gear 421, a second gear 422, a third gear 423, and multiple bearings 43. One set of multiple bearings 43 are respectively fixed in the grooves inside the cover 41, and another set of multiple bearings 43 are respectively fixed in the grooves on the outside of the rocker arm housing 1. The drive lever 27 is fitted with a first gear 421 and multiple bearings 43. Each bearing 43 is fitted on both sides of the first gear 421. The second gear 422 (reduction gear) has a large gear and a small gear. The second gear 422 (reduction gear) has a shaft portion 4221 fitted with multiple bearings 43. Each bearing 43 is fitted on both sides of the second gear 422. The first gear 421 meshes with the large gear of the second gear 422, and the small gear of the second gear 422 meshes with the third gear 423.

The cover 41 has a recess 411, and the third gear 423 has a driven rod 4231. One end of the driven rod 4231 is fitted with multiple bearings 43, each bearing 43 being fitted on both sides of the third gear 423 and the driven rod 4231. The other end of the driven rod 4231 passes through the recess 411 and is connected to the wheel 400. The first gear 421, the third gear 423, and one end of the rocker arm housing 1 are arranged along a horizontal axis (as shown in Figure 5).

The controller 3 in the above embodiment, comprising two stacked substrates (first substrate 31A and second substrate 31B), is merely an example and not a limitation. Please refer to Figure 7, an exploded view of the motor integrated device 100, which is a second embodiment of the motor integrated device 100'. The components of this embodiment are largely the same as those of the first embodiment, the difference being that the controller 3 in this embodiment includes only one substrate 31. The substrate 31 contains power transistors (MOSFETs, IGBTs), a microprocessor (MCU), current sensing, voltage sensing, or a communication module, etc., used to regulate the power supplied by the battery and precisely drive the electric motor 2. It converts the DC voltage of the battery into the pulsed current or three-phase AC power required by the motor. Furthermore, the substrate 31 has multiple power pillars 311, and each power line 21 of the electric motor 2 extends from the first accommodating region 11 to the second accommodating region 12 and connects to each power pillar 311.

In summary, according to some embodiments, by integrating the electric motor and controller together inside the rocker arm housing of the motor integration device, and combining the gear module outside the rocker arm housing, the integrated components are fewer and assembled in one place on the frame, which facilitates the maintenance or replacement of the entire motor integration device.

100/100’: Motor integration device 200: Frame 209: Hub 300: Shock absorber 309: Hub 400: Wheel 1: Rocker arm housing 11: First receiving area 12: Second receiving area 13: Divider 15: Side opening 16: Outer cover 161: Heat dissipation unit 17: Shaft hole 19: Rotating shaft 2: Electric motor 21: Power line 25: End cover 251: Drain hole 27: Transmission rod 3: Controller 31: Base plate 31A: First base plate 31B: Second base plate 311: Power column 312: Through hole 4: Gear module 41: Cover 411: Recessed hole 42: Gear assembly 421: First gear; 422: Second gear; 4221: Shaft; 423: Third gear; 4231: Driven rod; 43: Bearing

Figure 1 shows a schematic view of the motor integration device according to the first embodiment; Figure 2 shows an exploded front view of the motor integration device according to the first embodiment; Figure 3 shows an exploded rear view of the motor integration device according to the first embodiment; Figure 4 shows a schematic view of the gear module when assembled according to the first embodiment; Figure 5 shows a side view of the motor integration device according to the first embodiment; Figure 6 shows a side sectional view at position A-A in Figure 5; and Figure 7 shows an exploded view of the motor integration device according to the second embodiment.

100: Motor Integration Device

1: Rocker Arm Shell

11: First Detention Area

12: Second containment area

13: Divider

15:Side opening

16: Outer cover

161: Heat dissipation section

17: Shaft hole

2: Electric Motor

21:Power line

25: End Cap

251: Hole Array

3: Controller

31A: First substrate

31B: Second substrate

311:Power Pillar

312: Perforation

4: Gear Module

Claims (10)

A motor integration device is suitable for connection between a vehicle frame, a shock absorber, and a wheel. The motor integration device includes: a rocker arm housing, one end of which is connected to the vehicle frame and the other end of which is connected to the shock absorber, the rocker arm housing having a first receiving area and a second receiving area; an electric motor disposed in the first receiving area and for driving the wheel; a controller disposed in the second receiving area and for driving the electric motor; and a gear module disposed on the outside of the rocker arm housing, the gear module being connected between the electric motor and the wheel. The motor integration device as claimed in claim 1, wherein the rocker arm housing includes a partition located between the first receiving area and the second receiving area. The motor integration device as described in claim 2, wherein the controller includes a first substrate and a second substrate, the first substrate having a plurality of power posts and the second substrate having a plurality of through holes, each of the power posts passing through the respective through holes. The motor integration device as described in claim 3, wherein the electric motor has a plurality of power lines, each of which extends from the first receiving area to the second receiving area and connects to the respective power column. The motor integration device as described in claim 4 further includes an end cap that fits onto the first receiving area and covers the electric motor, the end cap having a row of holes through which each of the power lines passes. The motor integration device as described in claim 2, wherein the controller includes a substrate having a plurality of power columns, and the electric motor having a plurality of power lines, each of the power lines extending from the first receiving area to the second receiving area and connecting to the respective power column. The motor integration device as claimed in claim 1, wherein the side of the rocker arm housing includes a side opening and a cover covering one of the side openings. The motor integration device as described in claim 7, wherein the outer surface of the cover has a plurality of heat dissipation sections corresponding to the controller area. The motor integration device as claimed in claim 1, wherein the gear module includes a housing and a gear assembly located within the housing, the rocker arm housing has a shaft hole communicating with the first receiving area, the electric motor has a drive rod passing through the shaft hole, and the gear assembly is sleeved on the drive rod and connected to the wheel. The motor integration device as described in claim 9, wherein the gear assembly includes a first gear, a second gear, a third gear, and a plurality of bearings, the drive rod is sleeved on the first gear and the bearings, the second gear has a shaft portion that sleeves on the bearings, the first gear meshes with the second gear, the second gear meshes with the third gear, the housing cover has a recess, the third gear has a driven rod, the two ends of the driven rod are sleeved on the bearings, the driven rod passes through the recess and connects to the wheel, and the first gear, the third gear, and one end of the rocker arm housing are arranged along a horizontal axis.