Pushed, a brand new firm spun out of CeramicSpeed, has proven its modern Orbit Drive transmission for the primary time at Eurobike, Frankfurt. The working prototype of this all-in-one gearbox eBike motor weighs a claimed 4.6 kg – together with all gears, electronics, and energy supply to the rear wheel – and could be configured to supply as much as 90 Nm torque.
The design takes inspiration from techniques discovered inside hybrid automobiles – just like the Toyota Prius, for instance. Therein, planetary gears are utilized to mesh the enter of the combustion engine with the enter of an electrical motor, to ship energy to the car.
Pushed are taking that idea and, as a substitute of utilizing flat, planetary gearing, their Orbit Drive depends upon a rotating ball-like mechanism that delivers a variable pace ‘bevel differential’. Although the structure is definitely not novel, its utility in eBike expertise, is.
We’re instructed by Pushed, “It is a sport changer for the e-bike phase, bringing the very best stage of effectivity (extra battery vary), a extra nice using expertise, virtually zero-maintenance, and a bolt-on resolution for e-bike producers”.
Right here, Pushed’s Head of Engineering, Ryan Norris, takes the time to clarify the mechanism utilizing a neat 3D printed mannequin of the idea. And, he does so in phrases that don’t require a PhD in mechanical engineering to be able to comprehend.
Pushed Orbit Drive All-in-one Gearbox eBike Motor
The Pushed Orbit Drive is just a little additional alongside in its improvement course of than the above 3D printed mannequin would possibly counsel. The corporate has a working prototype they are saying is considerably extra environment friendly in its vitality utilization than any manufacturing eBike motor in the marketplace at the moment – upward of 85%, is the declare.
Not solely that, however upkeep intervals are set to as soon as each 10,000 miles, with solely an oil change required at that time. Clearly, such a design boasts some critical benefits over generally out there eBikes that rely on a motor and a completely separate derailleur-operated drivetrain – the pitfalls of which many people know all too properly.
Pushed inform us their system additionally provides a smoother journey expertise, with an computerized mode providing step-less shifting with gearing robotically adjusting pace, with the help motor complementing the rider’s enter. Guide mode can also be attainable, permitting riders to shift by way of gears as they’d on what Pushed are calling a “legacy bike”, i.e. an everyday bike.
Along with the claimed increased effectivity over comparable techniques, we’re instructed the Orbit Drive additionally has a regenerative braking characteristic to compound that.
Pushed plans to supply three variations on the Orbit Drive to its OEM prospects:
- Direct Drive – this configuration makes use of a shaft drive to ship energy from the Orbit Drive to the again wheel. That is the model’s most effective unit and it’s totally enclosed
- Chain Drive – the Orbit Drive with a series, partially enclosed
- Belt Drive – the Orbit Drive with a belt, partially enclosed
We requested Brian Baker, CEO of Pushed, why has nobody carried out this but. His reply…
“Certainly one of our advertising pitches is – why hasn’t anybody carried out this? I’ve been the CEO for one 12 months, and I would not have a solution for that. Everybody took what they’re doing at Toyota, on the Prius, and at Stellantis for instance – these are all flat planets and solar gears. All we did was take the planet and do this [make it that 3D orbit shape]. Now, it matches proper in the course of a q-factor, and we are able to get a 1:1 ratio out of the motor. We don’t need to downshift the motor, so we are able to use smaller motors, and so this complete factor works fairly a bit higher than a flat, planetary system”.
Pushed has extra expertise packed into there, too. In contrast to most eBike motors in the marketplace at the moment, this one lacks a torque sensor, not less than within the conventional sense. Pushed maintain a key patent for a sensor-less torque sensor.
CEO, Brian Baker, explains…
“There’s an algorithm we’ve developed based mostly on how a lot torque you’re placing into the system – and thus how a lot torque the motor sees – from which you can calculate the pace, so that you don’t even want sensors in any respect“.
Ryan Norris continues…
“We’re utilizing the electronics of every motor, and the way they speak to one another. So, after they sense you urgent down on the pedal – they understand it inside about 40 ms, and we’re gonna get that all the way down to about 20 ms, in order that’s as quick as an everyday torque sensor is. So, we don’t want the torque sensor. And torque sensors are literally fairly costly, so we’re truly fairly excited that this algorithm works. It’s nothing new. It’s utilized in industrial mechanical design on a regular basis however nobody has ever used this within the bike trade earlier than”.
How a lot will the Pushed Orbit Drive truly price eBike producers?
We’re instructed that, by way of the Journey Share market, the Orbit Drive will are available at a middling worth level – greater than the $800 USD that the most affordable choices go for, however lower than the $1,500 USD that higher-end choices go for.
Brian goes on to inform us he’s assured that gearbox eBike motors of this design, and comparable, will turn into the most typical design available in the market over the subsequent 10 years.
Certainly, with the launch of Pinion’s Mission ON:E eDrive earlier this week, the trade definitely appears to be urgent on with built-in options to shifting and help. Doubtless, we’ll see many extra such choices on show within the huge halls of Messe Frankfurt this week.
