Research on Chain-less Transmission Scheme | Core advantages of research, development, production and application of pulley transmission system of Taicang Yihai metal bicycle

With the rapid upgrading of urban commuter bicycles, retro recreational vehicles, electric power-assisted bicycles and long-distance station wagons, the traditional metal chain drive has some pain points, such as loud noise, easy rust and oil pollution, frequent maintenance, and rapid wear and tear of sediment environment. The belt-type chainless drive system has become the standard upgrade direction for mid-to high-end bicycles. Taicang Yihai Metal Products Co., Ltd., as a high-tech enterprise, has been deeply involved in precision metal processing for more than ten years, focusing on the independent research and development, integrated production and supporting scheme of the whole bicycle pulley transmission system. The product line covers a full range of accessories such as driving tooth plate, rear wheel flywheel, eccentric five-way, tensioning structure, adjusting washer and supporting high-strength synchronous belt, and the products are supported by famous cycling brands at home and abroad such as Giant, KMC, Wahoo and Decathlon. Products are exported to Europe, America, Japan and South Korea. By virtue of precision machining technology, systematic matching design and strict reliability testing, js-aya.cn, a complete set of belt drive solutions with multi-scenarios, long service life and high adaptability, has been created.

1. Independent R&D system and optimization of transmission structure with multiple patents.

Yihai has set up a professional R&D laboratory for transmission parts, carried out special R&D layout for belt meshing characteristics, riding load impact, high and low temperature environment aging, mud erosion and other working conditions, and held a number of invention patents for pulley strength detection and tightening wheel testing system, which can simulate the real riding environment such as climbing heavy load, downhill unloading, rain exposure, and temperature difference between four seasons to complete reliability verification, and avoid common problems in the industry such as belt jumping, gear tooth wear and transmission deviation from the source.

The team made bionic optimization design for the exclusive tooth profile of the belt, matched the meshing trajectory of the aramid/carbon fiber core synchronous belt, optimized the stress structure of the tooth root, and dispersed the peak impact force at the moment of trampling; Synchronize and optimize the supporting structure of eccentric five-way and frame hook and claw, accurately compensate the belt installation tolerance, simplify the assembly and adjustment process of the whole vehicle factory, realize the integrated supporting design of the belt transmission system structure, and quickly load and mass produce without secondary structural transformation of the whole vehicle enterprise.

Second, the precise numerical control processing technology ensures that the quality of the pulley body is solid and stable.

The company adopts five-axis CNC machining center to produce aluminum alloy pulley components, and selects aviation grade 6061 and 7075 aluminum alloy substrates, which are processed by forging, aging stress relief, high-precision cutting and hard anodizing.

1. Dimensional accuracy control: the gear tooth shape and position tolerance and the installation reference hole position accuracy are controlled at micron level, the whole set of tooth plate and flywheel have excellent coaxiality, the running swing of the belt is extremely small, and there will be no unilateral wear when riding for a long time;

2. Surface wear resistance and corrosion resistance: multi-layer hard anodic oxidation treatment, high hardness, sand erosion resistance, rain salt spray corrosion resistance, and it is not easy to cause tooth surface scratch and oxidation whitening when used outdoors all the year round;

3. Lightweight hollow structure: Lightweight perforated design is made on the basis of ensuring structural strength. Compared with the traditional steel sprocket, the weight of the whole vehicle is reduced by more than 30%, and the pedaling smoothness is improved. At the same time, the exquisite appearance of the product is taken into account, which meets the design requirements of high-end bicycles.

Third, the five core application advantages of the whole system are suitable for all kinds of riding scenes.

1. The operation is quiet and smooth, and the riding experience is greatly upgraded.

Relying on the flexible belt meshing transmission, the hard impact friction of the metal chain is abandoned, and there is no chain noise and gear shifting frustration during riding, and the transmission noise is reduced by more than 15 decibels compared with the chain; The belt has its own micro-buffering property, which can filter the transmission vibration caused by road bumps, make urban commuting and long-distance riding more quiet and comfortable, and is also the preferred transmission configuration for high-end fitness training bicycles.

2, the whole process is clean and maintenance-free, which solves the chain maintenance problem.

The whole transmission system does not need lubricating oil, the belt will not be contaminated with sand and dust to form grinding slurry, and the trouser legs and frame will not be polluted by oil; The surface can be cleaned by rain, and there is no problem of rust, elongation and relaxation. The service life can reach 3-5 times that of ordinary chains. After loading, it is unnecessary to clean, oil and cut the chain for a long time, which greatly reduces the maintenance cost of personal vehicles and the after-sales maintenance pressure of the whole vehicle.

3. The transmission efficiency is stable and the power loss is lower.

Yihai optimizes the bite fit of the tooth surface, so that the belt and the gear teeth are closely engaged without slipping and tooth loss, and the normal transmission efficiency is stably maintained above 95%; Different from the disadvantage that the efficiency of the chain is continuously attenuated after being used for a long time, the attenuation range of the long-term use efficiency of the belt drive is extremely low, the pedaling power is directly transmitted, the force response is crisp, and the power loss of climbing and high-speed riding is smaller.

4, strong environmental adaptability, universal and reliable in multiple road conditions.

The anode anticorrosion treatment of pulley is matched with high-strength polyurethane synchronous belt, which can withstand the wide temperature environment of-30℃~120℃ and is not afraid of riding in rainy days, muddy roads and coastal salt fog and humidity environment; The wheel body has excellent impact resistance, and it is not easy to be damaged by gravel impact in bumpy road conditions. It is widely suitable for various working conditions such as urban asphalt pavement, gravel pavement, long-distance crossing, daily walking, and electric assisted heavy-duty riding.

5. Modularization is complete, supporting standardized and customized development.

Yihai has the production capacity of full-link accessories, and besides the core pulley, it produces a complete set of accessory parts such as eccentric five-way, adjusting gasket, locking kit, frame mounting tail hook and motor adapter sleeve, forming a one-stop supply system. It can not only provide general products with standard BCD specifications in batches, but also customize the development of non-standard sizes and shapes according to the frame structure, transmission ratio requirements and appearance color matching of the whole vehicle factory, so as to meet the development needs of different models such as power distribution mopeds, retro bicycles, freight bicycles and folding bicycles.

Fourth, strict quality control+full-cycle supporting services, empowering car companies to mass produce.

All pulley products have undergone load fatigue test, wear resistance and durability test, salt spray corrosion test and reciprocating trampling aging test before leaving the factory, and can only be put into storage and delivered after passing the 72-hour full-load simulated riding test; Relying on Taicang localized production base, with mature import and export qualifications, we provide sample development, small batch trial production and large batch delivery services for domestic vehicle manufacturers, and at the same time provide technical support such as assembly guidance, structural matching optimization and loading problem docking.

The company has participated in Shanghai Bicycle Show and Eurobike Europe Professional Cycling Exhibition all the year round, continuously meeting the global market demand and iterating product technology, and constantly optimizing the stability and compatibility of the belt drive system.

Scope of industrial application

1. Civil field: urban commuter bicycles, retro urban bicycles, folding scooters and parent-child leisure bicycles;

2, sports equipment: long-distance travel bicycles, Gravel Gravel bicycles, indoor intelligent fitness bicycles;

3. New energy category: transformation and upgrading of transmission systems of central motor, in-wheel motor electric bicycle and electric bicycle with cargo.

In the future, Taicang Yihai Metal will continue to deepen the technical iteration of bicycle belt transmission system, continuously optimize the product strength, lightweight design and supporting integration capabilities based on the precision metal processing, and help the domestic bicycle industry to upgrade to high-end, comfortable and maintenance-free with high-quality chainless transmission parts and components, so as to provide stable and reliable domestic transmission solutions for global cycling equipment brands.