Test bench for Pedelecs
Client: Germany's Leading eBike Producer
The client is Germany's largest bicycle manufacturer and a leader in the eBike market. Several hundred thousand bicycles and eBikes are produced at the northern German site. The broad product range includes high-quality mountain bikes, racing bikes, trekking bikes, city bikes, cross bikes and children's bikes. The customer also has its own leasing brand, eBike insurance and other mobility solutions.
Brief
The bicycle manufacturer wants a performance test bench for current and future testing and development services for the dynamic development of the pedelec market and to ensure quality during and after development.
The enormous growth in the area of electric bicycles and the increased requirements for their approval have generated the need for a flexible test system. Derby Cycle specified the system as a test bench for a complete system, i.e. a complete bicycle. The main concern was flexibility in terms of performance development and variability of the test programs. In addition, the set-up time of the test stand was to be kept to a minimum so that different bicycle models could be compared quickly.
Challenge
The challenge during implementation lay in the selection of suitable components. A high power performance of up to 2 kilowatts had to be achieved as well as a power resolution of an R200 range test (ZIV certificate for precise and reproducible determination of the standardized range R200). In addition, the control software should be suitable for laboratory and test operation as well as for automatic programs.
EMEC has designed a platform for different performance classes based on an industrial controller from Beckhoff. The modular Plug&Play system allows the roller test stand to be flexibly adapted to the needs of other customers. For electric bicycles, for example, the braking power reaches up to 2100 watts and a rolling speed of 45 km/h. This means that S-Pedelecs can also be tested up to their performance limits. In addition, a pedal crank drive was developed that allows power to be applied to both sides. The pedal drive was programmed in such a way that it is possible to reproduce pedaling behavior. In order to be able to test everything from children's bikes to high-end mountain bikes, the pedal drive has a power output of up to 1400 watts and 120 Nm torque at a maximum cadence of 150 rpm.
Thanks to a flexible clamping system, a bike can be set up in just a few minutes. The test and validation programs range from ready-made tests such as the R200 range test to freely specifiable special tests. Depending on the test job, data acquisition includes the physical variables of voltage, current consumption or temperature behavior. The entire CAN protocol can also be recorded and evaluated.
Flexible test bench solutions for your goals
With our offers to buy or rent test benches, we support you in achieving your goals. The individual design of your test bench enables dynamic and efficient product development, series production and quality assurance. Get in touch with our team!
Results
Derby Cycle - as well as other customers - are able to test and evaluate existing systems in the shortest possible time by using the e-bike test bench. New drive systems can also be tested and validated in-house. This allows technical knowledge to be gained at an early stage, which can then be incorporated into the subsequent series production. Potential in quality management and assurance can thus be fully and directly exploited.
Quote from Derby Cycle: "Thank you very much for the complex implementation, I think together we have implemented one of the best test benches on the market"
Thanks to the modular design, the test stand can be extended to a 4×4 system, which can be flexibly adjusted in track width and axle width. All rollers are controlled individually, which allows complete variability in the functional test. In addition, the EMC test stand variant can also be used in an EMC measuring chamber.
Roller Test Bench - Your Advantages at a Glance
- Customized Test Bench Solutions: Tailored to meet your specific requirements and needs
- Flexible Systems: Easily adapt roller test bench measurements to accommodate a wide range of vehicle types and models
- Comprehensive Testing Options: From standardized procedures, such as the R200 range test for e-bikes, to fully customized testing solutions
- Efficient Test Execution: Achieve fast and precise results with our flexible clamping system
- Innovation and Expertise: Leverage our cutting-edge technology leadership and extensive knowledge in advanced test bench systems
- Real-World Simulation: Accurately replicate riding conditions with our HIL (Hardware-in-the-Loop) test benches
- Enhanced Safety and Durability: Stationary testing at our facility minimizes wear and mitigates safety risks
- Standard-Compliant Testing: Ensure regulatory compliance, including tests adhering to eKFV standards for electric vehicles
Contact us!
Describe the requirements for your project, the test bench or the measurements without obligation.
Our experts will check your request and contact you.
EMEC-PROTOTYPING GmbH
Dölzschener Straße 47
01159 Dresden, Germany
Phone: +49 (0) 35143873280
Fax: +49 (0) 35142442586
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