EMEC Prototyping’s new acoustic test bench sets a new standard for noise detection and NVH

The noise generated by bicycles goes beyond a simple nuisance. Rattling, clicking, or high-frequency vibrations directly shape how riders perceive quality—especially on high-end e-bikes and high-performance bikes. To tackle this, EMEC Prototyping developed a new acoustic test bench, successfully qualifying it alongside a scientific partner.

Acoustics as a development factor

Most conventional test rigs mainly focus on durability, load cycles, or structural strength. This new test bench, however, is specifically designed to analyze noise generation and noise transmission. The goal is to measure, analyze, and systematically reduce acoustic issues at an early stage of development under reproducible conditions. Alternatively, engineers can use the data to shift noises into frequency ranges perceived as less disturbing.

“In bicycle development, acoustics are often evaluated very late—usually when changes are expensive or nearly impossible to make” explains Dr. Beckert, CEO of EMEC. The new test bench bridges the gap between design, prototype, and final product.

The testbench tests complete bikes as well as individual parts like the drive unit or drivetrains. A major advantage is the inclusion of real riders during testing, enabling an evaluation that reflects everyday riding conditions.

Realistic test conditions

The acoustic test bench simulates real riding scenarios, including road vibrations, drive system load changes, and specific vibration inputs. Whether it is the frame, motor unit, bearings, or accessories, the setup analyzes individual components and complete assemblies.

By using high-resolution sensors for both structure-borne and airborne noise, the mechanically decoupled setup catches even subtle noise phenomena and is clearly assigned. This precision allows engineers to pinpoint the exact cause of a noise, such as resonance, friction, or a specific design flaw.

Validation with Fraunhofer IWU

A key milestone was the joint validation with acoustics experts from the Fraunhofer Institute for Machine Tools and Forming Technology (IWU). They contributed with their expertise in noise and vibration measurement and system-level NVH (Noise, Vibration, and Harshness) analysis. Throughout the program, they confirmed the bench's accuracy, repeatability, and readiness for industrial use.

The results confirm that the test bench provides reliable, comparable data for development, benchmarking, and pre-series testing.

Added value for manufacturers and suppliers

For bicycle and scooter manufacturers as well as component suppliers, the acoustic test bench offers clear benefits:

• Early noise optimization at the prototype stage
• Objective comparisons between different motors or designs.
• Faster development with fewer iteration loops.
• Higher perceived quality for the end user.