Our testing methods are well above the standard norms

For several years we have carried out the whole engineering process of our bikes and their technology in Waldershof, Bavaria. This means product engineering as well as design and comprehensive tests in our in-house test laboratory. Prior to every new product development there is an in-depth analysis of the conditions and influences of the proposed field of use. This makes it possible to guarantee a maximum of safety and riding enjoyment. For our Hybrid Series we did detailed research with our e-measuring bike, working out the impact and strain on the frame of the power from the Bosch drive system in order to optimize it.

Forces acting on the frame are recorded with a device called a strain gauge. These gauges are placed on the relevant areas of the frame and then calibrated. The value measured is an electrical voltage that is related to the deformation of the frame. Using a data logger, the signals from the strain gauges are recorded during test rides so that we can see exactly what‘s happening to the frame as it‘s ridden.

The most important part of measuring are the real rides with different people on the measuring bike. To be able to record every possible extreme situation we let a selected group of people go on a defined test route. These data are critical for the future development, as depending on the type of rider behavior and body weight can vary immensely.

Saving and transfer of data is done immediately after the particular measured ride. Additionally, the riders‘ subjective impressions are discussed collectively and documented. A statistical evaluation and analysis of the results is carried out once all the data are in, which serves as an important basis for the construction part of the development.

Another important aspect is the correct frame geometry. To develop this we use our specially designed  geometry bike. Various riders test different configurations and are surveyed on their subjective impressions.

It‘s the product designer‘s task to design a modern shape for the product, based on the construction requirements. Our attention is directed to the integration of engine and battery, as well as detailed solutions for the carrier rack. Freehand sketches are still indispensible for product development.

There is an intensive exchange between engineers, designers and product managers to be able to live up to the claim of developing the best and safest bikes together.

As soon as the design is finalised we can start drafting the 3D model using CAD software. Here technical features as well as the visual design are developed. When we have the first 3D draft in our hands, the results from the measuring bike are used. The measured strains are simulated with the Finite Element Method on the CAD model. This process displays the strain on the material in a colored graph, allowing us to evaluate the durability of the proposed design.

After the final optimization of the simulated 3D model, a real 3D model is formed using plaster. This makes it possible to get a first impression of the bike itself. Additionally, forms and additional parts can be inspected in detail. Then a prototype frame is produced by our manufacturers in Asia. The aluminum prototypes are checked and discussed between engineers and designers. This ensures that all requirements are met.

In a next step every frame has to undergo rigorous testing in our in-house laboratory. The basis for this test are the generally applicable standards as well as the DIN plus standard. Our tests are influenced by results from the measuring bike, giving a test level that is well above the necessary requirements.
A very important and critical testing machine is the roller drum test. The complete system weight of 140kg (to represent a rider and luggage) must cover a set distance on the drum, rolling over a set of bumps and obstacles of different heights. For example, a ride over cobblestones or the edge of a curb.

As well as the roller test rig, which represents the test of a whole bike, extremely critical areas of the bike like the head tube or seat tube have to undergo extensive specific tests. Forces are applied to the frame using pneumatic cylinders.

The double chain stay solution in the rear triangle of our trekking and hybrid models gave outstanding results not only in FEM analysis but also on test rides.

The double chain stay solution in the rear triangle of our trekking and hybrid models gave outstanding results not only in FEM analysis but also on test rides.

To be able to offer the highest level of safety and quality, handlebars, stems, seat posts and brakes are thoroughly tested. For example, the brake test rig assesses consistency of brake power, temperature sensitivity and pad wear. From the results, appropriate items for the particular application are chosen.

All new developments represent our entire knowledge and our passion for riding. Effective team work from our engineers, designers and product managers made it possible for us to meet our customers‘ requirements for design, comfort, functionality, equipment and quality in one product. We are confident that this is worth every effort.