Integration at core of drive system development

To optimise the riding experience, several parties have introduced integrated shifting technology into the market this year. Alongside performance benefits, ease of maintenance is another factor driving the development of integrated technologies. In a highly competitive market, other drive system manufacturers have developed high-grade products, but need financial support to bring them to market.

SRAM partners with Brose on e-MTB drive Eagle Powertrain

SRAM’s long expected introduction of an e-bike dive system came in September 2023. Remarkably and without giving any explanation, SRAM announced that the e-MBT drive unit named Eagle Powertrain is powered by Brose.

The Eagle Powertrain is presented as ‘a complete, seamless and holistic e-MTB system designed to turn on uninterrupted flow.’ It is indeed radically simple, with an unmatched integration of the Eagle Transmission and AXS controls. These provide an ultra-clean and intelligent wireless cockpit. But also, the Eagle Powertrain battery streamlines the interface between battery and drive unit. The toggle simply provides two modes: range and rally.

According to SRAM, “the Eagle Powertrain Drive Unit has been engineered with a reimagined power delivery tune that replicates a far more natural pedalling experience. It’s a feel only made possible by our holistic approach to the entire system, where we called upon the world’s best motor hardware (Brose e.d.) and paired it with Eagle Transmission. It’s an approach that took learnings from short-comings that plague other motors.”

The Eagle Powertrain battery comes in 2 versions. The 630W Compact size weighs 3 kg features 21,700 cells and a tilt-in-mount. The 720W Full size weighs 4.1 kg features 21,700 cells and a slide-in-mount. The mid-motor provides torque up to 90Nm and 680W peak power.

Intra Drive nearing market launch of integrated gearbox and motor

Since displaying at Eurobike in 2021, Intra Drive has focused on building a European supply chain and industrialising its e-bike motor unit with multi speed gearbox. Now to support bringing its 8-speed integrated drive unit to market, the B2B company has launched an equity crowdfunding campaign.

The latest version of Intra Drive’s durable drive unit features tighter integration into the Shimano EP8 mount, a redesigned motor with improved efficiency which is easier to manufacture, a lighter gearbox, integrated electronics, and a new display.

Intra Drive have developed the product through to TRL level 7, have fully working prototypes, filed two patents, and have gained interest from several bike brands. Through the equity crowdfunding campaign on Crowdcube, Intra Drive is focusing on finding financial partners who will help bring the product to market. "We look forward to offering pre-production units to bike brands in the coming months," says Mark Ravilious, Intra Drive Founder.

Intra Drive's 8-speed gearbox offers an 470% gear range, which it says is 20% more than the 7-speed Valeo system. The company says the sealed gearbox offers reliable shifting in harsh environments and dramatically increased service intervals compared to derailleur gearing. Intra Drive is applying a circular economy model to achieve the lowest environmental impact possible over the lifetime of the product. This means repairability, availability of spare parts, and long-term support.

Pinion unites motor and gearbox in new e-drive system

Gearbox specialist Pinion has developed a new product bringing together the motor and gearshift in one unit. "The Pinion Motor.Gearbox.Unit (MGU) is the e-bike technology of the next generation," the company stated prior to the launch at Eurobike. MGUs are available in the Pinion E-Line, as E1.12 and E1.9 versions and as E-Speed versions E1.12S and E1.9S.

The Pinion MGU aims to change the bad shifting performance, high wear, and high maintenance costs that comes from using a gearshift and motor from different manufacturers which are forced to work together. It combines a powerful electric motor with proven Pinion gearbox technology and electric shifting of up to 12 gears in a compact package.

Launch partner brands with the Pinion E-Drive System for the 2024 model year include Rotwild, Simplon and Bulls for E-MTBs; Kettler, Flyer, Tout Terrain, Pegasus, Zemo and I:SY for e-trekking bikes, e-cargo bikes as well as e-compact bikes.

Using a modular approach towards designing the Pinion E-Drive System allowed Pinion to develop several distinct configurations and versions of the MGU. Depending on the individual use-case, each version has either 9 or 12 gears and is actuated by electric shifting. Furthermore, the software of the system comes in two base tunes - 'Comfort' and 'Performance'.

All MGU versions are based on 48-volt technology and offer approximately 85 Nm of torque compared to conventional motors without integrated gearbox. However, due to the integrated gearbox, the output shaft values are not directly comparable with those of ordinary mid-motors. In the first four gears, the MGU delivers up to 160 Nm of torque to the rear wheel.

Mavic presents e-bike motor but needs investor for market launch

French manufacturer Mavic has developed a mid-motor targeted at the road bike market, the X-Tend. According to Mavic, the product is fully engineered and ready for mass production. However, the French family company lacks the resources to take the product to market.

“As soon as we have found a partner, we can start tomorrow,” explains Jean Michel Bourellier, co-CEO of Mavic. However, it will still take until 2025 or 2026 before the product will be available for the OEM market. He also underlines that he is not open for a take-over of the product by a third party. “We will not sell the concept. Our core business is hard and softgoods, that’s what we are good at. Our aim is to build up this competence in the e-bike market as well.”

Specifying the Mavic X-Tend drive train, the road-bike’s weight can remain under 10 kg as the BMC developed test bike proved. The system in total weighs 3.2 kg including the BB bearings and integrated power-meter. This power meter is integrated in the drive unit and gives better responses than the standard sensors. The drive unit is made up of a 4500-rpm high speed custom brushless motor, a patented cycloidal reducer and a frictionless clutch mechanism.

Mavic claims that the high efficiency and low waste of watts and energy makes it possible to get to a range of up to 3,000 meters elevation gain with the 360 Wh integrated battery. Specifying the X-Tend requires only a limited change of existing frame designs. All what’s needed is an oversized bottom bracket design as the motor cylinder measures 87 mm. This non-disruptive frame design makes the system also very suitable for MTB. Also, the Q of 146 mm is in line with the regular sizes.

Decathlon integrates motor and gears in newest e-bike

Decathlon, known for its development of mid-end e-bikes and bicycles, has added an e-bike with automatic transmission to its range. "This is not just a bike. It's a statement of innovation and design that is set to change what we know about cycling," the French retail giant states.

Co-developed with Belgian startup E2 Drives, Decathlon’s new e-bike features a combined motor and gears in one mid-drive unit. This follows hot on the heels of similar products from Pinion and Revonte which was declared bankrupt on 6 October 2023. However, at a price point of €2,990, Decathlon has the opportunity to bring an e-bike with a high level of technology to a broad European market.

Besides, automatic transmission, the motor of the B’Twin LD920E offers 65Nm torque with a gear range of 265%. The 702Wh battery provides a range up to 150 km. Other features include an integrated full-colour display with a built-in USB-C port and GPS location tracking via a smartphone.

“I am filled with pride in what the Decathlon team has been able to achieve,” says Decathlon CEO Barbara Martin Coppola. “It is more than a product; it’s a prime example of our enduring commitment towards a healthier, greener, and more connected world.”

Newcomer Aximo partners with Biketec's FIT system on hub motor

German automotive supplier Hirschvogel Automotive Group marked its entry into the micromobility field at both IAA Mobility 2021 and Eurobike 2022. At this year's Eurobike the first e-bike drive system as part of a component platform for cargo bikes and urban mobility, created under its own brand name Aximo, caused a stir.

"Aximo offers installable system solutions that are manufactured in-house by us in Kaufbeuren, Germany" sales and marketing micromobility manager Adrian Hellmann confirms. New is a rear wheel hub motor, for which Swiss FIT E-bike System Integration maker Biketec GmbH was brought in as a partner. With FIT on board Aximo can offer a complete drive system, for which the Germans specifically developed a direct-running rear wheel hub motor. To date, this is to be offered for 25 km/h e-bikes but according to Hellmann it is also powerful enough for 25 km/h e-cargo bikes.

In addition to the e-bike drivetrain, Aximo continues to rely on a drive axle, which Hellmann says is already used on the e-trike being offered by bike supplier Cube. As part of the development work for the drive axle, Aximo has also developed, among other things, a differential gear for multi-track cargo bikes. According to the supplier, this is "delivered ready for installation, is maintenance-free in operation and has a mileage of 35,000 km."