One pedal and then another. Five words are enough to summarize the traction mechanism that allows you to move on a bicycle, be it electric or lung. Everything is easy, silent, ecological and extraordinarily efficient as soon as the human and the machine balance forces. When that happens, the result transcends the simple sport to transmute in a way of life. Thanks to electrification, the passing of the years do not slow the practice of cycling. In this universe of sensations, technology and sustainability, Mahle Smartbike Systems, manufacturer of components and systems for some of the most innovative electric bicycles in the world is handled.
Based in Palencia, Mahle’s bicycle branch designs hardware and software solutions for manufacturers, distributors and users of electric bicycles. In its most advanced processes, the company is accompanied by Siemens’s technology, a partner with whom Simcenter Scadas XS and Simcenter Testlab has created, a development that allows Mahle engineers to “capture a complete image of the traction performance, without any detail being overlooked.
Federico López, NVH Mahle engineerexplains that the Simcenter SCADAS XS It is easy to configure, with always precise measurements. In addition, the fact of being able to configure and supervise the entire system from a tablet provides a relevant advantage on the ground. In that sense, “the Simcenter Testlab Neo offers considerable time savings in the test process. In fact, characterize a complete traction system now has only one hour, while with other tools it could take up to five. That is, the saving of time is encrypted in 80%. This acceleration of the test process It allows the company to market its products faster and maintain a high level of quality. As the demand for electric bicycles grows, this efficiency will be crucial to help Manufacturers remain competitive and continue to innovate in the electric mobility market.
Federico López also values the advanced audio reproduction option as an essential function to filter blades and frequencies. “We use audio reproduction for aerial and structural measurements. This helps us understand how traction will sound if we increase the contribution of specific orders or eliminate certain frequencies.”
SIMCANTER ADJUSTRY SYSTEM
For the final tests, Mahle uses the Simcenter Addis system, with the aim of checking the traction units and defining the limits of an approved or not approved result. “Whenever components are changed to reduce NVH (noise, vibration and hardness), we update the boundaries of approval in Simcentr Advis to reflect it. It is an excellent solution to identify the problems and discard the units that fail to comply with our strict standards.”
On the other hand, according to Siemens sources, “by integrating predictive analysis into the test process, engineers can identify possible NVH problems in early design, which allows more proactive adjustments to be made.” In this sense, López adds that these solutions are essential in Mahle’s work in helping “clearly understand where the units have failed and where noise levels are acceptable.”
In turn, López emphasizes that The close collaboration with Siemens has been important in the success of his team. “Our Siemens specialized engineer gave us an excellent training about Simcenter Testlab. He explained the processing of the firm, how We started using Simcenter Advis, we have the Siemens support to guarantee its compatibility with Simcenter Testlab and help us obtain maximum value of the product. “
The same sources affect that “constant cooperation between Mahle and Siemens is a testimony of the power of collaboration to boost innovation. Working together, they expand the limits of the possibilities in electric bicycle technology. This collaboration also ensures that consumers receive products of the highest quality available in the market.”
Siemens’s experience in simulation also contributes to the common cause. In this way, “to accelerate the development process, Mahle intends Add Simcenter’s simulation tools to your simcenter test solutions. With the simulation, we were able to check the frequencies of the gears between the teeth without having to manufacture the set of gears, “López explains.” We could also create a virtual model of the housing to predict acoustic radiation before building prototypes. This will allow us to try many more design ideas much faster and cheaperwhich will result in even better products. In this process of expanding the use of simulation tools, physical tests are essential to ensure that the models are realistic and precise. “Therefore, the incorporation of simulation implies a turning point for the company since we can predict the performance results without physically build each iteration, with reduction of costs and development deadlines.
The next step will be to integrate the potential of artificial intelligence into all the above. “During the tests, we collect large amounts of data, but we have no time or resources to analyze them in detail,” says López. However, “we hope to take advantage of Simcenter’s functionalities to automate part of the analysis of these huge data sets and get new knowledge about how to improve designs.”
The next fair Hannover Messe 2025which will be held in the first week of April, the Siemens stand will dedicate a corner to bicycle technology, where you can see different technological solutions that we have applied in companies in the sector. Among them are Rotor Bike Components developments, world manufacturer of bicycle components, with products designed by cyclists for cyclists. All your references are designed to provide maximum speed, efficiency and comfort to cycling experience.
The interest in offering solutions with the best technology to improve cycling performance It combines with the challenge of producing more than 250,000 components a year with more than 500 different references of road bicycles, triathlon, Mountain Bike and Ciclocross. To maintain innovation, the company considers essential to align the efforts of the Rotor Bike Components Department with the manufacturing professionals of its sister company, EDR System.
Experience is a degree, since, in the 90s, Edu System already became the first company in Spain to use aluminum and titanium for the manufacture of bicycle partsand is currently a technological leader in Computerized Numerical Control (CNC). In its case, the company works with Siemens since 99% of the Bike Components rotor designs are developed with NX CAD. In this way, “the engineering equipment has six licenses and uses the software modeling and drawing tools to make its 3D designs, generate documents and draw pieces of parts and assemblies,” says company sources.
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