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The Complete Guide to How Electric Bikes Are Made

The Complete Guide to How Electric Bikes Are Made

There are many details to think about regarding electric bicycles and their functions. They serve a range of purposes and demands for millions of riders globally. While many modern users prefer their electric bike over their everyday vehicles or traditional cycles, the concept of an electric bike is still hard to grasp for some folks.

There is a lot that goes into constructing e-bikes, and we took some time to discuss what goes on behind the scenes. In this article, we take you through how some electric bikes are made and why these unique and versatile rides are assets to the modern world.

A Brief Look at The Assembly Process

On the surface, constructing an electric bicycle usually takes about eight primary assembly steps. These steps range based on manufacturing demands, location, and equipment. But overall, the process follows this general assembly flow:

Phase 1

The materials arrive at the manufacturing facility and receive a quality control inspection to ensure viability before assembly. Once the materials clear initial inspection, the metals undergo a cutting and molding process to prepare the bike's framework.

Phase 2

Each part receives a temporary assembly before welding. In the temporary assembly phase, the framework receives another inspection to ensure the design concept is precise for final outcomes. The vendor will confirm or deny the framework per their design concept during this step. When the temporary framework receives approval, the unit goes through a rotating belt and receives a coating of primer.

Phase 3

The paint specified in the vendor's design concept is applied, and all parts receive heat exposure to adhere the paint job adequately. After thoroughly drying, the frame and pertinent parts enter the labeling phase, where a product engineer applies the brand's labels and stickers according to the brand's directive.

Phase 4

The electric bike is now ready for complete assembly. A product engineer will assemble the frame's structure, pedals, lights, tires, chain system, and electrical cables based on the bike’s specifications. The battery and motor installation also occur during this assembly phase. The final step in basic construction is complete design quality control and shipping. Each electric bicycle is carefully prepared for shipping and goes to its vendor.

It's essential to note that each step in the process receives an inspection by a specified product engineer, and the bike cannot progress in production before receiving the go-ahead. This allows manufacturers and vendors to ensure bike authenticity and integrity before reaching the consumer.

In-Process Inspection Measures

The in-process inspection measures ensure the electric bike's reliability once the consumer receives it. These are often referred to as "IPI," and the individual that performs these is highly knowledgeable in parts verification. These engineers inspect every component from start to finish, including the raw materials, finalized product, and shipment preparations.

These in-depth inspection measures primarily focus on ensuring the electric bike maintains compliance with industry standards. Through maintaining the step-by-step procedure, any minor or significant anomaly or defect is detectable at the root cause, and prompt action can be taken. Whether it be an issue in material handling or an issue with the assembly process, there is an easier path to resolution.

In-Process Inspection Verification

The inspection process is lengthy and quite detailed. However, the procedure plays a significant role in ensuring overall customer satisfaction and industry compliance, as well as meeting design concepts and directives. The primary basis for the verification process includes highlighting and confirming client standards, in addition to industry regulations.

Overview of Client Requirements

The components and features meet the client's requirements and specifications. Accessories include lighting, basket, information cards, battery details and notices, complete user's manual, luggage bags, declaration of conformity, and keys. Confirmation the labels and stickers adhere to all the client's requirements, including battery and charger labels, compatibility labels, motor labels, warning guidelines, EPAC labels, and stickers properly attached to the framework.

Workmanship Standards

Overall visual checks verify the workmanship of the core working components. This includes the battery, wiring, chargers, saddle, chain system, tires, and chain cover. A series of function tests are necessary before consumer rides can begin. Function tests include overall rideability, brake checks, sound checks, proper tire inflation, motor function, and battery capabilities.

Packaging Verification

Final product packaging also receives an inspection. Vendors want to know their product receives care throughout the assembly process, including final packaging. The battery installation occurs with the system switched off. And the carton houses all necessary information, including the brand, model, part, and frame number, in addition to the barcode.

One of the most important facets of how electric bikes are made is the assembly of the frame. Regardless of bicycle style, needs, and classification, the frame receives the most attention to detail. The inspections surrounding the framework receive in-depth and hands-on quality control to ensure the bike can withstand all the other components and the rider.

Most Common Identified Defects

When the raw materials arrive at the manufacturing facility, one of the things that often gets left behind early in the process is the inspection of these materials. Many manufacturers assume their relationship with the materials vendor is strong enough to pass the materials as usable; however, this is usually the most common place of many minor defects.

Minor defects usually include things like scratches or chips, paintwork flaws, or gear adjustment issues. These are all cost-effective to resolve and don't slow down the production process too far.

More significant defects, such as visual or technical design flaws, are more challenging to navigate and resolve and typically cost everyone in the long run. Common major defects include denting in the materials or framework, missing materials or parts, imbalanced framework, incorrect labeling, or excessively noisy motors. While resolving these issues is not impossible, they certainly come with challenges.

If a manufacturer deems a defect urgent, this means the electric bike likely cannot or will not pass compliance standards and thus stops the production process altogether. This means the e-bike could be dangerous to riders and pose a series of safety risks. Usually, an urgent defect relates to mechanical or electrical issues.

Here at Voltaire Cycles, each one of our electric bicycles meets and exceeds industry standards and compliance regulations. We proudly offer our consumers industry-leading, award-winning BESV e-bikes with the highest level of performance ratings. These award-winning e-bikes outperform, outrank, and comply with each regulation set forth. Contact us today to get your hands on one of these exceptional rides!

The Complete Guide to How Electric Bikes Are Made
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