Source: Electrek

Exemplifying the rapid innovation within the electric bicycle industry, LEVA-EU member Bafang, a major manufacturer of e-bike components, has undergone a remarkable transformation over the past five years.

Electrek recently visited the company’s production facilities in China and explored its new expansive manufacturing facilities and groundbreaking advancements in electric bicycle technology.

Comprehensive component production

Bafang has long been a significant force in the e-bike sector, producing a wide range of components integral to electric bike drive systems. Since the author’s initial visit in 2019, the company has substantially expanded its operations, now encompassing full e-bike battery design and manufacturing. The author described the contrast between their initial visit in 2019 and the latest tour, five years later, as “mind-blowing”. This expansion necessitated a move to a larger, state-of-the-art facility, highlighting the company’s commitment to innovation and vertical integration.

Revolutionary research and development

The journey begins in Bafang’s Research and Development (R&D) department, where a team of engineers and designers meticulously crafts the next generation of e-bike components. One of its impressive advancements is the development of internally geared hubs (IGHs) with integrated hub motors. Known as the Bafang Gear Variable Transmission (GVT) line, these components combine the clean, low-maintenance design of IGHs with the power and efficiency of electric motors. This innovation allows for automatic, cable-free shifting and opens new possibilities for e-bike design.

Rigorous testing and quality assurance

A rigorous testing process ensures the durability and reliability of Bafang’s products. Its motors undergo pressure, drop, and vibration tests, while soundproof rooms and electromagnetic compatibility chambers allow engineers to fine-tune performance and safety. The company has also developed a proprietary gear material, offering enhanced strength and reduced noise compared to traditional nylon or steel gears.

State-of-the-art manufacturing

On the factory floor, quality inspections are paramount. Components are scrutinized with micron-level precision before entering largely automated assembly lines. Robotic systems now handle tasks such as applying grease, winding copper wire for motor cores, and assembling motors with greater speed and accuracy than manual methods. Notably, new vacuum systems at soldering stations enhance worker safety by extracting fumes directly through the workstation surfaces.

Battery production: A bold new frontier

A standout feature of Bafang’s expanded facility is believed to be its battery factory. Traditionally the domain of specialized battery manufacturers, Bafang’s decision to produce its own high-quality battery packs represents a significant leap forward. The process begins with stringent cell testing, followed by robotic sorting and ultrasonic welding to create larger battery assemblies. After extensive performance testing, each battery pack undergoes a full charge and discharge cycle before packaging and shipment.

A one-stop shop for e-bike OEMs

The scale and sophistication of Bafang’s operations underscore its emergence as a comprehensive supplier for e-bike original equipment manufacturers (OEMs). By producing nearly every component of an e-bike drive system in-house, Bafang has positioned itself as a global leader in the electric bicycle industry.

Shaping the future of electric mobility

As the e-bike market continues to grow, Bafang’s commitment to research, innovation, and production excellence looks to play a major part in shaping the future of electric mobility. The remarkable advancements witnessed during this recent factory tour serve as a compelling indicator of what lies ahead for this dynamic and rapidly evolving sector.

Elektrek’s Bafang video tour can be accessed here.