This urban hybrid bike platform integrates an internal torque-sensing electric assist system with a lightweight aluminum frame architecture. Engineered for municipal commuting and utility fleets, the platform bridges traditional pedal efficiency with reliable electric propulsion. Available for OEM/ODM customization, the chassis accommodates hub or mid-drive motor configurations with integrated down-tube batteries, satisfying EN 15194 and UL 2849 safety frameworks.
Key Product Features
Integrated Battery Architecture: Removable down-tube lithium-ion battery pack with internal thermal management and lockable security interface.
Torque-Sensing Assistance: Bottom bracket torque sensor delivers proportional power engagement within 50 milliseconds of pedal input.
Internal Cable Routing: Full internal routing through headset and chainstays protects control lines against moisture, road salt, and mechanical wear.
Modular Cockpit Interface: Handlebar-mounted OLED display featuring diagnostic error codes, USB charging output, and IP65 weatherproof rating.
Puncture-Resistant Footprint: 700c urban tires featuring 3mm Kevlar puncture-protection casing and reflective sidewall banding.
Technical Specifications
|
Parameter |
Specification Standard |
|
Frame Material |
6061-T6 Double-Butted Aluminum Alloy |
|
Motor Type |
Rear Hub Motor (250W / 45Nm) or Mid-Drive (250W / 80Nm) |
|
Battery Capacity |
36V 14Ah (504Wh) using Samsung / LG 21700 cylindrical cells |
|
Control System |
Sine-wave controller, CAN protocol communication bus |
|
Sensor Type |
High-precision bilateral torque sensor + cadence sensor |
|
Max Speed |
25 km/h (EU EPAC) / 32 km/h (US Class 1/3) |
|
Range |
60 km – 110 km depending on assist level and terrain profile |
|
Drivetrain |
Shimano Altus 9-Speed external derailleur or Gates Carbon Drive CDX belt |
|
Braking System |
Hydraulic disc brakes, 160mm rotors, dual-piston calipers with motor cutoff switches |
|
Fork Options |
Rigid 6061 Aluminum or 50mm travel suspension fork with lockout |
|
Payload Capacity |
120 kg (Rider + Cargo) |
Frame & Structural Design
The frame utilizes 6061-T6 aluminum alloy tubes shaped via hydraulic press forming to optimize stiffness-to-weight ratios at high-stress junction points. Headtube junctions feature gusset reinforcement, while rear dropouts are forged to withstand higher torsional loads generated by hub motors and disc brake calipers. All frame welds undergo 100% automated TIG welding followed by manual cosmetic smoothing and alignment verification on jig fixtures. Frame structural integrity complies with ISO 4210-2 fatigue and impact test standards.
Components & Configuration
Bafang or Shengyi brushless gear motors paired with hardened planetary gears designed for low acoustic output (<55dB).
UL-certified lithium-ion cells integrated with a Hardware-based Battery Management System (BMS) offering overcharge, deep-discharge, short-circuit, and thermal runaway protection.
Ergonomic dual-density Kraton rubber grips and wide polyurethane foam urban saddle mounted on a forged aluminum seatpost.
Integrated 40-lux front headlight and rear fender-mounted tail light wired directly to the main battery pack, controlled via handlebar keypad.
Applications
Municipal Commuting: Daily urban transportation across asphalt, cobblestone, and moderate incline gradients.
Micromobility Fleet Operations: Public bike-sharing and corporate station-based rental schemes requiring high mechanical durability and IoT tracker compatibility.
Last-Mile Logistics: Urban courier operations equipped with front/rear heavy-duty cargo racks supporting up to 25kg payload capacity.
Customization Options
Paint & Branding:
Custom Pantone powder coating, liquid paint finishes, water-transfer decals, and laser-etched headtube badges.
Powertrain Tuning:
Firmware parameter flashing for customized torque delivery curves, speed cutoff thresholds (25/32/45 km/h), and throttle integration where legal.
Component Tiering:
Flexible specification substitution across drivetrains (Shimano, SRAM, Microshift, Gates), braking systems (Tektro, Shimano, Magura), and tire selections (Schwalbe, CST, Kenda).
Accessory Integration:
Custom rear racks, front low-rider mounts, full-coverage aluminum fenders, and integrated frame lock provisions.
OEM & ODM Manufacturing
Facility Metrics: 45,000 m² manufacturing plant equipped with automated robotic welding cells, CNC machining centers, and 4 dedicated assembly lines.
Production Capacity: 15,000 units per month output capability with scalable shift scheduling.
ODM Engineering Support: In-house industrial design team providing 3D CAD modeling, FEA (Finite Element Analysis) structural simulation, rapid prototyping, and open-mold tooling development.
Traceability: Laser-engraved unique serial numbers on every frame bottom bracket shell linked to production batch records and component lot numbers.
Quality Control
Incoming Material Inspection:
Spectrometer testing for raw aluminum alloy composition verification and tensile strength validation.
In-Process Checks:
Torque-controlled pneumatic fastening for critical bolts, wheel truing tension measurement, and electrical resistance testing of wiring harnesses.
End-of-Line Testing:
100% functional dynamometer testing evaluating motor output consistency, shifting accuracy, braking deceleration rates, and sensor response times.
Laboratory Testing:
Salt spray corrosion testing (ASTM B117) for 500 hours on fasteners and frame coatings; UV degradation testing on plastic housings.
Packaging & Shipping
Packaging Configuration: 85% pre-assembled configuration packed in a double-wall corrugated carton (BC flute, 5-layer stacking strength).
Protection Materials: EPE foam cushioning blocks securing front fork, handlebar, and frame contact zones to prevent transit abrasion.
Container Loading Optimization:
• 20ft Container: Approx. 160–180 units (depending on carton dimensions)
• 40ft HQ Container: Approx. 380–420 units
Logistics Terms: EXW, FOB (Ningbo/Shanghai), CIF, or DDP shipping options supported with palletized or floor-loaded container configurations.
MOQ & Lead Time
Minimum Order Quantity (MOQ):
• Standard Stock Configuration: 50 units per model / colorway.
• Custom OEM/ODM Specification: 200 units per model.
Lead Time:
• Sample Production: 15–20 working days upon specification sign-off.
• Mass Production: 35–45 calendar days following receipt of deposit and confirmation of pre-production graphics.
FAQ
Q: What international safety certifications do your urban hybrid bikes carry?
A: All production models comply with EN 15194 (epac electrical safety and mechanical requirements) and ISO 4210-2 (cycle safety standards). Battery packs and chargers are certified to UL 2849, CE, and RoHS standards. Test reports issued by TUV Rheinland and SGS are available for review prior to order placement.
Q: Can we integrate our proprietary IoT tracking module into the frame?
A: Yes. The frame down-tube interior and battery housing offer dedicated internal cavity space with waterproof connector terminals (Julet or Higo waterproof plugs) to support third-party GPS trackers, IoT telemetry units, and smart-lock control boards.
Q: What is the standard warranty policy provided for B2B orders?
A: The manufacturing warranty covers structural frame defects for 5 years. Electrical components-including the motor, controller, battery pack, and display-are warranted for 24 months. A 3% spare parts allowance (based on total order value) is provided free of charge with bulk production shipments for rapid local after-sales service.
Q: How do you manage battery shipping compliance and hazardous materials regulations?
A: Battery packs are shipped separately or installed within the frame in strict compliance with UN 3480 / UN 3481 regulations for Class 9 dangerous goods. All shipments include Material Safety Data Sheets (MSDS), UN38.3 test summaries, and certified DG packaging required for ocean or air freight.
Q: What is the protocol if a component defect rate exceeds acceptable thresholds?
A: Our quality agreement establishes an acceptable quality limit (AQL 2.5 for major defects, AQL 4.0 for minor defects). In the event of a documented component failure exceeding standard thresholds within the warranty window, replacement parts are dispatched via air courier within 7 business days following photographic or diagnostic evidence verification.
Q: Can you handle regional regulatory variations for electric assist speeds and throttles?
A: Yes. Motor controller firmware is programmable to match destination market regulations-such as 25 km/h max speed without throttle for the EU market, or 32 km/h with optional thumb throttle activation for the US market. Compliance programming is locked at the factory level according to client specifications.
Request a Quote
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