Whether in sunshine or rainy weather, downhill or on the trail – a European E-bike manufacturer not only sets new standards with its continuously variable automatic transmission for E-bikes but also relies on the innovative connection technologies of the Hamburg-based family business WERNER WIRTH.

The development of the E-bike drive system presented the start-up with significant technical challenges. The goal was to efficiently and safely connect a variety of electronic components – from lighting and sensors to displays – with the E-bike.

Given the limited space available for connection technology on the E-bike, a particularly compact design was required. It had to provide enough space for all necessary connections without compromising on user-friendliness or functionality. Moreover, the solution had to be cost-effective to produce, despite high quality and performance requirements.

Special attention was paid to the robustness of the components against various environmental influences. Whether it was vibrations from different terrains, temperature fluctuations, or the effects of moisture and dirt – nothing should impair the sensitive technology in its function or diminish the joy of riding.

For the implementation of these requirements, the manufacturer chose the Hamburg-based family business WERNER WIRTH, known for its comprehensive expertise and many years of experience in the field of custom connector solutions and component protection.

The first step: Design and prototype development

A major challenge was the miniaturization of the connection technology. It was designed to seamlessly integrate into the limited space of the E-bike frame. Using advanced CAD technology and simulation-supported design processes, the Hamburg team developed a modular terminal with a high density of slots, which, despite its compactness, did not have to compromise on performance.

From material selection to manufacturing processes – expertise from a single source

To meet the specific requirements of the project, the WERNER WIRTH Group pooled its diverse competencies. In cross-departmental collaboration, high-quality and economical materials and assembly processes were selected. The robust casings and the TPE seals were produced using injection molding, while the waterproof sealing of targeted components was achieved through Hotmelt Moulding. From development to toolmaking for Hotmelt and injection molding technology to delicate manual assembly – the WERNER WIRTH team covers all processes within its own group of companies, offering the customer a comprehensive experience.

Testing, validating, and producing

To ensure that the technology did not detract from the joy of electronically assisted riding, numerous test series were conducted in advance. The components were tested for their behavior under vibration, moisture, and at various temperatures. After successful validation, production followed, with a focus on efficiency and cost control without compromising on quality. A final end control before the start of the logistics processes ensured that all produced units could withstand the high requirements.

Thanks to WERNER WIRTH, the start-up found a partner capable of implementing all requirements without compromise and delivering a highly specialized, space- and cost-efficient connection solution for the E-bike. The project once again highlights WERNER WIRTH’s competencies as an expert in custom solutions and clearly shows the advantages for customers when diverse competencies are bundled under one roof.