The Steinbeis Transfer Center Innovative Drive Engineering and Waste Heat Recovery in Aalen, under the management of Prof. Dr.-Ing. Markus Kley, has joined forces with H+B Hightech GmbH (Adelmannsfelden) to develop a test rig for testing bicycle hub gears that gives the company partner a competitive edge. This outstanding collaboration has been rewarded: the project team receives the Steinbeis Foundation's Transfer Award - Löhn Award 2023.
H+B Hightech has been a specialist in high-precision engine components used in combustion engines since 2014. The medium-sized company from Adelmannsfelden is now also applying its know-how to the bicycle market under the brand name 3X3. The innovative, hi-tech bicycle components offered by this company are manufactured in H+B Hightech production facilities. A central element of its brand is an internal-gear hub system called 3X3 NINE. To develop a rig for testing bicycle gears, the firm sought expert help from Innovative Drive Engineering and Waste Heat Recovery (IAA), the Aalen-based Steinbeis Transfer Center specialized in the development and testing of drive units.
The newly developed test rig uses a motor to drive a belt pulley via a propeller shaft, which is supported by a bearing block. The test gearbox is operated via belts and pulleys attached at the points of input and output. It is also held in place by a fixed axle in the same way as a bicycle. Two measuring flanges are used to determine revolution speeds and torque around the bearing block. The test rig was designed purely as a testbed for bicycles, and overall the equipment can run for 45,000 km. The internal-gear hub system can be driven via a belt or chain. The gear units can be changed quickly and flexibly thanks to a rapid-release system made to mirror the back end of a bicycle.
Because the gear unit will be available as both a manual rotary shift system and an electric shift system, it was necessary to develop an electromechanical shift actuator. In addition to analyzing the durability of the gear system, the Steinbeis experts also conducted studies to determine the force required to shift gears and the level of shift torque.
Compared to existing test rigs, which evaluate entire bicycle wheels, the hub test rig offers the advantage of minimizing set-up times. It also makes it possible to try out different gears directly on the test rig. The newly developed testing unit is thus predestined for the development of new internal-gear hubs.
Thanks to detailed preparation work, the precise testing technology offered by the Steinbeis experts, and the excellent degree of interplay between the skills of the project partners, in July 2002 H+B Hightech was able to unveil the 3X3 NINE internal-gear hub to the public – a year ahead of schedule. The gear system is scheduled to enter serial production in 2023. The process know-how acquired by H+B Hightech when it comes to in-house hub testing represents a unique selling point for the company, especially compared to its competitors in the growing bike market. H+B Hightech has even set up a new Bike Technology unit, the aim of which is to secure the future of its 100 employees outside the automotive industry.
This project is an example of an extremely successful development partnership between Steinbeis and a company in industry. The business location of the project partners, not far from Aalen University, will allow know-how, even in an abstract form, to enter teaching and research, and thus contribute to the process of knowledge and technology sharing.
Prof. Dr.-Ing. Markus Kley
Steinbeis Transfer Center Innovative Drive Engineering and Waste Heat Recovery