How to design a connected e-bike
When you’re planning your next e-bike model, the IoT conversation shouldn't happen at the end of the production line, but on day one. If you want to build a vehicle that truly resonates with the modern rider, it needs to be built around connectivity, treating it as the central nervous system of the bike rather than just a bolt-on accessory.
Before kicking off the connectivity integration, it's worth thinking through the functionality it should include and the problems it will solve for cyclists and your company. Are there any other components that the connectivity solution should be able to communicate with, for example, controlling the lights or an external lock? Based on that, you can choose the most suitable IoT module for the e-bike.
Security as a core feature
One of the main challenges e-bike manufacturers tackle with connectivity is bike theft. It remains the biggest barrier for potential e-bike buyers. When planned into the design, security can be more than a physical lock. As mentioned, connectivity can offer a wide range of features, especially when it comes to bike security:
Digital lock and Movement alerts notify the owner the moment the bike is touched.
GPS tracking using satellite signals and cellular connectivity to position the vehicle
Immobilization through the motor controller prevents the bike from being powered unless permitted via an app
Theft report directly via an app
Smart frame lock, a physical lock that automatically engages when the bike is parked.
Smart hub lock: an automatic wheel lock. When in a locked state, this prevents the wheel from turning or being removed without damaging the bike.
Alarm to warn thieves if the bike is moved and trigger a loud theft alarm when the bike is being tampered with
Finding a place for the IoT module
Once you‘ve got a clear vision of what connectivity can do for you, it‘s time to start designing the bike. It's worth looking at the IoT module as a core component similar to the motor or battery. There are a few important things to consider when looking for a suitable placement in the bike frame for the IoT module:
1. When you design a bike around connectivity, start by ensuring the frame geometry accounts for antenna placement.
Placing an IoT device deep inside a thick aluminum down tube can act as a Faraday cage, severely degrading GPS and cellular signals. Instead, leading designs integrate the module in a dedicated non-metallic pocket near the motor where it has a clear line of sight to the sky.
2. Power management is the next hurdle.
A common pitfall is relying on the main e-bike battery to power the IoT module exclusively. If the main battery is removed or drained, the anti-theft and tracking features die with it. A robust design incorporates an internal backup battery within the IoT module itself, charged by the main system, ensuring the bike remains visible for weeks even when parked in a garage without its primary power source.
Making components speak to each other
True connectivity goes beyond simple GPS tracking. To offer a premium experience, your bike must communicate with its components. By using the CAN bus protocol, the IoT module can communicate directly with the motor controller and the battery management system (BMS).
This deep integration allows manufacturers to offer remote diagnostics and over-the-air (OTA) updates. Imagine a scenario where a rider in another country experiences a motor calibration issue. Instead of a costly return or a trip to a specialized dealer, your engineers can push a firmware update directly to the bike. This capability transforms your after-sales service from a reactive cost center into a proactive, data-driven value proposition.
Designing the digital touchpoint
When it comes to connectivity, the bike is only half of the product. The other half is the companion app that allows riders to access the digital features. The app is also the primary interface and touchpoint for the e-bike brand. It’s an opportunity to differentiate the brand and create a deeper relationship with the customer.
Software and hardware development should happen in parallel rather than as an afterthought. However, building an app from scratch is a monumental task that often distracts from the core mission of building great bikes.
Leveraging a white-label solution allows you to offer a branded, high-end digital experience while the underlying technology handles the complex telemetry and cloud infrastructure. This allows your team to focus on the hardware while providing riders with navigation, ride statistics, and remote control of lights or assist levels.
Still got some questions on how to implement IoT in your e-bikes? Get in touch with us, and we’ll get back to you.
