Development and manufacturing of connected eBike drive systems: motors, lithium-ion batteries, displays, and digital services
Bosch eBike Systems (Robert Bosch GmbH)
Reutlingen (Development) · Miskolc (Production/Logistics) · Farmington Hills, MI (North America)New on Amplifa
About Bosch eBike Systems
Bosch eBike Systems was founded in 2009 as a startup within the Bosch Group and is now an independent division of Robert Bosch GmbH. The company develops and manufactures complete eBike drive systems consisting of drive units (motors), lithium-ion batteries, displays, ConnectModules, ABS, and chargers, as well as digital services such as the eBike Flow App. Battery development takes place at the headquarters in Reutlingen, while the majority of battery production is carried out at the Bosch plant in Miskolc (Hungary) in a highly automated process using robots for cell loading, welding of cell blocks, and BMS installation. Battery cells are exclusively sourced from certified manufacturers; the cells are encapsulated in flame-retardant plastic. Over 100 leading bicycle brands worldwide rely on the modular system, including Trek, Scott, Canyon, Cube, and Riese & Müller. Distribution is handled in North America, Europe, Asia-Pacific, and Australia.
- Site
- Farmington Hills, MI (US Imprint)
- Processes
- Automated battery production (loading cell holders, assembly of cell blocks, welding,, eBike Drive Systems (motors, batteries, displays, ConnectModules, ABS, chargers), eBike Flow App / Flow+ Premium services, Digital theft protection (eBike Lock, eBike Alarm, GPS tracking), Software updates Over-the-Air, Navigation and route planning, Dealer training ('eBike Expert' program), Service and maintenance support (digital service book)
- Materials
- Lithium-ion Battery Cells, Flame Retardant Plastic, Battery Management System (BMS)
- Certificates
- Product Tests (Short Circuit, Crush, Shaker, Drop, Water Resistance), Certified Cell Manufacturers
- Founded
- 2009
- Industries
- eBike/Bicycle Industry (City, Touring, eMTB, Cargo, Gravel, Speed), Bicycle Dealership
- 01
Cell procurement from certified manufacturers
- 02
Voltage testing and automated loading of cell holders by robot
- 03
Encapsulation of cells in flame-retardant plastic
- 04
Assembly and welding of cell blocks by robot
- 05
Installation of the Battery Management System (BMS)
- 06
Sealing the housing
- 07
Packaging in specifically approved packaging
- 08
Logistics and distribution via dealer network
Materials & Processes
Lithium-ion Battery Cells
Energy source for eBike batteries, sourced from certified cell manufacturers with integrated electrical fuse per cell.
Flame Retardant Plastic
Enveloping the individual cells for mechanical and thermal isolation.
Battery Management System (BMS)
Monitors every single cell and protects against overtemperature, overload, and deep discharge.
Locations
Reutlingen
DEHeadquarters and Battery Development
- Materials
- Lithium-ion Batteries (Development)
- Battery Development
Miskolc
HUProduction and Logistics (Batteries)
- Materials
- Lithium-ion Batteries
- Robot for automated loading of cell holders
- Robotic cells for assembly, welding, and connection of cell blocks
- Automated BMS installation
Farmington Hills
USRobert Bosch LLC Site (North America)
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Automated battery production (loading cell holders, assembly of cell blocks, welding,Assembly | – | – | – | – | Lithium-ion cells, flame-retardant plastic |
1 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| Robot for battery assembly (automated loading of cell holders, assembly/connection of | Bosch | – | – | – | Bosch Plant Miskolc, Hungary (Battery Production); development at headquarters |
Additional services
Reference customers
Quality
The components undergo extensive tests; batteries undergo testing exceeding statutory requirements, such as short circuit, crush, shaker, drop, and water resistance tests. Dealers are intensively trained in the eBike Expert Program, and spare parts are maintained for at least six years after the last delivery.
| Evidence | Reutlingen | Miskolc | Farmington Hills |
|---|---|---|---|
| Product Tests (Short Circuit, Crush, Shaker, Drop, Water Resistance) | |||
| Certified Cell Manufacturers |
History
- 2009
Foundation as a startup within the Bosch Group
- 2011
World premiere of the Bosch eBike System at Eurobike
- 2012
Establishment of production and logistics in Miskolc, Hungary; Claus Fleischer CEO since July 1, 2012
- 2013
Portfolio expansion: Active Line and Performance Line; business units in North America and Asia-Pacific
- 2014
Nyon All-in-one Computer – entry into the connected eBike world
- 2015
Performance Line CX: Bosch's most powerful drive
- 2017
Acquisition of the connected-biking startup COBI.Bike
- 2018
World's first series ready anti-lock braking system (ABS) for eBikes
- 2020
Cargo Line: Drive specifically for cargo bikes
- 2021
Bosch eBike Systems becomes independent division of the Bosch Group; Kiox 300 appears
- 2022
More than 100 customers install the Bosch eBike system; smart system with eBike Flow App; Kiox 500 appears
- 2023
eBike ABS for the smart system is launched; eBike alarm and expansion of digital features
- 2024
Performance Line SX: lightest drive; evolved Performance Line CX (85 Nm); iF Design Award for the smart system
- 2025
Introduction of Performance Line CX-R and Performance Line PX
- 2026
New releases: Hub Line (first Bosch hub motor), Active Line Plus, new batteries, Intuvia 200, LED Controller, ConnectModule