(E-BIKE) Electric bicycle assembly line

The Electric bicycle assembly line​ consists of a floor conveyor system and a workstation operation system. The line body runs through the assembly workshop, and workers complete assembly tasks at each station on both sides of the Electric bicycle assembly line.

The floor conveyor system adopts a slat chain conveyor line. The slat chain is formed by connecting multiple metal plates with hinges, creating a continuous annular conveying surface. The slat chain is installed in a ground trench, with its upper surface flush with the ground. The driving device is located at one end of the slat chain, consisting of a motor, a reducer, and a sprocket, driving the slat chain to run at a set speed. The tensioning device is located at the other end to adjust the slack of the slat chain. Fixtures are fixed on the upper surface of the slat chain to position the frame. The frame is placed on the fixture and moves forward with the slat chain. The load capacity of the slat chain is designed according to the weight of the frame and assembly parts, and the chain and plates are made of steel. The running speed of the slat chain is set according to the production cycle time, and the dwell time at each station is fixed. The distance between stations is determined by the assembly content.

The assembly process is divided into multiple sections. The front section handles frame loading and pre-assembly. Empty frames are transported from the storage area or the previous process to the starting point of the line body and manually placed on the slat chain fixtures. The frame enters the motor installation station, where workers fix a hub motor or mid-drive motor in the middle and rear part of the frame. The motor is delivered to the station side by an independent conveyor line or material rack. Electric tightening tools are used for fastening, and the torque value is specified by the process documents.

The middle section performs electrical system assembly. Workers install the battery box, controller, wiring harness, and instruments on the frame. The battery box is installed in the middle and lower part of the frame or behind the seat tube; some stations are equipped with assist devices for handling. The wiring harness is routed along the frame, and connectors are plugged into corresponding sockets for the motor, controller, instrument, and lights. The instrument is installed in the middle of the handlebar, displaying information such as speed and battery level. After the electrical connections are completed, workers conduct a power-on test at the inspection station to check motor operation, lights, instrument display, and brake power-off functions. Test data is recorded at the station terminal.

The rear section carries out the assembly of exterior parts and the running system. Workers install body shells, fenders, seats, and baskets on the frame. Shell parts are produced in the injection molding workshop and delivered to the material racks beside the line via turnover boxes. Tires and wheels are installed at independent stations, where workers use special tools to inflate tires, mount wheels, and assemble the braking system. The handlebar assembly includes brake levers, twist throttles, lights, and reflectors, which are installed and adjusted by workers at the front-end station. Pedals and chain guards are assembled when required.

The final section conducts vehicle commissioning and testing. Workers perform functional tests on the complete vehicle at the end of the slat chain to check motor assist, lights, horn, and braking performance. After passing the tests, the vehicle leaves the line at the end of the slat chain and enters the packaging area. Packaging operations include installing protective materials, securing the vehicle, boxing, and labeling. Export products are labeled according to foreign trade requirements; in some markets, this product is classified as an electric bicycle or electric moped.

An auxiliary operation system is installed above the line body. Suspension rails are mounted on the workshop ceiling, equipped with pulleys and balancers for hanging pneumatic and electric tools. Air pipes and cables are connected to the tools via red spiral tubes or slide rails. Workers pull the tools within the working range, and the tools automatically return to position when released. The length of the spiral tube is determined by the station coverage to ensure the tool’s working radius. Some workshops have lighting bridge frames above the conveyor line, with fixtures arranged along the conveying direction, and the illuminance value meets assembly requirements.

The station layout is arranged according to the assembly sequence. Each station is equipped with tool racks, parts boxes, and work instructions. The work instructions display assembly steps and inspection points in graphic form. Material racks are placed beside the stations to store parts and fasteners required for the station. The number of layers and spacing of the material racks are designed according to the size of the parts. Yellow safety lines are marked on the station floor to divide the work area and passageways. Station screens are installed at key stations, displaying production cycle time, quality prompts, and call information.

The control system consists of a PLC and a touch screen. The PLC controls the start, stop, running speed, and positioning accuracy of the slat chain. The touch screen is installed in the central control cabinet or beside the line body, allowing operators to set parameters and view status through the interface. Multiple emergency stop buttons are set on the conveyor line, distributed on both sides of the stations and at the central control position. When the emergency stop is triggered, the slat chain stops running, and it restarts after the fault is eliminated and reset. The line body is equipped with audible and visual alarms to indicate equipment abnormalities or shift change information.

The cycle time of the Electric bicycle assembly line​ is determined according to the production capacity plan, ranging from tens of seconds to several minutes. The line length is calculated based on the number of stations, station spacing, and workshop dimensions. The width of the slat chain, plate thickness, and drive power are selected according to the load requirements. The track specifications and suspension point spacing of the auxiliary system are determined based on the tool weight and coverage range.

This assembly line is used to produce two-wheeled electric assist vehicles. In the domestic market, this product is commonly referred to as an electric scooter (electric‑bicycle). For export markets, it is classified as an electric bicycle or electric assist bicycle according to local regulations. Different markets have different regulations on motor power, maximum speed, and overall vehicle weight. The Electric bicycle assembly line​ meets the requirements of various markets by adjusting component specifications and software parameters. The slat chain conveying method is widely used in this industry, providing a continuous ground operation platform where workers stand in fixed positions to assemble the moving frames. All systems operate in coordination through a control program, forming a complete Electric bicycle assembly line​ for mass production.

Technical Parameter Supplement Table for the Electric Bicycle Assembly Line

Contact information

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