eBike Accessories & Drive Units Production Automation
Nextomation designs and integrates flexible production systems for eBike components and accessories. Our solutions combine precision assembly, controlled fastening and joining, electronics integration, software parameterization, calibration, functional testing and complete process traceability. We support manufacturers from the initial production concept through implementation, ramp-up and long-term service.
eBike component production systems
Electric Drive Units
Electric drive units combine motors, gears, bearings, housings, sensors and electronic components within a compact mechatronic system. We develop automated production solutions that support precise component positioning, controlled assembly, lubrication, fastening and comprehensive functional testing.
Processes
- Motor, gear and bearing assembly
- Precision positioning and component handling
- Controlled lubrication and dispensing
- Housing assembly and fastening
- Torque, speed and noise verification
- Functional testing and traceability
eBike component production systems
eBike Displays
eBike displays require accurate integration of screens, electronic boards, connectors, housings and sealing components. Our systems combine contamination-controlled handling, precision assembly, software configuration and visual and functional inspection to ensure reliable operation in demanding outdoor conditions.
Processes
- Display and electronics handling
- Connector and housing assembly
- Adhesive dispensing and sealing
- Software flashing and configuration
- Visual and touch-function inspection
- Electrical and functional testing
eBike component production systems
eBike Controllers
Electronic controllers manage power delivery and communication between the battery, drive unit, display and sensors. We integrate electronics handling, connector installation, thermal management, housing assembly, software parameterization and electrical verification within controlled production processes.
Processes
- Electronic component and connector handling
- Thermal interface material dispensing
- Housing assembly and sealing
- Software flashing and parameterization
- Electrical and communication testing
- End-of-line verification and traceability
eBike component production systems
eBike Battery Modules
eBike battery modules require controlled cell and electronics integration, reliable electrical connections and robust protection against moisture and mechanical loads. Our automation systems support module assembly, joining, BMS integration, sealing and safety-focused electrical testing.
Processes
- Cell and module handling
- Busbar and electrical connection joining
- Battery management system integration
- Controlled dispensing and sealing
- Insulation and electrical safety testing
- Functional testing and traceability
eBike component production systems
Throttles & Levers
Throttle and lever modules combine mechanical components, switches, sensors, wiring and compact housings. We design production systems that ensure accurate component positioning, repeatable actuation characteristics and reliable signal performance across multiple product variants.
Processes
- Mechanical component assembly
- Switch and sensor integration
- Cable and connector installation
- Controlled fastening and joining
- Actuation force and travel verification
- Signal and functional testing
eBike component production systems
eBike Sensor Modules
eBike sensor modules provide the data required for drive assistance, speed measurement, torque control and rider safety. Our automated systems support precise sensor positioning, electronics integration, calibration and functional verification while maintaining complete production data capture.
Processes
- Sensor and electronics handling
- Precision positioning and assembly
- Connector and cable integration
- Adhesive dispensing and sealing
- Signal calibration and verification
- Functional testing and traceability
ur projects
Selected case studies
Explore our case studies and see how custom automated assembly lines improve production efficiency, quality and scalability across complex manufacturing processes.
High-speed process validation
Consumer Goods · Food
Tea Bag Packaging Process Automation Validated with Simulation
Verification of a high-speed tea bag packaging concept using detailed process simulation.
Project scope
End-to-end quality control
Industrial Manufacturing
Multi-Stage Vision Inspection System
End-to-end quality control across multiple production stations with complete process data integration.
Project scope
Precision copper joining
Battery & Energy Storage
Optimizing the Welding Process in the Battery Industry
Laser welding process optimization for joining tinned copper with nickel-plated copper components.
Project scope
Let’s discuss your consumer goods production challenges.
Planning a new production line or modernizing an existing assembly process? Our engineering team can help you define the right automation concept for tool modules, electric motors, control units and sensor systems. We support the complete project lifecycle, from feasibility analysis and simulation to implementation, ramp-up and service.
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