VELOSPEEDER

Frequently Asked Questions

WHOM IS THE VELOSPEEDER SUITABLE FOR?

Range of application of the VELOSPEEDER

The VELOSPEEDER was designed for cyclists who want to continue to use their bike actively even with motor assistance, who can basically manage their terrain under their own power and who want to use their bike more often on longer routes with predictable riding times.

The concept of the VELOSPEEDER follows the idea of motorising classic bicycles by subordinating the bicycle motor to the vehicle concept of the bicycle (light & robust), just like a standard component that is always available when needed. Classic cycling is enriched by the motor option, without negative side effects. This is possible with the low-maintenance VELOSPEEDER. Cyclists do not have to choose between heavy e-bike mopeds or a modern classic bike.

Engine performance

At a total weight of 100kg, a pair of motors delivers a thrust of 40 Newton (type 3125 short design) or 60 Newton (type 3135 long design).

The thrust of the motors reduces the gradient of the road by 4% or 6%. The remaining slope can be mastered with the motor at approx. twice the speed.

Depending on the motor design (motor type 3125 short, motor type 3135 long), the continous power of the VELOSPEEDER is 230 or 250 Watt.

Limits of the range of application of the motors

The thrust performance of the VELOSPEEDER is not designed for pure off-road use. The VELOSPEEDER is designed for roads and for moderate gravel roads.

Distinct motor design

We have adjusted the calculation of motor design and motor performance to the conditions on bicycles. We do not use third-party brushless external rotor type motors, which are usually built for other industrial and consumer applications.

When pursuing the lightest possible motor design, exploiting maximum efficiency in mechanical and electrical engineering is a precondition for a function that satisfies the customers‘ demands. This can only be achieved with a specially developed motor design and control electronics.

The motors are positioned slightly elevated at the rear, which means they are well protected.  The ball bearings (sealed and lipped) are located far inside, enclosing the motor axle. The motor housing is air-cooled and air flows through holes on the underside and top. The design of the ventilation ensures that the motors are not sensitive to dirt, unlike, for example, roller dynamos under the bottom bracket, which did not survive for long on the market.

CUSTOMIZED CONFIGURATION OF SETS

Configuration of the motor sets

All delivered sets including all necessary assembly parts shall be assembled and delivered according to customer specifications.

Release, feasibility

VELOGICAL will assess the feasibility of installation on a bicycle either when you visit us personally or sending photos via e-mail. We will internally document the details discussed during the meeting with the customer.

For information on vehicle safety, maintenance and care, please refer to the owner’s manual.

Requirements rim & rear wheel

As driving surface for the VELOSPEEDER, the rear wheel rim needs a vertical flank, which should not be too short, even if it is a disc brake rim. For the VELOSPEEDER, the minimum height of the rim flank is 4mm!

On a black anodized rim, a visually visible silver raceway will form soon, but unlike rim brakes, it will not notch. The VELOSPEEDER in continuous operation does not cause any noticeable wear on the rim flank.

LEARN MORE ABOUT VELOSPEEDER’s MOTOR CONCEPT

Switching motors on and off

A mechanical handlebar switch with Bowden cable (index 3-fold) controls the folding and unfolding of the motors.

  • Switch position 1) off
  • Switch position 2) on
  • Switch position 3) on + increased contact pressure during rain

The slightly increased base contact pressure bridges aquaplaning on the rim during rain.

An adjustable electric microswitch is integrated into the path of the shift cable, which opens and closes the circuit at the pedal sensor.

When the motors are mechanically activated on the handlebars, the motors are energised via the microswitch as soon as a certain pedalling frequency is reached.

The pedal sensor is a motion sensor with 2-5 chainring magnets, no Hall Sensor. The response time is adjustable between 0.5 seconds up to 1.0 second; default programming is 0.7 second.

Via a “switching bridge” or “switching box” located behind the microswitch, the twin motors are brought up to the rim flank on both sides, where they finally wedge when they are energised.

Before the bike stops, the motors are centrally folded away and electrically deactivated by pressing the handlebar switch. This type of control works reliably and is failure-proof. We know this from several tens of thousands of kilometers / miles of test operation under mixed soil and climate conditions. The electromechanical handlebar control handles much less mechanical traction than gear shift components and can basically be operated as often as a light switch in the household.

Power control

The motor is controlled by setting various parameters on the controller and selecting a motor variant for the optimal desired speed range, because the VELOSPEEDER resembles rear-wheel hub motors with a fixed final speed.

On demand, the handlebar can be equipped with an additional rotary potentiometer for power control. It allows you to adjust the motor assistance level continously in a range between 25% – 100%. This current control serves to regulate the motor power in a power-saving manner, which also favours riding in wet conditions. The manual reduction of the motor power effectively helps to adapt to a slower speed level when riding in a group.

Due to the automatic temperature management of the motors, the control system initiates a power regulation by itself, i.e. a dosage of the battery current, so that the motors cannot get too hot on the mountain.

Maintenance interval, low maintenance

The extremly energy-efficient engine concept is both low wear-and-tear and low-maintenance. All our tests conducted to date yield the result that a friction ring needs to be changed after 7,000 to 10,000 kilometers / 4,350 to 6,214 miles only. Apart from the friction ring, the other motor components are largely maintenance-free when the system is used properly. So far, no increased rim wear due to the e-drive could be detected.

Stability & choice of bike for the VELOSPEEDER

The small VELOSPEEDER motors do not damage bicycle frames. Equipped with these small motors, bicycles yet remain bicycles, as intended.

The specifications for reinforcement in frame construction apply to heavy pedelec motors and e-bike motors. Strictly speaking, these heavy pedelecs and e-bikes are no longer bicycles, but light electric mopeds.

A bike that is approved by a quality manufacturer for normal everyday use is basically suitable for VELOSPEEDER motors, provided, of course, it is used properly and in a configuration that has been approved by us.

To motorise a bike with the lightweight VELOSPEEDER, customers can simply buy a quality bike of their choice. Often, customers send photos of the bike of their choice before purchase so that the later conversion to the VELOSPEEDER works without problems.

As a manufacturer, we conscientiously deal with customer bikes in terms of equipment and safety. This is why VELOGICAL does not sell the VELOSPEEDER sets anonymously on the web.

Speed on the road with the bicycle

What should I pay particular attention to with pedelecs and e-bikes?

  • Adjust your speed in to expected traffic conditions.
  • Expect unpredictable, sudden obstacles.
  • Expect that other road users may not be paying attention.
  • Expect other road users to misjudge the speed of cyclists.
How does the VELOSPEEDER work technically?

Lightweight motor, true freewheel, classic cycling – with the VELOSPEEDER, two friction wheel motors wedge in pairs on the rim of the rear wheel to drive the wheel. The VELOSPEEDER is the only friction wheel drive for bicycles with dynamic auto-regulation of the drive forces. It engages fully when starting, but when the wheel is already rolling, and only “leads” at full speed close to its final speed at lower contact pressure. The control of contact pressure works according to the principle “as much as necessary, as little as possible” (to minimise braking effects and wear). This is essential and decisive. There are no examples of this on bicycles and that is why VELOGICAL clearly stands out in this aspect. At any speed, the VELOSPEEDER finds the optimal contact pressure by itself. In wet conditions, the e-drive is not damaged, but will lose some of its power.

The highlight of this patented twin, friction wheel motor is 1) the geometric positioning of the motor suspension, 2) the folding angle of the motors, which wedge in pairs on the rim flanks of the rear wheel, and 3) the design with swing axis. Added to this is 4) the comparatively hard material of the friction roller made of polyurethane (hardness 92 Shore).

The adjusted wedging mechanism of the VELOSPEEDER on the rim flank with defined contact pressure and the exact rolling without scrubbing determine the function as a self-regulating friction wheel system with dynamic, passive autocontrol of the driving forces on a defined contact surface, i. e., the rim flank.

The friction rings of the VELOSPEEDER do not cause significant rubbing in the transmission zone (relative forces). Thus, there is no significant wear on the rim. The power transmission path is very short and corresponds to (only) 1 gear stage.

Rim flanks, including those for disc brakes, are very strong and designed to withstand high loads from brake pads, which is also known as a rubbing motion, a so-called relative motion.

The VELOSPEEDER is the only friction wheel drive that does not have to seek a compromise between wear and slippage on different (tyre) surfaces.

Static friction wheel drives in the tradition of the classic Velo Solex moped must continue to run with full contact pressure after the start-up load, i.e. with corresponding material stress. With the maintenance interval of static friction wheel drives, at least the tyre must be replaced after a few thousand miles and, in addition, engine parts will usually also be affected.

VELOSPEEDER engine types

The thrust of the motors (measured in Newton) subtracts percentage points of the rise of a road depending on the total vehicle weight. At 100kg total weight (bike+rider+load), the motors type 3125 short (all variants) subtract 4% from the slope.

The motors type 3135 long subtract 6% from a gradient at 100kg total weight.

The type 3135 motors are 10mm longer and weigh 60g more per motor (120g / 2 motors).The longer normal motors type 3135 have the same top speed as the shorter motors type 3125 at 40% more thrust.The shorter normal motors type 3125 have the same final speed as the longer motors type 3135 with 29% less thrust.

Surcharge motor type 3135 long: EUR 59.50 (EU retail price including 19% VAT).

The frame specific motor mounts fit both motors type 3125 short and motors type 3135 long, because the motors type 3135 are 10mm longer towards the bottom. When selecting the motor type, make sure that the aluminium plate at the lower end does not collide with the frame strut. If the distance to the frame stay tube is less than 5mm space, choose the motor type 3125 short or have a modified frame specific motor mount installed.

Vario bracket & tube profiles

The curvature of the quarter circle bowl on the Vario Bracket and the Universal Bracket is sized to fit most oval, hydroforming, or square tubes.

The Vario Bracket and the Universal Bracket simply rests on the seat stay in the direction of travel and is held stably in position by UV light-resistant, certified industrial cable ties with stainless steel tongues. In practical everyday use, there is no difference in the function of the vario bracket to the frame-specific motor brackets.

Photo-Link mounting gallery vario motor bracket

HOW TO MOUNT THE VELOSPEEDER ON THE BIKE?

Self-assembly or have it assembled?

For customers who do not consider themselves to be technically skilled, we recommend installation by VELOGICAL or a distributor.

Customers who consider themselves to be technically well versed (e.g. RC model builders) can see through our designs and assemble the e-drive themselves.

Installation costs for the VELOSPEEDER

For the assembly on standard wheels we suggest EUR 210 gross (EU retail price incl. 19% VAT). The calculation is based on three working hours.

One of the standard cases among special bikes is the Hase Pino Tandem with its rear end of a standard upright bike.

For real recumbents we calculate a reserve amount of EUR 219 gross (EU retail price incl. 19% VAT) as recumbents are often more complicated to motorize.

More support is required and the installation process is longer, so we offer B2B training for the installation of the VELOSPEEDER at EUR 357 gross (EU retail price  incl. 19% VAT).

Bicycle shipping

As a service provider, we recommend a forwarding company that transports upright bicycle boxes correctly on the road. Unlike usual parcel shippers, they will allow the use of larger bike boxes and apart from twisting the handlebars and unscrewing the pedals (check with the bike dealer), the bike will not have to be dismantled any further. Brompton and Tern folding bikes can be shipped in their original boxes throughout Europe at reasonable cost.

Mounting the motors

Motors will be mounted on the seat stay tubes on the rear triangle in front of the frame tube in the direction of travel (direction of rotation, wedging mechanism).

No motor mounting against the direction of travel behind the frame tube.

No front wheel assemblies in series production – with the exception of rehab bicycles (special design folding mechanism, mechanically exposed, long cable routes).

Check for disturbing factors

Is there an aluminum plate welded to the back of the left seat stay for a side runner dynamo mount (classic bottle shape)?

If so, you can remove these retaining plates, because the tube should be smooth near the rim, without protruding welded or soldered parts.

The rear wheel

Before assembling the motor, we check whether the rear wheels on customer wheels run exactly on track or whether they are seated in a reproducible position in the dropouts. If we notice obvious defects on delivered customer wheels, we inform the customer before rectification so that the engine assembly takes place on a fault-free rear wheel.

When mounting rear wheels after a VELOSPEEDER installation, please also refer to the operating instructions.

When removing and installing wheels after motor assembly, be sure to put all small parts back in their original places and reproducibly position the wheel exactly so that it 1) sits correct and symmetrical between the motors and 2) sits straight in the rear of the bike frame, which may not always be exactly symmetrical here.

When the engines are folded away, the friction rings must not touch the rim on one side.

Also note that when tightening axle nuts on one side of the hub, the steering knuckle will hug the inside of the dropout you are tightening. So if you want to tighten one side without moving the position of the hub, it is necessary to counteract on the other axle side with a second wrench.

Tighten well does not have to mean “slam on”, but that the hub does not loosen or change its position. Rear axles with quick releases are again worked differently.

Finally, please check that the rear wheel is still centered between the friction rings of the motors after installation.

For tire repairs on rear wheel mounting situations with higher adjustment effort, e.g. hub gears in combination with belt drives, it will often be sufficient to patch the tube without removing the rear wheel.

THE ELECTRONIC SINUS CONTROL

Characteristics Sinus Controller

The Sinus Controller of the VELOSPEEDER 2.0 is a fully integrated solution for silent motor operation. Smooth start-up at low speed and good control over the delivered torque at an ambient temperature of -10°C to +40°C.

The motors automatically wake up from sleep mode by detecting motor rotation.

After 60 seconds without motor rotation, the controller automatically switches to sleep mode and remains operational until the next wake-up.

A total discharge of the battery when the system is ready for operation is impossible. The switch-off voltage of the empty battery is programmed very solidly on the controller with a high safety reserve (stage 1 motors off, stage 2 light off after approx. 4 hours). The idle current consumption of the inactive controller with the battery plugged in is zero.

The Sinus Controller moves the motors towards its preset final speed. Start-up behaviour, start-up current, assistance level / output torque, final speed, pedal time-out (0.5 – 1.0 seconds, standard 0.7 seconds) are programmable in the software.

The innovative sine-wave control enables you to adjust the final speed variably without loss of performance.

The so-called vector-based sine controller efficiently delivers propulsion even on hills at low speeds.

There is no “best” setting for the controller. If the controller is turned up to top speed, you will drive faster, but with increased power consumption at lower range, or with increasing air resistance.

If a distance of more than approx. 30km / 19 mi is to be covered as quickly as possible, the larger Type C battery with 322Wh is a good option, due to the more favourable current drain. And of course, an aerodynamic riding position is an advantage.

You might also consider a second charger at the workplace.

The VELOSPEEDER with Sinus Controller operates particularly quietly at low speeds on hills. As driving speed increases, chassis-specific resonances inevitably occur with a friction wheel drive, but the new VELOSPEEDER 2.0 with sinus controller is much quieter than the VELOSPEEDER controller as of end of 2017 and quieter than other current friction wheel drives – not only in partial load operation on hills, but also towards the final speed. All that is audible is a whisper-quiet hum, typical of an electric vehicle, which customers and test drivers hardly even comment on.

The controller is programmed via a Bluetooth interface on a Windows PC.

We also provide an infinitely variable potentiometer for handlebar mounting. It allows you to control the motor support level while riding. Order separately at EUR 142.80 (EU retail price including 19% VAT).

The intended use is for group riders who want to ride side by side, or rehab bikes on level ground to be able to roll along at the same speed as a pedestrian.

A reduced level of assistance to increase the battery range provides some energy savings on the miniaturised VELOSPEEDER, which can be useful.

Controller recuperation: above idle speed there is a slight recuperation in the lower 1-digit percentage range.

Dimensions Sinus Controller

PCB dimensions are between a larger business card and a smaller cigarette pack.

Space requirements for vertical installation: Height incl. cable bend appr. 10cm / 4 inches, width appr. 5cm / 2 inches, depth highest point appr. 1.5cm / 0.6 inches. Vertical mounting position, mainly in the narrow side compartment of the frame bag “Vaude Cruiser Bag”, space requirement approx. 1/4 of the side compartment when mounted vertically.

Electrical connections Sinus Controller

Question: Do I have to disconnect the plug connection to the battery at the sinus controller after the end of the ride?

Answer: No, this is no longer necessary. A plugged-in battery does not consume energy that discharges the battery.

The battery plug is only disconnected from the charger for charging.

What if … a DC eBike LED light system is connected to the battery, which does not have a light switch? The battery plug will be disconnected from the controller. Most eBike light systems do not have their own light switch. The VELOSPEEDER does not use a main switch as standard, e.g. no handlebar display. VELOGICAL offers a light switch as a useful accessory.

Sinus Controller test of the electrical connections

Questions: Are the left (red) and right (black) 3-phase plugs of the motors marked clearly?
The connectors on the controller board are not marked. I call them socket #1 and socket #2. See picture below.
Is the left (red) plug inserted into socket #1 and the right (black) plug inserted into socket #2?
If I plug the connectors inverted, will the motors have the wrong direction of rotation, or will the motors be damaged?

Answer: As soon as both motors are connected to the rim and both are set in rotation when the controller is switched on, the controller shall recognize the direction of rotation of the motors and drive them in the same direction. Therefore, it is irrelevant which motor connector is connected to which controller connector.

Sinus Controller Wiring

Questions: The controller has an additional 2-wire cable (1 red strand & 1 black strand) marked with a paper label that says “24V DC “. I don’t see any instructions for connecting this wire in the final assembly document?
Is this the extra wire in case I want to connect the second battery pack?
Can I leave this cable unused? It has a much smaller cross-section than the main cables for the battery pack.

Answer: The 24V DC connection is an option, e.g. to connect a 6-42V e-bike headlight or a suitable DC-DC converter (for mobile phone, navigation system etc.).

The connection is short-circuit proof, can supply max. 1A and is switched off when the battery is empty to avoid total discharge.

ABOUT THE PEDAL SENSOR

Task of the pedal sensor

As with any pedelec, the motors start when the pedal sensor detects that the pedal crank is turning on the bike. To avoid failures in wet conditions, the pedal sensor is not encapsulated in the bottom bracket, but sits variably outside the bottom bracket housing on the frame.

Technology pedal sensor

The pedal sensor is a motion sensor (reed contact), not a torque sensor. Unlike most pedelecs, the VELOSPEEDER not only uses the indirect pedal sensor for activation, but also a handlebar switch with which you can activate and deactivate the drive very intuitively and directly, in seconds.

Pedal sensor and magnetic positioning on the chainring

On the smallest chainring, with the pedal crank in the vertical position, set magnet no. 1 on the circumference to position 1 o’clock and magnet no. 2 to position 7 o’clock. When the pedal crank is in the vertical or horizontal position, when climbing or in the rest position, it should not be possible to make contact with the pedal sensor that starts the motors. In addition, two pedal crank revolutions are necessary to start the motors. Each time, the chainring magnets must be moved past the pedal sensor twice.

ABOUT THE BATTERY

Battery ranges

Battery  A up to approx. 25km / 15.5mi

Battery B up to approx. 38km / 23.5mi

Battery C up to approx. 50 to 70km (max. 90km) / 31 to 43.5mi (max. 56mi)

Recharge battery

The rechargeable battery capacity of a trickle charge within 1 hour charging time is approx. 20km / 12.5mi range (75Wh) at 3A charging current.

Battery charger

The fixed charging voltage of the 6s Li-Ion batteries is 25.2V. We make sure that the supplied chargers comply with the final charging voltage and do not exceed it.

Battery storage

For storage of batteries the state of charge should be approx. 40% to 50%.

Normal cellar temperatures are optimal.

Maximum working temperature range:
minus 20 degrees Celsius to a maximum of plus 60 degrees Celsius.

In winter, the range of the battery may temporarily reduce to about 60% and will return to a normal level at higher temperatures.

Charging technology battery

The charging cycle defined as the complete charging and discharging of the battery. For a longer service life of lithium-ion batteries, it is recommended to recharge the battery regularly before it is completely empty, e.g. immediately after the end of the trip. If the battery is to be stored, it should ideally be given a partial charge of up to approx. 50%.

Battery safety

Our VELOSPEEDER batteries have a BMS board (Battery Management System) without standby current consumption. The electronic equipment is a proprietary development. When the battery is not in use, the BMS does not accelerate the minimal self-discharge. In the battery capacity settings we do not reach the limits of the battery cells. We leave a very well dimensioned safety buffer of battery charge in the cells. Battery safety and longevity greatly matter to us!

Battery Life - how many charge cycles do the batteries last?

The motors are a lifetime product, so to speak. Motor design and installation location support the long service life.

There is a discrepancy in the battery charge cycles in favor of the customer. Cell supplier Samsung speaks of about 500 charging cycles. We were able to identify a starting reduction of the range only after four years of almost daily charging.

Battery - cell type

We use 18650 cells for the VELOSPEEDER batteries. For each battery type A, B, and C, we use cells of specially selected specifications.

Battery - housing

As a rule, type B and C batteries are stored in the frame bag Vaude Cruiser Bag or in the luggage carrier top bags Vaude Silk Road S or M. Optionally, battery type B shall fit in a SKS Tool Box in water bottle format for insertion in a classic water bottle holder. Flat small battery type A shall fit in the narrow Vaude Carbo Bag.

The motor control unit (controller) may be optionally placed in the narrow compartment of the Vaude Cruiser Bag on the right in the direction of travel, in the Vaude Carbo Bag or in a plastic box to be placed on the frame/luggage carrier between strut parts.

Battery - external dimensions

Battery Pack A 93Wh: L 115mm, H 70mm, W36mm
Mainly used by air travellers

Battery Pack B 193Wh: L 140mm, H55mm, W55mm
Standard battery mainly used by commuters
Fits in a SKS tool box for water bottle holders, in a seat post bag and in all containers for Battery Pack C.

Battery Pack C 322Wh: L 190mm, H 70mm, W 55mm
Standard battery mainly used by touring riders
Fits in a frame triangle bag, Vaude Cruiser Bag, or in the luggage carrier top bags Vaude Silk Road S for narrow sporty luggage carriers, or in the Vaude Silk Road M with standard support surface for touring luggage carriers.
Additional benefit Silk Road M: storage space for various utensils.

GENERAL QUESTIONS

Warranty period for VELOGICAL products

Two years (as usual).

Brompton folding bike packing size with VELOSPEEDER

The packing size of the original Brompton folding bike remains the same with Velospeeder motors or without. For the best possible packing size, we recommend using the Vaude Cruiser Bag on the rear top tube with the saddle turned against the direction of travel.

Is the VELOSPEEDER theft-proof and vandalism-proof?

Like all high-quality bicycle components, the VELOSPEEDER is not theft-proof and vandalsim-proof. When parked, you should treat VELOSPEEDER bicycles the way you treat any other valuables and take the battery with you.

How to identify the real thing

VELOSPEEDER (standard motor for e-bikes):
Four hexagon socket screws on the red motor cover, two-sided mounting

RIM DYNAMO (bicycle lighting):
Engraving of the lettering VELOGICAL on the dynamo cover, single-sided mounting

Story - Taking the initiative & the path to innovation

VELOGICAL engineering GmbH manufactures special components in bicycle construction, in particular, miniaturized drive technology and electrical engineering.

VELOGICAL stands for smooth running, lightweight, efficiency.

VELOGICAL has realised that the rim flank of the bicycle can be used for more than just braking. The rim flank offers ideal preconditions to transmit drive forces – highly efficiently and via a short lever arm. As a result, we have developed the world’s lightest electric drive for bicycles, the VELOSPEEDER. Our principles are based on consistently translating logical relationships into products – for the benefit of our customers.

SPARE PARTS

What is the cost of engine pairs without kit?

Sale to existing customers

1 pair motor type 3125 short, price: EUR 229.77
(EU retail price price including 19% VAT)

1 pair motor type 3135 long, price: EUR 289.27
(EU retail price price including 19% VAT)

How much is 1 set of friction rings?

Set: EUR 14.28 gross plus postage (EU retail price including 19% VAT)