Structural Dynamics of E-Bike Drive Units: A Flexible Multibody Approach Revealing Fundamental System-Level Interactions

The design-related behaviour of structural dynamics for electric-assisted bicycle (e-bike) drive units significantly influences the mechanical system—e.g., vibrations and durability, stresses and loads, or functionality and comfort. Identifying the underlying mechanical principles opens up optimisation possibilities, such as improved e-bike design and user experience. Despite its potential to enhance the system, the structural dynamics of the drive unit have received little research attention to date. To improve the current situation, this paper uses a flexible multibody modelling approach, enabling new insights through virtual trials and analyses that are not feasible solely from measurements. The incorporation of the drive unit’s system-level topology regarding mass, moment of inertia, stiffness, and damping enables the analysis of critical system states. Experiments accompany the analysis and validate the model by demonstrating a load-dependent shift of the first torsional mode around 35 Hz to 60 Hz, capturing comparable resonance frequency ranges up to 6 kHz, and yielding qualitatively consistent peak positions in both steady-state and ramp-up analyses (mean deviations of 0.03% and 0.06%, respectively). Theoretical considerations of the multibody system highlight the effects, and the stated modelling restrictions make the method’s limitations transparent. The key findings are that the drive unit’s structural dynamic behaviour exhibits solely one structural mode until 0.5 kHz, and further 27 modes up to 10 kHz, solely originating due to the multibody arrangement of the drivetrain. These modes are also load-dependent and lead to resonances during operation. In summary, the approach enables engineers, for the first time, to significantly improve the structural dynamics of the e-bike drive unit using a full-scale system model.