Main Components List and Assembly Process for EV Motorcycles

A two-wheel EV contains six core systems: welded frame, 400-1200 W hub motor with sine-wave controller, 48/60 V Li-ion pack protected by an active BMS, disc/drum brakes on aluminium rims, twin-tube suspension and foldable bar, plus IP67 harness, LED lamps and smart display. Assembly follows an 11-step automatic slat conveyor: parts are robot-welded, laser-cleaned, balanced, torque-controlled and on-line tested for HV, insulation and 25 km/h limit before weighing under 55 kg and palletising. Colour-coded looms, servo-torque logging and ≤30 min battery dock keep quality traceable and safe.

Main Components List and Assembly Process for EV Motorcycles
  1. Main Parts List (BOM) – Industry-Common Specification
    (All brand names removed)

Level-1 System: Frame

  • Main frame: high-strength carbon-steel or one-piece aluminium welded frame, includes head tube, main beam and rear swing-arm
  • Rear rack / side cover: ABS or PP injection-moulded, snap-fit, colour part and paintable

Level-1 System: Power-train

  • Hub motor: 48 V or 60 V 400-1 200 W brush-less DC hub motor, 10 or 12 inch (popular: 10 inch 800 W)
  • Controller: 48 V or 60 V sine-wave vector type 15-35 A, with CAN or RS-485

Level-1 System: Energy Storage

  • Battery pack: 48 V 20-38 Ah or 60 V 20-32 Ah Li-FePO₄ or NCM, certified to GB 38031
  • Battery box: deep-drawn steel case plus silicone seal ring, IPX7
  • BMS: 10-16 S 60 A active-balancing board, with UART or RS-485

Level-1 System: Wheel & Brake

  • Wheel hub: aluminium one-piece die-cast, size 10×2.15 or 12×2.5, with bearing seats
  • Tyre: tubeless 3.0-10 or 90/90-12, wear-resistant compound
  • Brake: front Φ220 disc plus rear Φ180 disc (or drum), twin-piston caliper

Level-1 System: Suspension & Steering

  • Front fork: hydraulic twin-tube, 60 mm travel, dust-sealed
  • Rear shock: dual spring plus 5-step damping adjuster
  • Handle bar: Φ28 mm aluminium one-piece, folding mechanism

Level-1 System: Bodywork

  • Plastics: gloss ABS front shield, floor and side covers, ≥3-layer paint
  • Lamps: LED head-light 12 W, rear/brake combo lamp, brightness ≥1 800 lm

Level-1 System: Harness

  • Main loom: 0.5-2.5 mm² oxygen-free copper, flame-retardant PVC, connectors IP67
  • Meter: 5-7 inch LCD or IPS smart display, shows SOC, trip, Bluetooth
  • Sensors: Hall throttle, brake-cut, side-stand-cut, 25 km/h limit ring

Level-1 System: Accessories

  • Saddle: high-density foam plus leather, spring-damped
  • Stand: electro-plated steel, auto-retract
  • Charger: 48 V or 60 V 2-5 A smart pulse, 3C certified
  1. Industry-Common Assembly Process (slat-conveyor automatic line)
Two-Wheeler Electric Vehicle Assembly Process下载

Step 1 Incoming inspection
Sample test to GB/T 36972 for critical parts; barcode scan into MES.

Step 2 Frame pre-assembly
Robotic welding → weld NDT → shot-blast → electro-coat primer ≥20 µm.

Step 3 Frame on-line
RFID links order; install main cable, swing-arm, centre stand.

Step 4 Front wheel / fork sub-assembly
Auto press bearings & oil-seals → fit hub & tyre → dynamic balance ≤5 g; robot press fork into head tube 55 N·m.

Step 5 Rear wheel / motor sub-assembly
Stator heat-shrink → rotor fit → winding tests → one-piece hub press → tyre & disc → 100 % air-leak test.

Step 6 Battery pack (parallel cell line)
Auto grade cells → laser weld → BMS plug → HV test → close lid; AGV delivers to main line.

Step 7 “Big-three” integration
Robot locks battery box into seat bucket 18 N·m; mount controller → connect harness → servo drivers log torque.

Step 8 Covers & lamps
Auto screwdrivers fit shields, floor, side covers; plug head & tail lamps → light-on test.

Step 9 End-of-line adjustment
MES downloads parameters; auto align motor phase & Hall angle; roller bench checks no-load current, speed, brake force (≥220 N), light intensity; insulation, HV, ground, tamper-proof all OK.

Step 10 Final inspection
100 % cosmetic check → decals → weigh (e-bike ≤55 kg); rejects auto-route to repair island.

Step 11 Pack & ship
Auto fold handle-bar → waterproof bag → pallet → logistics label; OTA writes after-sale trace ID.

  1. Key Process Points (industry practice)
  • 48 V / 60 V harness colour coding to avoid mix-up burn-out.
  • Battery pack dock-to-line ≤30 min to reduce self-discharge spread.
  • Critical torques (fork, hub, battery box) all servo-controlled, values uploaded to MES for recall.
  • GB e-bike speed limit 25 km/h, tamper port lead-sealed, photo archived.
  • Vehicle insulation ≥20 MΩ, leakage ≤0.2 mA or vehicle blocked from release.

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