Electric Motorcycles Factory

After touring prototypes, Vancouver-based electric motorcycle company Damon Motors is preparing to start production. Its new facility will allow them to design and manufacture all of their bikes.

The Zeus 8’s sweeping chromoly frame features banks of sleek, visible battery cylinders. It’s a design feature that raises eyebrows, but one that’s essential for maximizing battery storage in a small package.

Origins

With electric cars having broken into the mainstream, many people are starting to look at the possibility of using an electric motor for motorcycles. While major brands such as Harley-Davidson have yet to introduce a production motorcycle that uses an electric motor, small companies like Energica and Zero are leading the way.

Almost a century ago, Louis-Guillame Perreaux developed the first Electric Motorcycles factory ever practical electric motor. He used powdered moss to make it work, but his invention didn’t gain much traction until the late 1860s. Later, Nikolaus Otto and Emile-Joseph Delaurier were able to create an electric bike that worked better than Perreaux’s version.

The modern electric motorcycle has become more feasible than ever with the recent developments in lithium-ion batteries and powerful electric motors that can be built into the frame of a conventional motorcycle. The new technologies allow for a higher performance and greater range while eliminating the need for traditional fuel tanks and exhaust systems.

While Mike Corbin is known for his custom motorcycle seats, he was also one of the pioneers of production electric motorcycles when he started developing his Corbin-Gentry bikes in the early 1970s. His XLP-1 City Bike looked fast, but it only managed to reach 30mph and had a limited 40-mile range. However, his efforts helped to pave the way for the electric bikes that would finally enter the market in the 2020s.

Technology

It’s true that the world is going to hell in a handbasket—oil prices are sky high, political unrest is running wild and climate change is the most urgent threat we face. But it’s not all gloom. EV motorcycles are starting to be a viable alternative for the motorcycling crowd that is geared towards fast, torque-centric machines.

In order to make a profit on electric bikes, manufacturers need to sell large quantities of them. This is a huge challenge given that it costs two to three times as much to build an electric motor than an internal combustion engine. This is why it’s so important for companies like Zero to reach a point of scale with their production facilities, so that they can pass on savings to consumers.

Several major brands, including Harley-Davidson and Ducati, have shifted their focus toward electric motorcycles. But it’s still very early days. Most of these companies are Electric Motorcycles factory still in the development stage and are producing prototypes for shows and events. They are also testing out different powertrain options, such as lithium-ion and fuel cells.

A lot of these new motorcycles are being fitted with lithium-ion batteries. Chinese company Niu Technologies is one of the largest suppliers of these batteries and was among the first to offer lithium-ion batteries for electric scooters and motorcycles. Other companies are exploring the possibility of using other types of batteries such as nickel metal hydride or lead acid.

Design

Despite the lack of emissions, electric motorcycles have to meet many of the same safety and regulatory requirements as traditional motorcycles. This means incorporating battery, motor, and control systems into an overall design that can withstand the stress of riding and driving.

This presents a real challenge for some motorcycle manufacturers, especially those who are already hampered by legacy or an entrenched design language. But for custom designers, it’s an unprecedented opportunity to push the boundaries of what’s possible with electric motorcycles.

For example, the Zero DS was first built as an off-road racing bike, because they needed to gather performance data quickly and didn’t need to meet Department of Transportation (DOT) street rules like lights and turn signals. The original prototype used lead-acid batteries with four cells in series for a 48V system, but was updated to use Lithium batteries with Farasis flat pouch cells when they went into production, doubling the battery pack voltage and power.

Other companies take a more rational approach to designing their motorcycles around the battery, which can be a significant component of an electric motorcycle’s weight and size. The Damon Hypersport, for instance, styles its battery in a way that blends with the rest of the bodywork, rather than hiding it away or making it an afterthought. This is a practical decision because the battery needs to be protected from extreme heat or cold, which could otherwise shorten its lifespan.

Production

Production of Electric Motorcycles factory involves a significant amount of time and money. Besides the purchase of raw materials, production equipment and tools also take up a major portion of the costs. Other costs include procurement and processing of core components such as batteries, motors and controllers. Moreover, the assembly and re-engineering of each individual unit takes considerable time and resources.

Some of the companies that are investing in this sector are focusing on increasing manufacturing capacity and efficiency. One example is Zero Motorcycles, a California-based manufacturer of high-performance electric vehicles. It recently achieved a quadrupling of its overall manufacturing capacity. This was accomplished by implementing engineering and manufacturing process improvements, as well as deploying new manufacturing lines.

Unlike traditional bikes, which have numerous bolt-on components and complex systems, electric motorcycles are simpler to assemble. This is largely because of the reduced need for wiring and complex electronics. Besides, most of the components are made in-house. This reduces the time required for quality assurance and testing. Moreover, it allows the company to maintain consistent production standards and improve production efficiency.

Besides increasing productivity, the use of new technology can help reduce manufacturing and operating costs. This can lead to a competitive advantage for the company. In addition, it can also enable a reduction in the retail price of the electric motorcycle.