Controller Archives

Future-proof

Jukka Mäennenä on 2021-12-17

The development of e-bike technology is happening fast, and not in a linear fashion. Even though forecasting is difficult, especially when it comes to predicting future events, we are very confident that the Revonte ONE Drive System will stand the test of time for many years to come.

Read further to learn why that is.

Software-first approach

Even though a heavy dose of good old-fashioned mechanical engineering has gone into the Revonte ONE Drive Unit, we describe ourselves as a software development company first and foremost.

To achieve this type of operation model, we have designed the Revonte ONE Drive System from the ground up as a software-based product. This does not negate the importance of a sound and robust mechanical design – on the contrary. The design of the Revonte ONE Drive Unit is based on a time-tested design that’s been used in a variety of applications, including heavy-duty industrial use.

By leveraging the features of the mechanical design, and pairing that with highly sophisticated control software, we are able to deliver something very special

With a sturdy base that’s standing on a pair of legs provided by a time-tested mechanical design, we can leave the finer details and features to the software side. This is where the highly honed control software and the development that has gone into it steps in. Not only does this approach enable us to provide a variety of features, and different ride characteristics, but also the ability to implement them very quickly, and efficiently.

More often than not, it’s easier and faster to develop new code than to replace hardware.

Time-tested Drivetrain Solution

Even though the current bicycle drivetrain is a respectable piece of engineering, it’s far from ideal or not to mention a pinnacle of drivetrain technology. Fragile parts, components that are subjected to high wear rates, and the need for regular maintenance are some of the most obvious shortcomings of current systems.

The Revonte ONE Drive System employs a highly reliable, and simple single-speed transmission. One chain paired to a pair of sprockets – could not get much more simple than that! With simplicity, the benefits of lower maintenance needs, very affordable spare parts, and overall robust construction are realized.

How would this look if it was simple? This is a question often raised in engineering. Our answer to the question is that the drivetrain should include as few parts as possible that are subjected to the elements, and thus oftentimes high wear rates.

The single-speed transmission has stood the test of time for more than a century, and it is safe to assume that it’s not going anywhere anytime soon.

It is worth noting that the long list of benefits also include the option for using a belt drive which is virtually maintenance-free, and the most “tidy” option available since it does not require any lubrication for proper functioning.

Fully Connected

The future of e-bikes will be focused more and more on the overall ride experience. Not only has the nature and performance of the assistance to be top-notch, but also other features found on the drive system, including connectivity to other devices. We’ve made sure that the Revonte ONE Drive System is future-proof by including a full set of connectivity technology inbuilt on the drive unit itself. The list includes Bluetooth, 4G, and GPS.

The versatile, and fast connectivity options enable software updates over the air, as well as connecting 3rd party applications if the need arises. In other words, we’ve left all the doors open for future development by embedding all the modern connection standards to the drive unit. This also means that we are not tied to a specific layout or standard, nor are there other limiting dependencies

In Closing

By leveraging the features of the mechanical design, pairing that with highly sophisticated control software, and full connectivity we are able to deliver something very special to the world of e-bikes.

“One hardware, all types of e-bikes”, is the motto of the Revonte ONE Drive System which can be realized with ingenious design work, and picking the best features from a varied field of technologies, including mechanical, software, and electronic engineering.

Combining all these factors we can say that Revonte ONE Drive System will retain its modern status for many years to come, and provide a ride experience that all other drive systems are compared to.

On Testing

Jukka Mäennenä on 2021-10-22

When it comes to developing a high-end product with a wide spectrum of features that combines technologies from a variety of fields like in the Revonte ONE Drive System, testing is paramount. In this article, we’ll provide an insight into what goes into developing and testing the smartest e-bike drive system out there.

Multiple Phases

Designing an e-bike drive system like the Revonte ONE is a task that requires a lot of engineering from several different departments; mechanical, software, and electrical are the main ones.

To verify that the design fulfills its intended purpose, testing needs to be done. The more detailed and systematic the testing procedure is, the better. This is to ensure that the drive system functions as it is designed, but also to minimize the risk of any unwanted events like error modes, or mechanical failures. As it is said, no stone should be left unturned when it comes to testing.

Testing takes place in several phases and in different phases, from lab to real-world conditions. This is to ensure that the component or feature works as intended independently and later as an integral part of the system in varying conditions.

In the Lab

The plentiful torque and peak power output of the Revonte ONE Drive System aren’t taken from thin air. A dedicated testing rig was developed to test that the drive unit’s calculated and actual performance metrics match. The tireless test rig has put out watts more than a grand tour contender during a Grand Tour race to hone the function of the drive system.

Even though the drive unit is the heart of the Revonte ONE Drive System (and software is the brains), no part of the system gets overlooked. All the components have gone through several testing protocols to ensure that they operate as intended. Testing for things like durability against vibration, water, and moisture resistance for IPX6 grading are just a few found on the long list.

Something as simple as being able to withstand the stress that the parts are subjected to under several years of use. For example, the paddles of our Controller was tested for the number of presses that would take place during a 2-year time period on average – and that’s a lot of clicks.

In the Field

Field testing follows next. Even though a lot can be done in the lab, there’s no substitute for real-world testing. Subjecting the components to the outside elements during prolonged use, leaving the bike unwashed for a period of time, riding in the pouring rain, tackling the steepest uphill one can find, or just simply pushing the paddles of the Controller with a bit more force than intended pose demands to the drive system that can not be replicated in the lab environment.

Hence, we’ve put the Revonte ONE Drive System through its paces in the field to reveal any hidden or unknown issue that had escaped the thorough trials so far.

A Straightforward Goal

The goal of all of this is straightforward: to deliver the smartest e-bike drive system which delivers what it promises and keeps on doing that for a long time to come.

For those eagerly waiting for the release of the Revonte ONE Drive System, we can, fortunately, say that the end is near, and the result is worth the wait.

What Makes a Good E-bike Drive System – And How We’ve Met the Demanding List of Criteria

Jukka Mäennenä on 2021-08-06

Even though the e-bike industry can be considered quite young, a considerable amount of maturation has taken place in just a couple of years. Gone are the days when a bike manufacturer can bolt a motor around the bottom bracket, place a battery on top of the pannier rack and call it an e-bike. Besides more polished looks the assistance behaviour has improved by leaps and bounds – and the Revonte ONE Drive System is going to take it to the next level.

Read further to learn more.

Ride Experience

When it comes to evaluating drive system performance, assistance behaviour rules the game. No matter how nice looking, light or easy to use the system is, it does not matter if the ride experience resembles that of a cheap scooter that gas water mixed in the gas tank.

We’ve taken great care in developing the assistance behaviour of the Revonte ONE Drive System to the extent that it feels as if the bike is thinking already one step ahead. How is this accomplished you might ask? By refining the software with the aid of continuous and prolonged testing and by using high-quality sensors to detect even the smallest actions performed by the rider.

A close second to the assistance behaviour is the ease of use. Conveniently the Revonte ONE Drive System scores the very top on this department, thanks to its automatic & stepless transmission. Just pedal – the bike will take care of the rest!

Configurability – on more than one level

It is already commonplace that a drive system has some level of inbuilt configurability by offering the choice between different assistance modes and possibly even more detailed settings. With the Revonte ONE Drive System, we’ve taken the configurability aspect to the next level.

First, the bike manufacturer can configure the drive system according to their needs, whether it’s a commuter bike or a heavy-duty cargo e-bike. After the initial specs the end-user – meaning the rider – can configure the drive system according to their wishes or needs via our dedicated app.

Inbuilt Modularity

What makes the Revonte ONE Drive System truly unique is that a single drive unit can be used in all types of bikes from a high-performance e-mtb to a commuter designed year-round daily use. From a bike manufacturer’s perspective, this is a very welcomed feature since it lessens the needed design considerations, product variants and stock overhead.

And that’s not all. The Revonte AKKU is the smartest e-bike battery out there for a good reason. Both AKKU 5 and AKKU 7 share the same form factor, i.e., they have the same physical dimensions, hence making them interchangeable. This enables the bike manufacturer, or the rider, to spec his or her bike with just the right amount of energy storage capacity.

The various inbuilt modular features make the Revonte ONE Drive System the ultimate choice both from bike manufacturers, but also from rider’s perspective.

Reliability

When it comes to power transmission, the century-old chain is still looking for a worthy rival. With the Revonte ONE Drive System, one can use a wide single-speed chain which is the most robust and durable type there is. Add to that the fact that the ingenious design of the Revonte ONE Drive Unit makes damage-prone derailleur obsolete, the reliability factor gets multiplied.

As a nice bonus replacing the whole drivetrain costs only a fraction of that compared to a set consisting of a complex cassette, multi-speed chain and compatible chainring.

Up to Date

Nobody likes to ride an old bike, especially if a newer or better model is available. There is no way to stop the ongoing technological development – which is only a good thing – but we’ve done everything in our power to keep Revonte ONE Drive System up to date and performing at its best for as long as possible.

How can this be done once the bike has left the factory floor then? By software updates which can be made swiftly and effortlessly, thanks to the inbuilt 4G connection which is a default feature in the Revonte ONE Drive System.

In Closing

An e-bike drive system has to tick a lot of boxes to be a top performer in all areas. Revonte ONE Drive System does this with flying colours and goes even beyond that. The automatic & stepless transmission and the simple construction of the drivetrain itself take the e-bike ride experience and ease of use to an unprecedented level.

The one and truly smart drive system out there – Revonte ONE.

2020 – A Year in Review

Jukka Mäennenä on 2020-12-31

It can be said without any hesitation that the year 2020 was full of surprises, rapidly changing situations, stretched deadlines, and general disarray. We kept our head low, concentrated on the tasks at hand, and continued developing the Revonte ONE Drive System for the upcoming launch in 2021.

Here’s a summary of what happened during 2020.

The Year of Revonte

A lot of things can take place within a year. This is especially true when developing a new and innovative product in a competitive environment. Steady progress and occasional challenges were accompanied with big breakthroughs and new partnerships.

Read the following list to know the essentials of Revonte in 2020.

03 March

During the first quarter of the year we announced our partnership with the innovative – even disruptive – company from the UK named EAV. Their forward-thinking concept of cargo e-bikes has set the pace for the whole industry. Cargo e-bikes solve the last-mile dilemma and EAV’s range covers every imaginable need and purpose.

Also, a story about our Drive System run on Pinkbike. If you’re interested of knowing what’ inside the Revonte Drive Unit, this is the one to read.

05 May

Simple, minimalistic, even elegant – those were some of the design goals of the Revonte Controller. We purposefully decided to go screenless with the design which leaves the final decision to the user. After all, configurability is in our DNA and the Controller is in line with that.

Instead of occupying more space from the usually crowded cockpit, we take the opposite approach. Two brake levers, and the Revonte Controller forms the complete interface between the bike and the rider. No separate trigger or shifter for the gears are needed. Less is more.

08 August

One of the many strengths of the Revonte ONE Drive System is the simple, robust and clutter-free single-speed drivetrain. Besides the traditional and time-tested chain, the Revonte ONE Drive System enables the use of a belt drive.

To answer the inquiries we built a prototype with the industry-leading Gates carbon belt.

09 September

An energy storage is needed to employ the features of the automatic and stepless features of the Revonte ONE Drive System. To make everything right from the start we decided to partner up with class-leading German battery manufacturer Akku Vision GmbH, and develop our own battery.

Meet Revonte AKKU 5 and AKKU 7. Both models share the latest Li-ion technology and physical dimensions to meet every need and price point in the market. A unique feature is the smart battery management system which makes it possible to connect up to four batteries with the combined capacity of over 2.8kWh!

10 October

Eurobike gets cancelled. First the premier event was postponed, and eventually cancelled. This was unfortunate since we had made big preparations for the upcoming show and were looking forward to it.

Revonte GmbH – a German subsidiary! To meet the demands of the European market we established a German branch to the ever-growing needs of the European e-bike market. Mr. Uwe Daniel, a long-time member of our team, was appointed as the CEO of the new company.

Cargo e-bikes are picking up and big time! An interesting development took place in a short timespan; cargo e-bikes rose to the position of becoming almost an industry leader. Our partner EAV is in the forefront of this movement and providing solutions to the challenges faced in the logistic chain. It’s not a coincidence that the Revonte ONE Drive System is the drive system of choice for cargo e-bikes.

We are looking forward to the year 2021 and we believe we aren’t the only one.

12 December

The release of the long awaited Revonte test ride video saw its premiere in December. Besides some test ride material the video included a general update of the past year.

See what’s up with the Revonte ONE Drive System by viewing the video. On that note, see you next year!

When the Whole Is Bigger than the Sum of the Parts

Jukka Mäennenä on 2020-08-10

Here at Revonte we’ve wanted to take the big picture view from the beginning. Our goal is to change how ebikes are ridden and thought of which requires more than just building a neat drive unit – although, that certainly is part of the deal. Besides providing a Drive System with unprecedented features, like the automatic & stepless transmission, we wanted to make the whole process of using the ebike easier, more pleasant and seamless, starting from the purchase.

Let’s call it the Revonte Experience.

Ease of Use Starting from the Registration

Usually, attention is directed only towards the things that can be noted while riding. When it comes to ebikes – or any other product for that matter – the things that happen before that do matter, and often quite a lot. The ebike itself might be a pleasure to ride, but the experience might be dwarfed by a cumbersome process of turning just the power on.

We’ve put a lot of thought to make the usability of the Revonte ONE Drive System as intuitive and smooth as possible. The process starts with registration, and at the same token claiming the ownership of the ebike. All of this is done via our App in a simple step-by-step manner. All the relevant instructions are clearcut and the amount of needed information is kept to a minimum.

If the registration process requires a PhD in electrical engineering or programming, then something has gone amiss.

When Ensuing Riding

One of the design drivers of the user-interface and general usability of the Revonte ONE Drive System was that it should be so easy to use that a child could use a Revonte-equipped ebike (and they probably will.)

Turning the power on and ensuing the ride should not be more complicated than starting a ride on a regular bike. In practical terms, this means that the power switch will be easy to use and no intricate button-pushing sequences are needed. Also, the app connects to the bike without a conscious effort by the user and starts tracking chosen metrics, if chosen from the settings.

Consequently, when the ride has finished or interrupted momentarily (remember, cyclists are big on coffee-breaks), turning the power off or putting the ebike on a stand-by mode should be just as easy as turning the power off. These things should be given but to our experience, there’s still a lot of room for improvement.

Controls

Making the human-machine interface – HMI for short – as simple as elegant as possible was high on our priority list. The Revonte Controller reflects this thinking in every way.

First, it simplifies the cockpit by replacing existing controls instead of occupying new space. Second, it’s intuitive to use and highly ergonomic. And third, it’s minimalist to the extent that the difference between a traditional shifter paddle can be hard to tell by a glance. Only the colourful LED’s reveal that there’s more hiding beneath the surface.

Going screenless was an easy decision for us since we wanted to keep the cockpit area as simple as possible, and most importantly leave the choice of having a screen to the rider. Any modern smartphone can be used as a screen with the aid of the Revonte App which has all the features one could ask for. And not only that, it’s continuously updated so that users can benefit from the latest developments.

Ride-experience

We’ve said it before that the ride-experience isn’t only about performance metrics. The goal of this article was to drive the point home that ebikes, and most importantly, the usability and the general feeling of using one is a lot more than just watts or newton metres.

The user-experience starts from the purchase and besides the riding itself, includes registration, servicing, charging and turning the power on and off countless times.

We feel that the ebike industry has a lot of ground to cover in this area. A lot of the controls, HMI’s and complicated button-pushing choreographies are something that would not fly in any other industry. Starting a drive on one of the leading electric cars is simple; hop on to the driver’s seat with the key in your pocket and start moving. Why should it be more difficult when moving from four wheels to two?

With this line of thinking, the whole is truly bigger than the sum of the parts. Ebikes should be easy and most importantly enjoyable to use. Could your grandma use one? And how would she find the experience?

The Story Behind Our Controller Design – Part 2

Jukka Mäennenä on 2020-05-15

In this 2nd installment of the story behind our Controller design blog series, we cover additional facts and considerations, features that weren’t introduced in the 1st part, and add some color to the happenings behind the design process.

Future-proof

Forecasting is very difficult, especially when it’s about the future. Some of the biggest breakthroughs and even crises – no matter the domain – have occurred without a warning. While recognizing these limitations we wanted to make the Controller as future-proof as possible.

What this means in practice, you might ask? Good question and we are glad you asked. As specified in the 1st part, our Controller is placed on the right-hand-side, therefore replacing the traditional shifter which is made obsolete by our design. Instead of adding more ‘stuff’ to the cockpit area, we choose the route of simplification. Less is more. Meanwhile, the right-hand-side placement leaves real estate for other controls, such as a dropper post lever which is a standard issue in e-mtb’s. Also, if a new technology comes along that requires input from the rider and therefore a human-machine interface (HMI, for short) that needs to be placed in the cockpit area, we have plenty of space available for it.

Ever-increasing connectivity is the direction we are going towards. Terms like Big Data and IoT (Internet of Things) are thrown around left and right on a daily basis. We wanted to make ourselves ready for widening the bandwidth of information by equipping the Revonte ONE Drive System with the latest technology when it comes to connectivity. Naturally, this includes the Controller as well.

Modular Structure

One very neat feature that we did not purposefully uncover in the 1st part is related to the modular structure. As can be seen from the photos, our Controller uses paddle-like levers which can be easily used with the thumb only, warranting the expression; rule of thumb. This is an important feature that reaches all the way to the level of safety. Index-finger should be free all times for braking purposes.

Back to modularity! The Controller is built with a modular structure that enables swapping the part that forms the actual surface for the HMI without sacrificing the water tightness and reliability. In other words, the levers can be detached from the Controller and replaced with a modular component that transforms it into a twist shifter. Although this shifter type has fallen out of favor in non-motorized bikes, there are clear benefits for e-bike applications. Or simply going completely without an option to manipulate the cadence or gears and let the motor do the work for you.

With the stepless and automatic function of the Revonte ONE Drive System, the twist shifter makes a lot of sense. For example, when running the non-automatic indexed mode, the twist shifter enables the use of truly stepless transmission and gear change.

In our experience, the trigger model is a good fit for performance-focused type riding (e.g. e-mtb) where intuitive and highly honed actuation is required. Correspondingly, the twist shifter is a good fit for casual type or riding, like commuting in city areas. One benefit to mention is this type of shifter simplifies the cockpit and is very easy to use. During Eurobike 2019 we had several inquiries if a twist shifter type of Controller will be available later on. We were happy to provide an answer that was satisfactory.

One More Thing About Going Screenless

As you’ve learned from the previous part, we decided early on to take the screenless route with our Controller. This matches our minimalist philosophy when it comes to the cockpit area.

Even more important is that by doing this, we leave the choice of freedom to the bike rider. Running the tidy and elegant look that we offer is the default option, but nothing prevents the rider – or the bike manufacturer – equipping the bike with the screen of choice and interacting with it by the Controller. Offering compatibility with the major head unit manufacturers is one of the reasons why we have considered the connectivity issue thoroughly.

Screen technology is progressing rapidly with leaps and bounds on an annual basis. If the rider wishes to use a screen, our solution enables the use of the latest technology whenever preferred. It is also worth mentioning that our App provides an ample amount of ride data and post-ride diagnostic options as well. Running a screen does not require the purchase of an additional head unit since we have harnessed the power of the smartphone for the task.

Running your e-bike with or without a screen – the choice is yours.

It’s All About DFM

DFM stands for the design for manufacturing, which is an essential part of product development. It’s one thing to make a good design and produce a handful of units accordingly. Oftentimes, it is a completely different game when the needs of high-volume manufacturing are taken into account. Some of the basic questions are:

Manufacturability. Is the design easy enough to manufacture with the costs allowed? Is the manufacturing process simple and robust enough to produce consistent quality?
Materials. The materials used need to be up for the task. For example, there are many, many types of plastics and some of them might be a very good fit for the Controller as others might be so brittle that the first push of thumb produces a snapped lever.
Tolerances. Dimensions and tolerances need to be defined early in the design process. Ensuring that the materials and manufacturing methods can reach them reliably is another thing that might throw you in the iteration loop for several rounds. Defining the driving dimensions (i.e. the measurement that is essential for the design to work) is also a part of this step.
Quality control. The design and manufacturing processes need to create a pair that produces quality parts consistently with the dimensions specified. Easy in theory, oftentimes much harder in practice. Quality control is the last line of defense in ensuring that only the components that meet the stated criteria leave the factory.
Costs. This point brings all the steps together. One design might be superior in many ways but is too costly to manufacture. One thing worth pointing out is that the costs go up and down considerably when moving into high-volume production. Producing a high-quality product with the highest consistency and a competitive price tag is the ultimate goal of the design process.

In the end, it’s not all about DFM, but it is an essential part of the design process that can not be overlooked.

That’s a small peek behind the curtains when it comes to our Controller that forms the HMI in the Revonte ONE System. Hope you enjoyed the read and found it interesting.