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Bosch eBike Systems sets new benchmarks in battery safety

How Bosch technology makes batteries safer

  • Combined battery safety mechanisms provide additional protection
  • In some cases, test procedures exceed legal requirements
  • Testing throughout the value chain and a high degree of automation ensure good production quality
Tamara Winograd

Tamara Winograd >

Stuttgart/Reutlingen - Bosch eBike Systems continuously optimises its products, and processes, to ensure high component quality. The same applies to battery production. This is because lithium-ion batteries are complex, finely tuned systems with a high energy content, whose ingredients can, in principle, be flammable in certain circumstances. For this reason, eBike batteries must undergo extensive legally prescribed tests and may only be brought to market once they have passed these. Bosch eBike Systems goes beyond the already stringent legal requirements, paying special attention to the issue of battery safety at every point along the value chain: Bosch sets new benchmarks in battery safety with a combination of various technological safety mechanisms, additional tests, and a high degree of automation in manufacturing.

Combined safety features: BMS, mechanical, electrical and thermal isolation

A Bosch battery consists of numerous high-quality lithium-ion battery cells arranged within a robust housing. A seal prevents the ingress of splash water and dust to an extent that the battery is prevented from any resulting damage. Bosch batteries are equipped with a Battery Management System (BMS). This continuously monitors the battery, detects potential fault sources and protects the cells from overloading. If the system detects a problem, such as excessive temperature, it automatically shuts down the battery.

The BMS is combined with other safety technologies built into the battery, such as mechanical, electrical and thermal isolation.

The individual cells of an eBike battery from Bosch eBike Systems are encased in flame-retardant plastic - the mechanical isolation. In the rare event of a short circuit within a cell, this casing provides protection for the other cells. The electrical isolation serves as an integrated fuse. It provides electrical interruption if the current flow between the cells becomes too high. The individual cells are also protected by thermal isolation. The fully encased cells, and additional separators, reduce the risk of both overheating in the battery and a potential thermal chain reaction between the individual cells. This enables a controlled process in the event of gas evolution in the battery: The gas is able to escape in a controlled manner via a predetermined breaking point, preventing it from spreading to further cells.

More tests, more automation in production: How Bosch optimises battery safety

Furthermore, numerous test procedures and safety tests are employed, which have been tried and tested, and continuously expanded over many years. Here, Bosch eBike Systems tests the batteries in-house and, in some cases, more stringently than required by law. Among other things, they are tested for short-circuit protection, protection against overcharging and resistance to external mechanical stresses. Bosch also tests the batteries without BMS, despite this not being a legal requirement. Safety tests are also carried out by suppliers along the value chain.

The result: Bosch eBike Systems batteries set high benchmarks for quality and safety. Not only do they comply with the legal requirements, but also exceed them in many respects. In the case of the batteries for the latest-generation "smart system", the degree of automation has also been further increased in production. This further enhances precision in the production process.

Despite the higher safety requirements that Bosch eBike Systems places on its batteries, a battery could still become damaged. Risks can be further minimised through careful battery handling. Batteries should not, for example, be stored near heat sources and should not be cleaned with a direct water jet or even a high-pressure cleaner. Nor should the batteries be opened under any circumstances. All information on the correct handling of Bosch eBike Systems batteries can be found in the Battery Guide.

Media contact:

Robert Bosch GmbH
Tamara Winograd
Head of Marketing and Communication Bosch eBike Systems
Tel.: +49 (0)7121 35-394 64
Tamara.Winograd@de.bosch.com

Bosch eBike Systems is shaping the future of eBike mobility with innovative products and digital services ranging from highly efficient drive systems to the first production-ready ABS for eBikes and Connected Biking solutions. On the daily routes through the city, on leisurely rides through the countryside or for sporting adventures in the mountains: Bosch eBike Systems offers eBikers the right drive system (drive unit, battery, display, and app) for every requirement and every area of use, ensuring a unique riding sensation. Today, more than 100 of the world's leading bicycle brands trust the perfectly coordinated, modular product portfolio. As an independent division within the Bosch Group, Bosch eBike Systems also makes use of the Group's technology and manufacturing expertise. For healthy, safe and sustainable mobility that is fun.

For more information please visit www.bosch-ebike.de

The Bosch Group is a leading global supplier of technology and services. It employs roughly 420,000 associates worldwide (as of December 31, 2022). According to preliminary figures, the company generated sales of 88.4 billion euros in 2022. Its operations are divided into four business sectors: Mobility Solutions, Industrial Technology, Consumer Goods, and Energy and Building Technology. As a leading IoT provider, Bosch offers innovative solutions for smart homes, Industry 4.0, and connected mobility. Bosch is pursuing a vision of mobility that is sustainable, safe, and exciting. It uses its expertise in sensor technology, software, and services, as well as its own IoT cloud, to offer its customers connected, cross-domain solutions from a single source. The Bosch Group’s strategic objective is to facilitate connected living with products and solutions that either contain artificial intelligence (AI) or have been developed or manufactured with its help. Bosch improves quality of life worldwide with products and services that are innovative and spark enthusiasm. In short, Bosch creates technology that is “Invented for life.” The Bosch Group comprises Robert Bosch GmbH and its roughly 440 subsidiary and regional companies in some 60 countries. Including sales and service partners, Bosch’s global manufacturing, engineering, and sales network covers nearly every country in the world. With its more than 400 locations worldwide, the Bosch Group has been carbon neutral since the first quarter of 2020. The basis for the company’s future growth is its innovative strength. At 128 locations across the globe, Bosch employs some 85,000 associates in research and development, of which nearly 44,000 are software engineers.

Additional information is available online at www.bosch.com, www.iot.bosch.com, www.bosch-press.com, www.twitter.com/BoschPress.

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