Technological innovation on a global scale
ROBOTISED PRODUCTION OF BICYCLE FRAMES
AND A RESEARCH AND DEVELOPMENT CENTRE
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Learn about the process
Design

The AG Motors Design Team is a group of professionals specialising in areas such as 3D modelling, FEM analysis, structural and equipment design, applied arts and product graphic design. With advanced project management software and state-of-the-art IT assets, they are capable of providing the desired results within short timeframes.

Development of a frame concept

The beginning of the work related to the creation of each new bicycle concept is a sketch made by the main designer

Frame modelling

After receiving the sketch, the team of engineers verifies the possibility of creating a frame with shapes similar to those drawn by the team of designers. A 3D model of the frame is created, and it is presented to the whole team to discuss technical and aesthetic issues.

Selection of components

At the same time, the team of designers prepares different variants of the bike specifications, such as gears, shock absorbers, brakes, wheels and other equipment.

A one-to-one scale 3D printout

A printout of the frame makes it possible to physically check the components included in the specification in order to verify that there is no interference between the equipment and the frame

Design development

The team of designers receives both drawings, a 3D model and a finished printout of the frame, in order to visualise the design to be applied to the frame

3D scanning

A 3D scanner is a device that analyses an object or the real-world environment to collect data about its shape and sometimes its appearance (for example, its colour). The collected data can then be used to construct digital 3D models. This makes it possible to apply so-called reverse engineering, i.e. to get the dimensions of the existing element and reflect it in the drawing, and also to create a physically identical element

Production

Robotised frame manufacturing based on automated lines is a technological innovation on a global scale. With this development, it becomes possible to produce a whole bicycle frame in a single, continuous welding process. Automation ensures the repeatability, high production rate and top quality of the final product.

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Technology
Tests
Research and Development Centre

The R&D team is totally responsible for the creation of designs from the concept stage, through sketches and 2D models, all the way to the detailed design documentation. Thanks to modern 3D printers the production of a frame model prototype takes less than 24 hours, which significantly speeds up the process from design to production.

Tests

We run fatigue and impact tests, as well as simulations in a climate chamber. We can test such components as frames, forks, wheels, saddles, handlebars, pedals, and drivetrains, as well as whole bicycles under load, in both impact and fatigue tests. By using extensive apparatus, every component of a bicycle can be tested in both virtual and real conditions, and, as a result, we are able to gain an insight into the processes which operate during the use of the bicycle.

Frames

We carry out frame fatigue and impact tests. We test and check the strength of vital areas of the frame, such as the saddle stem and the head tube. The impact test checks the material for impact strength.

Forks

We test steel, aluminium, and composite forks. The tested components undergo fatigue, dynamic, and impact tests.

Wheels

The wheel-centricity test involves checking the rotational accuracy of the wheel and rim. It is used to assess both the horizontal and vertical inclinations. The test simulates the use of the component when driving in real conditions, and on diverse terrains.

Brakes

We carry out both stress and fatigue tests. We check the disc brakes and v-brakes, both mechanical and hydraulic, as well as foot brakes.

Drivetrain

The fatigue test for the bicycle drivetrain simulates a system of forces which act on the component while the cyclist is pedalling, when both seated and standing.

Steering

The steering wheels tested by us undergo a series of static and dynamic tests that verify the deformation and strength of the tested component. In our laboratory, we will test different types of steering wheels, regardless of their purpose, size, material or shape.

Pedals

Bicycle pedals are tested for strength in a certain number of test cycles.

Saddles

The component is subjected to static and dynamic tests. The test result provides an assessment of the test piece’s deformation to allow meeting the standard and tolerance range.

Whole bike

The procedure is used for testing a bicycle for durability, when fitted with all components, with simulation of weather conditions. and the capacity of the brakes’ use.

Safety

The strength of the product plays a crucial role in the safety of its operation. The testing-machine unit we have at our disposal allows us to simulate the daily use of bicycle components. By carrying out fatigue, impact, static, dynamic, and climate-chamber tests, we identify and prevent damage and its possible consequences before the bike is ridden on real terrain.

Certification

A requirement to be met in order to market a product is its certification. This is the need to attest to a product’s conformity to the requirements laid down in a particular specification, and it also results from the provisions of the law. We have qualified personnel, and we are authorised to grant the ISO 4210 certification. Our laboratory carries out certification activities in the field of bicycle-component certification. We are accredited for ISO 9001 2015 & ISO/IEC-17025:2005.

Our projects
B2B Offer

ISO 4210:4 BRAKES
SAFETY TESTS

Brake-block and brake-pad assemblies - security test

ISO 4210:4.3

Hand-operated braking system - Strength test

ISO 4210:4.4

Back pedal braking system - Strength test

ISO 4210:4.5

Braking performance

ISO 4210:4.6

Brakes - Heat-resistance test

ISO 4210:4.7

ISO 4210:5 STEERING SYSTEM
SAFETY TESTS

Handlebar grips and plugs

ISO 4210:5.4.1

Handlebar stem - Lateral bending test

ISO 4210:5.4.2

Handlebar and stem assembly - Lateral bending test

ISO 4210:5.4.3

Handlebar Stem - Forward bending test

ISO 4210:5.4.4

Handlebar to handlebar stem - Torsional security test

ISO 4210:5.4.5

Handlebar to fork steerer - Torsional security test

ISO 4210:5.4.6

Bar end to handlebar - Torsional security test

ISO 4210:5.4.7

Aerodynamic extensions to handlebar - Torsional security test

ISO 4210:5.4.8

Handlebar and stem assembly - Fatigue test

ISO 4210:5.4.9

ISO 4210:6 FRAME
SAFETY TESTS

Frame - impact test (falling mass)

ISO 4210:6.4.1

Frame and fork assembly - impact test (falling mass)

ISO 4210:6.4.2

Frame - fatigue test with pedalling forces

ISO 4210:6.4.3

Frame - fatigue test with horizontal forces

ISO 4210:6.4.4

Frame - fatique test with vertical forces

ISO 4210:6.4.5

ISO 4210:6 FORK
SAFETY TESTS

Suspension fork - tensile test

ISO 4210:6.5.2

Front fork - Static bending test

ISO 4210:6.5.3

Front fork - Rearward impact test

ISO 4210:6.5.4

Front fork - Bending fatigue test and rearward impact test

ISO 4210:6.5.5

Forks intended for use with hub or disk brake

ISO 4210:6.5.6

Tensile test for a non-welded fork

ISO 4210:6.5.7

ISO 4210:7 WHEELS
SAFETY TESTS

Rotational accuracy

ISO 4210:7.4.1

Wheel/tyre assembly - Static strength test

ISO 4210:7.4.2

Wheels - Front/rear wheel retention devices secured

ISO 4210:7.4.3

Wheel/tyre assembly - fatigue test (city, trekking)

ISO 4210:7.A.1

Greenhouse effect test for composite wheels

ISO 4210:7.4.4

ISO 4210:8 PEDALS
SAFETY TESTS

Pedal - Static strength test

ISO 4210:8.4.1

Pedal - Impacts test

ISO 4210:8.4.2

Pedal - Dynamic durability test

ISO 4210:8.4.3

ISO 4210:8 DRIVE SYSTEM
SAFETY TESTS

Crank assembly road/CTR/youth - fatigue test (100 k cycles)

ISO 4210:8.4.6

Crank assembly MTB - fatigue test (45 degrees 50 k cycles)

ISO 4210:8.4.6

Crank assembly MTB - fatigue test (30 degrees 50 k cycles)

ISO 4210:8.4.6

ISO 4210:8 SEAT
SAFETY TESTS

Saddle/seat post security test

ISO 4210:8.4.6

Saddle - Static strength test

ISO 4210:8.4.6

Saddle and seat-post clamp - Fatigue test

ISO 4210:8.4.6

Seat-post - Fatigue test and static strength test

ISO 4210:8.4.6

ISO 4210:3 FULLY-ASSEMBLED BICYCLE
SAFETY TESTS

Structural strength of fully - assembled bicycle

ISO 4210:3 A1

Media about us
Contact

Podgrodzie 34 B
39-200 Dębica

Design Department

+48(14) 658 40 30
biuro@ag-motors.pl

Research and Development Centre

+48(14) 658 40 30
biuro@ag-motors.pl

The Company is registered in the District Court in Rzeszów, 12th Commercial Department of the National Court Register, under KRS No.: 0000343691. NIP: 8722361970