MAHLE’s latest electric XS system is built to make electric bike drives simpler, more sustainable and lighter.
It includes an external battery pack, named the eX1, offering a range of up to 60km, which incorporates all the system’s electronics and can be charged off-bike via USB-C.
The reduction in weight and the external battery means the system can be used to electrify bikes such as folding or children’s bikes.
The eX1 battery works with MAHLE’s existing X20 or X30 rear-hub motors.
It can also be used with a range of MAHLE’s other electric bike components to provide a lighter-weight ebike system that can be easily incorporated into pedal-powered bike frames with minimal product redesign.
You can expect to see bike brands launch a variety of electric bikes that are simpler and lighter than current models.
Just-right range and easy charging
Many electric bikes include a large integrated battery that’s heavy and difficult to integrate.
Although an internal battery enables bike makers to build a sleek-looking electric bike, they complicate charging because you need a power outlet close to your ebike.
MAHLE assessed how much battery capacity and range riders of its existing systems were using.
The data showed most riders weren’t utilising the full range offered by larger batteries. With this in mind, the XS system’s eX1 battery has a 171Wh capacity, rather than the 236Wh or 350Wh offered by its premium ebike systems.
This right-sized battery means the MAHLE XS system is lighter, easier to maintain, more versatile and offers a high power-to-weight ratio to boot.
Because the eX1 battery is mounted externally on the bike’s frame, it’s easy to remove and charge, either via USB-C or a standard charger. The battery can also be used as a range extender for MAHLE’s existing X20 and X30 motor systems.
Thanks to its lightweight design, carrying a spare battery for longer adventures is feasible, adding even more flexibility for ebike users.
The eX1 battery can fully recharge in only 2.5 hours using a USB-C charger.
For added convenience, MAHLE has introduced the Energy Hub, a charging platform that eliminates the need for heavy chargers.
It enables the eX1 battery to be charged quickly, while doubling as a power bank for other devices.
With the Energy Hub, the eX1 battery can charge a smartphone up to 10 times, or a laptop twice, making it a multi-functional tool for cyclists on the go.
Minimalist controls, maximum performance
The XS motor system’s on/off switch is housed on the top of the battery pack. Assistance levels are also selected using this button.
A single lightbar on the battery indicates both the assistance mode and battery level while riding, keeping controls simple and user-friendly.
The system integrates seamlessly with MAHLE’s other components, offering brands the option to add bar-mounted or top-tube controllers, as well as the Pulsar One bike computer for more detailed ride information.
A simpler, more sustainable ebike system
Mahle’s XS system pares down the components required to build an electric bike.
Bike makers only need to include in their designs the external battery, the XS smart controller, sensors to manage power delivery and the rear-hub motor.
There are fewer electronic components needed, but the modular design of the XS system enables bike makers to pick and choose their configuration.
Benefits include the use of fewer materials and simpler, low-cost maintenance.
The XS system works with MAHLE’s existing, well-established rear-hub drive units – the X30 and X20 motors.
The X20 is MAHLE’s top-of-the-range, more compact, lighter motor with 55Nm torque.
It provides a range of up to 60km as part of the XS system and weighs only 1.4kg. A complete ebike system, including the eX1 battery, weighs a claimed 2.5kg.
The X30 provides 45Nm of torque, offers up to 55km range and weighs 1.9kg, with a complete system weight of 3kg (claimed).
Those weights are around 500g lighter than MAHLE’s full X20 and X30 systems with their larger-capacity internal batteries, while still offering the same performance benefits – with a range better suited to most rides.
Expanding possibilities for ebike designs
The lightweight and versatile XS system opens the door for electrifying bike models that were previously difficult to integrate with ebike systems, such as compact, folding bikes.
There’s no need to design a frame specifically to accommodate the electric system, making it possible to create electric bikes based on existing pedal-only bike designs.
At the same time, it’s possible to expand the system with extra components such as a bar-top or top-tube controller and additional sensors for a more sophisticated ebike implementation.
Additionally, the external mounting of the system means brands can create adaptable bikes where the rear wheel can be removed to convert between assisted and unassisted modes.
By simplifying the components required and allowing for customisation with accessories such as its eShifters, Duo and Pulsar One, the MAHLE XS system enables manufacturers to create ebikes that are not only more accessible but also more innovative.
