Electric Bicycle Comprehensive Testing Machine

All-in-one roller-type test bench for electric bicycles. Covers maximum speed, maximum power, range, hill-climb, and dry/wet braking performance in a single machine — per EN 15194, ISO 4210, EN 14764, EN 14766, EN 14781, DIN 79100, and GB 17761. Computer-controlled automatic execution, real-time data logging, and Excel report export.

Quick Specs at a Glance

• Riding speed range: 0–40km/h

• Force sensor capacity: 200kg

• Roller diameter: 650mm (±10mm)

• Wheelbase adjustment: 1,000–1,600mm

• Braking actuator: Electric cylinder (precise force control)

• Dry braking standard: 25km/h — front brake ≤7m, rear brake ≤15m

• Wet braking standard: 16km/h — front brake ≤5m, rear brake ≤10m

• DC power supply: 60V / 50A

• Report export: Excel format; software supports Windows 10 / 11

Table of Contents

1. Why Electric Bicycles Need Comprehensive Performance Testing

2. Overview of the FH-ZD2988 Test Bench

3. Standards Covered by the FH-ZD2988

4. Main Test Functions and Applications

5. Design Features of the FH-ZD2988

6. Technical Specifications

7. How the FH-ZD2988 Testing Process Works

8. Benefits for E-Bike Manufacturers and Labs

9. Choosing the Right E-Bike Comprehensive Test Bench

10. Real-World Application Scenarios

11. FAQs for the FH-ZD2988

12. Related Testing Equipment

13. Get a Quote from Feihong Machine

Why Electric Bicycles Need Comprehensive Performance Testing

Electric bicycles occupy a unique regulatory position worldwide. They are classified as non-motorized vehicles in many jurisdictions — but they carry battery-powered drive systems capable of sustained high speed, significant torque output, and extended range that traditional bicycle safety standards were never designed to evaluate. This dual character means an e-bike leaving a modern production line must satisfy two overlapping sets of requirements simultaneously: the electrical system must deliver rated performance under load, and the complete vehicle — including brakes, frame, and drive integration — must behave safely at the speeds that electrical system enables.

Braking is perhaps the starkest example of why this matters. A conventional bicycle rarely exceeds 25km/h on flat ground. An electric bicycle can sustain 25km/h indefinitely with minimal rider effort, meaning the brake system encounters far more demanding duty cycles in normal use than bicycle-only standards were historically written to anticipate. Wet-road braking at 16km/h after sustained spraying is a requirement that exists precisely because e-bikes regularly operate in conditions where a conventional bike rider would have slowed naturally.

Similarly, maximum power output, motor efficiency, range per charge, and hill-climbing torque are performance claims that manufacturers must substantiate with real measurements — not estimates — as regulatory scrutiny tightens in China (GB 17761-2024), the EU (EN 15194 and related EN standards), and export markets worldwide.

The FH-ZD2988 electric bicycle comprehensive test machine addresses this by consolidating all major performance and safety test functions onto a single roller-type bench with computer-controlled automation — making it practical to run the full required test sequence as part of regular production QC, not just periodic certification events.

Overview of the FH-ZD2988 Test Bench

The FH-ZD2988 is a multi-function roller dynamometer for complete electric bicycle performance and safety validation. A fully assembled production e-bike is placed on the bench, weighted to the standardized test mass, secured with safety fixtures, and tested through all required sequences under computer control — without any manual measurement intervention once parameters are set.

The machine covers six major test categories:

• Hill-climb performance

• Maximum motor power output and efficiency

• Maximum speed and acceleration

• Range (mileage) per full charge

• Voltage and current monitoring with energy-consumption calculation

• Dry and wet braking performance (front brake, rear brake, and combined)

All results are logged in real time, with automatic stop and alarm triggers for out-of-spec results, and reports exportable directly to Excel for QC documentation or certification submission.

What distinguishes the FH-ZD2988 from single-function test rigs is its multi-standard coverage in one machine. Rather than running a speed test on one bench, a braking test on another, and a range test on a third, manufacturers can complete the full regulatory test matrix in sequence on a single setup — reducing floor space requirements, setup time, and the calibration overhead of maintaining multiple separate systems.

Standards Covered by the FH-ZD2988

The FH-ZD2988 is designed to test against the following standards. The specific clauses addressed by each test function are noted where applicable:

European Standards

International Standards

Chinese National Standards

Note on GB 17761-2024: China's updated mandatory national standard for electric bicycles fully replaced the 1999 version effective December 2025. The FH-ZD2988's test functions align with the performance test parameters addressed in both the legacy and revised standard. Manufacturers targeting China CCC certification under the new standard should confirm specific clause mapping with their designated certification body.

Main Test Functions and Applications of the FH-ZD2988

1. Hill-Climb Performance Test

Simulates uphill road loads via the roller system. Verifies that the drive system delivers adequate torque to maintain speed on rated gradients — a baseline requirement under EN 15194 and GB 17761 for EPAC vehicles claiming all-terrain capability.

2. Maximum Power and Efficiency Test

The computer automatically controls and measures motor torque and rotational speed simultaneously, using integration to derive peak power output. Current and voltage are logged in parallel, enabling automatic calculation of motor efficiency (electrical input vs. mechanical output) at peak power — providing both the performance figure and the efficiency curve in a single test run.

3. Maximum Speed and Acceleration Performance Test

The system monitors current draw as the vehicle accelerates. When current begins declining — indicating the motor has reached its governed maximum speed — the computer records the speed at that inflection point as the verified maximum. This method directly captures the actual governed limit, not a momentary peak, giving manufacturers a defensible maximum speed figure for regulatory declarations.

4. Range (Mileage) Test

Starting from a full charge, the computer activates the assist drive at maximum rated speed and logs continuous mileage. The test runs to depletion, recording the total distance traveled under standardized conditions for range claims and energy-labelling declarations.

5. Voltage, Current, and Energy Consumption Test

The bench supports both external power supply and on-board battery operation. The system automatically records speed, mileage, current, and voltage throughout the test and calculates actual energy consumption per 100km — the figure used for comparative efficiency labeling and export market compliance.

6. Dry and Wet Braking Performance Tests

This is the most multi-layered function on the FH-ZD2988:

a. Dry riding and braking (front, rear, or combined)

• Benchmark: 25km/h approach speed; front brake ≤7m stopping distance, rear brake ≤15m

• The system automatically measures riding distance, speed, and brake count throughout the run; out-of-spec results trigger automatic alarm and machine stop

b. Wet braking performance

• The spray system wets the braking surfaces for a minimum of 5 seconds before brake application begins, and continues spraying until the test cycle ends — replicating the EN 14764/14766/15194 wet-brake test protocol

• Benchmark: 16km/h approach speed; front brake ≤5m stopping distance, rear brake ≤10m

• Automatic measurement, alarm, and stop functions apply identically to the wet test

c. Dry/wet combined sequence

• Runs dry riding, wet riding, and braking tests in a configurable sequence, with independent pass/fail recording for each segment

• Brake count is freely configurable (0–999,999 cycles) for durability and endurance runs

d. Report output

• All results are stored on disk in freely configurable report formats, printable on demand, and exported directly to Excel — the standard format for most CCC and EN certification file packages

Design Features of the FH-ZD2988

Computer-Controlled Automatic Execution

Once parameters are entered, the machine runs the full test sequence without manual intervention — measuring, recording, alarming, and stopping automatically. This removes operator variability from test results and makes the bench practical for high-volume production-line QC, not just R&D lab use.

Electric Cylinder Braking Actuator

The brake application system uses an electric cylinder rather than a pneumatic or mechanical cam — giving precise, programmable control over braking force magnitude and application timing. This enables consistent reproduction of the standardized brake force specified in EN 15194, EN 14764, and EN 14766 across every test cycle.

Automatic Tyre Burst Detection

If a tyre fails during a high-speed run, the system automatically detects the event and halts the test — preventing secondary damage to the machine and protecting test data integrity.

Automatic Overload Shutdown

The 200kg force sensor monitors load continuously; any out-of-range reading triggers an automatic stop before mechanical damage can occur.

Adjustable Roller Wheelbase

The front-to-rear roller spacing adjusts from 1,000mm to 1,600mm, accommodating most e-bike wheelbases currently on the market without fixture changes.

Integrated DC Power Supply

The built-in 60V/50A DC regulated supply powers the vehicle under test directly where needed, without requiring an external bench supply or separate cable run — simplifying setup and reducing the risk of connection errors affecting test data.

Technical Specifications of the FH-ZD2988

Why These Specifications Matter

• 0–40km/h speed range comfortably exceeds the 25km/h statutory maximum for EPACs, giving headroom for tests that approach — and verify — the governed limit without mechanical constraints on the bench itself.

• ≤1% distance accuracy and ≤2% speed accuracy ensure that braking distance and range figures recorded by the FH-ZD2988 will align with independently measured values, making the data defensible for certification submissions.

• Electric cylinder brake actuation eliminates the force inconsistency inherent in pneumatic or mechanical systems — brake force is set digitally and repeated identically across hundreds of thousands of cycles.

• 0–999,999 configurable brake cycles means the same machine that does certification-level braking tests can also run endurance and durability testing on brake components without reconfiguration.

How the FH-ZD2988 Testing Process Works

Step 1: Vehicle Preparation and Mounting

The fully assembled e-bike is positioned on the roller bench. Test weights are attached according to the applicable standard (EN 15194 / GB 17761 specify total system mass including rider equivalent load). Safety fixtures are adjusted and secured.

Step 2: Parameter Configuration

The operator enters the test parameters on the computer: speed targets, brake force values, spray timing (for wet tests), brake cycle count, pass/fail distance thresholds, and the test sequence to be executed. Once confirmed, no further manual input is required during the run.

Step 3: Automatic Test Execution

The computer executes the full sequence — powering the vehicle, ramping to test speed, applying brakes via electric cylinder, logging all data channels simultaneously, activating the water spray system for wet tests at the correct timing, and advancing through each test phase automatically.

Step 4: Alarm and Auto-Stop Monitoring

Throughout the run, the system monitors force, speed, distance, and tyre integrity in real time. Any out-of-specification result, tyre burst, or overload condition triggers an immediate alarm and machine stop, with the failure event logged precisely.

Step 5: Report Generation and Export

On test completion, results are compiled into a configurable report format, saved to disk, and exported to Excel for QC records, certification documentation, or forwarding to the test requester.

Benefits for E-Bike Manufacturers and Testing Labs

Consolidate Multiple Tests into One Setup

Running speed, power, range, and braking tests on separate machines means multiple fixture changes, multiple calibration schedules, and multiple points of failure in a test workflow. The FH-ZD2988 handles the complete test matrix on a single machine, reducing setup time per vehicle significantly.

Defensible Data for Certification and Export

Faster Response to Standard Updates

As China's GB 17761-2024 and EU type-approval frameworks evolve, manufacturers with in-house test capability can validate revised designs immediately — rather than waiting weeks for third-party lab appointments. Under the 2024 revision of GB 17761, several performance test parameters tightened; manufacturers who already had in-house speed, torque, and braking test capability were able to verify compliance on new designs before submitting for CCC re-certification.

Endurance and Durability Testing

The configurable 0–999,999 brake cycle count means the FH-ZD2988 doubles as a brake endurance tester — validating brake pad wear rate, cable stretch, and hydraulic system integrity over a simulated product lifetime in the same machine used for initial performance validation.

Choosing the Right Electric Bicycle Comprehensive Test Bench

When evaluating comprehensive e-bike test machines for your production or laboratory environment, consider:

Standard Coverage vs. Single-Function Machines

Some labs buy separate machines for speed testing, braking, and range. This is viable when test volume for each function justifies a dedicated setup. For most e-bike manufacturers running QC testing on the full vehicle, a multi-function machine like the FH-ZD2988 gives better floor-space utilization and lower total calibration overhead.

Braking Actuator Type

Pneumatic actuators are common and inexpensive, but force output varies with supply pressure. Electric cylinder actuators hold set force regardless of ambient conditions, which matters when replicating the precise brake force specified in EN 15194 clause 4.2.6 and EN 14764 clause 4.6.9.

Wet-Test Capability

Not all comprehensive test benches include integrated spray systems for wet braking. If your products are marketed for year-round all-weather use — or if you are certifying against EN 15194 or EN 14764 — confirm that wet braking capability is built in, not an add-on.

Software and Data Output

Certification bodies and international buyers increasingly request raw logged data, not just a summary pass/fail table. Confirm that the machine software logs all channels continuously (speed, current, voltage, force, distance, time) and that export format is compatible with your documentation workflow. Excel compatibility is the baseline for most use cases.

Wheelbase Range

Confirm that the roller wheelbase adjustment covers your full product range. If you produce both compact folding e-bikes and cargo-style long-wheelbase models, verify the bench adjustment range accommodates both without a fixture change.

Real-World Application Scenarios

A mid-sized e-bike manufacturer preparing for EN 15194 EPAC certification used a comprehensive test bench to run the full power, speed, and braking test matrix in-house before submission, catching an under-spec rear braking distance at 25km/h early enough to adjust the brake pad compound before the certification test date — avoiding a retest fee and a six-week schedule delay.

An export-focused factory supplying European distributors used in-house wet braking test data to pre-qualify new brake caliper suppliers, verifying EN 14764 wet-stop distance compliance before committing to a volume purchase order — reducing the risk of a supplier change triggering a full recertification.

A testing lab serving multiple small-volume e-bike brands consolidated its previously separate speed dynamometer and braking test rigs onto a single comprehensive bench, reducing certification turnaround from 5 days to 2 days per vehicle by eliminating fixture transfer time between machines.

FAQs for the FH-ZD2988 Comprehensive Test Machine

What standards does the FH-ZD2988 cover?

EN 15194 (clauses 4.2.4, 4.2.6, 4.2.7), EN 14764 (clauses 4.6.8.5.3, 4.6.9), EN 14766 (clauses 4.6.7.5.2, 4.6.8), EN 14781 (clause 4.6.7.5.2), ISO 4210, DIN 79100, and GB 17761-1999 (clauses 5.1.4–5.1.8, 5.2.1, 6.1.1, 6.1.6). Manufacturers targeting the updated GB 17761-2024 should confirm specific clause alignment with their certification body.

Can it test both dry and wet braking on the same machine?

Yes. The FH-ZD2988 includes an integrated spray system that activates the required pre-soak period (minimum 5 seconds before brake application, continuous through the end of the test cycle) for wet braking tests, fully aligned with EN 15194 and EN 14764 wet-brake protocols.

What type of brake actuator does it use, and why does that matter?

The bench uses an electric cylinder actuator for programmable, precise braking force control — more consistent across test cycles than pneumatic actuators, which can vary with line pressure. This is particularly important for multi-cycle endurance runs where consistent force reproducibility is essential.

Does it require an external power supply?

A 60V/50A DC regulated power supply is built in, so no external bench supply is needed for operating the vehicle under test. The vehicle's own battery can also be used as the power source, depending on the test being performed.

Can it test conventional (non-electric) bicycles as well?

The braking performance functions — dry and wet stopping distance, brake cycle endurance — are applicable to conventional bicycles per EN 14764, EN 14766, and EN 14781. The power, speed, and range functions are specific to electric-assist drivetrains.

What data does the software log, and how is it exported?

The system logs speed, mileage/distance, current, voltage, braking force, and brake cycle count in real time throughout each test. Reports are configurable in format and exported directly to Excel (.xlsx), compatible with Windows 10 and Windows 11.

What happens if the tyre bursts during a test run?

Automatic tyre burst detection halts the machine immediately, protecting both the vehicle under test and the machine from secondary damage. The event is logged with a timestamp.

What is the maximum configurable brake cycle count?

0 to 999,999 cycles, freely configurable — covering everything from a standard braking performance test (typically fewer than 20 cycles) to long-duration brake endurance tests.

Related Testing Equipment

• Bicycle Frame Dynamic Fatigue Testing Machine — for frame and fork structural endurance validation per ISO 4210 and EN 14764

• Electric Bicycle / Motorcycle Chassis Dynamometer (FH-DL106) — for high-speed (up to 160km/h) performance testing of electric motorcycles and self-balancing unicycles

• Bicycle Multi-Function Impact and Drop Test Machine — for frame, fork, and component impact compliance testing

• Battery Charge/Discharge Test Systems — for isolated battery pack range and cycle-life validation

Get a Quote from Feihong Machine

Feihong Machine (Dongguan Feihong Instrument and Equipment Co., Ltd.) designs and manufactures precision testing equipment for electric bicycle manufacturers and testing laboratories worldwide. The FH-ZD2988 is available with configuration options to match your specific standard requirements and vehicle range.

To get started:

• Request a Quote — share your vehicle specs (wheelbase, battery voltage, test standards required) and we'll confirm the right configuration

• Request the Technical Datasheet — full mechanical drawings and electrical schematics

• Schedule a Remote Demo — see the FH-ZD2988 run a live wet-braking or range test sequence

Request a Quote →