Maintenance-free, durable bearing technology in heavy-load cargo bikes

Easy to open and close with every stop

It transports payloads of up to 350 kilos and is almost as easy to ride as a two-wheeled e-bike: the Cargobike from Fulpra is the ideal vehicle for the last mile of city logistics. Every component has been developed for high loads and minimal maintenance. For the sliding doors of the load compartment, the designers rely on drylin® W-profile rails, which are maintenance-free and run smoothly over the long term thanks to their dry-running properties. igus® bearings are also used in the drivetrain and in the parking brake - compact, lubrication-free and highly resilient.

Profile

What was needed: Profile guides for the sliding doors of the load compartment; alternative for metal roller bearings in the parking brake and in the drive train
Requirements: Smooth running, wear resistance and durability, corrosion-free, resistant to dirt and temperature fluctuations, compact installation space, maintenance-free
Area of application: Bicycle industry

Already successfully in use in the Netherlands, Norway and Sweden and being tested in Cologne: thanks to a special tilting system, the e-cargo bike from Fulpra Motors BV rides as comfortably as a two-wheeler when cornering. At the same time, the cargo body remains stable in a horizontal position and allows loads of up to 350 kilograms to be transported quickly through the city.

Problem

"The bike has been developed from the ground up for high loads and heavy-duty use with minimal maintenance. This applies to every single component", says Michel van Eynatten, co-founder of Fulpra. He and his team therefore only rely on bicycle components for the saddle and pedals, but otherwise on components from the motorbike industry that are designed for heavier loads. For the suspension and guidance of the sliding load compartment doors, the designers were looking for profile guides that were as robust as they were smooth-running. "It is very important that the guides achieve a long service life under adverse conditions. After all, the doors are opened at every stop." Changing weather conditions, vibrations and impacts while driving must not impair the function.
The parking brake also required particularly strong and heavy-duty bearing components. This is because the brake must be able to safely hold the fully loaded cargobike with a total weight of 600 kilograms on an incline of 20 per cent.

Solution

Joint engineering with the Dutch igus® representative Elcee resulted in the best technical solution for the sliding doors: drylin® WSQ profile guides. The 1.40 metre long guides made of hard-anodised aluminium can be easily integrated into the design of the load compartment. The special feature of the drylin® linear system: The housings are equipped with iglidur® J plain bearing foils, which ensure low-friction, smooth running without any lubrication. This eliminates the need for regular maintenance and the problem that greased bearings attract dirt and wear out more quickly. The linear bearings do not rust, rattle or jam and move smoothly even in wet conditions, frequent use, shocks and vibrations.
For the bearing points in the parking brake and in the chain tensioners, igus® offered the best solution: iglidur ® flanged bushings of the X series. They are characterised by a particularly high compressive strength and, like all igus® bearings, require no additional lubrication thanks to their incorporated solid lubricant. They are also much lighter and more compact compared to metallic bearings.