Zedler - Institut für Fahrradtechnik und -Sicherheit GmbH, based in Ludwigsburg, is part of the Zedler Group and has specialized in the development and construction of testing systems for bicycles and e-bikes since 1994. In the company's own test laboratory, bicycles and components such as frames, handlebars, saddles or luggage racks are tested for operational stability - both on behalf of manufacturers and dealers for prototype testing and for insurance companies and courts as part of expert reports in the event of accidents or damage.

In addition to carrying out tests, the company develops and produces its own testing machines, which are used in the test laboratories of leading bicycle manufacturers worldwide. The institute also produces standard-compliant operating instructions and manuals for bicycles and e-bikes. With four dynamic laboratories and around 50 fatigue testing systems as well as a consistently sustainable corporate orientation, Zedler GmbH is now a globally recognized partner for quality and safety in bicycle technology. "We are a classic hidden champion with customers from all over the world, although we are primarily known in the bicycle industry," says Dirk Zedler, founder, testing expert and expert of Zedler-Institut.

Not all wheels are the same - special requirements for testing systems

Bicycles and pedelecs are on the move, often on a daily basis and on changing surfaces. Bicycle frames range from very compact folding bikes with small 16-inch wheels to cargo bikes with a wheelbase of up to 2.15 m and wheels of different sizes at the front and rear to tandems for two riders. What's more:

City bikes often have a low bottom bracket so that you can comfortably put your feet on the ground when stopping at traffic lights.

Mountain bikes (e.g. Enduro), on the other hand, need a lot of ground clearance so that the pedals do not touch down so easily off-road, even if the suspension compresses.

In order to be able to precisely reproduce different geometries, wheelbases and bottom bracket heights, test systems must therefore be highly adjustable and at the same time very rigid and durable, as they have to transfer precise forces to a wide variety of bicycle frames over many years.

Customized testing technology at the highest level

To ensure that a frame can withstand these continuous loads over many years, there is a classic test in bicycle technology: the bottom bracket fatigue (BBF) test. The bottom bracket is one of the most heavily stressed areas on a bicycle and the point at which the pedals are connected to the frame via the cranks. Every pedal stroke generates alternating torques, bending and torsional forces that add up over a long period of time. Without sufficient stability, cracks could form that ultimately lead to breakage or failure.

In his test laboratory, Zedler simulates the forces that a person generates when pedaling, the so-called "pedaling forces". The bicycle frame with the bottom bracket installed is repeatedly subjected to artificial loads. This makes it possible to determine how many of these load changes (cycles) it can withstand before the first signs of damage such as hairline cracks, cracking or play in the bearing appear. The BBF system developed by Zedler is characterized by its special adaptability to different bicycle types and its durable design. As soon as all parameters have been adjusted, the test system reproduces the pedal load that a rider applies to the frame over the course of the bicycle's life within around 24 hours.

The institute works exclusively with test systems developed in-house, such as the "Performance" test machines. They measure the driving characteristics and also the properties of individual components and provide reliable results on driving stability, driving safety and comfort under comparable conditions. Statements can also be made about the consistently high quality of a production batch.

Powerful machines, reliable components

When building the testing machines, Zedler does not rely solely on its in-house expertise, but also relies on partners such as norelem and its extensive portfolio of standard and operating parts for mechanical and plant engineering, or in other words: Here you will find a lot of ideas and solutions that inspire Zedler again and again.