One of the complex but also ingenious components of the new TWIKE 5 will be its roll bar. In addition to its name-giving function of rollover protection in the event of e.g. involuntary rollover, other safety functions will also be integrated in it in favor of the desired lightweight design. For example, it absorbs the restraining forces of the upper deflection of the three-point belt, but also effectively absorbs crash energy in the event of a foreign body hitting the side wall.
The roll bar, which is made of high-strength fiber composite, is also an extremely weight-optimized structural component that connects the base frame and the rear chassis with each other and thus optimally takes into account its force influences. Furthermore, due to the low manufacturing tolerances of its manufacturing process, reliable sealing levels can be achieved with repeatable accuracy, which will help to reduce assembly times and will above all be reflected in a perfect finish of the related surfaces.
The special requirements and the desired geometry require the production of the bracket in specially developed tools. At first glance this seems expensive, since we wanted to avoid special tooling costs in small batches, but in view of the high degree of integration of the functions (safety, structural element, sealing levels, finished and matching surfaces) and the possible degree of lightweight construction, the initial costs are likely to be relative even for a 500 series and make the solution economical. Last but not least, the roll bar is an optical design object which also optimally communicates the basic character of the TWIKE 5 (safe, powerful, efficient).
If you would like to gain a deeper insight into the development process at this point in time, then visit us and take a test drive with the TWIKE 4.
We are looking forward to it!