Your safety. Our priority.

eBike battery safety

A cyclist on an eBike rides through an impressive cityscape. The dynamic, low-angle shot highlights the contrast between a state-of-the-art curved glass building and historic architecture under blue skies.

Safety is our top priority – including our batteries. We show you how we constantly make our batteries safer. And what you can do to be safer on the road.

The PowerTube 750 is depicted with its internal components exposed.

Mechanical isolation

Single cell of an eBike battery depicted separately.

The individual cells of an eBike battery from Bosch are encased in flame-retardant plastic.

Electrical isolation

The integrated protection of the eBike battery cells is depicted in a detached manner.

The integrated fuse in each battery cell ensures electrical interruption in the event of increased current flow in a cell.

Thermal isolation

A separating element of the eBike battery cells is depicted in isolation.

Isolating elements reduce the risk of overheating and a possible thermal chain reaction between the cells.

Battery Management System (BMS)

The battery cells' circuit board is depicted in a cropped image.

The intelligent BMS monitors the battery. It detects potential fault sources and protects against excessive temperatures, overload, and deep discharge.

Protection against water ingress

The seal protection of the eBike battery cells is shown separately.

The sealing concept of a Bosch eBike battery protects against water ingress and therefore against consequential damage.

We develop the batteries for our eBike systems at our headquarters in Reutlingen and produce the majority of them at the Bosch plant in Miskolc, Hungary.

Battery safety starts with the selection of the battery cells that we purchase from suppliers. We only work with reputable, certified cell manufacturers.

Many small lilac-colored battery cells in various boxes.

After a voltage check, a robot loads the cell holders fully automatically. The cells are encased in flame-retardant plastic, ensuring they are mechanically and thermally isolated.

The robot encases cell carriers in purple plastic. On display are plastic containers, some empty, and some filled with cells.

The cell connector is then fitted, which is responsible for the electrical interruption in the event of an increased current flow in a cell. The interlayer is then mounted on the individual cell blocks, thermally isolating them from each other.

A robot is securing one cell block, with many other cell blocks visible behind it.

Robots automatically assemble the individual cell blocks, weld them together and connect them to form a battery.

A robot is assembling several cell blocks, with a factory interior visible in the background.

The battery management system (BMS) is installed – in newer batteries, this is done automatically by a robot. The BMS continuously monitors the condition of the battery and checks each individual cell.

On the left, a secured cell block is visible, while on the right, a person is holding a green processor board.

The housing is closed with a seal and cover cap. The sealing concept protects against water ingress.

The housing of the PowerTube 625 is secured in a bracket in order to be sealed with a gasket and cover cap.

The battery is placed in specially approved packaging. It protects against damage and has the required markings.

The completed PowerTube 625 battery is placed into a cardboard box.

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How we test

Crush test This test simulates the incorrect use of a battery and must not be imitated.

A battery is loaded with 1000 times its own weight. This is how we test its safety in the event that strong mechanical pressure is exerted on the battery.

Shaker test

A battery is subjected to vibrations of varying intensity, simulating the load of an entire life cycle on different surfaces. This is how we test its durability.

Drop test This test simulates the incorrect use of a battery and must not be imitated.

A battery is dropped from a height of one meter onto a concrete block. This is how we test its robustness against falls or dropping.

Water resistance test This test simulates the incorrect use of a battery. To protect the electronics, do not clean the battery with a direct water splash and absolutely never use a high-pressure washer.

A battery is subjected to high water pressure of up to 100 bar from various angles. This is how we test its water resistance.

Cropped battery back, on which the security warnings can be read with a label.

CE marking

The CE security certificate 'CE' in black.

The CE marking indicates that the battery meets all relevant EU-wide requirements.

A triangle with a black outline. Inside the triangle, a checkmark with a black outline.

RCM marking demonstrates mandatory compliance with the safety and regulatory requirements for Australia and New Zealand.

Be careful when buying used batteries to avoid purchasing defective, repaired or stolen products. They may pose a safety risk.

Use our battery check to test your used battery when you buy it. Using the serial number, you can immediately see whether a service case has already been registered for this battery.

To the battery check

You must not open the battery housing. This is reserved exclusively for qualified and trained personnel. If you open the battery, you will interfere with the certified condition. This poses safety risks.

A person stands at a desk, talking on the phone. They're wearing a gray Bosch jacket and using a computer at the same time. In the background, there is a bicycle and some plants.

Exchange, don't repair

eBike batteries are wearing parts. For safety reasons, defective, old or used batteries cannot be repaired or refreshed. Take your battery to a bike dealer instead. They will ensure it is properly recycled.

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