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$47,442 pledged of $100,000 goal
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By Rakesh Dhawan
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About

Falco Fusion Sports Drive

Falco Fusion Press Kit is available here.

Rakesh Dhawan on Bloomberg
Rakesh Dhawan on Bloomberg
Transform your bike and use it with a heart rate monitor to automatically match your desired exercise level
Transform your bike and use it with a heart rate monitor to automatically match your desired exercise level
The Falco Fusion Sports Drive
The Falco Fusion Sports Drive

What is Falco Fusion Sports Drive eBike System?

Falco Fusion Sports Drive is an eBike drive system (or ebike kit as some call it.) which converts any normal bicycle into an electric bicycle. The motor goes in the rear of the wheel and the battery installs onto the down tube of the frame. The control unit slides onto the handle bar. The control unit is wired directly to the motor. This is a complete system. There are no additional controller, or components or messy wires to deal with. 

Smart phone allows you to add a ton of additional capability such as cycle computer, cardio control, fitness machine, power meter integration, eBike functions, social sharing and GPS mapping.

Motor can be activated with your feet (also known as pedal assist) or the control unit with built in throttle (also known as power on demand function). With the motor in the rear you can combine your and the motor power to go faster and farther.

Why should I use Falco eBike Drive System?

Technology Comparison with other eBike systems
Technology Comparison with other eBike systems

Falco eBike drive system is the most advanced eBike system in the market. It has been developed after years of research. It is powerful, robust and reliable and amazingly fast. You can control the system with your feet, hands or heart. There is no other system in the market which compares or even comes close to the Falco Drive System. 

The system is  Most Advanced; Light Weight; Powerful; Robust and Reliable; Gearless (no plastic or metal gears unlike the German or the Chinese Systems); Quiet (Gears make horrible noise even the German ones); Versatile (use it on any bike); Efficient (Geared Systems are inefficient); Cost Effective; Zero Resistance Pedaling; An Open System (see below for more info).

Falco eBike Drive Systems are an excellent alternative form of transportation. Although efficiency of the automotive has improved dramatically, so has the number of automobiles. Automobiles continue to wreck havoc on our cities and the environment. 

Now with Falco Fusion Drive,  you can use your bicycle for fun, fitness and transportation. There is no petrol or gas to be used. Electricity costs around $0.10 per 1000 watt-hour. That is enough to charge our battery pack twice. You stay fit, save the earth and have fun doing it.

Falco Fusion Sports App
Falco Fusion Sports App
The inbuilt smart phone charging. Without the inbuilt charging the smart phone is useless. It will run out of battery in less than 30 minutes while being used with all of its functionality
The inbuilt smart phone charging. Without the inbuilt charging the smart phone is useless. It will run out of battery in less than 30 minutes while being used with all of its functionality
The 50V, 400Wh Li-Ion Battery Pack
The 50V, 400Wh Li-Ion Battery Pack

How Does Falco Fusion Sports Drive System Work?

A Falco Fusion Sports Drive System converts any regular bike into an eBike or electric bicycle. There are only three components - electric wheel, battery pack and control unit. There are no messy wires or additional components or controllers to deal with. The controller and electronics are embedded inside the motor. The electric wheel simply replaces the rear wheel of your bicycle. The battery can be installed onto the down tube of the bicycle and the control unit simply slides over the end of your handlebars.

As you begin to pedal, the motor is automatically activated. This is called pedal assist. It senses the cyclists' torque and adjust the level of assistance accordingly. If you pedal harder, it will provide more assistance. If you pedal softly, it will provide less assistance. You can also activate the motor using the control unit. The plus can be used as a throttle. By holding the plus down, the motor can be activated without pedaling. The harder you press, more assistance you get. As you release the plus button, the level of assistance decreases. That is control of the motor with your hands (power on demand).

Built Reliably and Robustly for Off-Road Use
Built Reliably and Robustly for Off-Road Use
All the Information you may ever want to know about your battery and drive performance
All the Information you may ever want to know about your battery and drive performance

How easy is it to install the Falco Fusion eBike System on my bike?

The system is designed to be super simple to install. The step by step instructions and all the included hardware will guide you through the simple steps. The level of assembly does not require expert handyman skills or special tools. 

The whole process can be done in less than 30 minutes with only a few simple hand tools. The conversion process is simple and straight forward. Written and video instructions are included along with graphic illustrations.

All the hardware and instructions are included. Video instructions will be posted on our youtube channel.

Difference between 250 Watt and 350 Watt versions

The 250 watt version is an ideal solution for daily commuting. The 350 watt system is ideal for cyclists looking for more power and acceleration. 

 Since 250 watt system consumes less power, it will provide more range as compared to the 350 watt system. The 350 watt system provides 40% more power and is great for those looking for more performance.

The two systems are identical in appearance. The main differences are in the internal components such as magnets, winding and controller.

What is the range ? How far can I go ?

Max range of 100+ miles is achievable. Please see the chart below:

Range Estimation for Various Riding Conditions
Range Estimation for Various Riding Conditions

Under ideal riding conditions one can achieve great range. The ideal riding conditions include good roads, low friction tires inflated to recommended air pressure and well maintained bicycle components. The bicycle speed and rider weight also play an important part in determining the range. Lower speed dramatically improves range. Higher speed decreases range significantly. Changing the speed from 20 mph to 15 mph can increase your range by 30 to 50%.

In addition, using pedal assist is much more efficient than throttle only operation. It is impossible to increase range with throttle only operation. Motor will always overpower the rider and contribute 100% of the power. Under pedal assist, you are forced to contribute. Here you make a big difference. And with five assist levels you can have a fairly direct control over the range.

Please refer to the chart above to see range estimates.

Level 1 Range Estimates: 40 to 100+ miles

Level 2 Range Estimates: 35 to 85+ miles

Level 3 Range Estimates: 30 to 65+ miles

Level 4 Range Estimates: 25 to 55+ miles

Level 5 Range Estimates: 20 to 50+ miles

Throttle Only Range Estimates: 15 to 40+ miles

What is the difference between off-road and road legal versions?

Most counties regulate the speed and power an eBike can deliver. Some of the limits are mentioned below:

USA: Speed Limit: 20 mph (32 km/h), Power Limit: 750W

Canada: Speed Limit: 20 mph (32 km/h) , Power Limit: 500W

Europe: Speed Limit: 15 mph (25 km/h), Power Limit: 250W

Japan, Singapore, Australia: Speed Limit: 15 mph (25 km/h), Power Limit: 200W

India: Speed Limit: 15 mph (25 km/h), Power Limit: 250W

Below these limits, no license or insurance is required. 

Off-road versions go past these speed limits and provide pedal assistance to 28 mph (45 km/h). The off-road versions may not be ridden on public roads without certain licensing and/or insurance requirements.

Can the drive system be used without the smart phone?

Yes, the drive system can be used without the smart phone. All you need is the electric wheel, the battery pack and the control unit.  The drive system has all the performance and functionality to exceed any existing eBike in the market without the astronomical price tags and clunky noises of geared drive systems. 

And we go far beyond with our smart phone integration.

Smart phone adds the following functionality to the drive system:

  • Cycle Computer;
  • Off-Road Mode Activation;
  • Cardio Control;
  • Fitness Functions and Biometrics Feedback;
  • Power Meter Functions;
  • eBike Drive Data Display;
  • GPS Mapping;
  • Social Sharing.

Inside the Drive Technology

Inside the Drive Technology
Inside the Drive Technology

This is Falco Fusion Sports Drive. Falco fusion sports is based on a 5-phase technology researched in the Universities across the globe for a long time and we are the first to commercialize it.

It is:

  • Light Weight;
  • Powerful;
  • Robust and Reliable;
  • Gearless (no plastic or metal gears);
  • Quiet;
  • Versatile;
  • Efficient;
  • Cost Effective;
  • Zero Resistance Pedaling;
  • An Open System.

It is ANT+ and Bluetooth LE ready.The Falco Fusion Sports is disc brake and cassette ready. The drive can be spoked from 16” to 29” rim sizes or higher.The drive is available in 32, 36 and 48 spoke holes. It has an inbuilt torque sensor and a controller. There are 16 sensors inside which monitor human, motor and bike functions extensively.

 Not only have we achieved seamless integration of rider and drive power but also a system which can be cardio-controlled with biometrics feedback.

The drive has been tested for thousands of miles and under the most adverse conditions.

Falco's Lithium Battery

Open Architecture Lithium Pack: Falco’s Lithium Pack is based on our Open Architecture. This 50V high performance, light weight pack has 400Wh of capacity. It is extremely safe and easy to install and handle.

It has an inbuilt battery capacity gauge. The battery management system has advanced protection against short circuit, over temperature, low voltage and over charge. 

This state of the art battery pack is built with Panasonic cells. It is versatile and can work with almost all bikes. The pack merely weighs 5.5 lbs. (2.5 kg) and it delivers 50V with 400Wh.

Why an Open System is so important?

Let us imagine that you buy an expensive electric bike and after 2 years of use, you want to replace your battery. The manufacturer tells you one of two things:

  • It is a closed system, you can not use any other battery AND your battery replacement cost is more than 60% of your original cost. You have no choice but to buy it. Otherwise you risk losing all of your investment;
  • Your battery is no longer supported and hence you lose your investment because your drive can not work with other batteries. It is a closed system.
Falco Fusion Sports Battery
Falco Fusion Sports Battery

Falco fusion sports drive is an open system so that the drive can work with any other available battery in the market place. The drive has enough intelligence to work with any battery. 

The Control Unit

Falco Fusion Sports Drive Control Unit
Falco Fusion Sports Drive Control Unit

This is the control unit for the Falco Fusion Sports Drive. It is designed to be utterly simple and intuitive to use. The 5 bars on the top indicate the battery level. The 5 bars also indicate the pedal assist levels when used with the plus. The plus provides instant power. The plus and minus also control the pedal assist levels. The minus provides instant regenerative braking and 5 levels of regeneration. The control unit has an inbuilt charging port to charge the smart phones.

The App

Falco Fusion App
Falco Fusion App

This is the smart phone app for the Falco Fusion Sports. The app is built around ANT+ and Bluetooth LE. It works on iPhone, Android and most other smart phones.

Off-Road models can provide assistance upto 45 km/h or 28 mph.

Heart Rate Control
Heart Rate Control

The Falco Fusion Sports drive can be controlled with your heart. Set your target heart rate and the drive will do the rest.

The power training module allows you to set the target power and use the drive as a training device.

Power Training
Power Training

The app provides detailed information on the battery as well as the motor drive.

Detailed eBike Data Reporting
Detailed eBike Data Reporting
Drive Information on your finger tips with GPS functionality
Drive Information on your finger tips with GPS functionality

Falco Custom Colors

Color Options for Falco Fusion Sports Drive
Color Options for Falco Fusion Sports Drive

The Specs

The Drive Specs

  • Light Weight ~ 4.5kg //
  • High Efficiency ~ 90% //
  • High Torque ~ 30 to 45Nm //
  • Zero Cogging ~ 0.01Nm //
  • Rear Wheel Installation //
  • 24 or 36 or 48V Operation //
  • Wireless and CAN Communication Capability //
  • Precise Power and Torque Measurement //
  • Onboard Data Storage //
  • PC Diagnostic Interface //
  • High Speed Micro-Controller //
  • Disc Brake Mount //
  • Free hub/Cassette //

The Battery Specs

  • Li-Ion Panasonic Cells with Falco BMS //
  • 2.5 kg, 51V (Max Voltage), 10Ah //
  • 420 Wh //
  • Internal Impedance < 75mOhm //
  • Peak Discharge Current ~ 25A //
  • Regeneration and Power Consumption Control //
  • Operation upto 45 deg. C //
  • Cycle Life > 500 //
  • Cell Balancing //
  • Over-discharge protection //
  • Over-charge Protection //
  • Temperature Protection //
  • Secondary Protection //
  • Charge Voltage Limit ~ 51V //
  • High-Speed Processor //
  • Fast Charge (80%) < 4h //

The Development Process

Falco Circuit Boards - Five Phase Inverter and ANT+ eBike Console
Falco Circuit Boards - Five Phase Inverter and ANT+ eBike Console
First Hx Prototype was built using CNC machined components
First Hx Prototype was built using CNC machined components
The First Die Cast Motor Cover, Machined Axle and Bearing. Through validation and testing, we had to redesign all three components and re-tool the cover.
The First Die Cast Motor Cover, Machined Axle and Bearing. Through validation and testing, we had to redesign all three components and re-tool the cover.
Inside the 5-Phase Motor Technology
Inside the 5-Phase Motor Technology
Mark and Bob of Team Hybrid with Rakesh
Mark and Bob of Team Hybrid with Rakesh
Mark and Bob of Team Hybrid put the system through extensive testing in mud and rain
Mark and Bob of Team Hybrid put the system through extensive testing in mud and rain
Jesper Berggreen of E-Wheels tested the system in Denmark through cold and snow for more than 1200km
Jesper Berggreen of E-Wheels tested the system in Denmark through cold and snow for more than 1200km

Where can we use the Falco system?

The Falco system is versatile and can be used in just about any vehicle with pedals. Below are some of the example installations.

This is an example installation in a trike.
This is an example installation in a trike.
A Fat Bike Conversion
A Fat Bike Conversion
Falco Handcycle
Falco Handcycle

The Rewards

The Rewards
The Rewards

Why are we coming to you for support?

We have developed extraordinary electric bike technology. We believe that today's eBike technology is inferior for its use. It has many limitations. We want to change that.

In order to continue to evolve the technology and continue to stay ahead of the curve of the big companies such as Bosch, BionX, Yamaha etc.,  we need your support to scale up production and evolve the technology to the next level.

Timeline

Project Schedule and Delivery Timeline
Project Schedule and Delivery Timeline

 Shipping begins in April. The above timeline is based on a certain volume forecast.

The Falco Team

Video and Graphics: Bonita, Raymond, Aliyah, Melissa and John, Matt and Melinda, Marco and Simon.

Engineering Team: Rakesh, Dipak, Sumanta, Bhumika, Sumit, Pradip, Vivek, Ajay, Santosh, Sandeep, Shailendra, Girish, Alok, Shalini, Megha, Rinku, Bharati, Varsha, Vinod, Ashish and Vaishali;


Special Thanks to:

Melissa and John Franklin
Matt and Melinda Plumer
Marco Magni
Simon Harris
Troy Vasquez

#cardiocontrol, #ebikedrive, #eBikes, #electricbicycle, #electricbikeconversion, #falco, #falcofusionsports, #eBikekit

Risks and challenges

We have developed a mature supply chain with very aggressive quality control. However as with all new technologies, errors are possible at any level of execution. We have developed extensive principles and procedures to reduce these risks substantially.

Our track record is solid in terms of execution and we are confident that we can overcome any obstacles quickly.

Thank You for Your Support!

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Support

  1. Select this reward

    Pledge $10 or more About $10

    Thank You Card signed by the Falco team. Thanks so much for your support! You are part of the revolution.

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    An elegant Falco Fusion Sports Drive cap along with our huge thank you card. Your support means a great deal.

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    Falco Fusion Sports Polo Shirt along with a huge thank you card from the Falco team. Your support is greatly appreciated.

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    Falco Fusion Sports Drive ANT+ Heart Rate Sensor along with a huge Thank You card from the Falco team.

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    Falco Fusion Sports Drive Blue Tooth LE Heart Rate Sensor along with a hug Thank you card signed by the Falco team.

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    Pledge $495 or more About $495

    Early Bird 250W Drive and Control Unit Only. Road Legal Drive System (Europe limited to 25 km/h, North America limited to 20 mph, Other countries limited as per the legal requirements). Fully spoked wheel. Let us know the wheel size. Drive system is EN15194, CE (European regulations) and FCC compliant (US regulation). Shipping paid separately. Add $50 for custom color option. (see FAQ).

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    Pledge $695 or more About $695

    Early Bird 250W/50V/420Wh Road Legal Drive System (Europe limited to 25 km/h, North America limited to 20 mph, Other countries limited as per the legal requirements). Fully spoked wheel. Let us know the wheel size. Drive system is EN15194, CE (European regulations) and FCC compliant (US regulation). Shipping paid separately. Add $50 for custom color option. (see FAQ).

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    Pledge $795 or more About $795

    Limited Edition 250W/50V/420Wh Road Legal Drive System (Europe limited to 25 km/h, North America limited to 20 mph, Other countries limited as per the legal requirements). Fully spoked wheel. Let us know the wheel size. Drive system is EN15194, CE (European regulations) and FCC compliant (US regulation). Shipping paid separately. Add $50 for custom color option. (see FAQ).

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    Limited Edition 250W/50V/420Wh/OFF-ROAD Drive System (Europe limited to 45 km/h, North America limited to 28 mph, Other countries limited as per the legal requirements). Let us know the wheel size. Drive system is EN15194, CE (European regulations) and FCC compliant (US regulation). Shipping paid separately. Add $50 for custom color option. (see FAQ).

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    Pledge $995 or more About $995

    Limited Edition 350W/50V/420Wh Road Legal Drive System (Europe limited to 25 km/h, North America limited to 20 mph, Other countries limited as per the legal requirements). Let us know the wheel size. Drive system is EN15194, CE (European regulations) and FCC compliant (US regulation). Shipping paid separately. Add $50 for custom color option. (see FAQ).

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    Pledge $1,095 or more About $1,095

    Limited Edition 350W/50V/420Wh/OFF-ROAD Drive System (Europe limited to 45 km/h, North America limited to 28 mph, Other countries limited as per the legal requirements). Let us know the wheel size. Drive system is EN15194, CE (European regulations) and FCC compliant (US regulation). Shipping paid separately. Add $50 for custom color option. (see FAQ).

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    Pledge $3,475 or more About $3,475

    Reseller Package - Be our first partner to introduce Falco Fusion Sports Drive to the World. Limited Edition 5 of 250W/50V/420Wh/Road Legal Drive Systems (Europe limited to 25 km/h, North America limited to 20 mph, Other countries limited as per the legal requirements). Let us know the wheel size. Drive system is EN15194, CE (European regulations) and FCC compliant (US regulation). Shipping paid separately. Add $250 for custom color option. (see FAQ).

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    Pledge $4,475 or more About $4,475

    Reseller Package - Be our first partner to introduce Falco Fusion Sports Drive to the World. Limited Edition 5 of 350W/50V/420Wh/OFF-ROAD Drive Systems (Europe limited to 45 km/h, North America limited to 28 mph, Other countries limited as per the legal requirements). Let us know the wheel size. Drive system is EN15194, CE (European regulations) and FCC compliant (US regulation). Shipping paid separately. Add $250 for custom color option. (see FAQ).

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    Pledge $8,950 or more About $8,950

    Reseller Package - Be our first partner to introduce Falco Fusion Sports Drive to the World. Limited Edition 10 of 350W/50V/420Wh/OFF-ROAD Drive Systems (Europe limited to 45 km/h, North America limited to 28 mph, Other countries limited as per the legal requirements). Let us know the wheel size. Drive system is EN15194, CE (European regulations) and FCC compliant (US regulation). Shipping paid separately. Add $500 for custom color option. (see FAQ).

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Funding period

- (33 days)