Project Details

Helping to expand capabilities to reach more customers.

To expand their market reach, LeMond Cycling came to us to improve a connected power monitor for cycling training. When used in conjunction with the LeMond indoor training system, the device transmits the rider’s power and cadence data to any ANT+ compatible device, helping to expand the customer base.

CHALLENGE

The LeMond Revolution indoor trainer system is one of the most advanced cycling training systems on the market. By more accurately simulating riding conditions, the LeMond Revolution is crucial in helping cyclists maintain their training regimen and improve fitness in a constant, measured environment. The product is a rear flywheel system that connects to the frame of the bike, replacing the rear wheel and cassette. An alternative training option for cyclists is to utilize the LeMond Revolution Power Pilot, a pod that attaches to any indoor trainer system to gather data during workouts. The Power Pilot sends the data to a large display secured on the handlebars through a proprietary radio. The display then calculates and displays key training information such as speed, cadence, watts, and time.

However, in today’s market, most cyclists prefer to use their own bike computers to record training data and to transfer the data to their coaches for tracking. After their first successful venture with our team, Lemond Cycling returned to create a new version of the Power Pilot system, known as the WATTBOX. The WATTBOX would be compatible with an array of ANT+ bike computers. This enhancement will expose the indoor trainer to a broader market of cyclists seeking to measure and store their own training data. To making this update, LeMond challenged our engineers to improve the data outputs for increased accuracy.

SOLUTION

LeMond chose to work with our software engineers, electrical engineers, and manufacturing team to bring the new WATTBOX to market. To transform the current data collection system so as to be compatible with a variety of bike computers, our engineers used an ANT+ protocol to gather and send data via the cyclist’s compatible display. The ANT+ design encourages interoperability and open-access to data between an alliance of over 300 companies and manufacturers, opening up the Revolution product to a larger market of athletes.

To improve the accuracy of the data collected, we added real-time temperature and pressure sensors to the WATTBOX. The additional sensors coupled with the custom algorithm facilitated more accurate output measures to simulate pure power.

In addition, longer battery life is always a consideration when developing consumer devices. By utilizing a long history of experience in power and electronics product lifecycle management, CES was able to provide an extended battery life for the device.

Our manufacturing team got involved early during the product’s development. Through collaboration with trusted partners the new WATTBOX was designed to utilize the latest materials, components, and processes for a more cost effective product that could be rapidly manufactured and sent to market.

RESULTS

The new WATTBOX improved ease of adoption for cyclists by eliminating the need for an additional large display on the cyclist’s handle bars and improving the usability of the training data being displayed and recorded. Through this development, LeMond is able to broaden the appeal of their product to a larger segment of the cycling market.

CLIENT PROFILE

LeMond Cycling, a Greg LeMond company, designs and develops training equipment that set the standard for quality and performance in stationary cycles. Their line of equipment offers user-friendly adjustments and innovative cycling programs to make training more effective.

  • Project Name Wattbox Wireless Power Transmitter
  • Client LEMOND CYCLING