In the control centreA visit to Sram

Henri Lesewitz

 · 01.02.2021

In the control centre: A visit to SramPhoto: Henri Lesewitz
In the control centre: A visit to Sram
The US company Sram has shaken up the gear shifting market. But the drivetrains are not that American. A visit to Sram's Schweinfurt incubator of ideas.

After years in the shadow of Shimano, the American manufacturer Sram has completely shaken up the gear shifting market. However, the US company's drivetrains are not really that American. BIKE visited Sram's incubator of ideas in Schweinfurt. You can read the big company report in BIKE 3/2021. Here you can get a foretaste.

The enormous hall colossus is located in a business park on the outskirts of Schweinfurt. The main façade is mirrored, but if you look closely, you can guess what the interior is all about.
Photo: Henri Lesewitz

It was no longer an evolutionary process. It was more reminiscent of a wrecking ball gone wild, the force with which the switching trends have recently been crashing into established standards. 2x10, 1x11, 1x12, Bluetooth. Whereas there used to be a few years between development leaps, it suddenly felt like there was a hail of new products every year.

Hardly any other component has changed as radically in recent years as the gears on mountain bikes. A breathtaking development that has also shaken the balance of power on the gear shifting market.

Ten years ago, Shimano's 3x9 XTR groupset was still the undisputed ultimate in the high-end segment. Then competitor Sram, which until then had been more of a niche supplier, launched an innovation attack.

The radical 2x10 was followed in 2012 with 1x11 the burial of the thrower. Shortly afterwards 1x12. The Bluetooth variant AXS rounded off the whole thing. At least for now. The simple fact that people at Sram's development centre in Schweinfurt go about their work every day shows that the subject of shifting is obviously far from over.

German engineering expertise in the US group

What many people don't realise: The US company's drivetrains are primarily the product of German engineering expertise. All shifting components are developed at the company's Schweinfurt branch - from the shifter to the cassette to the actual rear derailleur.

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The Americans had taken over the former bicycle division of Fichtel & Sachs in 1997 as part of a global expansion programme. The then still tiny company Sram from Chicago, which had only started years earlier with a twist shifter called Grip Shift and was just trying to conquer the market with the new ESP rear derailleur, now had direct access to expertise and production facilities.

However, it would be some time before the gearstick market was revolutionised. How is a gear shift created? Why wasn't 1x12 invented right after 3x9? What will the drivetrain of the future look like? In search of answers, we paid a visit to the Sram gearshift centre in Schweinfurt. You can read the big company report "Tooth by tooth" in BIKE 3/2021. The photo gallery here gives you a foretaste.

  <a href="https://www.delius-klasing.de/bike-03-2021-bik-2021-03" target="_blank" rel="noopener noreferrer nofollow">BIKE 3/2021</a> is available from 2 February. Order the <a href="https://www.delius-klasing.de/bike" target="_blank" rel="noopener noreferrer">BIKE free delivery to your home</a> , or read the digital edition in the BIKE app for your <a href="https://apps.apple.com/en/app/bike-das-mountainbike-magazin/id447024106" target="_blank" rel="noopener noreferrer nofollow">Apple-iOS-</a> or <a href="https://play.google.com/store/apps/details?id=com.pressmatrix.bikeapp" target="_blank" rel="noopener noreferrer nofollow">Android device</a> . You can experience <a href="https://www.delius-klasing.de/bike-lesen-wie-ich-will?utm_campaign=abo_2020_6_bik_lesen-wie-ich-will&utm_medium=display&utm_source=BIKEWebsite" target="_blank" rel="noopener noreferrer">BIKE on subscription</a> at a particularly favourable price and conveniently.Photo: BIKE Magazin BIKE 3/2021 is available from 2 February. Order the BIKE free delivery to your home , or read the digital edition in the BIKE app for your Apple-iOS- or Android device . You can experience BIKE on subscription at a particularly favourable price and conveniently.  The enormous hall colossus is located in a business park on the outskirts of Schweinfurt. The main façade is mirrored, but if you look closely, you can guess what the interior is all about.Photo: Henri Lesewitz The enormous hall colossus is located in a business park on the outskirts of Schweinfurt. The main façade is mirrored, but if you look closely, you can guess what the interior is all about.  Cosy corner: Andreas Kölsch is the senior product manager and decides which idea becomes a project - and which remains a pipe dream. The plush red corner where he sits flanks the entrance to the myth-enshrouded development department, where around 80 engineers hatch circuit ideas.Photo: Henri Lesewitz Cosy corner: Andreas Kölsch is the senior product manager and decides which idea becomes a project - and which remains a pipe dream. The plush red corner where he sits flanks the entrance to the myth-enshrouded development department, where around 80 engineers hatch circuit ideas.  The prototypes are produced in-house and often tested by engineers on the trails around Schweinfurt. On trails that are as deserted as possible, of course, because the parts are subject to the strictest secrecy. The used condition of these Eagle prototypes shows how hard the parts are pushed.Photo: Henri Lesewitz The prototypes are produced in-house and often tested by engineers on the trails around Schweinfurt. On trails that are as deserted as possible, of course, because the parts are subject to the strictest secrecy. The used condition of these Eagle prototypes shows how hard the parts are pushed.  Development engineer Frank Schmidt is one of the "old hands" in the company. He worked at Sachs back in the nineties and helped tinker with the plasma rear derailleur that was popular with lightweight construction fans at the time. Here he shows an early prototype of the Eagle derailleur.Photo: Henri Lesewitz Development engineer Frank Schmidt is one of the "old hands" in the company. He worked at Sachs back in the nineties and helped tinker with the plasma rear derailleur that was popular with lightweight construction fans at the time. Here he shows an early prototype of the Eagle derailleur.  The door is wide open, everything looks inviting, but the entrance to the development department is a wall. Access is strictly forbidden to unauthorised persons. The fear of ideas being stolen is too great.Photo: Henri Lesewitz The door is wide open, everything looks inviting, but the entrance to the development department is a wall. Access is strictly forbidden to unauthorised persons. The fear of ideas being stolen is too great.
  Sram PR man Max Topp is responsible for providing the press with information. During our visit to BIKE, he attempts the difficult balancing act between openness and vigilance. The test lab is actually a "sensitive area", but we were allowed to enter and take photos. Of course, Max had made sure before the visit that nothing was lying around that should not be made public.Photo: Henri Lesewitz Sram PR man Max Topp is responsible for providing the press with information. During our visit to BIKE, he attempts the difficult balancing act between openness and vigilance. The test lab is actually a "sensitive area", but we were allowed to enter and take photos. Of course, Max had made sure before the visit that nothing was lying around that should not be made public.  From the first prototype to the series version: evolution of a rear derailleur.Photo: Henri Lesewitz From the first prototype to the series version: evolution of a rear derailleur.  The reliability of the parts is an important part of the development process, as too many warranty claims or even recalls can lead to economic disaster. In the measurement laboratory, all prototypes are converted into digital models before and after testing using a 3D scanner. Five million measuring points are recorded in the process. The room is kept at a constant 20 degrees in order to rule out deviations due to temperature-dependent material expansion. The measurements, which are carried out by engineer Thomas Fella (photo) and others, reveal every hint of wear.Photo: Henri Lesewitz The reliability of the parts is an important part of the development process, as too many warranty claims or even recalls can lead to economic disaster. In the measurement laboratory, all prototypes are converted into digital models before and after testing using a 3D scanner. Five million measuring points are recorded in the process. The room is kept at a constant 20 degrees in order to rule out deviations due to temperature-dependent material expansion. The measurements, which are carried out by engineer Thomas Fella (photo) and others, reveal every hint of wear.  The almost 80 "torture machines" in the test department run day and night. Almost 5,000 tests are carried out here every year - on wear and material dimensioning, as well as sensitivity to environmental influences such as cold or heat.Photo: Henri Lesewitz The almost 80 "torture machines" in the test department run day and night. Almost 5,000 tests are carried out here every year - on wear and material dimensioning, as well as sensitivity to environmental influences such as cold or heat.  The antique cooling chamber dates back to the days of Fichtel & Sachs. In the chamber, gear hubs were exposed to temperature fluctuations from minus 40 to plus 150 degrees. There is even still the original fur coat that the testers used back then when entering the icy chamber to avoid dying of cold. "When you press the on switch, you have to start up a nuclear power plant," grins André Gläser, head of the testing department. For ecological reasons, the chamber is no longer used today.Photo: Henri Lesewitz The antique cooling chamber dates back to the days of Fichtel & Sachs. In the chamber, gear hubs were exposed to temperature fluctuations from minus 40 to plus 150 degrees. There is even still the original fur coat that the testers used back then when entering the icy chamber to avoid dying of cold. "When you press the on switch, you have to start up a nuclear power plant," grins André Gläser, head of the testing department. For ecological reasons, the chamber is no longer used today.  A silent witness to times gone by: The drawing board with the hub sketches from the early Sachs years adorns a passageway in the company building. The Sachs company was famous for gear hubs. This tradition still lives on to some extent today. After all, small micro-gears work in the electronic Sram gearsticks.Photo: Henri Lesewitz A silent witness to times gone by: The drawing board with the hub sketches from the early Sachs years adorns a passageway in the company building. The Sachs company was famous for gear hubs. This tradition still lives on to some extent today. After all, small micro-gears work in the electronic Sram gearsticks.
  A rear derailleur on the test bench: During the tests, a total of 400 metres of chain are worn per month.Photo: Henri Lesewitz A rear derailleur on the test bench: During the tests, a total of 400 metres of chain are worn per month.  After the test: anything that fails ends up in the scrap bin.Photo: Henri Lesewitz After the test: anything that fails ends up in the scrap bin.  PR man Max Topp is responsible for the emotional charge of the products. It is not only the function, but also advertising campaigns and event appearances that determine sales success. Unfortunately, the famous show truck has to remain indoors until further notice due to the coronavirus pandemic.Photo: Henri Lesewitz PR man Max Topp is responsible for the emotional charge of the products. It is not only the function, but also advertising campaigns and event appearances that determine sales success. Unfortunately, the famous show truck has to remain indoors until further notice due to the coronavirus pandemic.  In the DSD area, which stands for Dealer Service Direct, employees wait for parts that have been sent in while answering questions from the hotline via headset.Photo: Henri Lesewitz In the DSD area, which stands for Dealer Service Direct, employees wait for parts that have been sent in while answering questions from the hotline via headset.  Here, a sent-in damper is being prepared for the upcoming operation.Photo: Henri Lesewitz Here, a sent-in damper is being prepared for the upcoming operation.  Just the bare essentials: The white MTB fragments are called "fake bikes" and are used purely for training purposes. They are normally used to teach dealers how to bleed brakes or adjust gears as part of workshops. The frames only contain the parts that are necessary for this.Photo: Henri Lesewitz Just the bare essentials: The white MTB fragments are called "fake bikes" and are used purely for training purposes. They are normally used to teach dealers how to bleed brakes or adjust gears as part of workshops. The frames only contain the parts that are necessary for this.  <a href="https://www.delius-klasing.de/bike-03-2021-bik-2021-03" target="_blank" rel="noopener noreferrer nofollow">BIKE 3/2021</a> with the big Sram report "Tooth by tooth" is available from 2 February. Order the <a href="https://www.delius-klasing.de/bike" target="_blank" rel="noopener noreferrer">BIKE free delivery to your home</a> or read the digital edition in the BIKE app for your <a href="https://apps.apple.com/en/app/bike-das-mountainbike-magazin/id447024106" target="_blank" rel="noopener noreferrer nofollow">Apple-iOS-</a> or <a href="https://play.google.com/store/apps/details?id=com.pressmatrix.bikeapp" target="_blank" rel="noopener noreferrer nofollow">Android device</a> . You can experience <a href="https://www.delius-klasing.de/bike-lesen-wie-ich-will?utm_campaign=abo_2020_6_bik_lesen-wie-ich-will&utm_medium=display&utm_source=BIKEWebsite" target="_blank" rel="noopener noreferrer">BIKE on subscription</a> at a particularly favourable price and conveniently.Photo: BIKE Magazin BIKE 3/2021 with the big Sram report "Tooth by tooth" is available from 2 February. Order the BIKE free delivery to your home or read the digital edition in the BIKE app for your Apple-iOS- or Android device . You can experience BIKE on subscription at a particularly favourable price and conveniently.

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