It's really difficult to understand exactly what happens inside: Fascinated, the tester colleagues crowd around the open Pinion demo gearbox. While cranking by hand, four pairs of eyes watch intently as gears mesh, shifting pawls click and freewheels whir. The chainring of the "transparent" Pinion gearbox actually turns faster when you shift up a gear. You recognise the two partial gears that make up the high-end unit - and suddenly understand that such a complex gear train on a bicycle is more than "just" a piece of technology for many: there are often very emotional arguments for and against gears. From a sober point of view, the advantages are numerous, but there are also disadvantages.
Less wear, less maintenance
What is certain is that no other bicycle gear system functions as reliably, trouble-free and with as little maintenance for as long as a closed gear system. Quite simply because disruptive factors such as moisture, dirt or lack of lubrication are not an issue. If you stick to the modest maintenance schedules of the respective manufacturers, an oil change is only due once every five or ten thousand kilometres, or once a year in the case of less frequent use. Otherwise, it is sufficient to keep the chain or belt, sprocket, chainring, shifter and cables clean and well maintained. A Rohloff hub with 100,000 kilometres is considered by experts to be just about well run-in.
Reliability and robustness are particularly important criteria for touring cyclists, who are especially dependent on functioning technology on routes far away from civilisation. But even those who use their bike all year round in everyday life don't want to be constantly tinkering with their bike with oily fingers because the derailleur is stuck or the sprockets are worn. Thanks to the encapsulation, the same conditions always prevail for the gears in the gearbox: the lubrication remains in place, external interference and corrosion are ruled out and mechanical wear remains calculable. The question of the efficiency of gearboxes is often asked: There are some complicated studies on this, but it basically depends on the particular gearbox model and the gear engaged. This is because more or less friction is generated depending on how many partial gears are currently in play.
Special gearbox for e-bikes
What is certain is that the efficiency of high-quality Rohloff or Pinion gearboxes is around two or three per cent lower than that of a new, well-maintained derailleur system. As a gearbox only needs a single sprocket on the rear wheel, a hub with a wider flange can be used: The symmetrically stored rear wheel is significantly more stable - an important argument for touring cyclists whose rear wheel is weighed down by luggage anyway. Critics criticise the fact that you have to briefly interrupt your pedalling during the shifting process. This can also cause problems on e-bikes with powerful centre motors. As a cyclist, however, you quickly get used to shifting gears with feeling; on an e-bike, this is regulated by sensitive electronics. However, too much power should not be applied to the gears: Manufacturers therefore only permit a few sprocket and chainring sizes for changes to the primary gear ratio. In order to withstand high motor torques, Shimano has developed a special e-bike hub with a reinforced shift servo and freewheel. The continuously variable Enviolo is also a powerhouse. It can even handle the forces of loaded E-cargo bikes with ease. This shows that gearboxes have real bite!
The gearboxes at a glance
Shimano - Variety for all cyclists
Beautiful and practical - with these characteristics, the Japanese manufacturer has managed to make the world of cycling a little more perfect for many years. The Japanese company built the first three-speed hub back in 1957, but it was not until 2006 that the renaissance of hub gears really began with the attractively designed eight-speed hubs of the (more affordable) Nexus and (higher quality) Alfine series. The eight-speed gears of both series are technically identical on the inside and, like the Rohloff hub, work with planetary gears shifted in series. Due to the design, the gears are not evenly spaced. At the beginning of a range of 307 per cent, this doesn't make that much of a difference. But when a gap of 22 per cent separates gears five and six in the middle of the most frequently used range, it is unpleasant.
The eleven-speed Alfine works almost silently with 409 per cent bandwidth as a helical gearbox and pleases with finely and regularly stepped gears. Overall, it has a very long gear ratio, offering only a few easy gears suitable for uphill riding, but almost too many gears for high speeds. Shimano specifies the primary ratios to prevent damaging overload. All hubs can be operated with the convenient twist shifter or the precise touch shifter. You have to briefly release the pressure on the pedal to shift gears.
Enviolo - Continuously variable
The Enviolo changes gear ratios completely steplessly within a total range of 380 per cent. The rider constantly makes slight adjustments using the twist grip, while balls move between inclined planes inside the hub. This ensures that the cyclist always cranks in the green speed range. Special oil lubrication with traction-enhancing particle additives keeps the mechanism smooth and helps to transmit very high torques of up to 120 Newton metres.
Formerly known under the Nuvinci brand, the Enviolo is currently experiencing a minor boom, partly because electrically assisted cargo bikes are on the rise. This requires powerful drives with high torque. At around 2.4 kilos, the hub is relatively heavy, which, together with its low maintenance and robust mechanics, makes it ideal for combination with powerful mid-drive motors. It runs with a chain or belt and can be shifted purely mechanically, semi-automatically with its own electric twist grip or fully automatically integrated into the Bosch motor system. The unique selling point is that the electronics and a servomotor adjust the gear ratio so that the cyclist is always travelling at their desired cadence without having to do anything themselves. The hub, control electronics and Bosch motor take care of the rest.
Rohloff Speedhub - A work of engineering art
The reputation that designer Bernd Rohloff has earned with his 14-speed gear hub is legendary. This marvel of mechanics packs almost the gear range of a 2x10 derailleur into a single box. It weighs just under 1,800 grams and is so solidly constructed that it has been proven to achieve astronomical mileages of more than 250,000 kilometres. 526 per cent total gear ratio, 14 usable, consecutive gears at regular intervals of 13.6 per cent, fully protected against dirt and moisture - that was an announcement in 1999 that is still valid today.
The low maintenance requirements and the well-balanced gear menu have made the Rohloff a favourite of frequent riders and globetrotters on two wheels ever since. The company in the Hessian town of Fulda takes customer service very seriously and even sends spare parts around the world if necessary, should a Rohloff cyclist break down somewhere on the globe.
Pinion P-Series - High-end gearboxes
In 2011, a small company with the peculiar name Pinion entered the bicycle scene with a completely new concept: the two founders and inventors Michael Schmitz and Christoph Lermen had developed their innovative bottom bracket gearbox according to automotive industry standards and brought it to market maturity. They proudly presented 18 regularly stepped gears with a huge total gear ratio of 636 per cent - which caused quite a stir in the cycling world.
The new gearbox is particularly popular with frequent riders and touring cyclists who are looking for reliability and don't care about every gram. The gearbox concept consists of three spur gears arranged one after the other, high-quality bearings and seals, hermetically packed in a milled housing and ideally positioned at the lowest point of the bike. Quality and performance were convincing right from the start and led to a series of smaller variants with twelve and nine gears for different applications. The robust gearboxes work with a chain or Gates belt and score points for their low maintenance requirements and long service life. With a five-year guarantee and dedicated customer service, Pinion sets the standard very high.
Pinion C-Series - the new middle class
While bikes with Pinion's top-of-the-range P1.18 gearbox can easily cost €5,000, the C-Line is aimed at more affordable bikes and e-bikes. The range currently consists of three gearboxes with six, nine and twelve gears. The inner workings are identical to those of the P-Line in terms of quality and design. Fewer gears mean fewer sub-transmissions, less material, assembly effort and weight.
The die-cast housing of the C-Line is more efficient to manufacture and lighter than the P-Line housings, which are milled from solid material. In addition, the Q-factor, the lateral distance between the pedals, has been reduced from 174 (P-Line) to 166 millimetres, making it more ergonomically favourable. As a result, the price and weight of the C models are significantly lower than those of the P series. The C1.12 is interesting for demanding everyday and touring cyclists, the C1.9 is suitable for mountain biking and everyday use and the six-speed model is suitable for e-bikes.
Gearbox in the e-bike
A delicate partnership with the engine
Gearbox and motor do not always harmonise on an e-bike. For example, Shimano hub gearboxes have a maximum input torque limit of 50 Newton metres when combined with a mid-motor. Some Bosch models are much higher, with up to 75 Newton metres, and must therefore not be paired with Shimano hubs. Rohloff's Speedhub and the continuously variable Enviolo hub are better able to withstand these forces. Both hubs can be operated mechanically using a twist grip or electrically. The Enviolo can be integrated into the Bosch motor management system and then automatically shifts gears according to the desired cadence.
Rohloff's E14 version is also a Bosch-compatible electric drivetrain with servomotor. With mechanically shifted hubs, the rider must briefly interrupt the pedal pressure, as on a normal bike, in order for the shifting process to take place. Under overload, Shimano gear hubs refuse to shift gears out of self-protection. With the Di2 system, Shimano also offers electric shifting, also automated with its own Steps drive. The electronics briefly reduce the motor power during the shifting process. Pinion occupies a special position: Here, the gearbox is located in front of the drive, so that the combination with the rear hub motor is completely uncritical and works harmoniously.
Framework conditions: A bicycle frame must be prepared for gear drive
Gearbox integration places special demands on frame builders: In contrast to a derailleur frame, they have to design some additional elements into the frame for gearboxes. Pinion gearboxes require a special mount instead of the bottom bracket, Rohloff hubs need long pins on the axle slot to accommodate the torque arm.
A tensioning mechanism must be provided for the chain or belt to compensate for elongation due to wear. For this purpose, bottom bracket eccentrics or slider axles with adjusting screws are recommended. The axle must not tilt during installation. For a belt drive, it must be possible to open the seat stay so that the closed belt can enter the frame. These additional elements mean extra work for the manufacturer in terms of development, use of materials and assembly, while for the user they mean higher weight, maintenance costs and specific expertise, such as how to separate the shift cables from the hub when removing the rear wheel. The belt drive also requires more space in the frame for the eleven millimetre wide Gates belt and its drive pulleys.
Practical test of gear wheels
Three test bikes demonstrate the range of high-quality transmissions for demanding cyclists.
Stevens Superflight
If you left out the "F" in the name, that wouldn't be wrong either: just under 14 kilos is a respectably low weight for a hub-gear bike. The Stevens realises this with a sporty, slightly stretched riding position, smooth handling and good-natured steering. Relatively wide but lightweight tyres give the bike a light-footed ride and allow it to accelerate quickly. The Alfine gear system with eleven regularly spaced gears is also designed for long distances: With its long internal gear ratio, it actually only offers one "mountain gear" and even that only in inverted commas: Its strengths lie on long stretches of flat terrain or only slight inclines. We have never actually used the highest gear, even on test rides.
Poison Phosphorus
Yes, it's titanium that shines here! The frame and fork of the Poison are made of this robust, durable metal that is difficult to work with. Although this makes the bike expensive, it offers extreme durability and steel-like flexibility. Together with the tightly tuned suspension support and wide tyres, the Poison rides with significantly less vibration than the other two test bikes. The fork flexes relatively heavily backwards under heavy braking, but it is solidly constructed and mounted. The frame also has fine weld seams, an almost invisible belt buckle and decent tube diameters. Unfortunately, the imperfectly aligned dropouts on the fork and rear triangle as well as the poorly positioned rear stand have a negative impact. Thanks to long mudguards, top lights, powerful brakes and a sturdy pannier rack, the Poison scores points even with demanding use. With its 14 well-spaced Rohloff gears, the bike covers the range from everyday use to travelling the world with ease.
Velotraum VK12
You can recognise the makers' many years of experience in this bike: the Velotraum is ready to go from a standing start. The specialists from Weil der Stadt have spent years developing, refining and optimising the handling, ergonomics and equipment. The geometry has been chosen so that the cyclist can transfer their power efficiently to the pedals; depending on the number of spacer rings under the stem, you can sit on the bike in a relaxed or sporty position. It rides smoothly and quietly, but is also manoeuvrable - ideal for both everyday use and touring with luggage. High-quality lights, long, rattle-free mudguards and a powerful, sensitive disc brake from Magura make the bike suitable for bad weather without any restrictions and usable all year round. The drivetrain with Pinion's 18-speed gearbox offers a gear for every situation thanks to the fine gradation and the wide range of ratios: with luggage, you will be happy about the opulent selection of mountain gears on climbs, while on flat terrain the optimum cadence can be maintained even in gusty winds or undulating terrain. A universal bike for every situation.
You can download the complete article with an overview of all 14 gearboxes and the three test bikes including all individual ratings as a PDF below the article. The article costs 2.99 euros.
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