Pinarello Nytro White Paper

0. Introduction

Cicli Pinarello is a renowned and highly successful bicycle manufacturer, established in Treviso, Italy, in 1952 by Giovanni Pinarello. The company specializes in producing high-end racing bicycles.

The Pinarello name is synonymous with legendary victories achieved by the greatest cyclists throughout history. Since 1975, starting with Fausto Bertoglio's victory in the Giro d'Italia, Pinarello has secured wins in all major global races, including the Olympics, World Championships, and the Tour de France.

All bicycles developed for professional riders are also made available to amateur cyclists, enabling everyone to achieve their best performance. The close collaboration with professional riders drives the development of cutting-edge technologies that are subsequently integrated into the bicycles available to the public.

1. Pinarello Nytro Bike Concept

a. Purposes of the Project

Designing a new Pinarello bike is consistently a challenge, with high performance expectations to meet. The creation of Pinarello's first e-road bike, aiming to replicate the unparalleled Pinarello riding feel while incorporating an electric motor for pedaling assistance, presented an even more exciting challenge. Through a complex process of engineering and testing, the result is the first e-road bike that delivers maximum riding pleasure on descents and provides non-invasive yet effective support on ascents.

Pinarello Nytro: riding overboost!

Image: A Pinarello Nytro e-road bike in a studio setting against a dark background, showcasing its design and components.

The primary objectives at the commencement of the Nytro project were:

• To imbue an e-road bike with the same riding sensation as a traditional bicycle.
• To establish a new benchmark for e-road bikes regarding powertrain and frame stiffness.
• To reduce the overall weight of the system (bike + motor).
• To minimize air drag.

b. Handling and Riding Feeling

The objective was to optimize the handling for an all-around e-bike, prioritizing riding comfort alongside agility, cornering precision, and stability on long turns. This was achieved by merging legendary Pinarello frame geometries with the integration of the Fazua Evation system.

The main areas of development included:

• Integration of the Fazua Evation system in the down tube: This ensures the center of mass is positioned as low as possible, promoting stability during long turns without compromising agility.
• Vertical tube and fork angle: These are consistent with the Dogma model to ensure agility and precision in corners.
• Wheelbase: Approximately 1% longer than the existing Gan model to enhance comfort and stability.
• Head tube: 10% higher for a more relaxed riding posture.
• Head Set: Tapered with a top bearing of 1 1/8" and a bottom bearing of 1 1/2".
• Flat mount disk: 160 mm for reliable braking in all conditions.
• Thru-Axle: 12 mm for both the fork and stays, ensuring increased braking stability and higher torsional rigidity.

c. Powertrain and Frame Stiffness

Frame stiffness is critical for preventing energy loss and ensuring balanced bike behavior. Power transfer primarily occurs through the head tube, down tube, bottom bracket, and chain stays. Increased stiffness in these zones is necessary to minimize energy-sapping deflections and enhance power transfer between the rider and the rear wheel.

A common challenge in e-bikes is the integration of the motor and battery system within the frame, often requiring modifications to traditional frame tube shapes. Consequently, the sections of the down tube, bottom bracket, and chain stays were enlarged to facilitate perfect integration and prevent power transmission losses.

Image: Close-up views of the Nytro's bottom bracket, chainstay area, and handlebar remote, highlighting the integration of the Fazua system.

Image: A comparison of frame tube cross-sections, showing the Nytro frame (light blue) with wider sections compared to a traditional road bike frame (green), particularly in the down tube and bottom bracket areas.

The images illustrate a comparison between the new Nytro frame (light blue) and a traditional road bike frame (green). The down tube and bottom bracket dimensions are visibly wider to provide the necessary frame rigidity and accommodate the Fazua Evation System. The chain stays also feature a wider section to support the increased power output from the electric motor.

The Pinarello asymmetry concept is further emphasized in the new Nytro. In an e-bike, the frame experiences higher stresses due to the combined forces from the rider's legs and the electric motor. The power transmitted to the frame can reach approximately 550W (with 400W originating from the electric motor). To ensure greater responsiveness to stresses and a more balanced, symmetrical behavior, the frame was designed with the following features:

• The right half section of the seat tube is considerably wider than the left section.
• The right side of the top tube is wider than the left side.

Image: A visual comparison of frame elements, showing the asymmetric design of the Nytro frame (blue) against a traditional frame (green), with detailed views of the bottom bracket and chainstay areas.

Image: A detailed comparison of frame tube cross-sections, highlighting the increased asymmetry in the Nytro frame (blue) compared to a traditional frame (green) to handle higher stresses.

The images above present a comparison between a traditional Pinarello road bike frame (green) and the Nytro frame. As clearly visible, the Nytro frame sections are more asymmetric to withstand the combined forces of the legs and the electric motor. To complete the frame analysis, the upper part of the frame (seat stays and seat tube) is designed to effectively absorb terrain roughness, ensuring a more comfortable ride.

d. Keep the Nytro as Light as Possible

Weight is a significant consideration for e-bikes. The motor and battery package typically adds considerable weight, and frame modifications to house the system further increase the overall bike weight. A heavier bike requires more energy on climbs, hinders quick accelerations, and affects braking performance.

This aspect was a key focus during the Nytro's development. One of the primary reasons for selecting the Fazua Evation system was its position as one of the lightest e-bike systems available, weighing just 4.7 kg. The compact design of the Fazua Evation system also allowed for the development of optimized tubing sections that provide stiffness without adding unnecessary weight.

The frame utilizes T700 carbon fiber, known for its high tensile strength, which enhances impact resistance and prevents breakage. By employing a high grade of carbon fibers, particularly those with higher strength, a lighter frame was achieved while maintaining its structural integrity.

The combination of appropriate frame materials, the market's lightest system, and high-quality components results in a bike weight of approximately 13 kg.

e. Reduce Air Drag

The objective was to minimize energy loss due to air resistance, even in a bike with an integrated electric motor. During the design phase of the new frame tubing sections, it was essential to utilize profiles that minimize aerodynamic drag while accommodating the electric motor system. The well-known Flatback profile was adapted to integrate the Drive Pack, and the design of the bottom bracket and chain stays prioritized maximizing the integration between motor components and the frame.

Image: A cross-section view of the Nytro's down tube, showing the integration of the Fazua Drive Pack and the aerodynamic Flatback profile.

Adhering to this philosophy allowed for the optimization of airflow along the entire bike, resulting in an e-road frame with the lowest possible drag coefficient.

f. Made4You

Every rider is unique due to their physical characteristics, such as height and limb length. To accommodate this, Pinarello produces five different frame sizes to ensure a proper fit for every rider. The Pinarello Nytro is the first e-road bike on the market to offer smaller sizes, including 46.5 and 50.

Furthermore, Pinarello is committed to ensuring that the bike maintains consistent performance across all sizes. Following the 'Made4You' concept, each frame size is designed and produced independently. Larger sizes are reinforced and shaped to withstand higher stresses, while smaller sizes can utilize less material, reducing weight. This approach allows every rider to experience the same riding feel and performance on their Pinarello bike.

g. Pinarello Nytro Features

As previously explained, the Nytro frames benefit from the traditional Pinarello design philosophy. However, several specific solutions distinguish it as a highly exciting e-road bike on the market, while preserving the characteristic style and feel of Pinarello bikes.

Image: A full view of the Pinarello Nytro e-road bike, showcasing its design, color scheme, and overall aesthetic.

The main features that make the Nytro a unique bike include:

• Fazua Evation system (with 250Wh battery pack)
• Asymmetric frame design
• Drop In bearing system with tapered headset
• Internal cable routing
• Italian thread BB
• Frontal seat clamp, integrated and aerodynamic
• Flatback profiles
• RAD System Disk Brake
• Front Thru-Axle 100x12 Shimano
• Rear Thru-Axle 142x12 Shimano
• Disk Flat Mount max 160mm
• Max Tyre clearance: 700x28
• Available Sizes: 465; 500; 530; 550; 580

2. Drive System Evation by Fazua

For its first e-road Pedelec bike, Pinarello selected the EVATION drive system from FAZUA. This choice was driven by EVATION's status as one of the lightest and most compact drive systems in its category.

The system, weighing just 4.7 kg (including the battery), can be installed and removed from the bike's downtube with a quick click release, allowing the bike to be converted between a Pedelec and a conventional bicycle swiftly.

The patented EVATION drive system, combined with Pinarello's frame expertise, enables the creation of a bicycle with a distinctive look and weight profile, offering riders dynamic rideability and superior riding pleasure.

EVATION is a drive system that assists the rider's pedaling in compliance with the EN 15194 standard. This means the system has a maximum nominal power of 250 W, provides assistance up to 25 km/h, and cannot propel the bike solely via the electric motor.

General Technical Information

• Max nominal Power: 250W
• Max Power: 400W
• Max Torque: 60Nm
• Battery energy: 252 Wh
• Weight: 4.7 Kg
• Max Speed with assistance: 25 Km/h
• Duration: 1400 m uphill in max. support level.

Image: A diagram illustrating the four main components of the Fazua Evation drive system.

The drive system comprises four primary parts:

• a. Drive Pack
• b. Battery
• c. Bottom Bracket
• d. Remote

a. Drive Pack

A removable motor and battery unit designed for efficiency. It consists of:

• High Power density brushless DC motor
• Highly compact Power Board with USB connection
• Exclusive Planetary Gear to reduce motor RPM, ensuring efficiency, compact dimensions, and low weight.
• Motion and electronic interface for power transfer to the Bottom Bracket.

Image: An exploded view of the Fazua Drive Pack, showing the motor, power board, and planetary gear system.

b. Battery

A replaceable lithium-ion battery offering an optimal ratio between energy and weight. The battery pack can be easily removed from the Drive Pack, allowing it to be carried separately and stored away from the bike.

Image: A cutaway view of the Fazua battery pack, illustrating its internal cell structure.

Technical Details

• Battery Energy: 252 Wh
• Rated Voltage: 36 V
• Weight: 1.4 Kg
• Number of recharges: 500 (to 100%), after which 60% battery capacity is assured.
• Time to recharge 0-100%: 3-4 hours
• Time to recharge 0-80%: 2.5 hours

c. Bottom Bracket

This component provides power transmission to the chain. The Bottom Bracket integrates double-side torque measurement and cadence sensors. These sensors enable the Drive Pack to continuously adapt the power delivered to the chain, resulting in pedal assistance that is both effective and unobtrusive.

Image: A detailed view of the Fazua Bottom Bracket, showing the integrated sensors and power transfer mechanism.

Technical Details

• Max Torque: 60Nm
• Weight: 1.3 kg

d. Remote

The remote offers simple, intuitive control over essential functions and displays riding data through three buttons and an LED bar. The Evation driving system features four assistance levels:

No Support (White): The motor assistance is deactivated, allowing the eBike to be ridden like a conventional bicycle.

Breeze (Green): Provides efficient support to maximize the eBike's range.

River (Blue): Offers solid support suitable for most riding scenarios.

Rocket (Pink): Delivers maximum support for the most demanding rides.

Additionally, there is a walk assistance mode that aids in pushing the bike up to a maximum speed of 6 km/h.

The visible display bar on the Remote consists of 11 LEDs. The bottom LED serves as a notification indicator for the eBike's status. The remaining 10 LEDs display the state-of-charge and the support level (each LED bar represents 10%).

Image: A close-up of the Pinarello Nytro handlebar remote, showing the buttons and LED display for controlling assistance levels and battery status.