Editor’s Choice
But there is one bike component
that can make or break a rider’s chances of winning like no other – the throttle actuator. Responsible
for controlling air flow to the bike’s engine, these actuators employ a DC motor to rotate the parts needed to open and close the
throttle plate. Reliable throttle control is
essential for bike acceleration, deceleration, traction and stability.
If the motor used in the actuator cuts out, the bike goes into failsafe mode, shutting down the engine and disqualifying the rider. When motorcycle electronics
specialist Bike Sport Developments
was tasked with producing electronic throttle actuators for racing motorbikes by an American customer working closely with Suzuki, reliability was a key consideration. “We have traditionally supplied mechanical actuators for client
Revving up bike performance
The Daytona 200 is arguably the USA’s biggest motorcycle race, with 2024’s event attracting 127 riders and eight million digital viewers, according to MotoAmerica.
P
lacing highly in the race is no mean feat and requires precise, advanced bike design, where the importance of reliable throttle control cannot be overlooked. Employing a high-power, compact brushed DC motor in the throttle actuator, such as those supplied by Electro Mechanical Systems
(EMS) for Bike Sport Developments, is essential. Motorcycle racing success doesn’t happen overnight. Teams
extensively plan and test their bikes, ensuring that the tyres, frame, telemetry and rider are prepared for each competition’s unique conditions.
14 May 2025
www.electronicsworld.co.uk
projects, which are operated by cables. However, the regulations of the American Motorcyclist Association races dictate that the actuator must be a computer-controlled ride-by-wire system. Essentially, these systems use the sensors from the electronic control unit, or the ECU, and the actuators to regulate the engine’s air flow supply,” explained Mick Boasman, Founder of Bike Sport Developments. “Terefore, when I first approached EMS three years ago, I was
looking for a reliable electronic solution that could withstand the high temperatures and vibrations produced by the bike’s engine. At that time, I had little indication of the product volumes the client would need, so I had to make sure that the motor was readily available with short delivery times.”
The ideal solution EMS supplied Bike Sports Developments with a FAULHABER brushed DC motor with a 23-millimetre (mm) diameter and a 26mm gearbox. EMS later reduced the motor size to 22mm, making the solution more compact and easier to integrate into the actuator assembly using the standard fixing points on the front of the gearhead and the flap on its outer shaſt. “As the sole UK distributor of FAULHABER motors, we have
access to its innovative iron-free skew wound drive systems,” said Paul Boughey, Area Sales Manager at EMS. “Tis technology minimises the moment of inertia in the rotor, resulting in low cogging torque, increased precision and faster reaction times for the throttle.” Aſter a prototyping process lasting approximately five
months, the electronic throttle actuators were delivered to Italy for verification from another partner, before being shipped to America for track testing. Te solution proved to be highly competitive in races, resulting in several other American teams
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