Technical Explanation: How the Aitour Family C Combines a Shimano Inte

Introduction

Yes—it truly works. The Aitour Family C successfully pairs a Shimano internal 7-speed hub (typically rated for up to 75Nm torque during safe gear shifting) with a powerful 110Nm motor. This seemingly risky combination is made possible by an intelligent gear sensor, which temporarily cuts motor output during shifts.

This clever design prevents the internal gearing from being subjected to abrupt loads while transitioning between speeds—ensuring both high torque performance and drivetrain longevity.

This article provides a technical breakdown of how the system works, the engineering rationale, real-world benefits, and what this means for operators, families, and businesses relying on a cargo e-bike fleet.

Aitour Family C System Overview

The Aitour Family C is a purpose-built cargo e-bike designed specifically for families and commercial urban use. It offers ample room, structural safety, and engineering tailored to the demands of daily hauling and stop-start riding.

Key System Highlights:

Drivetrain: A high-torque 110Nm motor coupled with a Shimano internal 7-speed hub, made shift-compatible through an advanced gear sensor.
Braking System: Equipped with German-made clamper dampers and Taiwanese hydraulic disc brakes, supported by a hill-hold system that stabilises the bike during stops and starts.
Cargo Design: The large marine-grade box is UV-resistant and securely mounted to a TÜV-tested reinforced frame—ensuring years of heavy-duty operation.

Together, these components create a robust and practical heavy duty cargo e-bike suited for urban families and fleet use.

Compatibility Challenge: High Torque vs Internal Gear Hub

Most internal gear hubs, like the widely used Shimano internal 7-speed, are engineered around human-level torque. These systems are designed with the assumption that gear shifts occur under low or no load.

By contrast, the 110Nm motor used in the Family C far exceeds what the hub would typically experience in manual cycling scenarios. Applying this high torque during gear shifts could lead to serious internal wear—specifically damaging the planetary gear system inside the hub.

The Core Engineering Problem:

If high motor torque is applied while shifting:

The hub's gear teeth may grind or slip under stress
Internal mechanisms could deform or wear prematurely
The gearshift may feel rough or cause drivetrain instability

Hence, the fundamental design challenge was to find a way to retain powerful torque for propulsion without overloading the hub during shifts.

The Gear Sensor: How It Works and Why It’s Essential

Shift Sensor Mechanism

At the heart of the solution lies a gear sensor, strategically mounted along the shifter line—whether on the cable or the twist shift housing.

Here’s how it functions:

When a rider initiates a gear change, the gear sensor instantly detects the input.
The sensor sends a signal to the motor controller, which cuts motor torque output momentarily.
This brief “torque-free window” allows the internal gear to change smoothly, without mechanical stress.
Once the gear shift completes, torque is automatically restored, and riding continues seamlessly.

Why It Matters

This smart torque interruption ensures that:

The Shimano internal 7-speed never receives abrupt torque during shifts
The internal gear mechanisms are protected from stress, even under full load
Riders enjoy both smooth gear transitions and powerful propulsion

This system is what enables the Aitour Family C to function as a reliable, heavy duty cargo e-bike—combining efficiency with durability.

Implementation Details on Aitour Family C

The integration of this sensorised drivetrain in the Aitour Family C has been fine-tuned for real-world demands.

Key Technical Integration:

Precise Calibration: The gear sensor and motor controller are synced in timing and voltage, ensuring immediate torque cut-off during gear changes.
Load-Aware Operation: Even when fully loaded with kids, groceries, or delivery goods, the motor’s torque is reliably paused during shifting—protecting the gear hub.
Proven in Practice: This setup has been validated through tens of thousands of units deployed across Europe, offering evidence-backed reliability.

This makes it ideal as a cargo ebike for business, commercial use, and private families demanding low-maintenance reliability.

Complementary Features That Protect the Drivetrain

To further safeguard the drivetrain and improve usability, the Aitour Family C includes:

Hill-Hold Parking System

Prevents the bike from rolling backwards on inclines
Enables controlled, stress-free starts and gear changes under load
Reduces rider fatigue and mechanical wear during urban stop-start riding

Advanced Braking Synergy

The use of hydraulic disc brakes paired with vibration-damping clamper systems allows smooth, controlled deceleration
Prevents sudden drivetrain jolts that could otherwise stress the gear hub

These features all contribute to a durable, heavy duty cargo e-bike ready for daily urban logistics.

Market Context: Why This Solution Matters to Operators

Fleet managers and family users often face a dilemma: you want strong torque for hauling power, but that typically shortens drivetrain life—especially in systems using traditional internal hubs.

The Aitour Family C eliminates that compromise.

Thanks to the gear sensor and clever drivetrain management, you get:

Full 110Nm motor torque for demanding use cases
Smooth gear transitions without damaging the Shimano internal 7-speed
Long-term drivetrain durability, with fewer mechanical failures

For those involved in cargo bike sourcing, municipal fleets, or business delivery e-bikes, this translates into:

Reduced downtime and maintenance costs
Improved rider confidence and safety
A smarter investment with long-term returns

Best Practices for Deployment and Maintenance

To get the most out of your Aitour Family C or similar cargo e-bike system, follow these expert tips:

1. Proper Installation

Ensure the gear sensor is correctly placed and calibrated. Misalignment may cause delayed torque cut-off or inconsistent shifting protection.

2. Routine Maintenance

Regularly check:

Gear sensor responsiveness
Internal hub shift smoothness
Motor controller firmware (if updates are available)

Preventive maintenance ensures continued system health and prevents unexpected damage.

3. Operator Training

Riders should be trained to expect a brief pause in torque during shifts. This is a built-in safety feature, not a flaw. Educated riders will better appreciate and maintain the drivetrain's health.

Conclusion

The Aitour Family C exemplifies how smart engineering can balance power and protection. By integrating a 110Nm motor with a Shimano internal 7-speed hub, and managing the connection with a precise gear sensor, the bike achieves:

High-load propulsion
Long-lasting drivetrain integrity
Proven reliability in real-world conditions

For any individual, municipality, or business evaluating cargo bike sourcing, this system offers a compelling choice. It’s a cargo e bike for business that doesn’t compromise—bringing together torque, safety, and long-term efficiency.

Technical Explanation: How the Aitour Family C Combines a Shimano Internal 7-Speed Hub with a 110Nm Motor – Safely

Introduction