I was wondering, though, if I could use thick gauge wire instead of nickel strips (copper wires are much more accessible). Would there be any downsides to that, given that I’m going to be using solder anyway?
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26′ rear wheel 48v 1000w hub motor (powerful Motor with hall sensor ) Electric Bike Kit With or Without Battery. 26′ size REAR WHEEL 48V 1000W ELECTRIC BIKE KIT WITH or WITHOUT BATTERY. 48v 1000w brus…
I am not sure their interests align with mine. I would happily live with 1500 recharge cycles () by which time i would be sick of it anyway) instead of 2000 if I could use 3c in or out when urgently needed.
Lithium Polymer is by far the lightest battery option out there. LiPoly cells that can handle very high discharge currents are becoming widely available and are especially popular in the R/C crowd for electric airplanes and helicopters, but ebike LiPoly packs are often made with cells that are only rated to 1C or 2C, and these don’t usually deliver a very good cycle life count. The cells are produced in a thin plastic pouch rather than a metal can, making them structurally quite vulnerable unless supplied with a rigid enclosure. Although Lithium Polymer has a reputation for being volatile and failing with spectacular pyrotechnics, there are companies making cells these days that are quite stable and can pass the fullUN 38.3 overcharging and puncture tests without any flames.
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You can certainly use a second 4.4AH battery in parallel to double your range, but you’ll want to make sure the batteries are at the same state of charge when you connect them in parallel, or use a diode in between them, to keep one battery from discharging the other if the charge states are unequal.
Most of the price involved these days in building an e-bike or buying a ready to go e-bike is the size and chemistry of the battery pack. For the consumer its important to understand the difference between a 24V, 36V, and 48V pack. Also know what a 10-Ah pack is compared to a 5-Ah pack.
Now I’m sure you’re all jazzed about building your own battery pack. But just in case, I’m going to leave you with an awesome video featuring battery builder Damian Rene of Madrid, Spain building a very large, very professionally constructed 48V 42AH battery pack from 18650 cells. You can read about how he built this battery here. (Also, note in the video his good use of safety equipment!)
Another disadvantage of lead acid batteries is the shorter lifespan. Most claim to be rated for over 200 cycles, but in practice I usually find many SLAs start showing their age at around 100 cycles. They’ll still work as they get up in years (or charge cycles), but you’ll begin seeing your range quickly decreasing. If you were traveling 15 miles per charge when the SLAs were new, a year later you could find yourself barely getting past 10 miles.
We also maintain stock of replacement vertical seattube batteries that have been in use in the eZee bicycle line since time immemorial. If you have an eZee bike circa 2008-2012 with the Phylion lithium battery pack, you’ll be in for a serious upgrade with over twice the capacity in the same size and weight.
For any other case, lithium batteries’ advantages greatly outweigh SLAs. Of course, for your specific ebike you might have other reasons that could sway you either way. At the end of the day, your ebike is all about you. I hope this information helps you make the right choice for your own battery needs.
Used PL-350 electric bike kit, The battery does not charge. Charger is fine but only shows a red light. It sat dead for about a year. Then the controller showed about 80% after charging. Everything wo…
Thank you for the very informative post, and it has helped a lot. I plan on building a battery pack with 20 cells with blocks of 4 in parallel, and then I am going to put those in series to make an 18.5V, 13.6A pack. Sorry if these sounds a little bit foolish, but I am not sure what kind of BMS I should be using. Would I be able to use any BMS or would there be an issue with having extra wires if the BMS can power more batteries in series?
For a heavy trailer, I’d add a second brushed motor to the cart, whether the bike has a motor or not. You’d only need 24V, and here’s a discussion about powered trailers. The most important thing for going over sand is to have the fattest tires you can fit onto the trailer.
This is how most Asian batteries are built, since they use the same size aluminum or plastic case, but offer different sizes and capacities of batteries in the same case. I’ve used arts and craft foam, which often comes in sheets up to about 5mm thick (and I use a few layers to fill larger gaps). For MUCH larger gaps where that thin foam is less desirable, I’ve seen people use styrofoam or even that green molding foam often used in pots to hold up fake plants. That stuff is a fairly rigid though, so maybe a combination of that stuff and a layer of softer foam for cushioning would be good.
hello. I have a KTM bike-trail’s 2013 model. I have problems with the battery. I had the bike wheel and I bought one original ktm 26V from the company. defect occurs so: I put the plug on the charger to charge the battery and flashing green LED lights and red and it is immediately interrupted – interrupted flashing red and the buzzer sounds and noises that can fix … ? Please help me if you know how. sorry for my English but I used google translator
The sense wires generally connect to the positive of each cell group, but sometimes there is one more sense wire than parallel groups because the first sense wire is intended to connect to the negative of the first cell group, then all the subsequent sense wires connect to the positive of each cell group. Each BMS should be labeled on the board to show where each sense wire goes (B1-, B1+, B2+, B3+, etc…)
I want to build some custom batteries, but I am hesitant to do the spot welding myself. Aren’t there modular and affordable pieces of hardware one can use to connect the batteries? Something like this?
It’s always hard to say exactly how much AH’s someone will need because every case is different. With that powerful motor sucking lots of juice and big hills though, you are going to want a minimum of 48V20AH. If I were you I would try to go even higher, but it may be even better to simply have two batteries at that point. It’s annoying to swap them, but if you ever had a problem with a 48V30AH battery that destroyed the pack, it would be a big investment straight to the garbage. A problem in one of your smaller packs would mean you still had the other. It’s not likely to happen, but it’s something to think about.
This is a very simple layout where each column of 3 cells is connected in parallel and then the 10 columns are connected across in series from left to right. The BMS board is shown at the http://twowheelev.com right end of the pack. You’ll see how the pack represented in the drawing will come together in real life shortly.
The best method is to use a trusted vendor. They interact with the cell providers and are the best way to confirm whether cells are fake or not. It can be incredibly difficult to tell whether a cell is fake or not just by picking it up from the table. There are some giveaways like different printing on the wrapper, slightly different color, different stamp, different weight or different shell design, but all of those can be mimicked. That’s why I use only a handful of vendors that I’ve worked with continuously and who I know have always given me good quality cells. I had to go through some low quality ones until I found the sources I buy from now.
When it comes to buying your cells, you might be able to find a local source, or you can order them straight from Asia. I prefer the second option, as you’ll usually get a much better price going straight to the source, even when paying for international shipping. One caveat though: do your best to ensure that your source sells genuine cells and not knock-offs. Do this by checking feedback and using a payment method that ensures you can get your money back if the product isn’t as described. For this reason, I like to buy my cells on Alibaba.com and AliExpress.com.
Sure, it is possible to solder directly to the cells (though it can be tricky without the right tools). The problem with soldering is that you add a lot of heat to the cell and it doesn’t dissipate very quickly. This speeds up a chemical reaction in the cell which robs the cell of its performance. The result is a cell that delivers less capacity and dies an earlier life.
Also I wanted to “hide” the batteries in the Brompton frame aligning the batteries in file, I understand it would not have a long range but would be quite stealthy. If you have any recommendations please do tell me