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--- ebike:ebikev1 [2019/09/09 09:12]
f4ija created
+++ ebike:ebikev1 [2019/09/09 09:56] (current)
f4ija
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 For that, I decided to make my own battery, and to solder it with a home made point solder unit, based on an Arduino program and a salvaged transformer of a microwave oven.
-==== Battery ====
+===== Battery =====
+The battery is made from standard 18650 cells (like in the Tesla car for example). You can buy online. I was able in 2017 to buy them about 1.25€ each, now it's more expensive.
+The battery I've used is the ICR18650-26F, with a capacity of 2600mah nominal. In reality, the capacity is a little more, at about 2900mah.
+The size of the battery is 13S12P, so 13 elements in serie (48.1V nominal) and 12 elements in parallel (31200 mah nominal).
+I needed to buy some nickel straps to solder with my solder unit. More info on [[other:soldering|DIY point soldering unit]]
+All the elements on a table :
+{{ :ebike:img_20171013_132153.jpg?600 |}}
+During soldering :
+{{ :ebike:img_20171013_205206.jpg?600 |}}
+{{ :ebike:img_20171013_211552.jpg?600 |}}
+The battery pack once soldered :
+{{ :ebike:img_20171014_002108.jpg?600 |}}
+You don't have to forget about adding a BMS (Battery Management System) to the battery pack, to preserve the battery life (you'll find enough informations on the Internet about why BMS are important).
+===== Attaching the battery to the frame =====
+During the tests, I've just attached the battery pack with black tape. It's Mad Max style but it's OK for the tests !
+{{ :ebike:img_20171015_134223.jpg?600 |}}
+On this early first version, I've adapted a brushed DC motor of 2kW to the wheel with 3D printing parts. But that was not a good idea. The motor was quite cheap, and that was difficult to put the chain in the right place.
+Also, After about 200km, I've burned out the motor because of too much current for a long period...
+So, after that, I've bought a wheel with a brushless motor inside, and the result is much more better :
+{{ :ebike:img_20171119_194858.jpg?600 |}}
+It's well integrated now.
+===== Battery enclosure =====
+After the tests, I've 3D printed the battery enclosure in ABS on a printer I've designed in my company and added 2 aluminium plates to close it.
+The battery is well integrated to the frame and it's working like a charm.
+{{ :ebike:img_20171113_174723.jpg?600 |}}
+{{ :ebike:img_20171119_194858.jpg?600 |}}
+===== Results and tests =====
+As I've said, the brushed DC motor wasn't a good idea and burned out quite quickly.
+After the installation of the brushless wheel, the results are very good.
+The max speed I was able to reach is about 62-63 km/h on flat roads.
+The range is about 200km with pedal assist set to 1 (minimal consumption, you need to pedal but without sweating you can reach 25-27 km/h.
+If you go without pedal assist (just with throttle, like a bike and going beetween 55-60 km/h, the range is reduced to about 60km (1 hour in fact).
+So, very good project, the global cost was about 700€, without the bike I already had.

F4IJA

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