For BMS’s, the highest quality ones come from a company called BesTechPower but they are more expensive. I have mostly used BMS’s from AliExpress. I’ve linked to a few examples of BMS’s I’ve used in the article above.

Lay your nickel strip on top of the three cells, ensuring that it covers all three terminals. Turn your welder on and adjust the current to a fairly low setting (if it’s your first time using the welder). Perform a test weld by placing the battery cells and copper strip below the probes and lifting up until the welding arms raise high enough to initiate the weld.

The lithium iron phosphate (LiFePO4) battery has had a of hype and media attention lately. This is the same chemistry used by A123 in the Dewalt power tool battery packs, where it has a 2000 charge and discharge cycle warrantee and has phenomenal current handling capability. The LiFePO4 batteries sold for ebike use generally have much lower current ratings, and the actual number of charge and discharge cycles that these generic packs will provide remains to be seen, although most manufacturers seem happy to claim 1500 to 2000 cycles. Iron Phosphate lithium packs are only slightly lighter than NiMH and a fair bit more expensive, but they could be the most economical in the long run.

Excellent, excellent, excellent (did I mention excellent) motor! So much fun, so much torque. I bought mine with 30q 52v battery, unbelievable power. Done about 300 km yet but absolutely no regrets. Get the 42 teeth Lekkie ring, makes worlds of difference. The new color display is also …

Charge voltage for li-ion cells is 4.2V per cell maximum. So for a 36V 10s battery you’d want to charge it to a maximum of 42V. Charging slightly lower will increase the life of the battery, but isn’t a requirement.

I want to take the apart and use the cells to make a 48V 16.8ah battery. Would you advice against this? Would 48V provide a noticeable difference in the power of my motor? (It is a 500W Falco Direct Drive Hub Motor)

Regarding your second question: I wouldn’t say the max amperage of the BMS is “dependent” on the controller, but it should be chosen with consideration to the controller. Think of it this way: your controller is what decides how much current your battery is going to supply. The controller is basically pulling that current from your battery. If it’s a 20A controller, that means the most it will pull out of your battery is 20A. So if you plan on riding in a style that uses full power for long periods of time (like hill climbing, dirt riding, etc) then you’ll need to make sure your BMS is rated at least 20A continuous. However, most people that ride on flat roads spend very little time at peak current. My ebike’s controller is a 22A unit, but I spend most of my time around 10-15A when cruising. A 20A continuous BMS would be good insurance in that case, because it means my BMS is rated to handle more continuous power than I generally will pull through it.

Historically, the process of regenerating electricity has created a slight vibration that has loosened spokes and vastly increased maintenance costs. (At $.005 of regenerated energy per battery charge it will take some time to pay off a $35 wheel retensioning)

Lithium Iron Phosphate is currently the most common lithium battery used in Ebike applications. It is considered the most stable lithium battery type available today (low risk of fire) and has a reasonably high life expectancy of over 1000 charges.

Electric bikes are a reliable source of transportation. With a new battery from Batteries Plus Bulbs, you can expect the same level of reliability. Our high capacity, replacement batteries will get your scooter moving again and keep it running for a long time.

If you want to test cells from different vendors, the best thing to do is run them through a discharger, preferably a fancy graphing one, and preferably at a high current rating close to the maximum discharge rating. Fake cells are lower quality and won’t be able to provide the same capacity, and will have a larger voltage sag under higher loads.

If you are thinking about building your own LiPo pack, a 48V / 10-Ah battery pack can be made for around $300. However to undertake this project you should research extensively on on how to build and take care of your pack. Expect hours of reading before you are ready to build a pack of your own.

Most of the problems occur when charging an ebike because they are unsupervised and that is when a LiPo fire can burn down a house etc. Use common sense on where you are going to charge your bike or battery pack, so that if it does burst into flames it does not take your house with you. I have a big steel barbecue grill set up in my entryway which  I charge my battery packs in  as nice safeguard.  This involved taking the battery pack out of the bike after each ride but I am OK with that:

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.

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Either way works, but my orange jig saves me one hot glue step which just makes for a cleaner looking pack. Of course it’s all the same after the pack gets covered with shrink wrap, so you can use any method you’d like. I’ve even found that some of those cylindrical ice cube trays are perfectly sized to hold 18650 cells. Cutting off the top would leave it clear for welding. I’d add some strong neodymium magnets to the backside to hold the cells in place like my orange jig has, but other than that it’s a perfect jig almost as-is.

It is possible to do it that way, however there are some compelling reasons not to. 1) By first joining all the series cells you would end up with multiple high voltage groups, which means both the chance and consequences of an accident are greater. When you’re working with lots of exposed batteries with nickel conductors and metal tools flying around, the last thing you want is more high voltage possibilities for shorts. 2) Doing series cells first would be come unwieldy, physically. A series group is only connected at either the top or bottom of alternating cells. Without having multiple cells side by side to add stability, a long chain of single cells will need either a pile of glue or some type of physical holder to support the chain. and 3) most battery spot welders can only reach about 2 cells deep into a pack, meaning you’d have to either add very short nickel strips to each series group connecting only two groups (which means twice the welding and twice the cell damaging heat) or have long uncontrolled nickel strips hanging off the sides, again risking shorting.

If you are upgrading or replacing an existing battery pack, it is always safe to replace it with a battery that has the same nominal voltage. If you have an 36V ebike setup that is not from us, and are looking to ‘upgrade’ to a 48V/52V pack, more often than not you can do this without damaging the existing electronics. That is because most 36V motor controllers use 60V rated mosfets and 63V rated capacitors, and so even a fully charged 52V battery will not exceed these values.

36v 10Ah Bottle Type Battery. Rated capacity: 10Ah. 36v 14Ah Rear Rack Type Battery. Rated capacity: 14Ah. 48V 14Ah Rear Rack Type Battery. Recommended to be used with 36V 250W electric bicycle motor.

How do you determine this exactly? Your battery is a 36v 8.7Ah and I guess it has something to do with the maximum continuous discharge rate. It would help me (and maybe others) to explain why 30A is more than enough for this battery.

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…

Sizing a bike correctly is important for pedaling efficiency and safety. Fitting a bike involves many factors. However, the basic considerations before buying a bike include frame size, seat height, and…

But there’s still another issue: now if I just slip my pack inside some shrink wrap tube, I’ll still have exposed ends. This is more or less ok structurally, though it won’t be very water resistant and it will look a bit less professional.

There is a recently introduced battery chemistry that we will likely be seeing a lot of soon. Lithium-Nickel-Manganese-Cobalt-Oxide, or LiNiMnCoO2/NMC. Since Asian battery manufacturers have been working on a wide variety of alternative chemistries, a manufacturer standards group has chosen the  abbreviation NMC for this chemistry (although one wholesaler stubbornly calls it NCM).

Lipo batteries are currently the “hottest” battery choice for electric bike enthusiasts. LiPo batteries are the most power-dense type of  battery available to electric bike riders today. The problem is that LiPo battery packs for e-bikes are hard to find, especially one with high output if you are building a racing bike for riding off road.

hello, firstly i would like to say that i think this is a brilliant article its really helped me understand a lot more about how this works and how i can use a similar system for my project but i am a little confused and i was hoping to pick your brains….

Love your youtube videos! I’m actually looking to make an electric longboard on the cheap. I have an 18V motor (from a battery drill) that I want to power and I have purchased 10 (AA) 3.6V 3000mAH Lithium-ion batteries with the intention of connecting them together in a series arrangement to run the motor. What would be the best way to arrange them? And is there a need for a BMS for a smaller arrangement? Or would it be more time effective/safer to just charge each battery individually? Any help is appreciated. [redirect url=’’ sec=’7′]