Long Range E-Bike

4 hours ago

Electric cars are great, but e-bikes have lower environmental impact and are better for commuting.
E-bikes in the Netherlands sell faster than electric cars but have limitations like a 25 Kph speed limit and limited range per charge.
Lithium-Ion cells (18650 variety) power e-bikes, with the best affordable cells offering about 3400 mAh per cell.
A typical e-bike battery setup is 10S4P or 10S5P, totaling 40-50 cells.
The author's first e-bike had a 500 Wh battery, offering 55 km one-way but causing range anxiety.
Purchasing a second battery helped but cycling at 25 Kph was frustrating compared to a regular bike.
S-Pedelecs offer higher speeds (45 Kph) but require insurance, license plates, and have worse range.
The author built a larger battery (10S17P) to increase range, diving deep into battery pack manufacturing and Bosch's e-bike system.
Challenges included Bosch's DRM, BMS limitations, and safety concerns with large Li-Ion packs.
The final battery pack was 2150 Wh, offering 180 km at full power and over 500 km in Eco mode.
The project successfully reduced car usage, offering a cheaper and more climate-friendly alternative.
Future improvements include a slightly wider design and thicker interconnects for better durability.

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