This 3D Printed eBike Battery delivers over 1500W - Slim Pack 2.0 Complete Build
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- čas přidán 12. 07. 2024
- Wouldn't it be nice to just 3D Print your own E-Bike Battery Case?
Especially if it had to fit in a really tight frame, without a lot of room?
Well, you guessed it, you certainly can.
This is a great option for bikes with suspension in the frame, not allowing for as much room. Also, we have designed a base plate that can be 3D printed as well that drastically increases mounting options and ease of removability.
Get the files here;
www.affordableebikes.ca/produ...
BMS:
www.affordableebikes.ca/produ...
Battery Indicator:
www.aliexpress.com/item/10050...
0:00 - Intro
1:42 - Parts
7:52 - Cell Layout
10:41 - Securing Cells
11:34 - Spot Welding Copper Plates
13:24 - Wrapping with Capton/Fishpaper
14:14 - Rewiring BMS
15:51 - Balance leads prep/installation
19:49 - Active Balancer
20:43 - Secure/Protect Balance Leads
22:05 - Charge/Discharge
22:39 - Splicing in Charge & Display Wires
23:18 - Setting up the Cap
29:34 - Shrink Wrap & Secureing into Case
31:33 - Outro - Věda a technologie
That's my Santa Cruz in the clip, and this battery format made for a super easy fit that just did not work with other common pack types. Works fantastic!
Nice wiring
Great job guys, and great video.
Thank you very much sir! :)
Thanks
Amazing!!!
Woah it didn't occur to me that this was possible!
cheers guys, i tested their BMS before. no way they will hold that current for long time. is gonna fail sooner or later. and they are saying the "equipment isnt enough to change to 12AWG is straight up a lie.
i do love the battery case!
We ran on the bench at 30A and the BMS only gets slightly warm. That being said I wouldn't try to push it.
You probably did not test this BMS as it was custom made for us, and they do not sell it openly. It was a modified version that stuffed a couple extra fets into the board. Otherwise it is a 20A rated BMS.
@@ElectricBikeLaboratory i am
living in china and know the factory boss from daly BMS. in dongguan right?
i am living in dongguan too by the way.
i had 300 amp custom made BMS. they didnt even hold 150 amps. huge pain. just be careful guys. if you need a contact localy to check stuff you can ask me since i am going to all these factorys regular for my projects. i like what you do! our engineering minds are alike 😊
Amazing ! Thank you so much for the feedback and the offer ! Truly appreciated 😊
@@ElectricBikeLaboratory no worries. i dont want any payment or something. just make sure you dont think i try to sell you stuff. i just love doing these electric project. 10 years ago i build 50kw electric scooters.
@@ElectricBikeLaboratory whatsapp is fine if you need anything. let me know
1) That was a fantastically put together video.
2) A+ battery construction.
3) Giving away the files for free? Hell yeah!
My only criticism: I've had several Daly bms' and I don't believe for a nano second that their "30A" bms can withstand half of what that battery pack can output.
Thank you for an excellent comment 👌👍🙏
We do load test these at 30A and they barely get warm, but you're definitely right in that the cells handle WAY more than the BMS. This was simply the most BMS we could fit into the small space 😁
Why don't you check the internal resistance of the cells before installation, only the voltage? It makes no sense to check the voltage itself.
Thanks for the video. Which filament type did you print the case with (PETG, ABS etc)? Also can you provide a link to the glue gun and black glue stick you use in the video? I like the way you use this for insulating some of your soldered connections.
Hey there thank you for the comment !
We actually use a special type of PLA manufactured in Canada called PLA Pro from filaments.ca it is a UV rated and temperature resistant PLA (a bit expensive but great stuff).
Glue stick wise we actually just use "black hot melt glue" off Amazon.
Thank you for the comment !! 😊👍
So on a hot day the PLA doesn't melt? Would be my last choice actually..
did you guys ever make that dual motor vesc ebike?
We still have to revisit the dual motor bike. Well hopefully have a couple more dual motor videos coming up in the future and definitely will be exploring the vesc
awesome. Looking forward to it!@@ElectricBikeLaboratory
how much Amper that bms in peak? sells 60-80Amps but bms? i build and drive 14S2P!
The BMS is 30A continuous and cuts off at 90A
Anyone have a link to the copper busbars? Can't seem to find them on Alibaba...
Super cool you guys are Open Sourcing this whole thing!!!
Hey Aaron got your email , looking forward to the 3P pack! We get our copper on Alibaba from "Shenzhen WLG Tech Co Ltd"
@@ElectricBikeLaboratory Can you share the sizes you ordered for the copper busbars (stl files or similar). Alibaba needs this to build and send the right types to us.
@@BitBike-Morten they didn't require any files from us just a picture and the cell size and cell spacing. Ask for Ken Bao, he is the man
@@ElectricBikeLaboratory Thank you. Yes, I was in contact with Ken, then forwarded to an associate. I gave them this info: 21.4mm cell size and 21.6mm cell spacing with 1mm plastic bracket thickness. Together with a picture of the busbars they will hopefully produce the right ones 🙂
@@ElectricBikeLaboratory Do you know if the busbars can be used on both sides? (flipped)
This is what I need, I think, can you please tell me the physical dimensions of the pack, I have limited space 👍
Check the site where the files are, dimensions are there too 👌😁
@@ElectricBikeLaboratory thank you
What liability insurance do you have?
Have a look at “down tube” style bike batteries. They are extremely ubiquitous and cheaply available.
Yes we have several videos on those as well. The "slimmest" battery I'm aware of is the Hailing G56 which is still 96mm height. This is almost half of that height, hence "Slim Pack". There are many, many battery styles out there for different use cases.
@@ElectricBikeLaboratory ShanShan supply batteries and cases down to 33mm thick.
Can you provide a link for me please ? Would love to check it out 😊
The slim rear rack batteries like from bosvh or shimano also seem quite slim
So...where is the 3D printed battery?
i cannot understand why you put the temp sensor at the top when most of the heat will be generated towards the centre total madness, iv been building ebike bateries for years and would never put the sensor there its total madness
Because he is an amateur. He doesn't know what he's doing. This is why.