Ebike pack with minimum effort!

LemacRecycle

New member
Joined
Jul 15, 2020
Messages
2
I want to build an e-bike pack with minimal fuss.

I have a source of batteries that come from medical devices. These packs contain power cells so are ideal for E-bikes. As such many have had little use or have been swapped out due to a bank of cells going down. Like most packs - there is lots of glue and welded strips that are a pain to get apart - so my question is - why bother taking it all apart just to build it back up.

Here are 3 packs that I took from the company's store faulty batteries (with permission of course!). Off with the wrapping and a quick test of voltage quickly identifies the parallel banks that have gone bad.

They are 4S3P configuration EVE 2000mAh cells with battery management board.
image_ztkxas.jpg


My idea is to chop out the bad strings and to re-weld the good strings together to make a 10S3P 36V nom. 6Ah battery pack - enough for 15 miles or so assisted E-bike use for getting to work.

Lets see how easy this is!!!
 

LemacRecycle

New member
Joined
Jul 15, 2020
Messages
2
Batteries are stripped down and dead "banks" of cells identified. Cut out just the dead banks giving me series parallel sets of cells which are showing good voltage. I know that it would be optimal to strip to cell level, test then optimally group but I'm trying to so this with minimal effort!


image_fwaunj.jpg


Then put all the good banks together to make the pack:


image_bcockk.jpg


Now to weld some new connection strips (and some already existing ones!)
 

DiggsUt

Member
Joined
Oct 30, 2019
Messages
65
LemacRecycle said:
- so my question is - why bother taking it all apart just to build it back up.
I also build bicycle packs and the reason I take them apart is two-fold. One - I want to test each cell for individual capacity which helps match the load on the pack when assembling and weed out any cells with issues and - two - it also allows me to more easily configure the pack to match the application.
 
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