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DIY eBike and Powerwall
#1
Hello battery freaks out there

I want to introduce myself to the forum. This is the first time ever i am writing something in a forum like that, i understand the benefits of swapping information regarding the same topics. I read a lot of stuff about batteries the last couple of weeks and how to safely handle them. I am scared but also fascinated about these cells and when you never risk something you will never get rewarded. I am 35 years old engineer and studied some mechatronics and machine tools stuff. So i have a little background in electronics, but not batteries. I did a lot of Rasperry and Arduino Projects and stuff like this. this is how i get here. 

My first plan is to replace my car by a ebike (one full gas tank = , i will need a good battery for that bafang 1kw motor i ordered. 
Second plan buy the house we are in, put a pv system on the roof and build a diy powerwall in my garage. 
With the heat pump, pv system, powerwall and the ebike i would be almost CO2 neutral. Would I? 

i want to do this mostly with recycled batteries if i can, from a green view i like this idea very much. 

I collected about 150 cells and ordered 100 new Samsung INR18650-25E. Checked all cells on capacity, self discharging and internal resistance and tried to decide which ones are the good and bad ones. not that easy than i thought it was. Does the internal resistance change over the battery lifetime? Is comparing the capacity with its original capacity a good indicator? Still a long way to go. 

I also made a deal with an ebike shop and i can pick up their "old" ebike accumulators. go there tomorrow to get the first few. 

thanks to all who share your information and journey through this secondstoragelife. and averagejoe and hppowerwall about their fantastic videos. 
my way would be to spotweld the fuses to the battery  Big Grin . can i do that? i ordered also some of these chinese spotwelders. any bets how long it will last? 
Is it also good to fuse every cell in the ebike battery? How would that work with the nickel strips? 

one last question. i know the Samsung INR18650-25E isn't the best joice for that ebike batterie. but would it work with a 14s7p configuration and the bafang motor? 20A cont, 56A peak? The bbshd motor would need 30A max. or am i wrong? Continous? 

Also a few pics from my journey:
My DIY Lab, recycled cells and the 1kwh bike pack. 

Let me know your opinion. Thx.
jdeadman likes this post
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#2
Welcome and looks like you have a great start there.
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#3
Welcome - looks like you have a very solid start & bonus points for carbon neutral goals !
If you'd like to support the forum please feel free to use my affiliate links to purchase all kinds of stuff for your projects 
Amazon - https://amzn.to/2qURmH2
eBay - https://goo.gl/6mrQHH 
Aliexpress - http://s.click.aliexpress.com/e/bNLW537E
Banggood -  https://goo.gl/FF2v6W
Battery Hookup - http://bit.ly/2Oe9PLW 
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#4
(10-02-2018, 09:42 PM)hbpowerwall Wrote: Welcome - looks like you have a very solid start & bonus points for carbon neutral goals !

Thank you very much. Many greets down under. 

Now its getting colder and i realise that the powerwall needs to be even bigger for the wintertimes. Maybe 20kWh instead of 10. I will start slow. I have the time. Want to be finish by summer 2020. 

I will keep you guys updated.
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#5
(10-01-2018, 06:08 PM)Haslero Wrote: Hello battery freaks out there

I want to introduce myself to the forum. This is the first time ever i am writing something in a forum like that, i understand the benefits of swapping information regarding the same topics. I read a lot of stuff about batteries the last couple of weeks and how to safely handle them. I am scared but also fascinated about these cells and when you never risk something you will never get rewarded. I am 35 years old engineer and studied some mechatronics and machine tools stuff. So i have a little background in electronics, but not batteries. I did a lot of Rasperry and Arduino Projects and stuff like this. this is how i get here. 

My first plan is to replace my car by a ebike (one full gas tank = , i will need a good battery for that bafang 1kw motor i ordered. 
Second plan buy the house we are in, put a pv system on the roof and build a diy powerwall in my garage. 
With the heat pump, pv system, powerwall and the ebike i would be almost CO2 neutral. Would I? 

i want to do this mostly with recycled batteries if i can, from a green view i like this idea very much. 

I collected about 150 cells and ordered 100 new Samsung INR18650-25E. Checked all cells on capacity, self discharging and internal resistance and tried to decide which ones are the good and bad ones. not that easy than i thought it was. Does the internal resistance change over the battery lifetime? Is comparing the capacity with its original capacity a good indicator? Still a long way to go. 

I also made a deal with an ebike shop and i can pick up their "old" ebike accumulators. go there tomorrow to get the first few. 

thanks to all who share your information and journey through this secondstoragelife. and averagejoe and hppowerwall about their fantastic videos. 
my way would be to spotweld the fuses to the battery  Big Grin . can i do that? i ordered also some of these chinese spotwelders. any bets how long it will last? 
Is it also good to fuse every cell in the ebike battery? How would that work with the nickel strips? 

one last question. i know the Samsung INR18650-25E isn't the best joice for that ebike batterie. but would it work with a 14s7p configuration and the bafang motor? 20A cont, 56A peak? The bbshd motor would need 30A max. or am i wrong? Continous? 

Also a few pics from my journey:
My DIY Lab, recycled cells and the 1kwh bike pack. 

Let me know your opinion. Thx.

Freak meets other freaks :Smile Hello to you too. Like you I studied Mechanical Engineering and was fascinated by Chemistry all my life. Finishing uni I did what most engineers do.. Work in IT.. Swapping coding for chemistry wasn't too bad.. Though I am loving this return to doing non coding work
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#6
Welcome

http://dalincom.ru/datasheet/SAMSUNG%20INR18650-25R.pdf

Those cells can do up to 20A max discharge but normal discharge should be below 1C for longeivity but they will cope with it
The Ultimate DIY Solar and build place
YouTube / Forum system setup / My webpage  Diy Tech & Repairs

Current: 10kW Mpp Hybrid | 4kW PIP4048 | 2x PCM60x | 83kWh LiFePo4 | 10kWh 14s 18650 |  66*260W Poly
Upcoming: 14S 18650~30kWh | Automatic trip breakers, and alot more
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#7
Project Update: 

Batteries: 
Im waiting for all the material i ordered and do some research regarding the BMS for the eBike battery.
Still no clue what the right one is except that it has to be 14s 30A. Any tips are welcome. Are there only Batrium or the chinese ones? Anything between? 
Daromer has some excellent explanation of active and passive BMS and i watched that video two times. 

I also designed and printed some cell holders (there is some stuff one thingiverse, but i want to have it adjustable):
 

And i need more batteries...

Next:
Big day yesterday. Bafang BBSHD was delivered. 


Now i have to do some mechanical adaption on the bike... my research was a little bad on this. i learned that my bike has a pressfit bottom bracket ball bearing BBS92. And Bafang motors are designed for JIS and BSA standards. whatever that is. 

but i knew i have to do some kind of this anyway. I printed some prototype parts to be sure everything is correct. Now i have to do them in steel. 



Keep you guys updated...
jdeadman and RevampKC like this post
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#8
weeks go by.. and i did my first testride with my awsome bike.  Idea
details about the battery build can be found here:

https://secondlifestorage.com/t-sparks-a...-the-place

next tasks:
forget the diy bike battery -> enjoy riding with a em3ev battery (wait 3 weeks) and concentrate on powerwalls?

or... 

designing a new battrery case with the bms on top? 

what would you do?
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