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DIY - How to make a battery pack from RC Li-Po batteries for eBike -electric bike

DIY - How to make a battery pack from RC Li-Po batteries for eBike -electric bike


A tipcal RC Li-Po battery is very small, cheap, light and hase ahigh discharging and charging current.
The discharging current  ranges from 10C onwards. So if we have a 20C 5000 mAh=5Ah battery pack, a short duration 100 A discharging current  (50A long duration) battery pack  can be obtained.
 
It is important to note that handling of Li-Po bateries  requires extreme caution! In particular, a damaged Li-Po cell  can easily short circuit, resulting in an excessively high current , heat, fire, and other damage.
 
In this demonstration, I am assembling an eBike (i .e. electric bike) Li-Po battery pack, but these cells could also be used for many other purposes, such as back-up power or for LED flashlights…
I have two 6S 5000 mAh RC battery packs. One pack has one defect cell. I remove the defect cell and one of the good cells from the defect battery pack and thus get a 4S pack. I also rewire the BMS connector.  Here, I use the BMS from my previous DIY post: DIY - How to Make an eBike Battery Pack from old Li-Ion 18650 laptop batteries
    
     
 
 
I connect the 6S and 4S packs together in serial to get a 10S battery pack. Wiring diagram is shown below.
 
I also cheek each battery pack using RC LI-Po battery tester. The RC Li-Po tester clearly indicates how many cells there are in the battery pack  (including the Voltage of each Li-Po battery cell). However, this particular RC Li-Po tester can only test up to 8 battery cells. Fully charged battery cell has a voltage of nearly 4.2V. The pictures below depict the testing of a 6S (number of cells) and a 4S (voltage of a single cell in a pack) battery pack.
     
 
 
 
 
 
When I connect everything together, I get a 10S 5Ah 36V Li-Po battery pack. I put the pack into the triangle bike bag for easy fitting on to the bike.
Total weight of the battery pack is only 1,42 Kg
    
 
 
 
  
Side by side:  The New battery pack and the battery pack from a previous DIY
On the left hand side in each photo a battery pack from an old laptop (18650 Li-Ion) batteries is shown.
 
 
 
 
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Objavljeno: 16. december 2014
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