In the last several years, electric bikes, sometimes known as e-bikes, have become much more popular. To travel more quickly and efficiently to stores, workplaces, or residences, more individuals are using this mode of transportation. The battery is one of an e-most bike's crucial parts because it determines its speed and range. E-bikes are considerably different from traditional bikes, so it seems sense that their batteries would be too. Maximizing the speed and range of a certain e-bike requires finding the appropriate battery solution.
E-bike Battery Types
One can power an electric bike with a variety of integrated e-bike batteries. They are priced differently and have various advantages and disadvantages. These are listed in order of importance.
One of the most well-liked and often utilised types of batteries is the lead-acid battery (SLA). Despite being extremely affordable, they have a short lifespan, can weigh up to three times as much as lithium-ion batteries, and are quite susceptible to environmental influences.
Nickel-cadmium batteries are more powerful than lead-acid batteries, but they are also more delicate and difficult to dispose of properly. Because of this, every battery manufacturer is attempting to remove them from their product lineup in favour of more effective and ecologically friendly alternatives like lithium-ion batteries.
One of the most common forms of e-bike batteries is made up of lithium-ion batteries, which are almost ubiquitous and can be found in portable speakers, smartphones, tablets, smartwatches, and other electronic devices. These batteries are the most powerful, lightest, and adaptable to practically any gadget. They are also getting less expensive.
The disadvantage of lithium-ion batteries is that they must be carefully handled and managed by integrated circuits in order to avoid overheating and fire. However, the majority of e-bike battery manufacturers take the necessary safety measures to provide a reliable lithium-ion battery that can be installed in every e-bike.
Knowing the Fundamentals of E-bike Batteries
One should first become familiar with the primary features of a lithium-ion e-bike battery in order to identify what kind of custom e-bike battery is necessary for a specific electric bike model.
Volts and Amps
Each e-bike battery has a specific voltage and amp capacity, such as 24 volts and 10 amps, etc. These figures show the battery's electrical power. Since the number of volts is typically related to actual power (or horsepower), the more volts an e-bike battery has, the more weight it can support and the faster it can travel. Companies looking for e-bike batteries that prioritise power over all other factors might request specialised batteries with a high voltage, such as 48V or even 52V.
However, the range of an e-bike is typically correlated with the number of amps (or ampers), therefore the more amps it has, the further it can travel. Companies should request a custom battery with high amperages, such as 16 amps or 20 amps, if they want to offer the greatest range for their line of e-bikes.
It is crucial to note that a battery may be heavier and larger if it has a high voltage and amperage. Before collaborating with a battery manufacturer to create a custom e-bike battery, e-bike manufacturers must establish the ideal size/power balance.
Cycles
It should be clear from the name how many times a battery may be fully charged throughout the course of its lifetime. Most batteries have a maximum charge cycle of 500, however certain versions can be designed to last up to 1,000 cycles.
It is possible to design the majority of e-bike batteries so that they can charge effectively at temperatures between 0 degrees Celsius and 45 degrees Celsius (32-113 degrees Fahrenheit). The discharge operating temperature can range from -4 to 140 degrees Fahrenheit (-20 to 60 degrees Celsius). The enquiring e-bike firm should expressly state that batteries may be made to withstand different weather situations.
Weight and Size
An e-bike battery's dimensions and weight are also crucial. Batteries for e-bikes should ideally be as light and compact as feasible while still delivering the maximum electric power. As an illustration, the majority of e-bike batteries can weigh up to 3.7 kilos (8 pounds). If a manufacturer wants to offer the quickest electric bikes on the market, it could need a bigger e-bike battery. Larger models might boost the range and speed of the e-bike.
Case Construction and Colour
The e-bike battery's construction material is also crucial. Due to its light weight and durability, aluminium alloy is used to make the majority of models. Manufacturers of e-bike batteries do, however, also provide ceramic or plastic as additional case choices. The majority of batteries are black in colour, although other colours can be obtained.
Recognizing the Steps Involved in Creating a Unique E-bike Battery
Although it is difficult, creating a brand-new battery from scratch is not impossible. When it comes to producing batteries, e-bike manufacturers should collaborate with specialist businesses managed by professionals with years of experience. It is crucial to make lithium-ion batteries as safe as possible in order to avoid overheating and even fires, as was previously stated.
E-bike manufacturers should first get in touch with research and development teams and elaborate on their requirements. Giving as much information as possible is the proper move because knowing the specifications of the e-bike that will use the battery is crucial. These specifics include the e-desired bike's speed, range, overall weight, battery form, and cycle times.
The new battery is imagined and given a basic framework by today's battery manufacturers using powerful computer systems and design procedures. They can totally waterproof the battery at the e-bike company's request. The battery won't have electrical issues if the rider's e-bike is in the rain thanks to this.
Professionals will work on integrated circuits and delicate electronics to assure the safety of the new battery model once the design and shape of the battery have been defined. In just a few weeks, professionals can create a completely new battery using cutting-edge 3D designing software. The Deep Sleep feature found on the majority of e-bike batteries helps conserve power and improves battery performance.
Additionally, modern lithium-ion batteries have a wide range of safety features that guard against unwanted electrical faults like overcharging, overheating, short circuits, excessive discharge, and others. One of the most crucial phases of the manufacturing process is this one. When a consumer eventually decides to purchase and frequently ride an e-bike, these protection features make the battery safe to use for years and increase their sense of security.
It's time to discover suitable battery casings and decide on the battery's final colour after the electronics have been created and assembled. To create a precise shell that exactly fits an electric bike, professionals collaborate closely with an e-bike company's employees. The majority of casing components are made of ceramic, plastic, or aluminium alloy.
There are often two alternatives when it comes to colour selection: either choose a neutral colour for the battery (like black) or match the colour of the e-bike overall for a seamless look. The final say in this situation belongs to the e-bike manufacturer who made the battery production request. A custom e-bike battery comes in a variety of colours, including red, blue, yellow, orange, purple, and green.
When the battery is ready, it will be put through a series of tests in various environments, at various speeds, and for varying lengths of time. The comprehensive testing process pushes the e-bike battery to its absolute limits to make sure that it can withstand any condition that can arise in real life. The experts go back to the drawing board to modify the e-bike battery if specific situations cause it to perform incorrectly.
The battery is transferred to the e-bike manufacturer for extra testing before going into production after passing the final manufacturing tests. For each e-bike battery they produce, reputable battery manufacturers offer a warranty that lasts at least a year. This fosters trust between the customer and the e-bike manufacturer by providing the customer with reassurance that his investment is secure.
Making a new battery from scratch is not an easy task, especially when many safety protocols, such as BMS or Smart BMS as well as UART, CANBUS, or SMBUS, are necessary for an appropriate design process. Working with a skilled battery manufacturer that can adapt its services to meet the needs of its customers is essential for an e-bike business.
Lithium-ion batteries and specialised battery packs for electric bikes are our areas of expertise at KESHEE battery. Our experts have more than ten years of combined experience in this field, and we go above and beyond to make sure that the batteries we produce are secure for use in any weather. Customers come to us from a variety of nations, including Germany, France, Italy, the USA, and Canada. Contact us right away if you're looking for a unique e-bike battery solution, and our professionals will be happy to assist you!