AramWhile Shushanik was working on the smartphone app, I got back to design of the battery pack.
We’ve purchased several types of battery packs for testing in the past, hoping that maybe we will be able to source a reliable, high quality bottle shaped pack, but unfortunately, we could not.
So we decided to make our own pack. We’ve started working with a company, that specializes in battery pack manufacturing. The challenge was to fit the battery cells into a standard size bicycle water bottle. But the main challenge is the safety of the pack and it is our top priority.
After many design iterations with our manufacturing partners we came up with this design.
It has three LEDs that indicate the state of the charge, a button switch that turns the battery on-off and a power connector.
It is about 220mm tall and fits the standard water bottle holder. We will also provide a simple rubber band that will go around the bicycle downtube and secure the battery to the frame.
The battery pack body is going to be made of stainless steel and the lid out of hard plastic.
It is 36V 7Ah battery, powerful enough for BikeOn.
We are in preparations to pass all necessary tests and certifications, including MSDS, UN38.3.
Here how it looks inside (without shrink wraps):
It is still a work in progress. Let me know what you think!
Aram
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It's unusual practice to have the male XT60 at the battery pack! Shorts could easily set the whole thing on fire. Standard practice is to have the female XT60 at packs and the male one on the charger/...
On another note I see no balancing connector for charging?
Are you sure? yes | no
@Jan You're right, it's my mistake, I've mounted the wrong part as I was making the pack model! Thanks for catching it!
Balancing is done by the BMS, which is inside the pack (the PCB is shown on one of the pictures), so the balancing leads go from cells to the PCB.
Are you sure? yes | no
Ah, you're right, internal balancing. Should've thought of it :)
Are you sure? yes | no