Batteries
First Generation Battery
The first generation battery packs used in this build were constructed using Samsung 25r 18650 Li Ion cells. Each pack is made up of 98 individual cells, arranged in a 14s 7p configuration and uses a 14s 100 amp battery management board. This made the pack 17.5 ah and 58.8 volts, just under the 60v maximum of the motor controller. This configuration allows each pack to be housed in a .30 caliber ammo can welded to the motorcycle frame.
The individual cells of the pack are electrically connected using spot welded nickel strips. A home made spot welder consisting of a car battery and an arduino controlled solenoid was used to weld the nickel strip.
To finish the pack, it was covered in double sided foam insulation tape and then shrink wrapped.
Two packs were first used on the bike for a range of approximately 15 miles. Two additional packs were added shortly after to extend the range to 30 miles.
Second Generation Battery
In the 2nd generation pack the cells are stacked vertically and are held in place using the original housings. Each cell connection is made by sandwiching the cell discharge tabs between aluminum blocks that are riveted together and are insulated with kapton tape before being covered by a 3d printed cover.
The pack is finished off by bolting polycarbonate sheets to the bottom and top, this allows the packs to slide into the boxes on the motorcycle on a track system for easy battery access.
The second generation battery packs are made using 60 ah lg chem pouch cells harvested from incorrectly manufactured Chevy bolt battery modules. These cells have better cold weather performance and are easier to replace than the 18650 cells used in the 1st generation packs. The lg packs are assembled in a 14s 1p configuration with a 200 amp battery management board for each pack. There is a total of two packs on the motorcycle giving it a range of about 50 miles.
