Electric Bicycle Battery

Fire-proof shell or Battery case
The fire-proof shell or battery case is the outer casing that holds all of the cells and BMS together. It's important to choose a case that is made from high-quality materials and is resistant to shocks and drops. This will help ensure your battery stays safe and performs well for a long time.
The materials include ABS and PC, which are produced by an injection mould. It owns a certain level of fire-proof ability so as to effectively protect users from secondary damage in an accident.
Also, the certification will affect the case materials and design.
For example the UL2271. It requests the battery able to pass the crash test. The crush test will have force at a different angle, and the battery should not catch fire or explode. In this case, the high-strength metal case with UL battery cells often passes the test.
On the other hand, waterproofing is also part of UL. That requires the case have a good selling design to help the battery pass the test.

LED display
It can show the battery SOC, as well as allow to show the battery conditions, for example, current, voltage, and temperature. However, such a LED display is not suitable for all electric bike battery packs, which are designed as per customers' ideals.
BMS (battery management system)of lithium battery
BMS short for Battery Management System is a circuit board and the key part of electric bicycle battery. Some are more dependable than others. But, generally speaking, the better BMS systems will use higher-quality components and have a longer track record of reliable performance.
As a BMS circuit board, it includes various parts: NTC, B+/B-, P+/P- to the controller, motor power, PAS, USB 5V / backlight, power switch, and charging cable/ CAN cable.

Battery Cells
It's also important to choose cells that are certified by a reputable organization like UL (Underwriter Laboratories). This ensures that the cells meet certain safety standards and are not prone to fire or explosions.
Electrode materials: the anode is triple elements NI, Co, Al, and the cathode is Graphite plus Si.
There are three cell types: NCM (triple elements Ni, Co, Mn), NCA (triple elements Ni, Co, Al), and FePO4.
Each cell manufacturer has a different cell type, for example, high-output cells usually have lower capacity. But can have up to 5C output current. It is often to be used in the power tool.

Cell holder
The cell holder is the component that holds each of the lev cells in place. It ensures that your lev cells are properly aligned and prevents them from coming out or shifting around during use, transportation, etc.
Like the battery case, it's important to choose a cell holder made with high-quality raw materials (i.e., metal) for durability purposes. Or specifically designed for your product.

Sealing ring
In order to achieve a certain level of water and dust proof, we will choose TPU material or metal screws to seal the pack.

Cell busbar
The cell busbar is the component that provides an electrical connection between all of the lev cells in the battery. It's important to choose a busbar made from a high-quality metal (like copper or nickel) for optimal performance and durability.
The thickness and metal also depend on the different currents of the pack. For example, the current of the 200A lev pack is thicker than 50A.
The busbar will help charge and discharge smoothly for a long time. The wrong or low-quality busbar will be the weak point of the battery and lead to failure. For a larger electric motor, the current usually will be high, and carefully choose the thickness of the busbar.

Connectors and cables for the battery pack assembly
The connectors and cables used to connect the battery cells are also an important part of the battery pack. Poor-quality connectors can cause problems with charging, discharging, and thermal management. They can also lead to a shorter life span for the entire battery pack.
Good connectors should consider the waterproof and also the vibrations. That can protect the contacts from water and dust, and also prevent the vibrations to damage the connection inside.
In a road electric bike, the connectors must handle the vibration and not fall off when the e-bike is moving. So, we use a connector with a screw to make sure it's more reliable.
The quality of the connectors and cables can be just as important as the quality of the battery cells themselves. Make sure you choose a reputable supplier that uses high-quality connectors and cables in their battery packs.

Inner battery
Electric bikes battery Charger
The battery charger is also an important part of the battery.
The charger is responsible for charging a li-ion battery and ensuring that it does not get damaged or overheated during the process. With a good electric bike, you should have two chargers: one to charge the electric bicycle battery while they're on your electric bike and another at home so you can fully recharge them in between rides.
The quality of the charger will affect the battery life. That is why most of our clients ask us to develop a matching charger for the battery project.
There are mainly two types of chargers: smart chargers and normal chargers.
The smart charger communicates with the BMS. It can adjust the charging current and voltage to make sure the battery is always safe. It also can protect the battery from overcharging and overheating.
The normal charger just uses a fixed current and voltage to charge the battery, it doesn't have any communication with the BMS. So, it's not as safe as the smart charger. The battery life will also reduce significantly.
The charger is a part of the battery which ensures your safety and protects your investment in the long run. Also, it can prolong the battery life of electric bicycle battery. So we recommend our client use a matching charger for their project if possible because that will give you better performance and a longer lifetime for sure.