E-Bike improvements

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It’s finally warm here in Canada and I have started to use my e-bike to go to work. I introduced some improvements to keep things tidy and easy to use.

Starting with my e-bike computer I used an old printer cable (with many cores) to re-wire the connection between the LCD screen and the main board. I also added a toggle switch that powers off the unit while I am at work or when the bike is not in use, avoiding battery draining.

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Everything looks so much tidier now!

I also re-wired the main board with 10AWG cables.

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The bike now uses the Hybrid battery (see previous post), 54V nominal and about 9.5Ah (with 7.5Ah of usable capacity to preserve cycle life). I was able to shrink wrap the battery in black PVC tubing, making it safer and more professional looking.The battery is secured to the frame with “backpack” straps.

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I am still working to improve the bike.

Next things to do:

  • Use the main battery to power up the e-bike computer (now is powered with an external battery)
  • Introduce a plug for recharging outside the wooden battery frame, weather insulated, and protected ( with a fuse).
  • Reduce the amount of wires.

 

I am also working on a “cell balancer”, I have done a few tests and I should be able to have a pcb ready for more testing next month..I will keep you posted!

 

 

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4 thoughts on “E-Bike improvements

  1. Great job Jacopo, just a question: did you twist each cable to reduce noise? I did not apply this precaution and in the last 3 months my LCD sometime starts displaying strange chars
    đŸ˜¦

  2. Hi Ccriss,
    The wires in the cable were already twisted. I believe this is a high quality cable, there was even a metallic mesh around it. I don’t think the “random/strange” chars you see are related to the noise. I had the same problem a while ago and it was due to a wire not soldered properly and every time the contact became loose, I could see strange things happening on the LCD. Now everything is running perfectly.

    • Not at the moment. You can use Ccriss (from Energeticambiente) sketch. As for the schematic I am designing a new circuit, this one has some mistakes in it, there is no point in publishing the current one.

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