In an effort to provide a high quality electric bicycle lithium battery, we have joined together some of the best and the brightest people in our company. We mainly concentration on the quality assurance and every team member is responsible for it. Quality assurance is more than just checking the parts and components of the product. From the design process to testing and volume production, our dedicated people try their best to ensure the high quality product through obeying standards.
Chamrider Battery stands for quality assurance, which is widely accepted in the industry. We spare no efforts to ensure our roles fully implemented in the social events. For instance, we frequently participate in technical seminars with other enterprises and showcase our contributions to the development of the industry.
For satisfying various needs of customers, the specifications and styles of all our products including electric bicycle lithium battery can be totally tailor-made by Chamrider Battery. Safe and reliable shipping method is also offered to ensure the zero risk of the goods during the transportation.
Almost all electric bicycles are powered by lithium-ion batteries. These batteries have a very high energy density, which makes electric bikes relatively lightweight while providing long range. Despite the advantages of lithium batteries, one major challenge they face in terms of safety is the potential release of energy in the form of a fire if something goes wrong.
In terms of suppliers, ChamRider ensures that we use the highest quality materials in our batteries, such as LG/Panasonic lithium-ion batteries. They also design batteries with protections against overcharging, overdischarging, overcurrent, temperature cutoff, and many other safety features.
At ChamRider, everyone shares the core belief in educating customers about the potential hazards and the importance of taking preventive measures to ensure their safety.
This article aims to provide you with a useful guide. Therefore, we will discuss tips for safe charging and storing of lithium-ion batteries, as well as measures to take in case of emergencies.
How to Safely Charge an Electric Bicycle Battery
Most reported battery fires occur during the battery charging process. Therefore, consumers must be extra cautious when charging. Here are some tips regarding the correct charging process:
Always use the charger recommended by the manufacturer; if you purchase an aftermarket charger, ensure that it has UL certification and specifications identical to the original charger. Using a fast charger for non-fast-chargeable batteries can be dangerous.
Avoid placing the battery near heat sources such as heaters. High temperatures can damage lithium-ion batteries and lead to thermal runaway incidents.
Do not place the charger or battery on or near flammable materials like wooden furniture or building structures. Always try to place the charger and battery on a fire-resistant surface or space.
Always keep the battery within sight while charging. As an additional precaution, place a smoke alarm near the battery.
In the event of a fire, the initial few seconds are crucial as you still have a chance to extinguish it before it becomes uncontrollable; therefore, prompt response is essential.
Turn off the battery while charging.
It is normal for the charger to become warm during the charging process, but the battery should never become hot (warm to the touch). If you notice the battery becoming hot, disconnect it.
Avoid charging in temperatures below zero degrees as this can cause dendrite growth on lithium-ion batteries, leading to short circuits and fire incidents.
Charge in a well-ventilated area.
Do not leave the battery charging overnight.
Proper Storage of Lithium-Ion Batteries
The lithium-ion battery of your electric bicycle requires proper storage, and you can take some measures to ensure appropriate storage.
When storing the battery for an extended period, charge it to around 60%.
Avoid storing it in extreme temperatures or high humidity.
Do not use damaged batteries that are dropped, punctured, squeezed, or otherwise compromised.
If a lithium-ion battery catches fire, use a fire extinguisher to put it out (be cautious as such fires produce toxic smoke).
Avoid extinguishing lithium-ion battery fires with water, although it can be used to extinguish the fire, a report by the U.S. Department of Energy found that it requires excessive amounts of water.
Do not store batteries or charge them near a single point of exit.
Safe Use of Lithium-Ion Batteries
If the battery starts smoking, making unusual noises, or shows signs of melting, stop using it immediately and place the battery in a safe location.
If you notice drastic changes in voltage/performance, discontinue using the battery.
If you immerse the battery pack/bicycle in water, have it professionally inspected before using it again (moisture inside the battery pack indicates water has entered and may cause a short circuit).
Always use the battery with the product it comes with; do not use it for any other purposes.
Emergency Response Measures
For any electric bicycle owner, following the tips mentioned earlier can reduce the likelihood of emergencies. However, accidents can still happen. Therefore, it is important to familiarize yourself with measures to ensure the safety of yourself, loved ones, or anyone around you.
In general, when a lithium-ion battery catches fire, you can take the following three steps:
Use a fire extinguisher:
Depending on the size and type of the battery, there are several methods to extinguish a lithium-ion battery fire. You need to react quickly and prevent the fire from spreading.
Since fires caused by lithium-ion batteries are classified as Class B fires, you should choose a standard ABC or dry chemical fire extinguisher. The Class B classification is intended for distinguishing flammable liquids. As lithium-ion batteries contain liquid electrolytes, they fall under this category.
When burning, toxic liquid acts as a conduit for the fire, aiding in its rapid spread.
You can use the fire extinguisher to spray the flames until the fire is extinguished. The steps are as follows:
Pull out the safety pin to enable the use of the fire extinguisher.
Aim the nozzle at the base of the fire.
Squeeze the handle firmly.
To ensure the flames are completely extinguished, sweep the nozzle back and forth at the base of the fire.
Take the battery outside the building:
If you suspect any issues with the battery, such as excessive heat, liquid leakage, or unusual noises, you should place it in a safe, open outdoor space and wait for the battery to return to normal. Note that you should not attempt to handle a battery that is on fire or leaking, as it may pose a danger to you.
If the battery catches fire, wait for all the batteries to burn out, and then attempt to extinguish the fire.
Call the fire department:
Fires caused by lithium-ion batteries fall under the category of thermal runaway incidents. Subsequently, a fire involving an electric bicycle battery can present multiple hazards, such as toxic smoke, flames, and metal projectiles. After taking the necessary measures mentioned above, if you are unable to control the fire, contact the nearest fire department in your area.
Assess the severity of the situation and avoid approaching a burning battery. If you are not comfortable handling the fire, wait for the firefighters to arrive.
What safety features does ChamRider Electirc Bike Battery contain?
In order to ensure that our products meet your highest quality and safety expectations, ChamRider seeks and has been granted Canada's first UL 2849 electric bicycle certification.
The latest advancements in Battery Management Systems (BMS) allow for better control of the electric bike's battery pack from various aspects, such as battery operation and its charging and discharging. ChamRider's ultimate goal is to optimize the battery's performance and lifespan.
While we ensure to provide electric bike batteries that exceed industry standards, here are some safety features of ChamRider batteries.
Charging Protection (Voltage and Current)
If the charging voltage or current exceeds the specified range, ChamRider batteries will cut off the charging process; this ensures that charging is stopped in case of any faults.
Battery Balancing
Battery balancing improves the available capacity of the battery; additionally, unbalanced batteries may be damaged and result in malfunction over the long term. That's why ChamRider batteries are equipped with battery balancing and battery balancing cutoff functions. This way, if one of the batteries is permanently damaged and unable to balance, the battery will shut down.
Discharge Protection (Voltage and Current)
During product operation, voltage and current values are measured; if the voltage is too low or the current value is too high, the BMS will cut off the battery for safety reasons.
Short Circuit Protection
Short circuits in lithium-ion batteries are always dangerous. They can damage your battery and shorten its lifespan. In the worst-case scenario, a short circuit can pose serious risks such as battery fires or explosions, resulting in personal injury, property damage, or even death. ChamRider batteries have short circuit protection designed to monitor battery voltage and prevent hazardous situations caused by battery short circuits.
Temperature Cutoff Protection
ChamRider lithium-ion batteries incorporate temperature cutoff protection mechanisms that shut down the battery when the temperature exceeds the safety threshold.
Conclusion
Today, lithium-ion batteries are widely used in electric bikes. While these batteries themselves are not inherently dangerous, improper handling by some electric bike users has resulted in numerous fire incidents. This article discusses the safety measures to be taken during lithium-ion battery charging.
We also discuss the proper usage and storage methods that can be followed when dealing with such batteries.
Lastly, we discuss the safety measures taken by ChamRider to ensure the use of high-quality batteries in our electric bikes. These measures include short circuit protection, battery balancing, discharge protection, and temperature cutoff protection.
The electric bike battery is one of the most important components as it transforms an ordinary bicycle into an electric one. On the other hand, it is also considered one of the most expensive parts of an electric bike, with prices ranging from $500 to $1000 for certain models.
Now, the question arises: Can electric bike batteries be repaired? Considering the cost of the battery and its significance to electric bike riders, it is a logical question to ask.
Can electric bike batteries be repaired?
Generally speaking, electric bike batteries can be repaired since their main components, such as the battery cells, BMS board, and wiring, can be easily replaced. Based on this, the battery can be repaired by changing these components.
Now let's discuss the most significant issues that can occur with electric bike batteries, their symptoms, and the possible solutions.
1.BMS Board Issues
The Battery Management System (BMS) is responsible for protecting the battery by regulating the flow of current into and out of the battery.
To understand how it works in practice, the BMS board is connected to all the cells in the battery and measures their individual capacities. When one cell discharges, the BMS completely shuts down the battery to prevent any potential damage.
From the functioning of the BMS, it becomes evident that charging or discharging is controlled by the BMS.
Therefore, if you find that the battery has some remaining charge but is unable to charge or discharge, it indicates a problem with the BMS.
How to solve the BMS Problems
To resolve BMS issues, there are generally two methods: resetting and replacing (I personally prefer replacement since BMS prices are not expensive either).
To reset the BMS, you can follow these steps:
1. Remove the outer cover of the battery.
2. Disconnect the cables connected to the BMS of the battery.
3. Connect the battery to the charger and start charging.
4. During charging, reconnect the BMS cables.
By performing the above steps, the BMS will be reset to its default settings.
Replacing the BMS Board.
BMS Main Cables
There are three main cables connected to the BMS:
(P-) cable is responsible for negative discharge to the connector.
(C-) cable is responsible for negative charging to the connector.
(B-) cable is responsible for the battery's negative terminal connection.
Tools Required:
Screwdriver
Soldering iron
Steps for replacing the BMS board:
1. Remove the outer cover of the battery.
2. Desolder the three main cables of the BMS.
3. Disconnect the connector connected to the battery.
4. Install the new BMS in the same position.
5. Resolder the main cables.
6. Connect the connector back to the battery.
7. Test the battery's charging.
If everything goes smoothly, reassemble the battery cover.
Important Note: In most cases, BMS damage is caused by faulty battery cells inside the battery. Therefore, it is advisable to measure the voltage of all the cells before reassembling the battery cover to ensure that all the cells are functioning properly.
2. Damage to One or More Cells
The second most common cause of electric bike battery failure is damage to one or more cells inside the battery.
In this case, you will be unable to operate the battery at all.
You can identify the damaged cells by individually measuring the voltage of each cell. You will find that most cells have a consistent reading (e.g., 4.1 or 3.8 volts). When you notice a significantly lower reading in a particular cell, that cell is the problem.
There can also be visible signs of battery damage that you can observe with the naked eye, such as the presence of black substances or cuts on the battery casing.
Note: Replacing battery cells requires specialized equipment to ensure the proper functioning of the battery, so it is best to have it done by a professional.
Don't worry, the cost will be minimal since you have already done all the work and identified the defect. All you need is to connect a new battery cell. You won't have to spend too much!
3. Wire Disconnection
The final major cause of battery failure is the presence of cut or disconnected wires inside the battery, whether it's in the main wiring of the battery or in the wires connected to the battery. This will result in the battery ceasing to function.
Usually, this issue occurs due to the battery being dropped or impacted on the ground. If you take good care of your electric bike's battery, you'll be safe from this.
To address this problem, simply remove the outer cover of the battery, locate the cut wires, and reconnect them.
Then, using a voltmeter, measure the voltage of the battery. If you find that the voltage reading is equal to the capacity of the same number of cells, you can determine the battery capacity using this formula (number of cells * 4.2 volts).
Connect the battery to a power source to ensure proper charging, and then close the battery cover.
4. Loose Battery Connection
When the battery is connected to the electric bike, it can cause damage or breakage to the battery pins, resulting in the battery ceasing to function.
You can visually inspect the pins to determine if the issue lies there, and in most cases, the battery will not be properly installed on the bike.
To address this issue, you can try modifying the pins using a screwdriver, but make sure to turn off the battery first.
Alternatively, you can replace the damaged parts within the battery entirely.
5. Charger Malfunction
The reason you are unable to use the battery may be due to a faulty charger rather than a problem with the battery itself. To determine if the issue is with the battery, try charging it with another charger or test the charger itself.
You can refer to this article, which provides detailed explanations on how to test an electric bike battery charger.
Conclusion
In general, electric bike batteries can be repaired by replacing internal cells, the BMS board, or fixing internal wiring.
One of the most significant issues that can occur with electric bike batteries is BMS damage, internal cell damage, or internal wire disconnection. Lastly, the battery pins may be damaged due to improper removal of the battery.
Battery Management System (BMS) is a technology specifically designed to monitor battery packs, which are organized electrically in an x-by-y matrix configuration to achieve desired voltage and current ranges for expected load scenarios.
The supervision provided by BMS typically includes:
1. Monitoring the batteries
2. Providing battery protection
3. Estimating the operational state of the batteries
4. Continuously optimizing battery performance
5. Reporting operational status to external devices
The overall goal of BMS is to optimize battery performance through intelligent management and protection, thereby extending battery life.
Types of Battery Management Systems
There are different types of battery management systems, each with its unique features and applications.
Some common types of battery management systems include:
1. Centralized BMS Architecture
2. Modular BMS Topology
3. Master/Slave BMS
4. Distributed BMS Architecture
Centralized BMS Architecture
A centralized BMS is a system where all battery management functions are handled by a single computer. Such systems are typically used in large-scale commercial applications where reliability and accuracy are primary considerations.
Modular BMS Topology
Modular BMS topology is a BMS that utilizes modules connected to the batteries. These modules can be placed at any location on the battery pack, allowing for easy addition or removal of functionalities as needed. Modular design also facilitates easy upgrades or replacement of components without impacting the overall operation of the system.
This topology is particularly suitable for applications that require a high level of flexibility and scalability.
Primary/Subordinate BMS
Primary/Subordinate BMS is a configuration where one master unit controls and communicates with multiple slave units. The master unit coordinates the overall operation of the system, while the slave units handle specific tasks or monitor individual battery modules. This configuration allows for distributed control and monitoring while maintaining centralized coordination.
Distributed BMS Architecture
Distributed BMS architecture is a system where each battery module has its own local BMS, and these local BMS units communicate with each other to collectively manage the battery pack. This architecture allows for a decentralized approach to battery management, providing redundancy and fault tolerance.
This topology is particularly well-suited for applications that require high levels of flexibility and scalability.
The importance of Battery Management Systems
One of the most critical features of any electronic device is its battery. Without a reliable and robust battery, your device is essentially of little value—it might not even turn on!
While electronic devices continue to become more powerful and efficient, batteries have not necessarily become smaller or stronger. In fact, a study found that smartphone batteries have actually been getting larger in recent years!
Hence, the popularity of Battery Management Systems (BMS) among electronic manufacturers should come as no surprise. BMS plays a crucial role in ensuring that the batteries in electronic devices have the longest possible lifespan and reliable performance.
Functional safety
Lifespan and reliability
Performance and range
Troubleshooting and maintenance
Reliability
Cost and warranty reduction
Functional Safety:
A battery management system (BMS) can help to ensure that batteries in electronic devices last as long and perform as reliably as possible. This is important because it reduces the chances of accidents – not just with the device itself, but also with related equipment.
Life Span and Reliability:
In addition to ensuring that batteries last as long as possible, a BMS can also help to improve reliability by minimizing the chances of battery packs failing during normal use. In fact, some studies have found that using a BMS can even result in increased life spans for individual cells!
Performance and Range:
Another important benefit of a BMS is that it can help to improve the performance and range of devices. This is because it can help to optimize battery usage – both in terms of how much power each cell can consume, as well as how long each battery pack will last.
Troubleshooting and Maintenance:
Finally, a BMS can also be helpful in troubleshooting and maintaining devices. This is because it provides accurate information about the health (and condition) of batteries – both individual cells, as well as entire packs. And because it can be integrated with other devices, a BMS can also help to simplify maintenance procedures.
Reliability:
BMS is considered to be extremely reliable – both in terms of its ability to keep devices working as expected, and its overall lifespan. In fact, some studies have found that even when failures do occur, they are typically mild and relatively easy to repair.
Cost and Warranty Reduction:
Overall, using a BMS can result in cost savings for device manufacturers as well as end users. This is because it can help to reduce the number of battery packs that need to be manufactured (and/or purchased), as well as the associated expense. Additionally, a BMS can also provide additional warranty protection for devices.
The Battery Management System (BMS) serves several different functions. The Electrical Protection Management of the BMS helps protect the battery pack from overcharging, incorrect charging, and over-discharging. Capacity management assists in optimizing the battery pack's discharge voltage and capacity by monitoring charging/discharging cycles and adjusting battery parameters accordingly. The Thermal Management System (TMS) prevents thermal runaway of the battery by monitoring battery voltage, current, temperature, and fan speed.
Electrical Protection Management - Current:
BMS helps protect the battery pack from overcharging, incorrect charging, and over-discharging. Essentially, these management system functionalities help optimize battery performance by monitoring charging/discharging cycles.
Electrical Protection Management - Voltage:
One of the key functions of the BMS is voltage management. By monitoring the battery pack voltage levels and adjusting battery parameters (e.g., battery voltage) accordingly, the BMS helps prevent over-discharging or undercharging of the battery. This helps maintain optimal pack health and performance.
Thermal Management:
Thermal management is another important function of the BMS. By monitoring battery voltage, current, temperature, and fan speed, the BMS helps prevent thermal runaway of the battery. The thermal management system functionality also helps optimize battery pack performance by ensuring that the battery stays within safe operating limits.
Capacity Management:
BMS also assists in managing the capacity of the battery pack by monitoring charging/discharging cycles and adjusting battery parameters accordingly. This helps optimize battery performance while keeping the battery pack within a safe operating range.
Components of Battery Management System:
The Battery Management System (BMS) is a specialized hardware and/or software device that helps optimize the performance and lifespan of battery packs in electronic devices.
A typical BMS monitors the health (and condition) of individual batteries as well as the entire battery pack. It also provides accurate information on State of Charge (SOC), state of health, energy usage, and temperature of the battery. This makes it an essential tool for device manufacturers who want to ensure that their devices operate reliably even under harsh conditions.
In addition to improving device operation, the BMS also simplifies maintenance procedures. This is because it helps identify and diagnose issues early, minimizing the time and effort required to rectify problems.
Battery Management System (BMS) Operations and Maintenance
The Battery Management System (BMS) is a computer system that monitors, manages, and maintains battery charging, discharging, and status. The BMS can also predict when a battery may need replacement or repair.
BMS should be installed in any facility that uses or stores batteries, such as factories, power plants, hospitals, and schools. Having a BMS is crucial because batteries are critical components of many devices, from electric vehicles to mobile phones, and improper management can pose safety risks.
The primary goal of the BMS is to maintain battery health and safety by monitoring the battery's charge level, temperature, and other performance indicators. It also provides warnings to users when the battery starts to lose capacity or approaches its maximum limits. Additionally, if the battery requires maintenance or replacement, it can initiate preventive maintenance procedures.
Overall, a good battery management system helps ensure the safe and efficient use of batteries now and in the future.
Conclusion
As you can see, there are many benefits to using a Battery Management System in battery packs. The technology ensures not only fast charging and safe driving but also ensures that the battery is always fully charged.
Most importantly, some systems have additional features such as remote monitoring and diagnostics, so you no longer have to worry about the health of your battery. Click here to learn more about how we ensure that your vehicle has everything it needs!
The first step in converting a regular bicycle into an electric bicycle is to install the battery. The installation process is relatively simple, but it is important to thoroughly understand the process before deciding where to place the battery.
How to Install an Electric Bicycle Battery
Electric bicycle batteries can be installed on the bicycle in various ways. Most electric bicycles come with pre-installed batteries and mounting features. However, if you want to change the installation orientation for convenience or install the battery on a new bicycle, you will need to follow some simple instructions.
What You Need:
Battery case
Heat sink
Rivet nuts
Bolts, screws, and nuts
Wires and connectors
Wrenches (regular, Allen, rivet)
Screwdriver
Installing the Battery on a Brand New Bicycle:
You can purchase a complete kit with a display, motor, throttle, and speed sensor online to convert your regular bicycle into an electric bicycle.
Step 1: Remove Old Components
Remove the chain, bottom bracket, pedals, mechanical lines, and brakes. Converting your regular bicycle into an electric bicycle means removing almost everything from the old bicycle.
Step 2: Install the Electric Bicycle System
Mount the motor on the bottom bracket and lubricate it. Install the display, brakes, and throttle on the frame.
Step 3: Initialize Connections
Connect the display, throttle, brakes, and motor to the controller. Additionally, connect the speed sensor to the rear wheel.
Step 4: Choose Mounting Options
Mount your front rack or rear rack or triangle pack onto the bicycle.
Or
Drill a few holes, insert rivet nuts, and tighten them. You can now install the sliding mounting options onto the bicycle frame.
Step 5: Install the Battery
Mount the battery onto the mounting option, connect the battery, and it's done.
Step 6: Connect the Battery to the Bicycle
The overall wiring of the electric bicycle may seem complex, but connecting the battery is the simplest part so far.
You simply need to place the battery in the installation position and plug the connector into the controller.
While the connection between the bicycle and the battery may be straightforward, the wiring connection to the controller can be quite complex. For more information, you can refer to the instructions.
Different Mounting Options for Changing the Battery
Various DIY Battery Mounting Options
Rear and Front Rack Mounting:
The most common mounting option for a DIY battery on an electric bicycle is the rear rack option. Almost all bicycles are rear-wheel-drive (rear tire moves first), which is helpful for bearing heavy loads at the back.
Front frame battery mounting brackets may not be as popular as rear frame options, but they are undoubtedly a convenient choice for installing a DIY battery.
Pack (Triangle and Top Tube) Mount:
Using a triangle pack for mounting a DIY battery will be the simplest and sensible decision. The pack will be placed in the middle, which is perfect for achieving optimal weight distribution on the bicycle. Additionally, you don't have to waste time searching for wrenches or screwdrivers every time you need to remove the battery—taking out the pack is simple and hassle-free.
Top tube packs for mounting DIY batteries may not be as common, but they are also easy to install and detach on the bicycle frame.
Dolphin Case and Water Bottle Holder:
Both dolphin cases and DIY battery water bottle mounts utilize the bicycle frame's water bottle cage.
Larger batteries may not fit in these, so you may need to replace the water bottle cage with a larger one.
The advantages of these two mounting options are ideal weight distribution and ease of detachment.
Safety Precautions When Using the Battery
When you are using the power source, it is essential to take the strictest safety precautions.
How Do I Secure My Electric Bike Battery
Ebike batteries are quite expensive and finding a proper replacement is also quite time-consuming. Here are some tips, following them will surely help you secure your electric bike battery.
Conclusion
Having proper weight distribution of your ebike depends on where you are mounting the battery. There is more than one way to mount a battery and putting the battery inside a bag or in the water bottle case is the easiest one.
You need to have a brief Idea about how to mount an ebike battery, whether you want to turn a regular bike into an ebike or just want to change the mounting position of the battery. It’s easy and simple.
