Here are the CAD files of the pogo pins terminals housing and the JBD SP17S005 BMS support for 3D printing, the template to drill the battery cover for pogo pins and the template for the battery spot welding if you want to replicate what I did. I also attached the reverse engineered battery CAD...
The I attached extra connectors for the battery on/off function.
In order to attach the new connector I drilled two holes in the battery bottom bracket
Tapped with M6
3D printed the connector housing out of ABS
Attached it to the bracket with a couple of 90 deg countersink M6 screws...
Here is the idea how the battery power cables are managed
The next step was to fabricate the interface for the battery BMS on/off switch
I teared the cup-pogo pins to use the cupped pins from it
Trimmed the pins
Drilled holes in the battery cover using laser cut template. The...
Connected the BMS to the computer with programming cable and checked the BMS reads the series connections properly in the BMS program (first time I connected it was reading 12 series instead of 14 for some reason, I disconnected the balancing leads from BMS and connected them back to BMS and...
And here is the battery pack building process.
Unsolder the original wires on the BMS and solder them on opposite side of the board (for proper cable management)
You can see this 80A BMS uses two 10AWG silicone insulated wires on each side
Make sure all the battery cells have the...
And here the custom high power output 80A 52V 14S4P 1050Wh battery pack. The pack is fully functional just like the stock battery (can be turned on and off with the button on the bike frame, has low voltage on the terminals when the battery is out of the frame for safety and to protect the...
Alright, I have finished the new 52V 80A battery and wiring harness and finally tested my 3000W Innotrace X1 at full power. That thing is a monster! I was able to reach 40 mph on flat with not so much effort and that thing can coast 30-35 mph on flat effortlessly. It can easily keep up with...
It looks like you do not use fuses for the battery. Do you feel it is OK to make it without fuses? I am trying to cram one MAXI fuse (80A 58V for discharge) and one MINI fuse (7.5A for the battery charge and level indicator) but it is extremely difficult to allocate them in such limited space...
If they state it runs more efficient and they redesigned the stator and the rotor they probably use thicker wires for the stator coils which means it can take more amps than M620 and be more powerful with aftermarket controllers without overheating.
Increasing torque and reducing RPM without...
If that Bafang gearhub can hold 250NM torque then they also got the Kindernay killer. Especially with that maximum gear ratio (over 3) bigger than Kindernay VII maximum gear ratio (about 2) that thing can go crazy fast, faster than any drivetrain on the market.
Great news! Innotrace software was completely bypassed and now you can setup you motor up to crazy 3500W power and 100A current.
Now you can squeeze all the juices out of you Bafang m620...
By the way, on my rear triangle some fasteners got loose after a few hundred miles and I tightened them with red locktite and marked with silver Sharpie to see keep an eye on them.
All the spokes on the rear wheel got loose too after a few hundred miles so I had to tighten them too.
After...
I think the rear triangle does not flex and does not have freeplay, but the rear axle has a little freeplay. Plus I use Kindernay VII and it has some freeplay too so yes under load the rear wheel turns a little relatively the rear triangle.
No, not mandatory, but it a good safety feature.
I disconnected the rear brake wires from the harness to be able to wheelie. The front brake is still connected.
I think I figured out why some manufacturers mark 14s Li-ion BMS as 48V instead of 52V. That 48V indicated not the battery nominal voltage the BMS is designed for but it indicates the standard voltage of the electrical system the battery with such BMS can work with. Most of the electrical...
Innotrace does mention about 60A connector for 3000W motor on their website.
I think it was worth all the trouble to have the motor with such power.
I am planning to use 50s or p42a cells whichever will be available. 50s has smaller lifespan than p42a at maximum amperage usage scenario but at...
I could reuse the original battery box but I already use the bike for commute and doing it would not allow me to use the bike while I am building the battery.
I also do not know what cells they use with the original battery (I did not tear the battery down completely to check it because of the...
Alringt, it looks like they started sorting things out. Krasnodar from Innotrace was able to fix my motor remotely! Now it is 3000W !
The issue was the wrong firmware and not adjusted to the necessary power motor.
Now at 3000W it pulls so hard that it almost lift the front wheel! The BMS...