News

Setup of an ebike battery

Modern e-bike batteries are complex systems that have to fulfil the highest requirements in terms of safety, efficiency and durability. In this article, we will show you how an e-bike battery is constructed - from the mechanical structure and energy storage to the intelligent control electronics.

As a manufacturer with our own design and production facilities in Haibach and development and BMS production near Stuttgart, we can map almost the entire process in-house - from design to final testing.

1. the components of an e-bike battery pack

An e-bike battery pack consists of several central components that are precisely harmonised in close cooperation between the construction, hardware and software development and production departments:

• Corepack - the centrepiece forms the energy storage unit of the battery.
• BMS (Battery Management System) - the intelligent control and monitoring
• housing - defines the available installation space and protects the technology from external influences

The result is a safe, powerful and durable battery - developed and manufactured to the highest quality standards.

2 The core pack - energy storage and power base

The core pack is the actual energy source of an e-bike battery - it largely determines the capacity and therefore also the range of your e-bike.

A core pack consists of three central components:

• Cells - mostly modern lithium-ion cells with high energy density
• Cell holders - plastic holders fix the cells in the desired arrangement and ensure defined spacing - important for stability and cooling.
• Cell connectors - These metallic connections (usually made of nickel-plated copper or pure nickel) are connected to the cells by spot welding and conduct the current within the cell pack.

Our core packs are optimised for safety, efficiency and durability and are manufactured in Haibach.

And what does 10S4P mean?

This designation describes the electrical interconnection of the cells:

10S = 10 cells in series → 10 × 3.6 V = 36 V nominal voltage
4P = 4 cells in parallel → 4 × 3.5 Ah = 14 Ah capacity

This results in a core pack with a total of 40 cells, suitable for standard 36 V systems.

Depending on the desired capacity, other configurations can also be realised, such as 10S3P (lower capacity) or 10S5P (longer range).

3. The BMS - Monitoring, protection and control

The Battery Management System (BMS) is the central control unit of the battery - comparable to the ‘brain’ of an electronic system. It monitors and regulates all safety-relevant parameters during operation and protects the battery from damage due to incorrect loading.

The following components are installed with the BMS:

• Circuit board (BMS) - with specially developed hardware and software that permanently monitors the voltages, currents and temperatures of both the individual cells and the entire core pack.
• Cable - to connect the circuit board with the cells, sensors and interfaces (e.g. charging and discharging socket).
• Temperature sensors - placed directly on the cells to detect critical heating at an early stage

Our BMS is developed and tested in accordance with international standards and fulfils several protective functions that in many cases go beyond the minimum legal requirements.

These include, among other things

• Shutdown in the event of overvoltage or undervoltage of individual cells
• Protection against excessive charging or discharging current
• Temperature monitoring and automatic disconnection in the event of overheating

If a critical value is exceeded, the BMS intervenes immediately and disconnects the cell pack from the system - for maximum safety and longevity.

Thanks to a Bluetooth chip, the battery can be easily updated with software updates via the mobile app AV-Toolbox or the dealer tool, the Akku Vision Test Tower.

4. the housing - protection and functional unit

The housing protects the sensitive technology inside and at the same time gives the battery its characteristic appearance.

It consists of the following components:

• Housing halves - They mechanically enclose and secure the entire battery system. At the same time, they provide protection against the effects of weather, dirt and impact.
• Charging and discharging socket - The battery is connected to the charger or the e-bike system via these interfaces. In some models, a second charging socket is also integrated - e.g. for quick-charging functions
• LED film with button - An integrated status display shows the current charge status via an LED strip. Many models also have an on/off switch to activate or deactivate the battery.

Before a battery leaves our factory, it is fully tested in the so-called EOL (End of Line) test using special software: Only if all parameters are correct is the battery released for dispatch and packed securely

Technology on the inside, quality on the outside - every Akku Vision battery is the result of well thought-out development, precise production and strict final inspection.