Wow... Man.... That was one radical trip down memory lane !
Terrific job ! I'm gonna sticky this for a while, the video and sound quality was pretty rough but well worth watching..
Batteries are the by far the weakest link in the mass market ebike industry to be.. The 250w setups are pretty easy, but the 500w+ range of ebikes just plain need more..
I have a 1700$ paperweight sitting next to me, was supposed to be best thing since sliced bread, arrived with no BMS ( because i had been waiting for months on end for it, and it could not be hacked to work, so shipped it without one ) supposed to be good for 80 amps ( 24ah pack ) .. could not manage 20... and looked like it was assembled by a chimp.. Can't even imagine the feeling of having 50 on a pallet to deal with ...
Oh, the original eZee battery pack back from late 2007 http://ypedal.com/ezee.htm
finally kicked the bucket this year, BMS and charger kept working but the cells finally swelled and are down to 5ah.. all 10 cells !!.. if they all worked like that it would be great.
About Lithium cells going to 0v and not recovering, after a whole lot of hours ( Doctorbass knows all about this too !!! ) testing defective power tool packs, and also on PSI cells, and with Turnigy lipo cells too, i've had situations that cells will either self discharge to 0v from a long trip across from china, or be discharged over a period of 3 weeks or so ( by soneil chargers none the less, plugged into the packs but not on AC ) viewtopic.php?f=14&t=22885&start=0
They sometimes survive !!! with no immediate signs of capacity or performance loss..
While some other cells die instantly below 1v ( like the 12ah prismatic lifepo4 for example )..
The nicad packs have been the longest lasting and trouble free ( other than a thermistor replacement or 2 ) .. the one's i got that are over 4 years old now are still going, higher internal resistance but giving 6 to 7 ah from an 8ah pack..
The " Best " 48v 10ah pack i have used ( and still do ) i built myself from PSI cells, no BMS, but using 16 gauge wires with anderson powerpoles.. overboard, but damn it works well..http://ypedal.com/PSI/PSI.htmhttp://ypedal.com/PSIChopper/index.htm
what is it with batteries, i lov'em so much.. but i hate them soo much too....