How a Lunacycle / UPP / Hailong battery fares after 2 years..

Batteries, Chargers, and Battery Management Systems.
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neptronix   100 GW

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How a Lunacycle / UPP / Hailong battery fares after 2 years..

Post by neptronix » Oct 14 2018 4:13pm

I'm working on a bike from a customer who has had his second BBS02 part fail on him and he wanted me to look over the whole build.

Here's part of the carnage. It's a hailong style battery pack sold by Lunacycle in 2016. AKA 'shark pack'. Supplier is probably UPP.
IMG_20181014_143957.jpg
IMG_20181014_143727.jpg
Okay, we've got multiple design issues here..

1) the only thing protecting the battery cells on the top and bottom from the hard plastic case is a layer of kapton tape.

2) The battery cell assembly can shift side to side ~5mm and bash up against the plastic screw area seen in picture 1. Eventually this could damage on the nickel tabs and make the tabs separate from the cell, potentially puncturing the cell in the process ( depending on how it was welded )

3) If you install this battery pack vertically or diagonally on your bike, the whole 6-8lb. cell assembly rests on a single piece of duct tape. As you can see in picture 2, this is less than adequate. I imagine this could eventually deform that cell and short it.

Lunacycle and a bunch of various alibaba vendors, American vendors, etc sold these for a long time. I really wonder how many battery fires are due to shitty designs like this.

If you have one of these, i'd put it in a frame bag since the mounting points are known to be janky as well. And add high heat rated insulation on the weak points.
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EbikeAus   100 W

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Re: How a Lunacycle / UPP / Hailong battery fares after 2 years..

Post by EbikeAus » Oct 14 2018 8:12pm

Bit of a worry!
This is why I use cell holders..and cell level fuses
Choose LiFe 8)

May all your batteries be fully charged and perfectly balanced :P

Punx0r   10 GW

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Re: How a Lunacycle / UPP / Hailong battery fares after 2 years..

Post by Punx0r » Oct 15 2018 8:35am

Protecting anything delicate from vibration or impacts means holding it firmly but gently. I.e. stiff but compliant foam to wedge it into a case so it can't rattle around.

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fechter   100 GW

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Re: How a Lunacycle / UPP / Hailong battery fares after 2 years..

Post by fechter » Oct 15 2018 9:07am

One of the reasons they started making potted packs.
"One test is worth a thousand opinions"

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