Black Sabbath: Teleport Prime, Weldless Battery

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drdrs   1 W

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Posts: 50
Joined: Jun 10 2018 11:55am

Black Sabbath: Teleport Prime, Weldless Battery

Post by drdrs » Jan 03 2021 3:25pm

This bike (black and built while on sabbatical) is a typical hub motor with enduro frame build.

The unique aspects are:

- Teleport Prime 90 frame
- Custom weldless battery design (14s5p VTC6, 80 mOhm IR)
- ENNOID SS BMS
- CircuitPython-based dashboard display
bike.jpg
bike.jpg (353.21 KiB) Viewed 508 times
Most of the parts were taken from a previous build (viewtopic.php?f=6&t=101184) and moved to the teleport frame.
battery.jpg
battery.jpg (237.21 KiB) Viewed 508 times
The battery uses connector bars from Vruzend packs along with laser cut acrylic to hold the contacts and cells in place and provide mounting points.
display.jpg
display.jpg (117.79 KiB) Viewed 508 times
The display is based on the Grand Central board from Adafruit and uses CircuitPython for the code. The repository is located here: https://github.com/dsoto/ASI-ENNOID-dashboard
viewtopic.php?f=6&t=101184
5kW ASI 2000, Crystalyte, Vruzend 14s5p

viewtopic.php?f=6&t=104324
VESC, MG 310, Vruzend 12s3p

viewtopic.php?f=6&t=109860
VESC, Crystalyte, Custom Compression Battery 14s5p

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fechter   100 GW

100 GW
Posts: 15840
Joined: Dec 31 2006 3:23pm
Location: California Bay Area, USA

Re: Black Sabbath: Teleport Prime, Weldless Battery

Post by fechter » Jan 03 2021 3:55pm

Nice. What forks are those?

It will be interesting to see how the battery holds up long term. It looks like you have thru bolts between each cell? At least it will be possible to repair if a cell goes bad. I would predict contact failures before cell failures, but I don't have much long term experience with a setup like that.
"One test is worth a thousand opinions"

drdrs   1 W

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Posts: 50
Joined: Jun 10 2018 11:55am

Re: Black Sabbath: Teleport Prime, Weldless Battery

Post by drdrs » Jan 03 2021 4:31pm

The fork is the garden variety DNM USD-8 with the badging removed.

I rode a Vruzend for a year without any noticeable contact degradation. That battery was the 2.0 contacts and didn't have the barrel bolts so I did external compression plates. I had contact issues before I got sufficient compression on the plates. The weldless design adds bulk and weight and contact resistance, but the ability to easily rebuild outweighs that disadvantage for me.

Correct, I went fairly maximal on through bolts. To keep watch for connection issues, I display max and min cell row voltages on my display during riding and charging. In the past, cell connection issues presented as a row that charges or discharges more quickly than the neighbors since it has N-1 cells in contact. If I go out of balance that will be the first thing to check.

My measurements suggest that I'm getting about 3 mOhms contact resistance per cell with polished bolt heads compared to 0.5 mOhms published values for spotwelding. Was about the same for the Vruzend packs I've done. So, about a 10% penalty on a 30 mOhm cell. There may be some more gains possible with increased surface treatments.

Hope to see you again at the next Lost Sierra festival.
viewtopic.php?f=6&t=101184
5kW ASI 2000, Crystalyte, Vruzend 14s5p

viewtopic.php?f=6&t=104324
VESC, MG 310, Vruzend 12s3p

viewtopic.php?f=6&t=109860
VESC, Crystalyte, Custom Compression Battery 14s5p

User avatar
fechter   100 GW

100 GW
Posts: 15840
Joined: Dec 31 2006 3:23pm
Location: California Bay Area, USA

Re: Black Sabbath: Teleport Prime, Weldless Battery

Post by fechter » Jan 04 2021 1:06am

That's a good point; with cell level voltage measurements you should be able to spot a connection going bad.
"One test is worth a thousand opinions"

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