Battery performance - what really matters?

Jeremy Harris

100 MW
Joined
Oct 23, 2007
Messages
4,208
Location
Salisbury, UK
OK, I absolutely do not want to see this thread denigrate into another slanging match about sales techniques etc!

I've been trying to establish what the really important, simply expressed, attributes of an ebike battery are and see how we can best make trade-offs to match our personal circumstances. I've ignored reliability, because there doesn't seem to be enough data around to make a judgement. The idea was to look at selecting a battery based on personal requirements, making sure that all the really important things were picked up.

Capacity
Very important, as useful capacity, at the average operating current, is the only thing that matters. Theoretical capacity is meaningless, it's only the Ah you can actually get out of the battery that is any use. SLAs seem the worst, some Lithium technologies seem to be the best.

Max continuous discharge current
Pretty important, as this often has a major bearing on useful capacity. Discharging a cell at more than it's rated current will result in less useful capacity.

Weight
Important, probably more so than volume for any given capacity, as bike handling and performance is directly related to weight.

Cycle life
Important up to a point, but a comparison needs to be made between cycle life, probable use and calendar life to work out how significant it is in each individual case. Cycle life is only meaningful if it represents full charge/discharge cycles. For many battery technologies, like NiMH, limiting charge/discharge cycle depth can easily extend life into the hundreds of thousands of cycles (see the Toyota Prius case, for instance). If we want the maximum useful capacity from a battery then it's vital that we understand the effect this has on life.

Calendar life
Often overlooked, but most probably more important than cycle life for many (most?) ebike users. For example, a battery than has a 1000 cycle rated capacity life, but a two year rated capacity calendar life, will most probably die of old age before it dies from being over-cycled. I doubt that many users will average more than 300 cycles a year on a battery (although accept that a few might). If your riding pattern means that you're only going to average 100 battery cycles a year, then calendar life almost certainly completely dominates when it comes to battery selection.

Volume and shape
Probably the least important attribute in practical terms, as even worst case batteries in this regard seem to be able to find a home on some bikes. Shape may be more important than volume, as cells that can be re-arranged to fit the frame space available will be simpler to use than those batteries that come in big, fixed size, blocks, like SLA.

Cost
Importance depends entirely on the means of the purchaser. Some will pay a premium to get exactly the battery they need, others may choose to trade some of the above to get what's affordable to them.


For me, useful capacity, weight and calendar life are the three key attributes, as I doubt I'll ever achieve more than 100 cycles a year on average. My riding is a short daily commute, with an occasional longer ride. I can go three or four days on 10Ah without recharging. Weight was pretty important, as my 'bent handles badly when weighed down. For my initial experiments I didn't want to spend heaps of money, in case things didn't work out, so I opted for cheap batteries. If these work OK then I will look to upgrade to some with a better calendar life as soon as the cheapos start to fade.

I guess we'll all have differing views on the "best" battery, as all of us likely to want different things from one.

Jeremy
 
I'm not sure exactly what your after, but if your soliciting opinions then my top 3 considerations will probably be different from most people.
For me the primary requirement is the shape & volume, then calender life with weight only being a factor so long as it's not too much.
My pack has to fit in the space between the forks, which means D-size or shorter & severely limits my choices.

Personally I view capacity, max discharge & cycle life all as a function of cost.
If I want more range or more power or more frequent trips then I can achieve that by spending correspondingly more money to get it if I really need it.
But (almost) no amount of money can incrementally buy me more of the other attributes.

As I've frequently said it here b4, there is no such thing as best, only best for what.
 
Me, personally.. the cost is a factor but not the primary one..

Reliability, safety, size, weight, mostly in that order.

Reliability: When i leave home 10 minutes before i start work, i want this thing to work.

Safety: I want as fool-proof of a battery as possible, plug the charger in.. and go to bed anyone ? I trusted my nimh enough to do that.. i do NOT trust my lithium packs and chargers enough to do that yet...

Size : A large pack sitting above the rear tire on a tall rack.. is the worst.. someone please make an enclosure that clamps to the frame down low.. etc.. the smaller the better.. but the lighter the better as well.. otherwise you end up pulling over after a harsh pot-hole to check your straps...

Price : This is something that will matter to different extents to different people, if you use your bike for commuting, daily, etc.. then justifying an expensive pack is worth it imo.. if you use your ebike for show off with friends on weekends while slugging down a few cold one's.. then hey.. get SLA and have some fun..
 
Price is very important... but that calculation is more complex than it seems. So "true price" would be my primary criteria.
 
Weight and size are really important. Add in form factor to that equation. Large cells are less complicated but smaller cells make form factor more variable. But the larger the vehicle the less that is a problem. At this point Lithium is cheap enough that if you can DIY that it is a no brainer to me. It seems that most lithium technologies today are close enough to each other that once you decide on Lithium then it really wouldn't matter from one brand to another.

"True cost" Kinda wraps shelf life, cycle life and $ per Watt into one equation. I have no problem with a higher upfront cost if I am truly getting a better product that over its lifespan will be less expensive.

Capacity and Max Discharge kinda go together as well with today's Lithium, unless you are trying to do a 1/4 mile drag.
 
I was trying to work out a basis for comparing battery types, prices etc for the role we're using them for. It's interesting that price weight and size all come out as important to folk, plus reliability and safety, a couple of things that'd slipped my mind.

For me price is important when I'm taking a risk, maybe by experimenting, as I don't want to lose a lot of cash on something that doesn't work out. For the final version, price is less important to me than reliability, safety and useability.

We have some big battery price differentials, even for notionally the same chemistry, which makes some of this stuff hard to get to grips with. What I'm trying to do is come up with a simple way to build a model that allows the value of different options to be assessed, as a sort of weighted spreadsheet that will pop out a personalised "best fit" choice.

At the moment we seem to be comparing apples and oranges the whole time, which makes it difficult to determine if a $600 battery is actually better or worse than a similar spec $300 one.

It's not helped by the rubbish quality of some of the data that's available. It seems as if very few battery suppliers have any really meaningful data that applies to the typical operating regime that an ebike uses.

Jeremy
 
So we're comparing batteries based on these qualities? Seems like a good basis.

For the record: my primary concerns are volumetric energy density, cycle/shelf life, and price.

Only 2/4 means SLA is out for me 8).
 
Size/Volume Above everything else, this is the most important factor to me. Make me a 1Kw battery thats 1 cubic foot, but weighs 1 pound and costa $1, and another 1Kw that weighas 50 pounds, is $1000 and is the size of a Pen, and I'll pick the $1000 option.

WeightNot as important to me at all, but still second on the list. I want the lightest option possable.

Then you have, in rough order, Reliability, Cost, Cycle life, shelf life, and safety.
 
Drunkskunk said:
Above everything else, this is the most important factor to me. Make me a 1Kw battery thats 1 cubic foot, but weighs 1 pound and costs $1, and another 1Kw that weighs 50 pounds, is $1000 and is the size of a Pen, and I'll pick the $1000 option.
:idea: Interesting...

I really don't care about volume and weight is not all that important because my body weighs much more than the battery does... when it comes to climbing hills it's total weight that matters. Even with 86lbs of battery my body weighs 185lbs, so it's less than 50% of my weight.

For me it's dollars-per-watthour... pure and simple... just get me as far as possible at the cheapest price. Cycle life and shelf life apply towards the bottom line.
 
Drunkskunk said:
Then you have, in rough order, Reliability, Cost, Cycle life, shelf life, and safety.

LOL, how many others here have safety at the bottom of their list? +1 here.

I'm with you on the battery size. I'll take a 40lb battery that I can slip down the seatpost over a neutrally-buoyant thing that i have to strap on the side of the bike any day.
 
On a personal level I did a LOT of research, asked a lot of questions and waited a long time for my LiPO4's and still feel after almost four months I made the right decision based on my primary requirement which was range. I picked my bike up last night to work on the kickstand and placed it on a couple of five gallon buckets (a trick I learned on Endless Sphere) and with the Crystalyte 5304, steel beach bike frame, baskets, batteries and other stuff feel it weighs in excess of 100lbs. Put my fat butt on it, another 225 lbs and it's a heavy machine.

Safety is always an issue but of the varying lithium technologies, especially with a quality BMS, the LiPO4 met my requirements. Other battery technologies may have been less expensive but also required more knowledge and what appeared to be more dedication to the technology. I wanted plug and play.

Expense was a factor but range was a much bigger one. At the moment, with a little over 2,000 miles on the bike with the Crystalyte motor, I figure if I lost it down a hole it would have cost about a buck a mile to operate it. Barring unforeseen difficulties I really don't expect to spend any more on it and will continue to operate it about 50 miles a week 'till the cows come home without spending any more money except maybe for tires in a long time. My tires have almost 2,000 miles on them and still look new. Brake pads are cheap and I carry spares.

One day this week I rode 8.6 miles to the golf course, 14.6 miles from there to a doctors appointment and then 11 miles home and still had plenty of battery left. That is what's important and SLA simply couldn't do it. (48 volt, 20 AH LiPO4's) If I didn't need the range I'd still be running the original SLA's. I believe each individual has their own requirements and that is what will dictate the technology.

In summation: range, safety, cost.

Mike
 
I doubt that many users will average more than 300 cycles a year on a battery (although accept that a few might).

I don't know if that is a good assumption. Some of us are more users than dabblers.

I got into this strictly as a personal carbon-reduction project, and use my electric motor scooter for mearly all local day-to day transportation whenever weather permits. I used the scooter 98% of the days from April through November last year, and charge at both home and work, so that's probably more than 300, (25-30 percent) cycles right there.

But admittedly, with LiFePO4's I won't have to do the charge at work anymore, since they benefit from sitting partly discharges anyway - so even with milder winters, 300 cycles will probably be the maximum.
 
Well for me the batteries have to fit into a 8in (H) x 5.3/4in (L) x 4.1/8in (W) steel container which is under the seat of the bike (it replaces the down tube).That's the most important consideration for me.

Cost and reliability come in second.Now that I'm on a fixed income I can ill afford to be trying new expensive battery chemistries and making that one mistake that renders the battery KAPUT.I rely on this bike as my sole mode of transportation and without it I'd truly be stuck.The nearest bus stop is ~1 km away and if I were to rely on public transit I'd spend most of the time enroute rather than using that time to actually get things done.

Capacity isn't much of an issue for me as everywhere I go is within a 10km radius from where I live,groceries,banking,doctor,the wife's and my aging mother who lives the farthest at the 10 km mark.Most of my friends live within the range of my bike as well.The 36v 7ah sla that I use take me 10 km's no problem with some pedaling and when I arrive I plug the batteries into my 36 volt charger for the time I'm there and I unplug and ride home.I've never had the batteries go below 50% depth of discharge.At the end of this month my batteries will be going into year # 2 and racked up close to 1000 miles and are not showing any signs of wear yet.

I will try another chemistry of batt,down the road but for now getting 1000 miles on 60 bucks ain't bad at all and my life has been made alot easier because of my ebike...

Sorry for going a tad off topic oops

Eric
 
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