Le petit Porteur - with solar Trickle Charging

[aega]

So i just got my "Petit Porteur OG" Frame.

I ordered it as the frame size and structure seems to be one of the best possible compromises between a lot of things. Build quality looks very good!

Now this is my first (and hopefully last) EBike project i want to make.

For this reason i am going with the CYC Photon Gen 2 motor as a middrive solution. It supports 36 - 72 V

The battery is a bit complicated. The space between the two upper spars is limited - 460 x 110 x 75 mm is the maximum. I would not mind a permanently installed battery, nor would i necessarily mind building my own enclosure (I have a 3D printer, small CNC and various tools for such projects). I would prefer however not to weld the battery cells together myself, as i do not have a spot welder or cell tester.

--> First question: Can you recommend a (chinese?) company that would make a battery on order to custom dimensions with a MOQ of 1?
What voltage would you recommend to run this with?

Then there is the large space on the back: It screams solar panel, e.g. this guy: LensunSolar 30W 12V Black Flexible Solar Panel
Combine this with a Carbon fibre backing plate (Carbon-Prepreg-Platten 1,0mm) and i believe this should be super solid.

--> Second question: What is the best way to have a easily accessible charging port for regular charge via power outlet + constant trickle charging through the solar cells? Obviously a MPPT would be needed to get any sort of meaningful charge out the panel. Then a BMS that can handle trickle charging and two charging ports as well. Schotky diode to protect the MPPT / solar panel i guess?

In general i would be super glad for some guidance to get a first idea how to make this project nice and neat and reliable as well

Thanks!

 

[aega]

LensunSolar 30W 12V Black Flexible Solar Panel

LensunSolar Flexible Solar Panel is a highly efficient and innovative choice for RVs, campers, boats, roof tents, and more.

lensunsolar.com

Lensun Buck Boost Solar Panel Charge Controller 24V 36V 48V

Lensun Buck Boost Solar Panel Charge Controller 24V 36V 48V 60V 72V Battery

lensunsolar.com

These two seem like th most straight forward approach. As a first step i can simply plug it into the battery directly for charging, and unplug if i use the wall connector. Unable to find batteries with dual charging ports in any case as of right now.

 

[RunForTheHills]

EM3EV is located in China and used to make custom rectangular batteries. I don't know if they still do, but most people would recommend them as a quality battery manufacturer. That rear rack screams cargo/groceries to me more than solar panel. 30W isn't going to extend your ride by much and a cargo bike is more of a grocery getter / transport the kids a few miles bike than a long distance touring bike.

 

[aega]

Thanks for the tip with EM3EV looks promising! Ill check out what they have.

And yeah i suppose youre right "scream" is a big word. Its a gimmick. But its one i find fascinating . 30Ws parked outside in the sun for 3h is 90Wh - a nice 10% charged for free

 

[RunForTheHills]

Thanks for the tip with EM3EV looks promising! Ill check out what they have.

And yeah i suppose youre right "scream" is a big word. Its a gimmick. But its one i find fascinating . 30Ws parked outside in the sun for 3h is 90Wh - a nice 10% charged for free

Consider that you could have a larger solar panel permanently mounted outside your home and tilted for optimal sun exposure instead of mounting it on the bike then.

 

[aega]

Yeah but ultimately its not about Solar Charging per se but rather the idea of having a bike that can in principle charge itself. Anyone here have experience with the CYC batteries and if they support trickle charging without more mods? E.g. just plugging the MPPT into the battery charging port - while it is being discharged from use at the same time?

I dont really see a danger for the MPPT and solar cells themselves no?
Should it not work i could get a second A52, mount it on the back and plug the solar cells into that one... redundancy, charging and range extension when i need it. Definetly not the most cost effective way of doing it though

With such a small battery as the A52 the solar charging would also become much more relevant... from 10% charge to more like 20% in 3h. Nothing to sneeze at in my view?

 

[99t4]

Now this is my first (and hopefully last) EBike project i want to make.

FYI: This ^ is a popular goal for many new project builders here. Almost none get away with it.