Which parts do I need?

Which components (except frame or bike) are at least needed to build an e-bike?

needed parts for Ebike

How much power can I get out of my system? The rough answer is volts x amps = watts (V x A = W) 
An example: I have a battery with a voltage of 72 volts and a controller set to 50 amps, then I get a maximum of 3,600 Watts. 
1,000 Watts or 1 kW is 1.36 hp. In total nearly 5 hp of input. Multiplied by the efficiency you get the output power.

Imagine this almost silent without local emissions and with a high fun factor. What does this mean in terms of speed? It depends on the windings (speed or torque), the rolling resistance (tires), wheel diameter, air resistance, weight, etc. You can compare the speeds in the motor specifications.

Higher voltage = more speed, more amps = more torque. The motors do not like low voltage and high amps…

Motor

We distinguish between two common types of motor:

  • The geared motor is well suited up to 1,000 Watts – it has a light, compact design and a freewheel. The problem is, that because of the transmission, additional mechanical parts are in motion, whichcan break and are usually louder. At 50 km/h it sounds like a bumblebee under your ass. In addition, no recuperation is possible because of the freewheel.
  • The hub motor has no mechanical parts in motion (beside bearings) and is therefore very quiet and low-maintenance, has recuperation and is the first choice for more power.

Which motor is now right? There are the 35s, the 40s, the Crown- and the '54 series …
The bigger the motor, the more power it can deliver, and thereby develop less temperature which can go so high that the cable insulation melts and cause a short circuit. You can get a high power output for a short time, if the temperature is monitored. Therefore, all our motors are equipped with a temperature sensor, which can be read with the appropriate speedometer computer (e.g. Cycle Analyst V3). Here you can see an example of a modified Crystalyte 3540, which is loaded with 112 V and 400 A (yes, 44.8 kW).

here you can see more

We recommend for the 35XX series up to 2,500 W, for the 40XX series 2,800 W and 3,600 W for The Crown. For a short burst more is possible, but the temperature should not exceed 90°C. For a longer uphill climb, keep in mind the motor has less time to cool down than on a flat.

To the windings:

  • the HS-windings (also high-speed) are made for high speed. The best choice in the lowlands
  • the HT-windings (also high-torque) are made for more torque. They overheat less uphill, are slower in the flat, but also slightly more efficient

Here you can compare the motors and controller

Controller

The controller is the interface between the battery and motor. At the same time all accessories like the brake circuit, the computer, the throttle and/or pedal sensor etc. are connected. More amps = more power. A controller at full capacity will get quite warm. Therefore, the controller should always be mounted outside and it is recommended to buy one size larger. More FETs generates less heat. There are also different types of FET, common are 3077, 4110 or 4115 (higher is better for more voltage). 

Batteries

For how long will a battery last? Let us continue with 72 volts and a capacity of 15 ampere hours (Ah). If we multiply these two values ​​I get the available energy in watt-hours (Wh). The result is 1,080Wh or almost 1.1kWh. 

That means I can use 1,080 watts for one hour. It doesn't sound much – but it is more than you think. In the acceleration at full throttle the consumption is high, but when reached the top speed goes back considerably. 
For this purpose, we take an example on a sophisticated car with electric drive: The Tesla Model S. The motor has a maximum output of 310 kW and a battery of 85 kWh and the range is given as 502 km ... 

There are many different kinds of battery with different properties: 

  • Lithium-polymer battery or short Lipoly (e.g. from Hobbyking):
    Advantages: Compact size, light weight (140-260 Wh/kg) and high C-rate, inexpensive
    Cons: 300 to 600 charge cycles, sensitive to overcharging, deep discharge and mechanical influences (fire or explosion), operating temperature range restricted (about 0-50°C), requires battery management (BMS)
  • Lithium iron phosphate battery or LiFePO4 (e.g. Headway 40152):
    Advantages: more than 1,000 cycles, high safety, reduced environmental impact, very low voltage drop at discharge, low self-discharge
    Cons: Low C-rate, needs 30% more space than Lipoly, higher weight (80-130 Wh/kg), requires BMS
  • Lithium-nickel-cobalt-aluminum oxide battery or NCA (e.g. Samsung 20R with 10C or 29E 2C):
    Advantages: high energy and power density at a reasonable price, 500 to 700 charge cycles
    Cons: not really safe (possible with additional shell protection), requires BMS
  • Lithium-nickel-manganese-cobalt battery or NMC, partially NCM (eg Samsung 22P):
    similar to NCA, but somewhat shorter lifetime (Manganese can decompose) and less expensive
  • Lithium-manganese battery or LiMn (eg Sony V3 or Konion, VTC4)
    Advantages: can be operated without a battery management, drift-free and safe, high C-rate, min. 90% capacity after 500 cycles

A cheap BMS can destroy the whole battery pack, that’s why is also called BatteryMurderSystem! We advise to pay attention to widespread counterfeiting!

How fast can a battery be charged? It depends on the charging C-rate and the charger. If the battery has a capacity of 15 Ah and the charger a power of 5 A, then the battery in three hours is full. If the charger has 15 A, the battery is full in one hour but consider an efficiency of 90% in that scenario.

What is the C-rate? This value indicates how high a battery can be discharged or charged. We distinguish between maximum (peak) and continuous. The C-value is multiplied by the battery’s capacity: C x Ah = Ampere discharge or charge. 
For example, 2C on 15Ah = 30A or 10C on 8Ah x = 80A or 1.5C on 12Ah = 18A 
As you can see, a cell with a low C-rate can be compensated by a larger battery. Watch out! The manufacturers exaggerate sometimes with the values, look over the internet and forums to get the proper information.

Here you can see the types of different connectors

Safety

Please always wear a helmet! If your bike exceeds the allowed power of law in your country, it may only be used on private land. 

Prices

Should you choose to order parts from the USA, Canada, China, etc., then do not forget to add import tax and duty (total about 25%). People from customs are not sleeping and the allowances are relatively low (Germany: 26,30 Euro, Austria: 22,00 Euro). Normally, the courier charges another 10 euros for the processing and handling. At first glance the price may seem low, but in the end it can cost more than buying locally. For a price comparison, you can change the currency above in the right corner. Also consider returns in case of defects.

For more information look at this forum: www.endless-sphere.com

they have a beginners info as well

All information is provided without guarantee.