1. Structural protection and hardware design
Battery shell reinforcement: The explosion-proof shell is made of aluminum alloy or carbon fiber, with a flame-retardant PC material lining, which can withstand an extrusion impact force of more than 2000N. At the same time, the shell must pass the IP67 waterproof and dustproof certification to prevent rainwater from seeping in and causing a short circuit.
Thermal management system: Built-in liquid cooling or air cooling module, real-time monitoring of battery cell temperature through temperature sensor (temperature difference controlled within ±5℃), automatic start of cooling fan when temperature exceeds 60℃, triggering power-off protection in extreme cases to prevent thermal runaway.
Cell spacing design: Ceramic insulation sheets or aerogel materials are filled between the cells to block heat conduction when a single cell experiences thermal runaway, thus reducing the risk of chain reactions.
2. Electronic control system and safety mechanism
BMS battery management system: real-time monitoring of voltage, current and SOC status, with overcharge protection (automatic power-off when charging voltage exceeds 4.35V), over-discharge protection (forced sleep when single-cell voltage is lower than 2.5V) and over-current protection (circuit cutoff when current exceeds 120% of the rated value).
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Short-circuit protection design: The main circuit is connected in series with a PPTC resettable fuse or solid-state relay. In case of a short circuit, the power supply is cut off within 0.1 seconds. At the same time, the PCB board adopts an arc-proof coating to prevent fire caused by line breakdown.
Collision power-off mechanism: The vehicle body has a built-in G-Sensor acceleration sensor. When a collision (acceleration exceeds 8G) or severe bumps are detected, the battery output is automatically cut off to prevent battery damage and leakage after tipping over.
3. Usage and maintenance specifications
Charging environment control: Avoid charging in high temperature (over 40°C) or humid environment, keep the battery ventilated during charging, and use the original charger (compatible with trickle charging mode) to prevent overcharging and heating.
Regular safety inspections: Use professional equipment to inspect the battery internal resistance (the internal resistance deviation of a single battery cell should be <5%) and capacity attenuation (capacity retention rate ≥80% after 100 cycles) every 5,000 kilometers, and replace aging batteries in a timely manner.
Storage protection measures: When the High power electric motorcycle pedal electric motorcycles battery is not used for a long time, keep the battery charge at 40%-60% and store it in a cool and dry place (temperature 5-25°C). Recharge the battery every 3 months to avoid internal short circuit caused by battery deficiency.
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