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[Jawbreaker]

Got a question about the controller and BMS for the Zero range of bikes.

i'll presume that each bike is carrying the same controller and BMS setup (physical components and not setup of components such as firmware, etc)and am curious to know what is the limit of cells that the BMS and controller can handle (ie, how many volts and amps, not complete amount of cells).

i have a project in mind that isn't a bike and will have the adequate room to accommodate more cells/batteries.

my idea was in my setup to use TESLA cells (can see the groans now lol) but my plan was to strip down a complete battery and use 15/16 cells from a model p100d

this would be my ideal cell and i know these will become a lot cheaper in the future.

https://evshop.eu/en/batteries/124-6375wh-tesla-module-6s86p.html

i'm wondering how many i could run on stock controller and bms from a ZERO bike setup or would i be aiming too high with this type of cell (ie, the total amount of cells from a tesla being controlled and managed by the controller and BMS)

go easy, i'm doing research and am only looking for people with good knowledge of the ZERO to help me decide if this is a path i want to pursue or decide to not use the bms and controller from the zero and go something different. i can self criticise, ask me how i know? lol

just so people reading this are on the same wavelength as me in terms of design, i was going to design a cell (not dismantling the tesla cell but arrangement of cells) in a 5x3 design (5 cells across by 3 rows up) to total 15 in all.

now according to this website, https://www.quora.com/How-much-voltage-and-amperage-do-Tesla-battery-packs-have the packs are approximately between 300 and 400 amps total. and upto 1400~ or thereabouts in ludicrous mode (which i won't be dealing with AT ALL)

A couple of questions come to mind like:

if i configured the cells in a particular way, would both the controller and BMS be happy with this? ie, keeping within the limits of both.

please be nice as i'm not looking for criticism, just advice on what my best angle would be to go with this configuration.

if you need some elaboration on what i am doing, i will be happy to explain.


thankyou for your time.

[MVetter]

just so people reading this are on the same wavelength as me in terms of design, i was going to design a cell (not dismantling the tesla cell but arrangement of cells) in a 5x3 design (5 cells across by 3 rows up) to total 15 in all.

15 cells in series is a voltage range of 51-63 vdc with a nominal rating of 54.74 vdc. The inverters Zero uses do not run at that voltage.

Why would you want to switch from the Farasis pouch cells which are ridiculously energy-dense and have a ludicrous 10C discharge rate to less space-efficient cylinders?

[TheRan]

Zero lists their controllers as being 550A and 775A for the non-R and R models respectively, giving 64kW and 90kW which is well above the 35kW and 52kW that the bikes put out. The motors may be the limiting factor (they are also different for the non-R and R models), considering that the 14.4 models use the same battery but still differ in wattage and the controller in the non-R is theoretically capable of R power levels.

[victor6.7y]

I will only mention this onces, I hope you know what you are doing/ have the background knowledge to be comfortable with what you are trying to create.
(In anyway I would say have fun and experiment, do try to do it in a safe way.)

I found a lot of information on https://zeromanual.com/wiki/Main_Page. I guess this will also answer your questions.

In general there are about 3 things to consider.

• Why would you want to know how much "POOOOOOOOWAH" the zero could take?
  
  The power is regulated by the motor controller. So if you can supply the correct voltage and minimum amount of power, the motor controller will handle the rest.
  Depending on how much power that is needed to overcome:
  - the rol resistance
  - the wind resistance
  - the fun (amount of acceleration you want)
  the motor controller will be able to handle the momement you want, Or... propably(i guess, i assume, i hope) have a safety to not: burn your motor / burn itself.
  
  *disclamer (it might not be as simple as connecting the power cable to the motor controller.... I am not sure about the communications and safety checks that the motor controller is doing.) https://zeromanual.com/wiki/Gen2/Motor_Controller
• I am not sure what you want to do with the BMS, but I would not advice to,,, re-use it when you build up a different battery. Something regarding a BMS that is made for a specific:
  - cell type,
  - numer of cells in series,
  - amount of current that it can handle (I guess your "POOOOOOOOWAH" question is for this part.).
  What you could do,,,,, And I still, Do Not Recomend it (cuz this could seriously burn your house down) unless you know what you are doing and work safely. Is increase the capacaty of the current battery by setting more cells in parrallel and stuf... In your case I would recommend a different battery
  
  When you do want to use an different battery and BMS, there is the point of communication with the Motor controller and Main motherboard (not sure which parts you want to re-use). And you have to supply the correct voltage and handle the corrent minimum amount of current that the motor controller needs.
  
• I would advice to make an electric skateboard as a start. You will learn a lot of the principals that are also applicable to your project. (Yes please explain more, I am interested about the system that you have in mind.)

I hope this helps