Category Archives: Repairing Guides

How to fix an E-scooter not running at full Throttle

Why E-scooter?

E-scooter is one of the hot topics in the recent past in several major cities of the world. It has become an inevitable mode of transportation due to less impact on the environment compared to other vehicles running with gasoline or fossil fuels.

It incurs a lesser cost on maintenance and cheaper serviceable parts compared to other motor vehicles. However, critical technical problems may result, if the owner does not undertake proper maintenance. However, this inventor has also encountered some issues such as failure to start, unexpected stops in the middle of the ride, the motor does not perform properly or the Throttle does not support the ride. Each of these stated problems are occur due to different reasons for the gadgets and these problems should address separately and carefully.  

We will discuss the specific problem though out this article. It is one of the major issues out of the above issues where E-scooter not running at full Throttle. 

What happens if your E-scooter doesn’t accelerate even at full capacity?

If you have ridden an E-scooter you may have experienced a situation where it is not accelerated even if the battery is at full capacity. In such situations, the rider should actively seek the assistance of a repair guide to solve this issue to avoid accidents on the road. 

This may happen due to several reasons. The main reason for this issue might be a fault in Throttle. What is Throttle? It is the key device that moderates the flow of electricity from the battery to the motor. Out of several Throttles, the most common one is the half-effect Throttle.  Accelerator or Twist bar are general names used for these tools. On and off the Throttle, High-end Throttle, Thumb foot Throttle, and Half Twist are other kinds of Throttles.

Test the issue with E-scooter to find out which device is faulty

We suggest you carry out a test on all devices to identify whether the issue is happening with which device. We have listed down the steps of the troubleshooting for you to undertake easily which takes only a few minutes.

Step 01

  1. Lift the back wheels once you ensure that both fuse and the E-scooter turn off.

 Step 02

  1. The red wire which supplies electricity to the positive terminals of the Throttle must connect to a DC 4.3 volts positive multi-meter. 

 Step 03

  1. The black wire is the –ve terminal which must connect to the DC 4.3 volts ground.  

Step 04

  1. Before replacing the fuse, you must ensure that the voltmeter connects to the black, green, or blue wires properly. 
  2. Then, switch on the E-scooter. 
  3. Check whether the motor of the E-scooter functions properly once you twist the motor.

If you have noticed that there is no issue with the motor, then it may be a fault of the battery, power connection, or the ignition key.  

However, there may be an instance in which you switch on the motor and it does not start as you expect, then the tests should carry out on the battery and ignition key. Because the power generate from the battery is not sufficient enough or the throttle does not control the power received from the battery to the motor. 

Additionally, the fuse and the circuit breakers have also broken or melted due to overheating of the charger.

When the Battery Charger indicates green light, it implies an issue with the charger port, wiring, connector, fuse between the charger port and the controller, harness, and the connector of the battery pack, charger plug, or battery pack. Only smart chargers automatically detect the issue with the battery pack.  

Does your E-scooter indicate less voltage?

You may experience some instances where the scooter functions for a relatively lesser period even if it was fully charged or on the other hand, the E-scooter may refuse to start due to lack of power. 

As the first thing that you have to do in such an instance is to check whether it is undercharged or is not chartered at all. Once you make sure of these the next move has to undergo the inspection with the other devices of the E-scooter while considering the age of the E-scooter.

If this is an issue after two years of buying your brand new E-scooter, it is obvious that the living space of the rechargeable battery. The battery is made out of lithium and the ion is only two years. It implies that the battery or the E-scooter will show off poor performance after two years. 

After two years it is indeed important to check the life span of the battery and make necessary think of a replacement. A faulty charger is another issue we discussed further which is to be addressed properly and quickly. To check the flow of the power of the charger, indicator batteries are not light up and the battery may result not charge. Once the batter is actively used over 60% of the capacity, you may search for a replacement. However, to check the capacity of the battery, the first thing that you have to do is, check the voltage of your battery using a multimeter.  

It will be useful to test the indicator lights of the Throttle. If the light does not function or it is doing its half capacity, then it indicates below voltage where the battery or charger is defective. To maintain the continuous flow of voltage and to ensure the optimum capacity of the Throttle, the battery or the battery pack has to replace. The old or defective battery pack is a common reason for the failure of accelerating E-scooter.

It is important to keep in mind that a lead-acid battery pack needs deep charging before the replacement to ensure that it works at the optimum capacity. In this case, the E-scooter will function when only the charger is plugged into the charger where the battery pack is being discharged with the non-availability of the required voltage to run the motor. It is because of issues with the circuit, connection, or fuse.

 Thorough charging of lead-acid batteries for around 48-72 hours, is the expectation for such kinds of batteries. We recommend you to do it a few times annually in the case where it losses its full capacity.    

Additionally, the power charger and the charging port are the other devices that require similar attention in case of less voltage of the E-scooter. If a battery charger is working properly it shows with an indicator light. Unless there is less voltage, the multimeter will indicate ensure the performance of the charging port and charger. However, you should be careful when dealing with terminals made of metal. 

If there are no issues with the charging point, connect the e-scooter charging port and the plug on the wall, and check with some additional features that differ from brand to brand.  

A kill switch is one of those advanced features which support the rider to turn while saving energy. Most of the riders are not known that the kill switch has to be turned off in instances where the E-scooter is not functioning or while charging mode is on. Check whether the kill switch is on at the low or dead battery status. If there is no issue with the battery or the motor, the scooter should restart at the kill switch is off.

Another advanced feature of an E-scooter is restarting option or the restart button. You must aware of the features available with your E-scooter at the point of buying. Check the manual or the guide. If a manual is not available search through the internet with your model number. You will find the manual on the internet. 

If you have not noticed any issue with the mentioned devices, then you are to stray your concentration on the Throttle.

Have you encountered a problem with Throttle?

First of all, the E-scooter has to undertake the proper mechanical investigation. If you are not in a position to undertake this, you may get the support of the e-scooter service center or the repair shop to test the voltage of the battery, charger, or charging point. 

Fix the issue with Throttle

Fixing the issue with Throttle is not so difficult with your self-study material available on the internet. If you have experienced that the E-scooter is unmovable even if it is in power-on mode, firstly you should ensure that there is no issue with the wire connection. Open the lead on the top deck and check whether it functions properly.

The throttle of the E-scooter comes with three different colors of wires such as black, red, green, and blue.  

If you found any issues with them, you know what to do with them. Unless you have not noticed melted wires, obviously you must tighten them. 

If there is a burnt smell over there, we recommend you to check thoroughly whether there is any melted component.  

In case, if you noticed a melted wire it may be due to overheated Throttle which needs an immediate replacement. 

If there is no issue with the connection, check then the physical components of the Throttle. This is proved with the low voltammeter reading below 0. If the reading is between 0 to +3, that is the perfect number showing there is no faulty in Throttle. 

It is important to ensure that the above range of voltage is accurate. When the battery voltage increases at a slow speed, it implies that the charger is performing well. Let it charge completely and check the voltage correctly to ensure that the battery is charging at a maximum level of 100%. If you notice any defect in the battery and the battery pack, this means that you should think of a replacement. It is suggested to look for an original or branded item to prevent future issues.  

If you identify the issue, it is important to take not only necessary corrective actions but preventive actions as well.

With this sufficient evidence through the investigation, you can narrow down your findings to the exact problem of the Throttle. Please replace it immediately if you have noticed a burnt or damaged Throttle.

In a case where the failure of the Throttle is identified during the guarantee period, then you can open a complaint and demand the replacement or repair from the merchandiser. we recommend you contact the manufacturer for necessary repairs or replacement of it.  

On the other hand, it is fixable on your own or with the support of a mechanic. 

Replace the E-scooter Throttle within a short time

If you encountered any issue related to your E-scooter throttle and you have decided to go for a replacement, the following is the basic procedure to be undertaken. 

  1. Slope the grip using an air pump.
  2. Once you lose the brake lever, make sure to unplug the LCD as well with 3mm Allen.
  3. Unplug the old Throttle and fix it with the new one into the E-scooter. 
  4. Tight up the brake lever, slide back the LCD, and finally, make sure to fix the hands’ grip and thumb Throttle. 

However, if your E-scooter has not been purchased with a plug-and-play Throttle, the procedure of replacement is slightly different from the above. The below-listed steps will assist you to carry out it easily.

  1. Buy a new Throttle with similar features.
  2. Use the air pump and open the handlebar grip.
  3. Separate the Throttle screws once untie the handlebar grip. 
  4. Make sure that you will fix the new throttle with the respective old colors.
  5. Repair the wires and shield them.

How to fix a Throttle of a Razor E-Scooter?

We suggest you replace the Throttle of the Razor electrical scooter if it is not working. It is a different process that requires operating within the deck. Following simple stems will make your life easy with such a problem. 

  1. Open the deck and remove screws and brackets
  2. Cut the zip ties using two scissors which have to tighten up the cables
  3. Unplug the cables connected to the Throttle beneath the deck.
  4. Untie the throttle and handle the grip.
  5. Once you fix the Throttle, make sure that your handlebar grip is fixed.
  6. Fix the cables properly

 Sum up the story.

The Throttle act as the heart of the E-scooter. It indeed brings life to the E-scooter. It is a vehicle that requires relatively low maintenance and incurs leaser cost on maintenance. 

However, it also depends on the product quality, brand, and availability of the spare parts. 

You should at least be aware of the parts of your E-scooter to ensure that you can fix or address the issue instantly even on road to minimize accidents to have happened on road or to enjoy the rides.  

If your E-scooter is not functioning at its optimum level, you will not be able to ride smoothly. Carry out inspections on battery and motor regularly other than the Throttle. 

It is not difficult to fix the issues with the E-scooter. However, if you require any assistance, you may search for a quality and experienced service provider. Further, make sure that you do maintenance properly. 

 

How to fix the pedal assist on your e-bike?

 

Everything you should know about a Pedal Assist System (PAS)

Typically Electric bikes have two types of motor engagement: the throttle and the pedal assist. The motor takes part only when the pedals revolve with pedal assist. But the throttle takes part in the engine even when you’re not pedalling. The exciting thing is that Europe does not allow e-bikes with throttles. So every bike should have a pedal assist mode.

What is a pedal assist?

PAS is the main feature which is the operation mode on e-bikes. When the pas is activated, the motor boots when you are pedalling. The PAS assists you in pedalling. The different pas settings will help you pedal effortlessly on long rides at the desired speed. When the PAS is on, you would feel extra energy moving you forward, which makes it easier to ride your bikes on long journeys without getting exhausted.

How does the PAS work?

The PAS uses a cadence sensor to assist in pedalling. It builds into the drivetrain of the bike. The sensor monitors the rotation of the pedals when you are pedalling. Then it sends an alert to the ebike motor and mentions how much help to give based on your selected assistance level.

How do the PAS and throttle work?

The most pleasing thing about an e-bike is that you get to select if you’re down for a workout or to relax. So an e-bike gives freedom to the riders, which is lacking in regular bikes. You will be able to ride for longer and farther with the assistance of the throttle and PAS. You can ride faster on an e-bike rather than on a standard bike.

What is a throttle?

The throttle mode is very much comparable to a scooter/motorcycle. When it takes part, the motor gives the power and moves the bike forward. That will provide you with energy with no automatic help involved. The throttle permits you to stay calm and enjoy your ride. If you’re looking for a voyage, you can relax as the bike can operate without you pedalling. You can use the throttle when passing others on a path or speeding up the hill, or stable yourself as you’re about to go on a ride.

Pedal assist bikes VS throttle bikes 

There are many differences between a pedal assist system and a throttle. Some may be advantageous, while others are disadvantageous. So you must check all the pros and cons of the throttle and the PAS and consider what is best for you.

Let’s start with the pros and cons of pedal-assist bikes.

Pros ;

  • The pedal-assist e-bikes offer a natural feeling for the riders if they are intimate with riding regular bikes.
  • It helps the riders to have a free ride without worrying about whether the throttle is in the correct position. You can ride for long journeys freely when you pedal.
  • The function of PAS is more suitable for the riders who identify throttle e-bikes as heavy.
  • By using pedal assist bikes, you can cover the targeted miles more productively. 

Cons ;

  • Some countries have rules when using pedal-assist e-bikes, which limitate the use of them among the citizens. But class 1 pedelecs are allowable so you can use them instead.
  • The e-bikes can be at different prices depending on their brands and models. But the most expensive is the pedal-assist e-bikes. It is more costly than throttle bikes.
  • You might find it challenging to ride a pedal-assist e-bike in traffic. Their function of abrupt acceleration is not very effective in riding in traffic. So pedal assist bikes are dangerous for consumption in towns full of people and vehicles.
  • The poor cadence sensor used in pedal assist can destroy the performance of your bike.

Let’s take check the pros and cons of throttle electric bikes;

Pros ;

  • It is easier to navigate, and you won’t have trouble riding in busy towns and traffic. Most throttle bikes have a boost button that helps you change the speed. So you can quickly decrease the speed on a busy road and also be able to increase the speed on inactive roads whenever you want to.
  • The most pleasing thing about the throttle e-bikes is that you can ride without pedalling. So throttle bikes are more flexible than pedal assist bikes.
  • THrottle bikes are very much helping if you choose between riding along hills or fun rides. 

Cons ;

  • The modulation of a throttle bike can be poor or good. If there’s a good modulation, the riders can generate more power. But if there’s poor modulation, there can be a change in the power or speed. So a throttle e-bike is not a good option for a beginner.
  • There is a limited battery range to the throttle bikes usually. So the drive should be with additional care to prevent it from any harm.
  • In throttle bikes, the gears are not that adjustable to some local conditions because of the hub motors used in them.

The PAS or the throttle is better?

 

The throttle and Pedal assist has the same outcome on a bike that moves it ahead using electric power. The difference depends on how the rider links with the system. So the answer to this question is some hoe complicated. You should consider what your intention is before riding your bike. If you are looking forward to a relaxing ride where you can sit back and relish the scenery, you must use the throttle. But if you’re looking forward to a good workout and active pedalling, you must use the pedal assist. Mostly the bikes only have one of the two options, but some brands might have both the throttle and PAS. Ex; peageo has throttle and PAS on their bike models. It is very beneficial as it allows you to use both control methods to choose to relax or work out when you want to.

There are two types of sensors for pedal assists

  1. speed sensor
  2. torque sensor

Before you make any purchase, you should consider the difference between these two.

  • Speed sensors

The speed sensor gives a push to your bike when you start to pedal. When you begin pedalling, it carries on with helping you pedal based on the chosen setting. So you can ride around or do a little exercise with little armpit on physical effort.

When you increase the energy, the bike will feel like it’s riding itself without your help. So you can shift the gears and reduce the service to feel your pedalling again. The speed sensor can be detached when your bike reaches the top speed.

  • Torque sensors

Torque sensors are a little bit more progressive in their function. But rather than stabilizing based on your pedal assist like a cadence sensor, the torque gives you corresponding assistance depending on how dense your pedalling is. So if you pedal harder, it will provide more power to the motor. Torque sensors are present in a few Pedego models. EX:  Ridge Rider and Platinum

Nevertheless, if you have which type of assist sensor, the PAS will always help you to ride farther and longer. It also flattens hills and makes riding mostly effortless, withstanding any road you have ahead.

There are some issues that you might face with the pedal assist system cadence sensor. The details about how to fix those problems are as follows, 

  • The bike will stop moving due to some issues in the parts as follows
  • rear or front brake issue

You might encounter a situation where your bike stops moving ultimately whilst pressing the crank. There are several reasons for this problem. 

The rear or front brakes can be a problem because they are always working. So the motor will close and stop working even if you press the crank so many times that the bike won’t move. You can do a test to fix this issue: disconnecting the front and rear cable and clutching the crank to the right hand. You can do this with the rear brake too.

If the motor proceeds to move when the front and rear brakes stop, then the issue might be in the detached brakes. You can also decide if the PAS stops working because of the brakes or not by this. If the break lamps work continuously without stooping, the issue is in the rakes, which avoid motor movement.

  • magnet issues

  • The most popular reason for the pedal-assist cadence is that THe agent next to the sensor is far from it. It causes the sensor to be adequate to measure the magnet movements, and the sensor won’t deliver the signals to the controller that makes the motor move. To fix this issue, there should be a minimum distance ( below 3mm) between the sensor and the magnet.
  • Another problem that arises in the magnets that stop the bike from moving is that there might be dirt or mud on the magnet. This will prevent the sensor from sensing the movements of the magnet. To fix this issue, you have to clean the magnet excellently.

 

Sensor cable issue

 

Another problem with the pedal assist system that stops it from functioning is not connecting the sensor and controller cable. To fix this issue, you must check whether the cable is connected correctly or not broken. Before that, you can measure the potential difference using a tester, 

throttle issue

If your bike has a PAS and a throttle, there can be an issue with the throttle that can have an effect on the PAS’ operations. So you must check that it doesn’t happen frequently. If you want to find out if the issue is with the throttle or the PAS, you should disconnect the cable of the throttle and aim for the PAS. If your bike start moving, then the throttle is the one that has issues.

Bike cut out during increasing PAS Speed.

The e-bike can cut off when you increase the speed of the pedal assist. It is proof that the sensor or the battery installation is wrong. That stops the sensor from delivering a signal to the controller. To fix this problem, you should install the magnet and the sensor correctly. You can use cable tires to install the magnet and the sensor.

 The benefits of using pedal-assist e-bikes

The pedal-assist feature is the main reason for the bikes’ popularity among the people and the price getting cheaper.

 Here are some advantages of using an e-bike instead of other modes of transportation.

  1. You will be able to ride further

The pedal assist system in your e-bike helps you to ride for extended distances without getting exhausted. It limits the physical effort you have to apply when riding a standard bike.

  1. You will be able to personalize your riding experience

The pedal assist system is optional and personalised to your liking. So you can choose to balance between using your physical effort, or you can just have a relaxing journey. If you want to be somewhere within a limited time but are too fed up to pedal, the pedal assist system would greatly help save your time and energy.

  1. More people will tend to ride bikes

The pedal assist system is very beneficial for people with less physical power. For example, older people and people who have several injuries. It will help those in need to have a relaxing journey and be able to ride a bike and enjoy the trip without any physical effort. And it is for people who live in hill countries because there are more mountains that you will face to ride, but you will be able to do it without any energy.

  1. They are faster than other transportation modes

t is much faster than different modes and will help you reach your destination without exhausting yourself. The courier services are on board with the installation of the bikes as it is much faster

 In conclusion;

The standard rule is that you can solve the problems of a pedal assist system by ensuring a distance between the sensor and the magnet that is explicitly set. Some parts of the bike influenced the work of the pedal assist system. Ex: front and rear brakes/ throttle.

 

Would it be okay if we used copper wires instead of nickel strips for a 18650 e-bike battery

E-bike sales are soaring all around the world. With the pandemic, people have drawn their attention towards long-term health, outdoor activities, and ways of keeping entertained while social distancing. Thus, many of us have picked up biking to keep ourselves company. Statistics from NPD show a staggering 240% increase in e-bike sales from 2020 to July 2021 in the US.

The e-bike industry has undergone significant advances during the past decade. The big players in the automotive field like Bosch and Yamaha have made significant contributions. Riders now have a lot of options with very few compromises. E-bike enthusiasts, hobbyists, and freestylers are always on the lookout for opportunities to push the envelope of power and speed. Over the past few years, companies and other third parties are manufacturing e-bike hardware and conversion kits that have fueled the excitement in enthusiasts. 

The battery is one of the core components of a bike and directly correlates with the power, speed, and range of an e-bike which is why it is an area that engineers and enthusiasts like to tweak and fine-tune. 

One of the common questions that arise is the usage of the material for batteries. In this article, we will be answering whether copper wires or nickel strips are ideal for 18650 e-bike batteries. 

 

E-bike batteries

E-bike batteries have come a long way since the earliest days of e-bikes. Starting from Lead batteries that got up to a life span of 300 charge cycles, today Li-ion batteries can hold up to 1000 charge cycles. When it comes to e-bike batteries companies pay a lot of attention to details, and it is probably the most researched and upgraded element in e-bikes. 

  • The size of batteries is a crucial detail because you are looking to keep e-bikes at a low weight while packing the highest power. There are also constrictions in space since your design has to work alongside the bicycle frame.
  • Charge time is a massive concern for e-bike riders. Companies have made significant improvements in this aspect, and now an average e-bike takes under 6 hours to be fully charged. Similar to other consumer electronics charging time can never get too low. A lot of research goes into this charging aspect because users always get hooked on products that juice up the fastest 
  • Safety of batteries – This is a no-brainer. E-bikes riders can pack over 500W of power right under their body. Sometimes DIY projects crank the power well above 4kW. High energy battery packs can pose serious safety concerns like they recently did in New York during the pandemic. In New York, the incidents of e-bike fires this year were double that of last year and included 75 incidents with 72 injuries and 3 deaths. 

The top companies in the e-bike industry set very high standards in their battery production stages. For DIY e-bike makers, it is vital to know how the above factors are affected when making decisions on battery connections, layout, materials, etc.

 

The 18650 e-bike battery

18650 is the widely used battery for e-bikes these days. These 18650 batteries go in laptops and other rechargeable devices. Companies manufacture the battery packs on a large scale with the help of automatic CNC spot welding machines. 18650s come in all sorts of capacities, voltages, and qualities while they are relatively cheap, which is why they are pretty prevalent among DIY electric bicycle makers.

The most critical ratings that you need to look out for when selecting 18650 batteries are:

  • Capacity – The capacity of a battery is denoted in Amp-hours, and it gives an idea about the maximum energy that will be drawn from a charge cycle. So higher the capacity, the longer the battery life, provided all the other conditions remain the same.
  • Voltage – The voltage of a standard 18650 is typically indicated on the surface of the battery and can vary between 2.5V to 4.2V.
  • Maximum discharge current – It is the maximum current that can be drawn without damaging the battery. Your circuit should function within this limit under all working conditions. This rating varies between different manufacturers and is a critical factor when designing battery connections for e-bikes. 

These ratings and your battery arrangement will allow you to determine what range of current your e-bike will be drawing under different pedal assist levels. Knowing the amount of current is the most decisive factor when choosing copper wires or nickel strips as connectors.

 

Copper wires over nickel strips

Both copper wires and nickel strips are used as 18650 connectors in various applications.

The following comparison between copper and nickel will help you make an informed decision for your e-bike battery configuration.

  • Copper is cheap and readily available. On the other hand, nickel strips are significantly more expensive.
  • Copper has very high conductivity thus low resistivity. Nickel is 5x more resistive than copper. The resistivity tells us about the difficulty for current to pass through, therefore it is a good indication of the amount of energy wasted (heat generated) as current passes through a material. 
  • Nickel has good corrosion resistance, hence used a lot for alloying metals and as coatings for alloy wheels, coins, etc. Copper has a lower resistance to corrosion and usually requires a protective coating for applications that require durability.
  • Copper is difficult to spot weld as it requires a lot of heat. Spot welding is the widely used mechanism to connect 18650 batteries. Spot welding with Nickel results in a stronger weld compared to copper. 

Copper and Nickel have their pros and cons. It’s about weighing out your options and prioritizing your requirements. 

 

When to choose copper wires for a 18650 battery?

There are several cases where using copper wires could be advantageous. Here are a few scenarios where you might want to consider using copper.

  • If your circuit is drawing a high current from the 18650 cells then copper wires would be good. Having low resistivity connectors like copper means the pack will not heat as much as it would with Nickel. Overheating is one of the main reasons for the decline in battery performance and fires. The rule of thumb is that if each battery in your setup is drawing over 7A then copper does a better job than Nickel. 

 

  • You have a plan for how you are going to bind the batteries to the copper wires. As mentioned previously spot-welding is not going to work with copper wires. Unless you have experience soldering copper wires to 18650 batteries successfully then soldering is out of the question. If you are not careful, the excessive heat could most certainly cause irreparable damage to the internal compounds and thereby reduce the capacity and charge cycles of the battery. The recommended/safer option is to use magnets to clip the copper onto the battery terminals. People have posted such builds using Neodymium magnets on forums so they could be a good source of information for your build.

 

  • Of course, the budget should be the last thing on your mind when working with e-bike battery packs. Nevertheless, copper is the cheapest option out of the two, and it should be easy to find copper wires.

 

Concerns when using copper wires for 18650 battery

If you believe copper wires would be a good fit for your project based on the essential factors discussed in the preceding topics, then these tips would come in handy for your build.

  • Choose the right size for the amperage. If too large currents run through the wires it could heat the entire pack and cause detrimental damage to the batteries. Refer to the wire gauge current ratings chart published by the manufacturer of your respective wire. You should pick the gauge that has a maximum current load rating above the maximum current your circuit extracts. 

 

  • Use new copper wires for your connections. Corrosion is one of the major causes of the accelerated drop in battery performance and reduced lifetime. As discussed earlier copper wires are less resistant to corrosion in air, therefore avoid using copper wires that have been hanging around for too long. 

 

Conclusion

18650 batteries are now in every DIYer’s arsenal. They are frequently incorporated in electronic projects like e-bikes, robotics, and other wireless builds. Nickel strips have been the prominent choice of connectors owing to their characteristics. Nickel strips are easier to weld using commercial spot welders and show higher resistance to corrosion, hence producing a durable connection between batteries. With high power projects that draw over 7 Amperes through a single 18650, you could go for copper wire connections as an alternative to prevent excessive heat generation. Copper wires are a viable option, provided you have a method to attach them to the terminals of batteries. Spot welding doesn’t do a satisfactory job with copper. Soldering can damage batteries if not done with precision. As long as you reasoned out the particular factors it is okay to use copper wires instead of nickel strips, and it may even possibly be the better option.