Ed Benjamin, Xiao Bin Ultra Motor UK, Suzhou Phylion Lessons Learned About USA / China Enterprises Cooperation on Lithium E Bikes Ed Benjamin, Xiao Bin Ultra Motor UK, Suzhou Phylion

中美企业在锂电池电动自行车合作中获取的经验教训 艾德.本杰明, 肖斌 英国宇劲, 苏州星恒

Problems and Solutions in Export of Chinese Lithium Batteries for Ebikes AECF (Now Ultra Motor USA), Suzhou Phylion, and Wettsen Ebikes cooperated to produce a high power, lithium ebike for USA Market. Many problems occurred. Much money was lost. Many lessons were learned!

中国的电动自行车用锂电池在出口方面的问题和解决方案 AECF (现为宇劲美国),苏州星恒和玮辰电动车合作 为美国市场生产大功率的锂电池电动自行车。 出现了很多问题。损失了很多钱。 得到了很多宝贵的经验教训!

Phylion’s Vision: Provide the Best Media Between Grid and E-Appliances

星恒的展望:提供电网和电器设备的最佳媒介 The best media between grid and E-appliances

PHYLION: Builds a complete Value Chain Powder Fundamental Research Cell Engineering Mass Production Customized Solutions

星恒:打造完整的价值链 粉末 基础研究 电池 工程 规模生产 定制方案

AECF / UM Intro USA distributor , sold to Ultra Motor Experienced team – Ed, Mike Experienced assembler – Wettsen / Percy Ultra Motor Strong in Indian Distribution, Technical and Design Team. Strong technical resources – unusual for distributor USA Distribution

AECF /宇劲简介 美国经销商, 被宇劲收 购 经验丰富的团队– 艾 德.本杰明, 麦克.弗瑞 斯 经验丰富的整车厂–玮 辰/简敬修 宇劲在印度拥有优秀 的销售，技术和设计 团队 技术资源强大– 一般 经销商不具有的优势 美国销售

Wettsen Introduction Taiwanese invested, Longkou location, experienced builder of ebikes in Taiwan and China. Lee Iacoccoa experience. Percy Chien, Mike Fritz, Ed Benjamin all friends.

玮辰简介 由台湾投资，坐落于龙口，是台湾及大陆地区经验 丰富的电动自行车 制造商。 Lee Iacoccoa 经验。 简敬修,麦克.弗瑞斯, 艾德.本杰明是朋友。

Existing Wettsen Lead Acid Model Converted to Lithium Battery

现有的玮辰铅酸电池模型转为锂电池

Technical Outline of Product Heinzmann brand German made motor. 24V, able to demand high amperage Chinese controller from Wettsen Battery from Phylion – 36 V 10 AH Li- Manganese, with BMS, packaging and charger. Users are USA people, taller, heavier, than Chinese. Power on Demand, not pedelec. Often used in hills in California. Users not knowledgeable about ebikes.

产品技术概要 德国产Heinzmann 牌24伏电机，可承受 高电流量。 中国产玮辰控制器 星恒电池– 36 伏 10 安时锂锰电池, 带有 电池管理系统, 包装 和充电器。 消费者是美国人，与 中国人相比更高，更 重。 随选动力式，而非助 踩式。 经常在加州的山区使 用。 消费者并不了解电动 自行车。

Product Development 2005…. We know a lot. We are strong. We will create a new world. We are the best. We are good partners.

我们知道很多。 我们很优秀。我们可以创造一个新世界。 我们是最棒的。我们是很好的合作伙伴。 产品开发 2005…. 我们知道很多。 我们很优秀。我们可以创造一个新世界。 我们是最棒的。我们是很好的合作伙伴。

Product no good！Supplier No good! Late 2006 …Problems! Product no good！Supplier No good! 0 voltage battery BMS heating BMS shutdown

2006年 年末…问题! 产品差！供应商差! 电池出现零电压 BMS 发热 BMS 停止工作

AECF (UM) Blames Wettsen and Phylion They should solve the problem, it is their problem! 0 voltage battery BMS heating BMS shutdown

AECF (宇劲) 指责玮辰和星恒 他们应该解决这个问题,这是他们的问题! 电池出现零电压 BMS 发热 BMS 停止工作

Wettsen Blames Phylion, Phylion Blames Wettsen and AECF! They should re-design the product to reduce the cost. 0 voltage battery BMS heating BMS shutdown

玮辰指责星恒, 星恒指责玮辰和AECF! 他们应该重新设计产品来降低成本。 电池出现零电压 BMS 发热 BMS 停止工作

Conflict Between Partners Stalls Solving the Problem! 0 voltage battery We do need to solve the problem. We should work together. BMS heating BMS shutdown

三方的争端拖延了问题的解决！ 电池出现零电压 我们需要解决问题。我们应该共同努力。 BMS 发热 BMS 停止工作

Low voltage battery Why low voltage battery? Because the battery is over-discharged. Why battery is over-discharged? Because the data recorder continues to consume the power. Power consumption by data recorder should have been part of original specifications. Why a problem? The work current of the data record is twice higher than its spec. This was not known before. It is only 2 mA more. But it is twice the spec, and causes big problem and loss of money.

只高两毫安。但是原有规格的两倍, 造成大问题和经济损失。 电池低电压 为什么电池会出现低电压? 因为电池被过度放电。 为什么电池被过度放电? 因为数据记录仪继续耗电。 数据记录仪耗电应在原有规格中体现，为何会存在问题？ 数据记录仪的实际工作电流是原有规格的两倍高。这一点以前并不清楚。 只高两毫安。但是原有规格的两倍, 造成大问题和经济损失。

BMS heating Why BMS heating? Soft ware and heat sink cannot handle heat generated by BMS. Why so much heat is produced inside BMS? Because the current is higher than expected. Why BMS is designed like this? The current information is wrong. No enough good self-protect function in BMS. Original information is wrong, and without additional testing, problem was not foreseen.

原有信息错误，没有进一步的测试，未能预见问题。 BMS 发热 为什么BMS 会发热? 软件和散热器无法应付 BMS产生的热量。 为何BMS内部会产生如此多的热量? 因为电流强度比预期要高。 为什么如此设计BMS? 电流相关信息错误。 BMS自我保护功能欠缺 。 原有信息错误，没有进一步的测试，未能预见问题。

BMS shutdown Why BMS shut-down? Because of the self-protection function of the BMS. Why self-protection inside BMS? Because unlike other batteries, good performance of lithium ion battery can only be obtained during specific conditions of charge / discharge. BMS Design wrong for this customer. Entire system (motor, controller, battery) needed evaluation and testing.

为客户设计的BMS 错误 。整个系统 (电机, 控制器, 电池) 需要评估和测试。 因为不同于其它电池，锂离子电池只有在特定的充放电条件下才能有良好表现。 为客户设计的BMS 错误 。整个系统 (电机, 控制器, 电池) 需要评估和测试。

Solutions found, but costs are high for all partners! Many Lessons Learned. Costs of Lessons Very Large! 0 voltage battery solved. BMS heating solved. BMS shutdown no more.

找到了解决方案，但三方都付出了高代价！ 吸取了很多教训!教训的代价非常高！ 电池零电压问题解决。 BMS发热问题解决。

Developing Communications, Testing, Learning to Trust Each Other, Working Together… 0 voltage battery solved. BMS heating solved. BMS shutdown no more.

加强沟通, 测试,学会相互信任, 共同努力… 电池零电压问题解决。 BMS发热问题解决。 BMS停止工作问题解决。

How Problems Were Solved Leadership was key. Bosses of all three companies good communicators, determined to solve problems. Created more communication – multi channel, multi level. Boss to boss, technology person to technical person, sales people to sales people. Question every detail. Listen to every answer carefully. Improve testing and rely more on test data than opinion. Bosses focused on keeping team going, keeping everyone thinking about results – not who is to blame. Face to face meetings in Suzhou, Longkou, Los Angeles helped a lot. Everyone learning to admit mistakes and discuss honestly and focus on how to fix. Wettsen and Phylion willingness to spend money and effort to fix. Group learned that many original ideas about specification and use patter were wrong. Change batteries and BMS several times. Still failing in field. Finally…change battery cells to higher power that suits high power motor. Add capacitor.

问题是如何解决的 领导是关键。 三方领导沟通能力强；有解决问题的决心。 更多的沟通和交流。 多渠道，多层面。领导之间, 技术人员之间，销 售人员之间。 询问每一个细节，仔细倾听每一个答案。 改进测试，更多的依靠测试数据，而非意见。 三方领导专注于保持团队前进，使每个人思考结果-而不是思考到底 是谁的问题。 在苏州，龙口，洛杉矶面对面的交流帮助很大。 每个人都学着承认错误，诚恳的交流，专注于如何解决问题。 玮辰和星恒愿意投入金钱和精力来解决问题。 三方意识到原来许多对规格和使用模式的认识是错误的。 数次更换BMS和电池 。在实际使用过程中仍出现问题。 最终…提高电池功率适应大功率电机。安装电容器。

Costs of Problems Were Huge! 2 years of unsatisfactory sales in USA market. Sale of company complicated by battery problems. New high power batteries working well but expensive for Wettsen and Phylion All three companies and all staff involved much more capable than before!

为出现的问题付出了巨大的代价！ 两年来美国市场的销售额不尽人意。 电池问题使公司出售复杂化。 新的大功率电池运行良好，但对玮辰和星恒是昂贵 的。 三家公司及参与员工的能力比以前大有提升！

Lessons Learned Together If we can learn from our mistakes and experiences, we can benefit in the future. AECF, Phylion and Wettsen have all learned a lot. Here are some of the lessons learned from our experience and from other experiences at Phylion, AECF and Wettsen.

共同吸取的教训 如果我们现在吸取经验教训，将来定会受益。 AECF, 星恒和玮辰都从中学到了很多。

1.Build the Bike Around the Battery! 2. Consider the Whole System! Battery must be first determinant of performance and power. Motor, Controller, Battery must be considered as one system! Not parts that can be bolted together.

1.以电池为中心制造整车！ 2.通盘考虑整个系统! 电池是决定性能和功 率的第一要素。 电机，控制器和电池 必须作为整体通盘考 虑! 而非固定在一起的部 件。

Example of Whole System Analysis Battery (Phylion) 10Ah/1C 5Ah/2C (suspected root cause for shut down/turn on operation) BMS (Phylion) Thermal relay protection(75C) Over current protection(30A) (Been complained but not likely by jump wired) Over discharge protection (2.7V/cell) (BMS variation suspected) (EMC issue suspected) Controller (Wettsen) Over current protection (Successful functioned)(18A+/-2A or more variation) Low voltage warning (<33V) Low voltage cut off(<31.5V) (12 sec average calculation) Thermal relay protection (Protection function been removed) Motor (Heinzmann) Thermal relay protection (145C)(Protection function been cut off) Demagnetized by over heat at non-gear side suspected Over temperature failure by large current over 10 cycles (20A/20min) discovered Demagnetizing found after 3 cycle. Vehicle (Wettsen) 32kph top speed with 12A current consumption in normal condition On vehicle 296 rpm/4.5A/40.4V no-load

整体系统分析 Battery (Phylion) BMS (Phylion) Controller (Wettsen) 10Ah/1C 5Ah/2C (suspected root cause for shut down/turn on operation) BMS (Phylion) Thermal relay protection(75C) Over current protection(30A) (Been complained but not likely by jump wired) Over discharge protection (2.7V/cell) (BMS variation suspected) (EMC issue suspected) Controller (Wettsen) Over current protection (Successful functioned)(18A+/-2A or more variation) Low voltage warning (<33V) Low voltage cut off(<31.5V) (12 sec average calculation) Thermal relay protection (Protection function been removed) Motor (Heinzmann) Thermal relay protection (145C)(Protection function been cut off) Demagnetized by over heat at non-gear side suspected Over temperature failure by large current over 10 cycles (20A/20min) discovered Demagnetizing found after 3 cycle. Vehicle (Wettsen) 32kph top speed with 12A current consumption in normal condition On vehicle 296 rpm/4.5A/40.4V no-load

Possible reason to trigger BMS over discharge protection function Electro Magnetic field inference (from wire harness arrangement or power system compatibility) Motor deteriorate (demagnetized by over heat or aging) BMS variation or instability Cell unbalance Other Minor reasons (controller variation)

可能启动BMS过度放电保护功能的原因 Trigger BMS over discharge protection function Electro Magnetic field inference (from wire harness arrangement or power system compatibility) Motor deteriorate (demagnetized by over heat or aging) BMS variation or instability Cell unbalance Other Minor reasons (controller variation)

Suggestions for corrective actions BMS over discharge shut down before end of capacity Larger Capacitor (Help on EMC issue) (Help to prevent voltage drop due surge current) Larger Capacitor High power battery (eliminate capacity decrease due to high C discharge) Restore motor thermostat (prevent high temperature demagnetize) No Jump wire (keep battery protection function) High power rating motor (meet US customer requirement and higher efficiency, no over heat) US side more statistic information US office more detail investigation program Conduct full scale test program before shipping

改进建议 US office more detail investigation program BMS over discharge shut down before end of capacity Larger Capacitor (Help on EMC issue) (Help to prevent voltage drop due surge current) Larger Capacitor High power battery (eliminate capacity decrease due to high C discharge) Restore motor thermostat (prevent high temperature demagnetize) No Jump wire (keep battery protection function) High power rating motor (meet US customer requirement and higher efficiency, no over heat) US side more statistic information US office more detail investigation program Conduct full scale test program before shipping

Skill in Bicycles or Other Products Does Not Carry Over to Ebikes! Bicycle Industry model of buying parts from many sources – assembled by non ebike experts – does not work for ebikes. Electric system must be integrated carefully. Parts are NOT interchangeable. Normal bicycle or motorcycle manufacturing ideas do not work well for ebikes.

自行车及其他产品的技能并不适用于电动自行车! 自行车的产业模式-多 处采购零部件，由非 电动自行车专家组装– 并不适用于电动自行 车。 电子系统必须仔细整 合。部件不可相互转 换。 正常的自行车或摩托 车的制造理念并不适 用于电动自行车。

Need Strategic and Long Term Relationship Dropping supplier after one problem means all lose – no chance to learn from mistakes, and no good alternative suppliers that can solve problem instantly.

需要建立长期战略合作关系 出现一个问题便更换 供应商意味着没有机 会吸取教训，并且没 有其他供应商能够迅 速解决问题。

Specifications May Not Be Enough Information Bike buyer may be testing batteries, but battery company needs to be testing the proposed bike at the same time.

仅有规格是不够的 自行车买家也许会测 试电池，但电池厂家 同时也需要测试自行 车。

Communications are the Key Issue Not just language. Also internal politics, cultural differences, technical issues. Must consider and work on all aspects of communication – find correct person, find what is real issue.

沟通是关键 不仅仅是语言。还有 公司政治,文化差异和 技术问题。 沟通必须从各方面着 手–找到正确的人和问 题的关键。

Price is Not the Way to Choose! Most expensive cost is a failure in the market.

脱离实际的价格不是正确的选择 高昂的成本在市场中 会遭遇失败。

Everyone Need to Speak Same Technical Language! Same testing equipment, same process, same way of reporting results.

所有的人需要用相同的技术语言沟通！ 同样的测试设备,同样 的测试过程, 同样的测 试结果表达方式。

Lithium Is the Future Of Ebikes

锂是电动自行车的未来

E Bike Not Simple, Lithium Bike Even More Complex Lead Acid vs. Lithium issues Assemblers and distributors usually do not understand Li batteries. Complexity demands care and caution. Safety issues very important. Battery Management System, Charger very important.

电动自行车复杂, 锂电动自行车更复杂 铅酸 与锂 组装厂 和经销商通常 不了解锂电池。 复杂性需要谨慎。 安全问题非常重要。 BMS和充电器非常重 要

Lithium ion e-bike battery, 2001 Lithium ion e-bike battery, 2008 Battery Price Lead Acid Price Going Up Lithium Price Coming Down Lithium ion e-bike battery, 2001 US$1.15 per watt hour Lithium ion e-bike battery, 2008 US$0.49 per watt hour

电池价格 铅酸价格上升 锂价格下降 锂离子电动自行车电池2001 每瓦时US$1.15 锂离子电动自行车电池2008 每瓦时US$0.49

Lithium Battery is More Complicated Than Most People Know…System Integration Key to Success Test Electrical performance. Safety test Life verification Combined life Test EC system Cathode Anode Electrolyte Interface Li-ion Cell Electrical Performance Safety Cycle life Calendar life Motor Motor controller Li ion Battery Battery charger Models Battery model Thermal model Life Prediction Model System model Module system Electrical Performance Safety BMS EMC Thermal management.

锂电池比大多数人想的复杂…系统整合是成功的关键 测试 电气性能 安全性测试 寿命确认 综合寿命测试 EC 系统 负极 正极 电解 界面 锂离子电池 电气性能 安全 循环寿命 使用寿命 电机 电机控制器 锂离子电池 电池充电器 模型 电池模型 热模型 寿命预测模型 系统模型 模组 电气性能 安全性 BMS EMC 热管理

Thanks! 未来是电能的时代

Thank You! 谢 谢!