What requirements do electric two-wheeler batteries need to meet?

Electric two-wheeler batteries need to meet several technical, safety, and regulatory requirements to ensure performance, longevity, and user safety. Here's a breakdown of the key requirements:

1. Technical Performance Requirements

Voltage and Capacity Compatibility

• Must match the system voltage of the vehicle (typically 48V, 60V, or 72V).

• Capacity (Ah) should meet the expected range and power demands.

High Energy Density

• Batteries (especially lithium-ion and LiFePO₄) should provide high energy output with minimal weight and size to ensure good vehicle performance.

Cycle Life

• Should support at least 800–1000 cycles for lithium-ion, or 2000+ for LiFePO₄, to ensure long-term usability.

Temperature Tolerance

• Operate reliably between -20°C to 60°C.

• Good thermal management systems are essential for regions with extreme climates.

Power Output

• Must deliver sufficient peak current for acceleration and hill climbing.

• Should maintain voltage under high load conditions.

2. Safety and Protection Features

Battery Management System (BMS)

• Protects against:

  • Overcharging

  • Over-discharging

  • Overcurrent

  • Short circuits

  • Overheating

• Balances cells to ensure uniform aging.

Thermal Runaway Prevention

• Particularly important for lithium-ion chemistry.

• Use of quality separators, thermal cutoffs, and venting mechanisms.

IP Rating

• IP65 or higher for water and dust resistance, especially for outdoor use and rainy conditions.

3. Regulatory & Industry Standards

Certification Requirements

• UN 38.3 (for transportation safety of lithium batteries)

• IEC 62133 (safety standard for portable batteries)

• ISO 12405 (testing of lithium-ion traction batteries)

• Local regulations may include:

  • BIS certification (India)

  • ECE regulations (Europe)

  • GB standards (China)

Environmental Compliance

• RoHS and REACH compliance to limit hazardous substances.

4. Mechanical and Structural Requirements

Shock and Vibration Resistance

• Batteries should be securely enclosed and resistant to vibrations from rough roads.

Modular Design

• Optional swappable battery design for shared scooters or extended range.

5. Sustainability and Afterlife

Recyclability

• Battery materials should be recyclable or designed for easy disposal.

Second Life Use or Take-back Programs

• Many governments are mandating that manufacturers take responsibility for battery disposal or repurposing.