Understanding Battery Performance: Testing the 500W Falco e5.3 System at Level 5 Assistance

Introduction

We conducted a real-world test using a Diamondback mountain bike equipped with the 500W Falco e5.3 system to understand battery performance better. The system was supplemented with a Cycle Analyst V3, a Cycle Analogger (to log volts, watts, amps, and amp-hours), and a Falco console for controlling the level of assist.

The primary objective was to analyze the motor and battery performance under real riding conditions, assess the system’s capabilities, and determine its limitations.

Test Setup

The test was conducted using the following equipment:

• Bicycle: Diamondback 26” mountain bike

• Motor System: Falco 500W e5.3 hub motor

• Battery: Falco Lithium Li3

• Console: Falco Hxd console

• Data Logging Devices: Cycle Analyst V3 and Cycle Analogger

Total Weight:

• Bike (with system installed): 38 lbs

• Rider weight: 172 lbs

• Total weight: 210 lbs

Test Methodology

The test was performed on Level 5 (+5) assistance, the highest level of motor support available. The ride took place on the Washington & Old Dominion Trail, starting at Route 28, heading west through Leesburg, and returning—a total round trip of 30 miles.

Data collection tools included:

• Cycle Analyst V3 & Cycle Analogger (for motor and battery performance logging)

• Strava iPhone App (for tracking ride distance, elevation, speed, and power output)

Ride Data & Observations

• Total Distance: 30.2 miles

• Moving Time: ~2 hours

• Average Speed: 14.3 mph

• Total Elevation Gain: 300 ft

• Total Battery Consumption: 10Ah

• Battery Capacity Used: 81% (340Wh out of 417Wh)

• Regenerative Energy Captured: 0.43Ah (~4.3% of total battery usage)

During the ride, the battery voltage gradually decreased as expected. Power draw from the battery peaked at nearly 1000W, particularly during acceleration and climbing. The system also demonstrated regeneration capability, capturing energy that would otherwise be lost during braking and coasting.

Battery Performance Analysis

To analyze the battery’s performance, we consider two key factors:

1. Average Current Draw:

   Using the formula:

Average Current = Watt-Hours/(Ride hours*Nominal Battery Voltage)

= 340/(2*36) = 4.8A

Alternatively, using:

Amp-Hours/Ride Hours = 10/2 = 5A

Both methods yield an average current of approximately 5A.

1. Peak Current Draw:

   • The system reaches a peak power of 1000W.

   • At 36V nominal battery voltage, the peak current is:

     1000/36 = 28A

   • Given the 10S4P battery configuration, the peak current per cell is 7A, while the average current per cell is 1.2A.

Impact on Battery Life

To optimize battery longevity, we must consider:

• Current Draw: Lower current draw extends battery life.

• Temperature Rise: Higher temperatures degrade battery cells faster.

• Peak Stress: Repeated exposure to high current (e.g., 28A) stresses the battery pack, reducing lifespan.

Key Questions

1. How do peak stress levels impact battery life?

   • Frequent high-current draws (such as climbing or acceleration) can degrade cells faster.

2. How do average current and temperature affect battery capacity and longevity?

   • Lower average current and controlled temperature rise (~10°C observed) help prolong battery life.

Conclusion

The 500W Falco e5.3 system performed efficiently, covering 30 miles with 81% battery consumption at Level 5 assistance. The data suggests that managing peak currents and temperature rise is crucial for maintaining battery health. Future tests could focus on lower assistance levels, longer ride durations, and temperature monitoring to optimize battery performance.