Awesome project and 500 km range is a cool achievement! Kudos to OP for all the effort and research that went into this.
I’ve run into the same issue that standard battery packs on eBikes are just not enough. The problem is not so much needing to do super long trips but if you forget to charge one day, you’re going to be stuck the next. Luckily it’s become more common for OEMs to offer dual battery setups with the piece of mind of extended range but also having a warranty! We own two cargo eBikes in the family and both have two Bosch batteries. Range varies from 80 to 200 miles depending on level of assist and is more than enough for our daily ~20 mile errands.
I’ve run into the same issue that standard battery packs on eBikes are just not enough. The problem is not so much needing to do super long trips but if you forget to charge one day, you’re going to be stuck the next. Luckily it’s become more common for OEMs to offer dual battery setups with the piece of mind of extended range but also having a warranty! We own two cargo eBikes in the family and both have two Bosch batteries. Range varies from 80 to 200 miles depending on level of assist and is more than enough for our daily ~20 mile errands.