Electrification of go-kart with second-life lithium-ion batteries: Performance analysis and optimisation

This research paper presents the design, modelling, and performance analysis of an electric go-kart retrofitted with a second-life lithium-ion battery pack. A 10 kW brushless DC (BLDC) motor and a 50.4 V, 100 Ah repurposed battery pack (14S5P NMC configuration) form the core of the powertrain. Technical performance measurements achieved included a top speed of 67 km/h and peak acceleration of 9 m/s², demonstrating that the electrification of a go-kart with repurposed second-life cells was on par with or even improved over conventional internal combustion engine (ICE) go-karts. Through the first principle, theoretical modelling of resistive forces and drivetrain dynamics, the selection of a 4:1 gear ratio was determined to produce a required wheel torque of 122 N·m to meet performance targets. The pack delivered up to 287 A during peak acceleration with an acceptable voltage sag from 52 V to 41 V. Real-time telemetry monitored speed, current, voltage, and battery temperature, providing insight into the current state of the battery during testing. Thorough safety measures, including a battery management system (BMS), ensure that safety concerns are mitigated. The results demonstrate that second-life lithium-ion cells can be successfully reused in a dynamic, high-power application without significant performance compromise. This work offers a sustainable approach to recreational vehicle electrification and performance optimisation through modelling and simulation, highlighting how battery reuse can reduce costs and environmental impact while delivering competitive performance.