New consulting relationship with GreenTecAuto begins
What actually goes wrong with the batteries????
A look at todays Hybrid and EV battery packs
Battery packs exposed
2006 and up civic packs
Lead acid battery failure examined
Testing the sticks at the cell level
MaxIMA stick full discharge
Bumblebee battery replacements for the stock subpacks
Inside the cells
Seprating the cells for reuse
How it is wired
PTC strips exposed
The PTC thermistors
Battery current sensor
Inside the 100A semiconductor battery pack fuse
Did it again for the last time
A bad Prius subpack explored and fixed????
Rebalancing the Insight battery?
Insight battery
Insight Battery switching/current monitoring
The battery controller
Prius battery pack
State Of Charge (SOC) determination with NIMH batteries
Battery pack monitoring
What happens to a Prius subpack when you overcharge it?
Keeping Warm In New England
Plugging into the SUN
Making a small solar concentrator
Building MIMA and the plug in adapters
Converting a telephone truck to electric
DIY dual pulse Capacitor Discharge Spotwelder
Chevy Bolt EV joins the family
Getting in shape while making electricity
Replacing gasoline with solar electric lawn equipment
What is Genesis One?
How to stop the aging process DIY
MIMA Install Day 2005 a Big Success!
Building a hybrid car grid charger
Tapping into the Wind
Expanding MIMA with the Distribution board ( users projects )

Insight battery

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The insight battery pack is made up of 120 D cell NIMH batteries, grouped into packs of 6 cells. You can see that the air path for cooling the pack is not very open, therefor the cooling of the pack is not very agressive. The pack has a strip of thermal sensing material that is in intimate contact with each cell in the pack. The D cell subpacks are terminated with a large stainless steel nut that can handle the 100A output. This is the special part of the pack, as we have not found a D cell that has similar high current contacts, so cell replacement with new subpacks is not an option at this time. The civic packs up to 2005 are drop in replacements, so you could get one of those much more readily available used packs and rebuild your Insight pack with the civic subpacks which are direct replacements with a more robust cell structure. The 2006 and up civic packs are built differently and are not direct replacements.