New England Hybrid Festival 2013
Mikes You Tube Videos
Mikes Saturday Hybrid-Solar- Electric Workshop
Insight 20 AH lithium battery system
assembling the pack core
BMS board mounting position?
Capturing the mounting boss positions
Cell tester is modified and lithium test fixture takes shape.
Charging experiments
Cleaning the cell tabs
fixing and deburring the heat spreaders
Final assembled pack core
Finishing the connection blocks
finishing the fins and end plates
First discharge graph
Getting started on the final design and build
Heat sink fins
heatsink vs no heatsink comparison
Higher thermal sensitivity look at the cell heating still shows no dents
Hot and cold cells compared.
How do the big guys do it
Is using this asking for a problem?
main I/O terminals and Heat shrink
Making the 50 insulating strips
Painted cells to increase emissivity
Punching the holes in the tabs
Same discharge with huge heat sink on one side of cell
Testing the fans and layout of the BMS boards
The Battery case starts to take shape
The case is nearly finished
the connector plate is made and mounted
The tab punch
The world in IR Cool
Grid charger Users page
Mikes Surplus Loft
Renewable energy exhibits
New England Hybrid festival 2014

assembling the pack core

assembling the pack core
carefully assembling the pack

Now that I have made all the required parts, it is time to do the final core pack assembly, hopefully with no shorts.
The first issue was the small burr on the punched holes, that would be a very big job to remove. The fear is that the clamps would only apply pressure on the raised burr, and therefore all of the current would pass through the rather small area. The simplest fix was pretty easy, I put a nice counter sink on the clearance blocks, so the burr would be able to fall into the countersink and therefore allow the full area of the blocks to apply pressure. The assembly process proceeds as shown in the photo. The anti oxidation paste is heavily zinc filled, so it should provide corrosion protection while not effecting the contact resistance. The connections were insulated with the preformed heat shrink, and then an additional piece of the preform is slid over the end to prevent shorting. This extra protector will be removed when the contact plate is attached. Each cell took about 10 minutes to prepare and connect. Long day!