New England Hybrid Festival 2013
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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
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New England Hybrid festival 2014

BMS board mounting position?

BMS board mounting position?
BMS boards mounting

Now that I have the battery assembly in hand, we can start to look at the mounting options for the BMS boards. We plan on moving the stock BCM and MCM to the area between the seat back and the IMA box.
I can see now that this would have been easier had I made the fins ~ 1/4" shorter,(would require complete disassembly now, so that is not a good option), but the cooling / heating can use all the fin length we have and more, so it was a tough call. The ability to see all the BMS LED while charging will be a nice aid in keeping an eye on how well the pack tops off, so it may be nice to let the BMS part of the pack cover stick through the IMA box cover, and to have clear lexan cover area so the leds and the board are visible?
No need to hide the cool looking "flux capacitor" boards. Could mock up a MR Fusion machine to give it the back to the future look. May be able to find some clearance under the stock pack to gain some height?
Time to look at the IMA cavity closely.