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
Insulators
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

Capturing the mounting boss positions

Capturing the mounting boss positions
battery case fixture

To make a drop in pack, we need to accurately have mounting bosses in the exact position as the stock pack. After a careful look at the empty IMA bay on the green Insight. I decided that it would be easier to duplicate the mounting boss position on the new pack, if I had a solid fixture. I used an empty case as a template to hold the angles, and then welded them to the 3/4 inch steel plate.