New England Hybrid Festival 2013
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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

The Battery case starts to take shape

The Battery case starts to take shape
making the battery enclosure

Finally got the rear shop cleared enough to cut up the aluminum sheets. 1/8" 4X8 sheet is a bear for one guy to handle.
After rigging up some support I was able to cut the sheet in half, and that size can be handled with good control.
After giving up trying to cut the stuff with the jump shear, I found that an 80 tooth carbide blade cuts the sheet easily, so I was good to go.
I cut off the rear protrusions (HV terminal insulators) and the top mounting bosses, as I will be mounting and wiring it differently than it was on a stock pack.
Got my big brake set up so I can make nice bends, so I think I will make the pack so it screws together rather than welding it together. This will allow better access in the event of a problem.
Still need to make the air inlet and outlet sides and then locate and drill the main mounting holes for the pack core into the case, as well as the 4 main mounting bosses