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

The case is nearly finished

The case is nearly finished
getting it covered up

Got busy with the aluminum and roughed out the rest of the enclosure. With my simple tools, making a well fitting 1/8" aluminum case is a bit tricky, so there will be some rough corners.I built it to screw together at this point,with the idea that if it needs more rigidity, the screwed together joints could be TIG welded.
The air handling system wants to allow lots of air flow. This gets tricky when you look at the present pack inlet air side where all the air needs to pass through a small louver behind the passenger seat,then take a couple of corners, and pass through the narrow slot where it passes through the IMA box sidewall. Finally it expands out to the full pack inlet.I decided that 3 - 3" fans tucked right in the inlet duct should suck in a much bigger flow of air. On the outlet side, instead of trying to suck out the air with a single fan,I would add 2 more 4" fans directly on the outlet side, and eliminate the fan shroud completely.To control the fan noise, I will build in a temperature controlled PWM fan speed control. The HV connections on the relay board will have big wires attached and will feed into the terminal side of the pack. The cut off relay panel is secured to the pack in exactly the same position as on the stock pack.