AKE Powerwall

Andreas Kvernes

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Joined
Oct 18, 2016
Messages
17
Hello!
Setting up this thread to give you all an easy way to follow my power wall build.
This is all one school project.
My power wall will feature moduleslike : solar mppt battery charger, BMS,Inverter, and touch display.
All these systems will be builtin one unitand controlled by anArduino.
Hope to see you and others following this project.


All cells have their origin from laptop batteries.
First stage: Taking out cells and getting them ready for charging. This step involved measuring each and every cell by their voltage. All cells with voltages greater than 1V have been accepted.
Second stage: Charging the cells UP TO 4.2 Volts and storing them for at least 10 days.
Third stage: Measuring voltages on each and every cell again before discharging. All cell with voltage drop greater than0.1 volts werenot accepted.
Fourth stage: Discharging the cells. 1900 mah minimum.
Fifth stage: charging discharged cells back up to storage voltage 3.8 Volts.


All cells is fused with fuse wire (positive side) . Tests have been done on this particular wire. Criteria like max Amp draw by length of wire have been tested and checked. Updates will follow on this subject.
From a total of 149 laptop batteries i got 895 cells. 560 (62.6%) of these is usable in form of a power wall. All the other cells were ether dead, had to high inner resistance or to low capacity.


The process so far..


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image_ruwkxw.jpgimage_vkjclx.jpg

Say goodbye to Voltage regulators. Too much Heat!





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New and final layout for my ArduinoBMS/ Charge controller


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Moving my Powerwall for final assembly and testing





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PCB Done!





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Working late nights with my most important tool.. Coffe :D





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Nearly there.. PCB for BMS almost finished.




2 NEW and essential deliveries.. Inverter and..
Custum made "fuse box" for my powerwall components. This will give you an idea were i'm going with this project..
Testing out possible layaut for batteries and inverter. Solar mppt, bms and Arduino will fit down in the bottom right..
Ventilationand other essentials will be fitted later
A lot of work is alsodelegated hardware components (BMS, Charge Controller,etc)


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Arduino progress.. BMS code and mppt charger code70% finished.
These codes will eventually be implemented true this TFT 3.2" lcd Shield + Touch Screen


image_wrtxzo.jpgimage_wnyuuw.jpg

Early stage in TFT screen program andYes, this layout is written in Norwegian. Code will be open source in anEnglish version as well(when finished).




Huge updates right around the corner..

Arduino updates will follow shortly..



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First pack done:D 7 packs done:D:D





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Soldering my first pack..


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10 mm2 wire (7 AWG). Finalbusswire idea. Testing out layouts for the packs..
As you see the wires are fastened by sip ties
at four points. Sip ties glued to battery
holders. These buss wireswere changed to
one wire running back and forward..
See images further down..


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Soldering negative side.





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Getting there..


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Early stage.. Packs 3/4 done. All cells getting one of these.
Missing some cells for a80 cell config.





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Fist patch of batteries ready to be dismantled Loots of colors


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Ready for charging


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My charging/ discharging station




 

Minatugar

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Oct 8, 2016
Messages
56
Looks great.
 

Andreas Kvernes

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Oct 18, 2016
Messages
17
Thanks :D
 

daromer

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Nice wire!
 

hbpowerwall

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Oct 7, 2016
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can't wait to see this up and running looking good so far
 

Korishan

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The red circles are protectors for the positive end.
 

hbpowerwall

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For just that little extra protection.. a good idea for sure
 

Andreas Kvernes

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Oct 18, 2016
Messages
17
hbpowerwall said:
For just that little extra protection.. a good idea for sure

Exactly. Never really liked the idea of hot solder at the positive terminal. This made me a bit more comfortable :p
 

Korishan

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Twice as many for almost 1/2 the cost:

http://www.ebay.com/itm/200pcs-1865...345421?hash=item1c80a4738d:g:A1EAAOSwsW9Y2OIF


Here's another one, tho you can't choose your colors:
http://www.ebay.com/itm/280pcs-29-5...911140?hash=item3adcd2e224:g:Ta8AAOSwSlBYyA54

Another from Banggood as the previous:
http://www.banggood.com/280pcs-29_5...8650-18500-Battery-p-958259.html?rmmds=search



You can get the rolls, but then you have to cut them. Since I don't have a blade slice cutter (kinda like a paper cutter used in school or offices), I think I'd pay the little extra to get the pre-cut ones.
 

Alec_J

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Joined
Mar 16, 2017
Messages
90
What are you powering your charging station with? Can you give a brief list of parts and sources?
 

Andreas Kvernes

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Joined
Oct 18, 2016
Messages
17
[size=small]Here are some parts for my charging station. ;) [/size]


* Plastic Storage Case Holder Box Clip 4 Pin DIY For 4x 3.7V 18650 Battery
http://www.ebay.com/sch/i.html?_fro...kw=Plastic+Storage+Case+Holder+18650&_sacat=0
* DC-DC CC CV Buck Converter Step-down Power Supply
http://www.ebay.com/sch/sis.html?_n...95517418&&_trksid=p2057872.m2749.l2658[/size]
[size=small]*AC 110V-220V TO DC 5V 12V 24V Switch Power Supply

[size=small] http://www.ebay.com/itm/AC-110V-220...em3ad527ad56:m:m8ThR7A3-XTn45AHeYfj4zQ[/size]
[size=small]* Eco six balance charger[/size]
[size=small] https://hobbyking.com/en_us/catalogsearch/result/?q=eco+six+balance+charger[/size]

[size=small]Charging station looking pretty much the same as the picture listet..[/size]
[size=small]I haveonly used my Eco six for charging the batteries.[/size]
[size=small]The single 18650 chargers were onlyused a fewtimes at the beginning. Same story with the Computer fan above the discharge modules.[/size]


Alec_J said:
What are you powering your charging station with? Can you give a brief list of parts and sources?

;)
 

Andreas Kvernes

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Joined
Oct 18, 2016
Messages
17
mike said:
Nice work, love the super clean look. How do you like your inverter? I have the same one but rated for 1500w. Was thinking of upgrading to the 2500w.

Tnx! Has notreally tested the Inverter, yet! But anyway, it fits my project excellentand it seems topacksome good wattage considered the size of it.
Aah,Do you have any experience with the 1500w versionMike?Does it deliver the wattage its supposed to? :)
 

LithiumSolar

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AndreasKvernes said:
mike said:
Nice work, love the super clean look. How do you like your inverter? I have the same one but rated for 1500w. Was thinking of upgrading to the 2500w.

Tnx! Has notreally tested the Inverter, yet! But anyway, it fits my project excellentand it seems topacksome good wattage considered the size of it.
Aah,Do you have any experience with the 1500w versionMike?Does it deliver the wattage its supposed to? :)

I've been using it 24/7 since October-ish. I have the 1500w 48vdc to 120vac specifically. It works great, especially for a Chinese cheapo! The most I have pulled has been a sustained 1300w for about an hour while testing. I plugged in my aquarium heater/pumps. It successfully starts and runs my shopvac without any issues, but when I tried plugging in my regular floor vac (sticker says 12A) it blew the fuses instantly, so the surge capacity doesn't seem optimal. I don't need to run my mammoth-sized vacuum on it though, was more or less testing it's limits.

I'll give it a B, because the fan is loud and kicks on at times I don't consider appropriate (low load, low heat). :)
 
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