Battery Pack Setup-Ideas

I have an imagination. It's just not attuned to graphics; hense the reason why i stink at drawing and graphics designing :p So yeah, it is just a little harder for me to visualize the full concept, especially since you are only showing pieces of the full product. It's kinda like seeing only a tire, or a transmission of a car and trying to visualize the full car from those few details. At least, that's the way it is for me. Others may see this and be like "Ohhh, that's how it's gonna be". Just not me.
 
Check post #16, only difference is the space between the cellholders and the mounts between the cellholders, same concept though
slide in fromthe front and lock with 2screws through the front and back plate
 
i got the ordered parts today, and my enthusiasm is "slightly" dented

1 row of 14s with 100cells per pack weighs 179kg +cables, connectors, busbars, covers for the front and back
not to mention the supportstructure to hold the row inplace
for planning purposes i guess each row comes in at about 200kg, the support somewhere between 50 and 100kg, so with 5 rows and 50+kwh you have a ton of aluminium and lithium, i do not really want to know the price for that, so much for "cheaper" uh, i think i need something with alcohol today....

hmm a 12v 200ah leadacid batterie weighs 72kg, the same as 14 packs, but with 48v 200ah, maybe i am not that far of then?

this MOAB comes in at 260kg+, 70kg of these are cells. it might be cheaper, but it sure is not lighter..^^


image_qwxvab.jpg


btw, we are talking about the mount in green and only the bottom row of cells, still no weight for cables, busbars and such
 
so finally some progress with the casing, it killed quite some braincells, weight, cost, partcount, different parts overall.... quite streamlined atm


image_ietmzq.jpg


image_cunplv.jpg


image_bdpeyp.jpg


this is the 5kwh+ version, i do not dare to put 10 packs in there, but who would need that much anyway, right?^^
up to 5 rows of 14 packs with up to 100 cells
 
Korishan said:
I have an imagination. It's just not attuned to graphics; hense the reason why i stink at drawing and graphics designing :p So yeah, it is just a little harder for me to visualize the full concept, especially since you are only showing pieces of the full product. It's kinda like seeing only a tire, or a transmission of a car and trying to visualize the full car from those few details. At least, that's the way it is for me. Others may see this and be like "Ohhh, that's how it's gonna be". Just not me.
Click to expand...

Korishan - I agree with you, when I have to look at a diagram or blueprint it takes me so long to understand. I need a youtube video to go with the prints that provides a detailed explanation. I am having this very problem with now trying to understand AC coupling. The great thing about this group is that we do have people who can understand. I suspect all of us have strengths to bring to the forum.

MajStealth said:
so finally some progress with the casing, it killed quite some braincells, weight, cost, partcount, different parts overall.... quite streamlined atm





this is the 5kwh+ version, i do not dare to put 10 packs in there, but who would need that much anyway, right?^^
up to 5 rows of 14 packs with up to 100 cells
Click to expand...

MajStealth, I am with Korishan on this one, what am I looking at???? It looks like a pack mounting system, however many of the aspects look like their take from a Tesla battery pack. I question how expensive this will be. Just remember, the price of a Tesla Powerwall2 installed is coming down and you get brand new 18650's and a warranty.
 
never seen the insight of a tesla powerwall

the mainfocus is exchangeability

to my understanding, any powerwall atm is a solid block of "dont touch it, we do it", which most likely results in taking the powerwall of the wall and sending it in for repair warranty, anything

no field maintanance intended

what happens when a cell burns in a powerwall? mostlikely the hole damn thing burns down. yes it is monitored, yes it is cooled, yes it shouldnt burn
 
MajStealth said:
never seen the insight of a tesla powerwall

the mainfocus is exchangeability

to my understanding, any powerwall atm is a solid block of "dont touch it, we do it", which most likely results in taking the powerwall of the wall and sending it in for repair warranty, anything

no field maintanance intended

what happens when a cell burns in a powerwall? mostlikely the hole damn thing burns down. yes it is monitored, yes it is cooled, yes it shouldnt burn
Click to expand...

While I have not actually seen one in the flesh, there seems to be a lot packed in those systems. I believe they are liquid cooled and have cell monitoring. It is my understanding that is a cell goes bad it gets bypassed and a maintenance alarm is triggered. I am sure the modularity of the Tesla Powerall 2 means that it is just like the old days of TV.... The monitoring system already knows the defective part and only need to schedule a service call, the technician just swaps out the part and takes yours in to be rebuilt. They quoted my 6,000.00 for a 14kw system installed with a 10 year warranty. I still have a few weeks to think about it since I am in the utility review and approval process of my PV system.
 
if price is your only reasoning, i could also just attach the cellholders together, remove the busbars inbetween the cells, kill the modularity and end up with something like that

image_cghxij.jpg


approx 14x ~20 = 280 for the 100x100x4 quadpipe

just to say, powerwall 2 is 6200 incl taxes+ other stuff for 13.2kwh, atleast here in germany, at least that is what they advertise it at

hmm looks like it will be 1phase only, so sort of not that usefull, not useless, but not usefull either
 
hmm seems potetional should be used, brought the price down by 1,5-2k to just short over 3k for the stand with 14 cell holders, connectors, cables screws and such, not yet any cells in it, just missing some small pieces, lets say another 200 and it might be done

after checking datasheet after datasheet, it seems these profiles are made to take a heavy beating, thanks to more foots it could easily take 10 rows of 14 cells, but who needs 100kwh, residential, at least

rough estimate without asking for discount on the mass

weight of the first row 56,220kg price 1536,97

support structure weight 60,960kg price 1464,385

i am thinking about adding something to mount a screen to, enough space for the inverters is already there
 
MajStealth said:
hmm seems potetional should be used, brought the price down by 1,5-2k to just short over 3k for the stand with 14 cell holders, connectors, cables screws and such, not yet any cells in it, just missing some small pieces, lets say another 200 and it might be done

after checking datasheet after datasheet, it seems these profiles are made to take a heavy beating, thanks to more foots it could easily take 10 rows of 14 cells, but who needs 100kwh, residential, at least

rough estimate without asking for discount on the mass

weight of the first row 56,220kg price 1536,97

support structure weight 60,960kg price 1464,385

i am thinking about adding something to mount a screen to, enough space for the inverters is already there
Click to expand...


MajStealth,

How are the cells arranged in the tubes? How many cells per tube? This is a clever design.

-John-
 
5x 4x5, so 4 high, 25 deep, it will be a tight fit, but it should also be able to hold ~4x22 2170s , needs different holes for the spacer though.

hmm by thinking about that, i could make the spacers so, it would fit both, 1865 and 2170, but that will be a really tight fit for the 2170.
89mm for cells and holder, 10 to work with

just to show something, quite final atm
 
MajStealth said:
5x 4x5, so 4 high, 25 deep, it will be a tight fit, but it should also be able to hold ~4x22 2170s , needs different holes for the spacer though.

hmm by thinking about that, i could make the spacers so, it would fit both, 1865 and 2170, but that will be a really tight fit for the 2170.
89mm for cells and holder, 10 to work with

just to show something, quite final atm
Click to expand...


image_lnuobc.jpg


Is this what goes in each tube?

-John-

So your powerwall will be 500p14s?
 
MajStealth said:
Basically yes, but 4x25 is 100, not 500
Click to expand...

I understand. But your picture shows an array of 14 x 5 tubes. So if each tup has 100 cells then your total is 14s100p x 5. Am I not understanding something correctly? Or is each tube just 4x5?

Thanks,

-John-
 
Yeah, if you account for the fully build setup it would be 14s500p, but anything above row 1 is optionaly
 
MajStealth said:
Yeah, if you account for the fully build setup it would be 14s500p, but anything above row 1 is optionaly
Click to expand...

I understand. Thanks.
 
"weight of the first row 56,220kg price 1536,97

support structure weight 60,960kg price 1464,385"

got the first quote today, not complete, nor completely right but hey it got down to 1,5k + approx 400 for the parts that were missing. thing is, they attached my email and it was right there in it....^^

i will check next days with some local metal-companies which parts they could do, most likely the 100x100x4 and the covers, front rear, in between the tubes, maybe the busbar, well see

cables and connectors will be sourced through my customer electirian, most likely

looks better than my not growing 18650 stack.....
 
cant update pictures in old posts, strange..


image_iiwwxz.jpg



seems like i have to put it a little bit on hold, we will mostlikely have to build a house in the next year/s, but this gives me the opportunity to design a space for the wall aswell
 
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