Building Solderless battery pack

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Dan Lim

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May 28, 2017
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59
It has been a few month backsince starting working on the concept of solderless solution.
I need something that can build around bigger pack for high power application like powerwall.
Tried many concept and fail due to adding too much stuff and weak structure.
The final concept is very similar to everyone's build but with added panels on both sides.. with "Fuse"
It takes me literally months tocome out the design and correct dimension to work with.
"Fusing" is also not easy to come back even spending days doing research and finding suitable method to implement.
Overall I pleased with the result amid some minor improvement.
I was surprise during the first prototype how fast the assembly takes when building a battery pack. Only ~15mins.
You may wantcheck out my blog on this project.
https://danlimblog.blogspot.com/2018/10/p1-416-open-frame-power-pack-kit-its.html
 
Joined
Dec 8, 2017
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image_kwufkb.jpg
Nicely done!


Your individual cell fuses are quite brilliant!


image_kytvcc.jpg
 

Dan Lim

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May 28, 2017
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spinningmagnets said:
image_kwufkb.jpg
Nicely done!


Your individual cell fuses are quite brilliant!


image_kytvcc.jpg




Yep, I search high and low to come out with this simple solution... Sometime simple thing is not easy.
 

clupton

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Aug 24, 2018
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Do you have an idea of what each kit will cost to purchase?
 

TheBatteries

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Dan Lim

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May 28, 2017
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mike said:
DanLim said:
clupton said:
Do you have an idea of what each kit will cost to purchase?

You may want to visit my blog on the details....

https://danlimblog.blogspot.com/2018/10/p101-416-ofppk-pre-order.html

or send me a message.

Thanks
Daniel

$155 for one? That means a 14s powerwall setup would cost $2170 in just holders. That's ridiculous...

For 14s is $140/pack. I understand from your point of view. This cost is pretty high at the moment due to the low quantity run as I want to test the market feedback. What's your acceptable range you're looking at...
 

BlueSwordM

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Jul 5, 2017
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If you can large bulk quantity battery holders, then something like 999$ for a 14S pack would be your best bet.
 

Dan Lim

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May 28, 2017
Messages
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BlueSwordM said:
If you can large bulk quantity battery holders, then something like 999$ for a 14S pack would be your best bet.

Thanks for your feedback...
I'm open to all feedback at this stage. Any feed back will take into consideration and look into.
At the moment is a pilot run, we hope there'll be more people to support this project.
With the pricing are more affordable, more people will get to build their battery power pack simpler andfaster...
 

BlueSwordM

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Jul 5, 2017
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423
Yep.

Is there a way you could save on material costs?

What are the connections/busbars made of? Going from copper to aluminium would be good since it would be lighter, quite a bit cheaper, and you wouldn't lose much conductivity over a busbar.

Making a smaller pack of 32p cells would also be good for people on a tighter budget wanting to start.

Edit: Meant 32P.
 

Korishan

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Do you happen to have some more images, perhaps larger and different angles?
 

Dan Lim

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May 28, 2017
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Thanks BlueSwordM
The material doesn't cost a lot actually... The reason is costly is each plate is CNC milled. And each plate is estimated to have 150-200 big & small holes/slots... some is with threaded. There're 5 plates in total for each pack. So a lot of work and cannot make any mistake. Failure rate is high.
I love the quality of CNC, it makes the pack look professional.
My first prototype was using 28P, too small and too much pack needed to build a full blown powerwall. The cost will be even higher. More cells within a pack will drive down the cost/cell calculation and less work overall.


Korishan said:
Do you happen to have some more images, perhaps larger and different angles?

This is a pack assembly video I did a few days back. Will be better to see howthe process is...

416 OFPPK Assembly



Another test I did on the pack is to test the vibration... yes is not scientific, I'm looking at normal usage.
Pretty stable..

Vibration Test

Let me know any areas I can look into...
 

Dan Lim

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May 28, 2017
Messages
59
DanLim said:
Thanks BlueSwordM
The material doesn't cost a lot actually... The reason is costly is each plate is CNC milled. And each plate is estimated to have 150-200 big & small holes/slots... some is with threaded. There're 5 plates in total for each pack. So a lot of work and cannot make any mistake. Failure rate is high.
I love the quality of CNC, it makes the pack look professional.
My first prototype was using 28P, too small and too much pack needed to build a full blown powerwall. The cost will be even higher. More cells within a pack will drive down the cost/cell calculation and less work overall.


Korishan said:
Do you happen to have some more images, perhaps larger and different angles?

This is a pack assembly video I did a few days back. Will be better to see howthe process is...

416 OFPPK Assembly



Another test I did on the pack is to test the vibration... yes is not scientific, I'm looking at normal usage.
Pretty stable..

Vibration Test

Let me know any areas I can look into...



The pre-order is closing on Feb 8, those interested may want to reserve your unit.
Thanks
Dan
 

Wolf

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Sep 25, 2018
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DanLim said:
Two days more before Pre-Order Close..
Still have some slot available.

Love the idea. Will the price come down any with volume production?
Any plans to increase cell numbers maybe to at least 100p?
Don't know if that many is feasible in this type of system.
For my planned powerwall I would have to buy at least 42 of them if not 56.

Still a great concept for a 12V system.

Wolf
 

Dan Lim

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May 28, 2017
Messages
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Wolf said:
DanLim said:
Two days more before Pre-Order Close..
Still have some slot available.

Love the idea. Will the price come down any with volume production?
Any plans to increase cell numbers maybe to at least 100p?
Don't know if that many is feasible in this type of system.
For my planned powerwall I would have to buy at least 42 of them if not 56.

Still a great concept for a 12V system.

Wolf

Hi Wolf
Thanks for your interest...
Currently this is still in pilot run stage, is a small run. Yes, definitely we're looking ways to bring down the cost. We need some support.
Yes, we'll consider bigger pack for future ideas.

If you're interested in getting 40+ pack, send me a message or email.

Yes, can be used on any configuration, just series or parallel.

Thanks
Daniel
 

Dan Lim

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May 28, 2017
Messages
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Those who's interest can send me a message, we can do built-to-order if there's a quantity.
 

Overmind

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Jan 16, 2019
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Very good job. It doesn't look easy to home-build.

For the experienced ones: what could be wrong with just using 2 plates with springs as connecting option ?
 

Korishan

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Springs will get weak over time
Don't provide constant pressure over a large area
Have high energy losses thru resistance
Most are chrome plated steel or nickel plated steel

There are some that are good. Beryllium springs have good retention and low resistance. They cost more, too.

"If" the springs have plates that make contact with cells then they would probably work. Think of the plate/spring assembly backwards or the spring is sandwiched between 2 plates. But this only solves part of the issue, there's still retention issue and if the plates aren't directly connected with a separate wire then resistance is still am issue too.
 
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