Wolf's PowIRwall

[Wolf]

So my initial idea of using make your own hose clamp kit was a bit of a fail, both aesthetically and functionally.
I wanted to hide the worm gear under the end covers but alas to fat.
So the new option now is a banding strapping kit. I think that will look much better plus I can hide the metal sealer/clamp under a cover.


Speaking of the end covers I will need about 54 of them if I plan on using the 8 cells left over from the split and combining them for another 14s Battery. Basically need the end supporting structure and the cover. Both sides are identical.
If anyone has a 3D printer and wants to take on the challenge of reproducing these let me know.
More than willing to pay for time and materials. I would ship an example to you and we can go from there. I am not concerned about the logo.
PM me if you are interested.
Wolf

 

[harrisonpatm]

Speaking of the end covers I will need about 54 of them if I plan on using the 8 cells left over from the split and combining them for another 14s Battery. Basically need the end supporting structure and the cover. Both sides are identical.
If anyone has a 3D printer and wants to take on the challenge of reproducing these let me know.

How big are they, rough dimensions? They look a bit large. 3d printing is cost-prohibitive when it comes to large production parts, especially if you need 54 of them.

Maybe 3d print one as use it as a mold or stencil for another method of fabrication?

 

[OffGridInTheCity]

If you mount them on some kind of racking system or shelves or enclosure - maybe you can put side panels on the rack or shelves or enclosure(s) using more conventional materials and no one will see the ends

 

[Wolf]

How big are they, rough dimensions? They look a bit large. 3d printing is cost-prohibitive when it comes to large production part

The pouch cells are 161mm X 227mm so the covers are around 6.5" X 9"
Besides being astatically pleasing, these covers, at least the inner ones, serve several purposes. That would be the electrical contact points
and a very tidy way of cell compression via 2 strapping bands.
But being a complete noob to 3D printing I would not necessarily know what's involved.
That does not mean I wont go out and get a 3D printer and make it happen. At least make them as I need them. They certainly do not need to be as elaborate as the original ones but the rudimentary function of the cover needs to be the same.
The contact points are easily made, cut some steel/brass/cooper/aluminum bar round the edges drill and tap for 6x1.0mm bolts.
Still need to support them somehow though. I will also need to construct the final termination points (+ and -) with some cooper /nickel sheets cut to size and either soldered or spotwelded to the cells ends, which of course needs to interface with the end contact points. These need to be very sturdy as the bolts that attach the wire lugs need to be torqued to at least a "yup that's tight" level.
Please be aware I can make 48 of these batteries using the original end caps/covers. Its the 27 other ones I can make using the split off cells.
So looking at the end caps/covers and knowing what purpose they serve ..............................more brainstorming please.
There is no hurry here as building 48 of these will take me long enough.

Wolf


P.S.
Some suppliers web sites

A123 Systems Cells and Battery Modules ( Endrich Co., Ltd. )

A123 7s3p 60ah Battery Module Electrical Vehicle - Buy 24v 60ah Battery,7s3p Battery Module,A123 60ah Battery Product on Alibaba.com

A123 7s3p 60ah Battery Module Electrical Vehicle - Buy 24v 60ah Battery,7s3p Battery Module,A123 60ah Battery Product on Alibaba.com

www.alibaba.com

 

[harrisonpatm]

The pouch cells are 161mm X 227mm so the covers are around 6.5" X 9"
Besides being astatically pleasing, these covers, at least the inner ones, serve several purposes. That would be the electrical contact points
and a very tidy way of cell compression via 2 strapping bands.
But being a complete noob to 3D printing I would not necessarily know what's involved.
That does not mean I wont go out and get a 3D printer and make it happen. At least make them as I need them. They certainly do not need to be as elaborate as the original ones but the rudimentary function of the cover needs to be the same.
The contact points are easily made, cut some steel/brass/cooper/aluminum bar round the edges drill and tap for 6x1.0mm bolts.
Still need to support them somehow though. I will also need to construct the final termination points (+ and -) with some cooper /nickel sheets cut to size and either soldered or spotwelded to the cells ends, which of course needs to interface with the end contact points. These need to be very sturdy as the bolts that attach the wire lugs need to be torqued to at least a "yup that's tight" level.
Please be aware I can make 48 of these batteries using the original end caps/covers. Its the 27 other ones I can make using the split off cells.
So looking at the end caps/covers and knowing what purpose they serve ..............................more brainstorming please.
There is no hurry here as building 48 of these will take me long enough.

Wolf

View attachment 32676View attachment 32677
P.S.
Some suppliers web sites

A123 Systems Cells and Battery Modules ( Endrich Co., Ltd. )

A123 7s3p 60ah Battery Module Electrical Vehicle - Buy 24v 60ah Battery,7s3p Battery Module,A123 60ah Battery Product on Alibaba.com

A123 7s3p 60ah Battery Module Electrical Vehicle - Buy 24v 60ah Battery,7s3p Battery Module,A123 60ah Battery Product on Alibaba.com

www.alibaba.com

It's just that this is a rather large piece. The build plate of most standard 3d printers is 220x220, so right off the bat you'd need an extra-large print bed. Plus, the cost of filament becomes detrimental at scale, at at larger pieces. Rough estimate, you'd be looking at 3-6 hours of print time and $2-8 of material for a single piece, and you want 54.

How about piece of wood? They'd help with compression at either end, and some rudimentary wood working tools could get them a bit more shapely than just a square cut.

 

[Wolf]

Rough estimate, you'd be looking at 3-6 hours of print time and $2-8 of material for a single piece, and you want 54.

How about piece of wood? They'd help with compression at either end, and some rudimentary wood working tools could get them a bit more shapely than just a square cut.

I hear you and I do understand. Wood of some sort is definitely an option the edges can be rounded especially the strap corners and the connector area can be routed out to place them in the appropriate area with a strong epoxy. Painting them black would then more or less make them look professional. Then a black lexan/plexi cover with standoffs to leave room for the BMS. Again this is not an immediate requirement as I have 48 complete modules with the ends and covers.. Just something to consider in the future. I also have a good friend that has CNC machinery that could potentially take a block of "plastic" and make something similar. Just exploring all options, as I want this to look quite professional.
I deeply appreciate all the ideas and brainstorming.

You are all the best

Wolf

 

[100kwh-hunter]

Regarding Daly bms:
The blue tooth or wifi thingy with the new update in the app requires your location, without this "approval" you can not change your parameters.
As you will notice the fabric parameters are set beyond what we want. from 2.5v to 4.3v.
Regarding colors you can get them in blue, black, purple, white and red.
All are fake/rip off, the red ones from Daly official are the original ones.

I am very fond of Daly bms, they are really mean junk yard dogs cooperating as one pack to protect the battery.

The first boundary that is set and met, the bms will shut all down to protect the battery pack.

If your chois is 100a then the max discharge is 100a and max charge is 50a.
If all the bmses are set to max v charge at 54v they will all quit at that v, if one is set to 54.1v that one will proceed charging till 54.1v is met.
After this he also will stop charging.
If charge is set to max 25a they will let pass no more then 25a.
Max on cell level likewise. they will just cut off charge if it gets 0.005v higher.
With discharge also.

All plusses in my opinion, except the latest update they require your location, why i have no clue, without location approval the app will not open anymore and new instalment will be in order.

But they work perfect and do even a 1ah balancing, for bigger batts no problem.
And they have a slow start, no problem to connect a full battery to a empty one, one will give and one will take, both building up a slow start.
I think you will be very happy with your Daly bms, i am a very happy user, except the needed location part.(why its needed)

Change parameters you, padwan...Change you must

3 are working for almost 3 years now no stop, never one issues, nada.

Best Igor

 

[Wolf]

All are fake/rip off, the red ones from Daly official are the original ones.

So your telling me when I purchased the 100balance BMS from the DALY Official Store its a fake?
Please explain.
Wolf

 

[Oleksii]

So your telling me when I purchased the 100balance BMS from the DALY Official Store its a fake?

Just do not listen to him. Not sure why he is saying that b**shit ...
Any BMS is not ideal!
All have pros and cons, we can just select what is optimal for us.

A person who does not know that BLE stack usage on Andriod OS requires location permission from an App ... makes everyone scary.
No sense to comment the rest b**shit

One possible weak point for the Blue ones - they do not use a dedicated fronted IC (with delta-sigma ADC), which usually also does the coulomb counting, i.e. it should be doing it well for different type of pulsed current. The Blue one does current measuring by the main MCU ADC and does own math and maybe it's doing the ADC sampling and math not so well for pulsed current. Yesterday I've got a sign of that.

 

[100kwh-hunter]

So your telling me when I purchased the 100balance BMS from the DALY Official Store its a fake?
Please explain.
WolfView attachment 32680

I must apologize, some time ago there were some different colors that were not originally Daly.

Just do not listen to him. Not sure why he is saying that b**shit ...

Why so hard replay? people make mistakes, we all learn.
And i was reading to fast and they developed also other bmses what i was not aware of.
And where did you read that i wanted to scare people....i am very fond of the Daly bmses that i have.
The only drawback they have right now is that you must approve your location to that device, maybe they want to send me a happy meal.
I you dont approve that the APP is knowing your location you cant exces it anymore.
Sure that there are ways around this "blockade" but most people (including me) have no idea what you are talking about.
Thanks to that conversation i was digging on the internet.
Again i am very happy with Daly bmses.

Victron has also once a year a mandatory update, why? Is there a way around it?
If you know please tell me.
So no hard feelings, we all learn

With best regards Igor

 

[Wolf]

Update on the new battery build.
Well we have a fully functional 48V nominal 78Ah pouch cell battery prototype
First off I had to figure out where to put the BMS. Well the obvious place would be on one of the end caps.
However to fit the BMS and have the cover also fit and be functional some carving work was required.
Michelangelo had nothing on me man. I cut and carved for almost 2 days but the results are cool.
Also this will serve as a template for the CNC machine that will recreate this within minutes for the however many of these I will build.
the potential is 75 3p14s for 48V nominal, but other options are possible.

The banding was also a much better idea than the "hose" clamp system.

I'm considering adding a Display on the other side of the Battery . I have 2 types one is just a simple UART Voltage Temp and Amps, the other one gives individual cell voltages. I will see which one works looks and functions the best.
In the meantime the battery is charging to 4.15V and I will be testing the actual capacity with my CBA V Pro 100 Precision battery capacity tester.
Also drilled a small observation hole on the cover to see BMS green light.
Wolf