Rad's powerwall build

R

Rad

Member
Joined
Aug 18, 2017
Messages
72
Well, like many, I have been quietly gathering cells over the last few months. Watching YouTube at the same time,I am sure I must have spent days watching the guys experimenting and passing on their knowledge. What I set out to do initially has surechanged a lotas I learn about better methods.


I have now gathered about 2400 basically testedcells and have just completedand started using my30 baymass charger. The base is apiece of polycarbonate:


image_qsqncq.jpg



I ran one pair of busbars per 10 battery holders:


image_embxur.jpg



The TP4056's were attachedto the battery holders first, using the + and -copper wires:


image_vktshw.jpg



Then the battery holders were screwed down into the base:


image_xgyvst.jpg
 
Santiago said:
Wow, this is not a charger, this is an sculpture.
Click to expand...


Thanks Santiago, maybe if I spent more time on the powerwall build itself,rather than the charger,my project would have progressed further:)
 
Rad said:
Ibiza said:
Hi Rad, which of the PC boards you linked is actually one you use?
Regards
Click to expand...

Hi Ibiza

I use these TP4056boards,they areavailable from many sources. There are two types, one with protection and one without protection. I used the ones without protection.

example:
https://www.aliexpress.com/item/Fre...0c3b05a&transAbTest=ae803_1&priceBeautifyAB=0
Click to expand...

Thank you so much for your advice

One more question if you don't mind Rod: what is on the right top on the first photo? Is that a power supply ?
 
Yes thats a 5.1volt 30amp power supply. No fans needed in cool weather but fans are definitely needed when its warm.
 
thanks again

I like your design and, if you don't mind, will copy it.
How many cells you are able to test in 24H?
 
Ibiza said:
thanks again

I like your design and, if you don't mind, will copy it.
How many cells you are able to test in 24H?
Click to expand...


Yes please copy and improve it. I can charge approximately 200 cells per day. This varies a lot, especially when I forget to check for green lights! Please note this device is not testing the capacity of the cells. It only charges them in preparation for a self discharge check and acapacity testthat will follow.
 
Wow, that's one of the best charger setups I've seen in awhile. Very clean. I agree with Santiago, that's more of a sculpture ;)
That thing should hung on your wall even after you're done processing cells just for the sentimental value :cool:

Just curious, how long did it take to build it? There are a lot of precise bends and such. Also, what do you do for a living?
 
  • Like
Reactions: Rad
As Korishan says, hang it on a wall.. the very first framed wall art charger.. should be on display (Powered up !!!) !
Like the charger layout and ideas, very neat.
 
  • Like
Reactions: Rad
Thank you Korishan, haha yes it seems crazy that it will be used for a relatively short time after all the effort of design and construction. The actual build took about 7 hours but if you add all the time spent sourcing the parts and working out the design it could easily be a couple of days. I did some of the bends of the six main input bus bars in a vice before attaching them to the crossbars. I used an assembly jig to attach the TP boards to the battery holders. This ensured a consistent and reliable alignment. I am an electronics tech, work on various surveying related products.

completelycharged said:
As Korishan says, hang it on a wall.. the very first framed wall art charger.. should be on display (Powered up !!!) !
Like the charger layout and ideas, very neat.
Click to expand...

Thank you, maybe I should add one of those RGB LED case lighting kits, pimp it up a bit!
 
I am working on my mass discharger layout. I wired up a couple of the discharger boards as a testand noticed the resistors get quite (actually very109C)hot. They are 2 ohm 10 wattresistors, current is approximately 1.8 amps.So I have arranged the resistors above the board in an attempt to keep them away from the batteries and boards. This is what I am considering:


image_vwvspi.jpg


closer view:


image_udzdyv.jpg



Question, how can I get rid of all the discharger heat? Fans? Heatsink?
 
1.8A seems high for a 10W resistor. I discharged all of mine using that style units on 3.3 Ohm 10W resistors and was getting 1.1 when the battery was full and .9 when at 3V
 
jdeadman said:
1.8A seems high for a 10W resistor. I discharged all of mine using that style units on 3.3 Ohm 10W resistors and was getting 1.1 when the battery was full and .9 when at 3V
Click to expand...

Thanks, maybe I should get 3ohm resistors instead. Did your resistors get too hot to touch? How long did a discharge test take on a typical good 2600 mAhbattery?
 
The general Consensus is to discharge at 1A continuously. I have tried the continuous and the resistive dischargers and both work fine as long as you only use 1 method of testing to get relative data.
 
Yes, agree with jdeadman. You don't want to capacity test using both methods, Constant Current and Constant Voltage. This can cause a discrepancy in your results.

However, you could do this specifically and make two different strings. String A is only tested with CC, and String B is only tested with CV. Could turn out some interesting results in the end.
 
  • Like
Reactions: Rad
My mass discharge tester is working well. I have nowcompleted testing more than 2500 cells. Similar to my mass charger I used a piece of poly-carbonate as a base:


image_xkjzjm.jpg



I used ZB2L3 boards fitted with 2R7 ohm 25 wattresistors.


image_xfifev.jpg



The 5 volt power to theboards was connectedusing two parallel 1.7mm diameter copper busbars. I used the thicker copper wire for rigidity even though the current flow is quite small:


image_cxclwz.jpg



The cell holders and theresistors were also connected up using 1.7mm copper. I used a bending jig to get some consistency in the layout:


image_gflyxb.jpg
 
Impressive !
Your charging/testing rig is really a work of art.
 
You must log in or register to reply here.
Back
Top