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Wolf's PowIRwall
#1
Brick 
It is time!
The journey is about to begin its second phase and I will record the progress here.
If you are an avid reader of this board you already know that I have been collecting sorting and testing 18650 cells for about 8 month now.
I already have a functional Pb based system up and running and it is working very well for what it was designed to do. Supplement my electrical usage from the grid by about ½ to ¾. That has been successful.

This is the next step in the evolution of the design. To take a throwaway product extract the best cells out of them and reuse these cells to store and recover energy produced by a totally green energy source. "The Sun".

I would have started this thread sooner but I had a small setback with my cells as I was initially going to go by pre IR measurement of the cell as the criteria of acceptance into the PowIRwall build, but changed my mind to go with post 30 day voltage and IR checks for the acceptable IR range. That decision set me back about 162 cells from my goal of 2856 cells. That deficiency has been made up and knowing what I know about IR the cells that are waiting for their 30 day check are more than likely going to make the grade. So here I am to start sharing my journey to the 492Ah, 27.5kWh PowIRwall.

In this journey I have discovered and learned to use many new tools among them  Excel, Ubuntu, Influxdb, Grafana, Microprocessors, Arduino IDE, Sensors and many more things. Notwithstanding the collective minds of this board and their guidance and influence. I could not have made it this far without you. Thank you!
My Cell count goal sheet.


So without further adieu the prototype of soon to be 14 packs of 204 cells each.
This is just a prototype to experiment with for buss bars, fuses and construction.

So stay tuned and experience the journey with me.

Wolf
Nemo, Sean, chuckp And 4 others like this post
If 18 X 650 = 2200+mAh then we have power! 
May all your Cells have an IR of 75mΩ or less Smile
Last count as of 01/23/2020
Total Number of Cells Recorded and processed                 6263
Total Cells required for PowIRwall  14S80P+1                  1200
Total Cells ≥2200mAh, ≥80%, ≥35mΩ, ≤75mΩ, ≥4.12V   3286
For Info Google Drive
Not your average Wolf       
            Cool
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#2
(08-07-2019, 12:59 PM)Wolf Wrote: It is time!

So stay tuned and experience the journey with me.

I.R. ... yeah. Succes! I will follow your steps.
Great timing. Today started a first small project marked ' dasPil #1 '

4s24p - 96 cells - avg 2000 mAh   -> learning attempt with weakest kept cells
4x 4.1 V -> 0.78 kWh
3x 2.5 mm² copper twisted busbar - 2A fuse/positive pole
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#3
Congratulations! Look forward to following your progress.
Oz18650 likes this post
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#4
I have enjoyed your contributions so far and I am looking forward to the next part of your project.
Good luck with it.
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#5
Yes...Wolfman, finally! congrats!

Again i will keep a close eye on you.

Best and thanks for your effort.
chuckp and Oz18650 like this post
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#6
Nice going Wolf! Congrats on making it to Phase 2! I love the cell arrangement, your attention to detail is second-to-none.
Formerly known as Dallski
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#7
Hello All,

After a large setback in time as my dog Houdini got very sick ( the vet said he had 3 paws in the grave and 1 on a banana peel ) and after considerable expense I am back to the building project. Houdini is doing well but has to have insulin twice a day.

So after careful consideration on what and how to build I have decided to go with 14S80P as the initial pack.
I believe a smaller pack size (I was considering a 204 pack) is far more serviceable than the monstrosity I was planning to build.
Easier to handle and easier to diagnose if something goes bad.

As you all know I have over 6000 cells documented in my spreadsheet so I did some filtering with the results and decided to 
narrow the field. I decided to go with ≥ 85% SOH, 40mΩ to 55mΩ, 2250mAh to 2750mAh, and 4.1V after 60 day test and up.
I have many cells with a great SOH ≥ 80% with IR <40mΩ  or >55mΩ  with which I will build separate packs. The idea is to keep the IR of each pack within a reasonable proximity.

As you all know I did an extensive testing scenario with how cells work in parallel and decided to keep the mΩ range and mAh range as close together as possible. These parameters resulted in 1556 cells meeting the criteria. I will be building 14 +1 as to have a spare just in case.

I am using Nemo's Repackr and am measuring each cell as I check it off and the mΩ has changed very little if any on these cells. mostly to the + by 1 or 2 mΩ. The cells that have a V below 4.1 or a substantial (>3mΩ) increase  will be set aside.

The plan is to use the common 18650 cell holders in a  5X4 X 4 configuration and the Battery Hookup  cell level fuses on both the + and - sides.
I will be using a KWeld which I really like as I seem to have it dialed in just right. (picture is a 4S6P build for my covered utility trailer)

   

Once I get all the cells checked out and the packs populated pictures of the process will be posted.

Till later

Wolf

PS: My Houdini  has a go fund me page if you are interested in helping my buddy out. https://www.gofundme.com/f/help-my-houdini
Houdini would thank you.
If 18 X 650 = 2200+mAh then we have power! 
May all your Cells have an IR of 75mΩ or less Smile
Last count as of 01/23/2020
Total Number of Cells Recorded and processed                 6263
Total Cells required for PowIRwall  14S80P+1                  1200
Total Cells ≥2200mAh, ≥80%, ≥35mΩ, ≤75mΩ, ≥4.12V   3286
For Info Google Drive
Not your average Wolf       
            Cool
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#8
Hi all. Progress report.

OK I have sorted all the cells of which 1207 made the grade.


I have entered them into Nemos RePackr with these results.


I'm pretty happy with that! All cells are ≥ 2250mAh and ≤2750mAh. Also IR is ≥40mΩ and ≤55mΩ. Voltage of course is ≥4.1V.

Layed out the 15 holders


And started to populate them. Rechecking each cell for proper IR and V.


That's it for now.

Wolf
hbpowerwall likes this post
If 18 X 650 = 2200+mAh then we have power! 
May all your Cells have an IR of 75mΩ or less Smile
Last count as of 01/23/2020
Total Number of Cells Recorded and processed                 6263
Total Cells required for PowIRwall  14S80P+1                  1200
Total Cells ≥2200mAh, ≥80%, ≥35mΩ, ≤75mΩ, ≥4.12V   3286
For Info Google Drive
Not your average Wolf       
            Cool
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#9
Update

861 to go.


Wolf
If 18 X 650 = 2200+mAh then we have power! 
May all your Cells have an IR of 75mΩ or less Smile
Last count as of 01/23/2020
Total Number of Cells Recorded and processed                 6263
Total Cells required for PowIRwall  14S80P+1                  1200
Total Cells ≥2200mAh, ≥80%, ≥35mΩ, ≤75mΩ, ≥4.12V   3286
For Info Google Drive
Not your average Wolf       
            Cool
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#10
Update

So I now have all the holders populated.
I was almost there with this picture.


Then came the question to re-wrap or not.
Since I had devoted a year to these cells I decided what's another couple of days to re-wrap.
I already had a bunch of wraps from 18650ed so I decided to try to go with the closest color of the cells original wrap.
I kinda like the color difference.
Turns out it was a good idea. As I removed the wrap of one cell I took the insulator off and lo and behold underneath was a bunch of what looked like rust. Now maybe it was coffee from a spill but it looked suspicious so I replaced the cell with one of the same value.
Better safe than sorry.

Plus it gave me one last chance to test V and IR before totally committing the cells to the pack.

Lined up ready for the wrap.


Now lined up for the shrink.


And the completed pack. only 14 more to go. Smile


Wolf
If 18 X 650 = 2200+mAh then we have power! 
May all your Cells have an IR of 75mΩ or less Smile
Last count as of 01/23/2020
Total Number of Cells Recorded and processed                 6263
Total Cells required for PowIRwall  14S80P+1                  1200
Total Cells ≥2200mAh, ≥80%, ≥35mΩ, ≤75mΩ, ≥4.12V   3286
For Info Google Drive
Not your average Wolf       
            Cool
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