Hard to say for sure, but I'd expect the range to be significantly reduced if the BMS senses low voltage on that segment and goes into shutdown. It may prevent a full charge on the other segments during charge also if one part comes up too early.
That would be a good outcome if the range limitation is not to extreme.
The good cells would last very long that way and the lower capacity cells would be protected from repeated damaging over-charge and over-discharge.
A bad outcome could be if the electronics just show me the battery warning symbol and the "Wrench of Doom", as another Vectrix rider termed it, i.e. the "maintenance required" telltale, and refuse to move the scooter an inch...
I hope to avoid this by placing all cells back into the scooter in fully charged state. There are basically no voltage differences obvious at full SOC and the voltage drop would gradually grow as the battery empties.
The incomplete charging of the good cells you mention might be a problem if I install a charger as described below. The ability to recharge low capacicty cells form the strong cells depends of course on the presence of "excess" charge in the good cells.
Not sure what you want to do with the power supply. First figure out what voltage/current you want.
I think I'll use what I already have: A 100-240V 50Hz to 15V DC at 5A switch-mode power supply from a dead laptop computer, and the IMAX B5 charger. The IMAX can accept input voltages from 11V to 18V and could therefore get powered straight from a string of 12 cells inside the 102 cell string; but that would introduce more imbalance.
So I hope to power the switch-mode supply from the 89 stronger cells in the pack, and the IMAX B5 gets powered by the switch-mode power supply and charges all (or some) of the 13 weaker cells. It can charge up to 14 NiMH cells in series and can charge at up to 5A (50W max).
One other thing, if the cells have vented a lot there's pretty much no way to restore their capacity. They will need to be replaced.
The bad cells improved about 12% to 18% with reconditioning, similar to the good cells. So the absolute difference in capacity is maybe even greater now than before reconditioning! But the overall range and power should be improved anyway.
I have come across a nugget regarding the venting: It might be possible to determine if and how much the cells have vented by weighing them!
I will tackle that in the near future and find out if the low capacity, slightly swollen cells are also lighter.
In regards to my safety concerns about exporting lethal voltages out of the battery safety housing: I now plan to place the 13 low capacity cells adjacent to each other and wire them up for voltage measurement during riding and charging as well as for individual or group charging and discharging/reconditioning.
The rest of the 102 cell string will be wired so that I can measure voltages of modules of 9 or 8 cells. I will also be able to recharge or discharge these modules of 8 or 9 cells after taking off the battery container cover, but the wires leaving the battery container from these cells will be originating from in-line 150kOhm resistors and therefore the maximum current leaving the safe container through those cables will be 1mA.
I am still not certain about how I will fuse the tap wires (coming from the cells to a junction inside the battery compartment.)
This affects the wires planned for the weak cells as well as the good (modules of) cells; the tap wires for both are probably going to be rated at 30A.
I have been unable to melt "20A Fusible Link Wire" at 40A so far. And several attempts to find good explanations on how to use Fusible Link Wire have yielded little. The length of the wire appears to be important, I guess it's because if it is too short then the heavier gauge wires soldered to it will act as a heat sink and prevent opening of the fusible link.
The CBA2 battery analyzer
is only capable of maintaining 40A discharge current for NiMH cells for a short time. It turns itself off after about 30s at 40A (from 2 of the NiM cells.) Supposedly it works better for Lithium cells.
After several fruitless attempts to blow the "Fusible Link" I attached a 20A blade type fuse instead. It blew in under one second (at 40A.)
So unless I get lucky somehow and find out more about fusible links, I'll have to manufacture a bunch of custom (holderless) fuses....
There is always a way if there is no other way!
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