Hey Endless Sphere,
I'm working on my first bike, and I've done something different with my battery that I'd like your opinions on! I disassembled a 20AH 48V battery, composed of 32 10AH prismatic LiFePO4 cells. They are now reconnected in my case in the same configuration (16 parallel groups).
The difference is that I've used all-wired connections (crimp-on eyelets) instead of busbars, in order to position all of the cells in my custom-built housing. The BMS circuits are connected this way too, with all of the circuits connected in the same order as in the factory battery configuration.
Can you see any problems with wiring the cells this way, instead of using busbars? I have used 10 gauge copper wire throughout. I have an eyelet bolted onto the each of the four cell posts in each group. Those four wires are then connected together using very strong press-in style blocks. My blocks have only four slots each, so I have connected the BMS wire in each group to one of the eyelets on the cell posts.
Pictures Attached. In the pictures, the orange wires are to the BMS. Red and blue are connections between the cells. They are colour coded by length, and not for any electrical reason. Before I installed the cells in the case, I also stretched cut sections of inner tube over the tops of the cells to prevent any shorting between cells, which are in close proximity to one another.
My number one concern in asking for your advice is safety of course!
This pack will power two Golden Motors MP4 hub motors.
Thanks!!
I'm working on my first bike, and I've done something different with my battery that I'd like your opinions on! I disassembled a 20AH 48V battery, composed of 32 10AH prismatic LiFePO4 cells. They are now reconnected in my case in the same configuration (16 parallel groups).
The difference is that I've used all-wired connections (crimp-on eyelets) instead of busbars, in order to position all of the cells in my custom-built housing. The BMS circuits are connected this way too, with all of the circuits connected in the same order as in the factory battery configuration.
Can you see any problems with wiring the cells this way, instead of using busbars? I have used 10 gauge copper wire throughout. I have an eyelet bolted onto the each of the four cell posts in each group. Those four wires are then connected together using very strong press-in style blocks. My blocks have only four slots each, so I have connected the BMS wire in each group to one of the eyelets on the cell posts.
Pictures Attached. In the pictures, the orange wires are to the BMS. Red and blue are connections between the cells. They are colour coded by length, and not for any electrical reason. Before I installed the cells in the case, I also stretched cut sections of inner tube over the tops of the cells to prevent any shorting between cells, which are in close proximity to one another.
My number one concern in asking for your advice is safety of course!
This pack will power two Golden Motors MP4 hub motors.
Thanks!!