DIY assembly kit for 18650 without spot welding/Soldering

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reptilian   10 mW

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Re: DIY assembly kit for 18650 without spot welding/Solderin

Post by reptilian » Apr 17 2017 5:02pm

VRUZEND wrote:Hello Everyone,

A very kind client from Germany, Joris, sent me a mail as to how he is going to use the kit for powerwall applications for his RV. He has even connected the fuse wires. Do have a look. Might help! He is yet to try it out though.
I was planning to do an instructable on the power wall I am planning to make vor my RV.
I had some thoughts about the tesla style fuses incorporated into the kit. I came up with two versions.
In both versions the fuse wire will melt at about 7 amps. So the load to the battery pack should be way less. I am planning to make a 1kWh 7s power pack for my RV. The estimated max load should be around 600W peak. This means about 25A to 20 cells in parallel, which is about 1,25A per cell. Even if some fuses blow due to internal shortening the fuses will not blow due to the load (hopefully...)
I'm hoping to do this same thing. I can't seem to find any information on what gauge of wire to use though

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Re: DIY assembly kit for 18650 without spot welding/Solderin

Post by 999zip999 » Apr 17 2017 6:25pm

What shut up. Make a pop lever. Diy. Wood or plastic . Next he wearing the wrong shoes. Michael is it the shoes is it ?

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Marin   1 kW

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Re: DIY assembly kit for 18650 without spot welding/Solderin

Post by Marin » Apr 17 2017 6:40pm

Got 4 packs of these today they look real good. 86mm with a cell installed.
Image

Looks like room for 18 x 8 of these blocks will fit my Luna cargo battery box.
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tomjasz   10 GW

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Re: DIY assembly kit for 18650 without spot welding/Solderin

Post by tomjasz » Apr 17 2017 11:02pm

Works for me...
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Thanks Justin_le we're here thanks to you. All the best to the mods for their tireless work keeping it on an even keel.

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tomjasz   10 GW

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Re: DIY assembly kit for 18650 without spot welding/Solderin

Post by tomjasz » Apr 17 2017 11:02pm

Will secure with loctite 290 wicking green.
Thanks Justin_le we're here thanks to you. All the best to the mods for their tireless work keeping it on an even keel.

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Re: DIY assembly kit for 18650 without spot welding/Solderin

Post by VRUZEND » Apr 18 2017 12:32am

Marin wrote:Got 4 packs of these today they look real good. 86mm with a cell installed.
Image

Looks like room for 18 x 8 of these blocks will fit my Luna cargo battery box.
Thank you for the post and the feedback.

May I kindly know your name. It will be a lot easier for me to follow up.

Thank you.

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Re: DIY assembly kit for 18650 without spot welding/Solderin

Post by VRUZEND » Apr 18 2017 1:04am

rumme wrote:Looks like a solid product so far. Once the packs are assembled, and then hammered together for a very tight friction fit , how difficult is it, to get the packs apart ?

Just wondering if it is a bit difficult , maybe there could be a improvement on that end of the spectrum if a person needs to disassemble the plastic casings from the batteries, to repair/replace a particular cell .
To be honest it is a bit of a hassle. But the easiest way is to unscrew the bus bars from one side. Then pass a wooden stick between the batteries and leverage upwards to remove the block. Do it a few times from different angles and it will come of easy. With practice it becomes even more simpler.

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fechter   100 GW

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Re: DIY assembly kit for 18650 without spot welding/Solderin

Post by fechter » Apr 18 2017 8:06am

tomjasz wrote:Will secure with loctite 290 wicking green.
That stuff is incredibly strong. You may not be able to take it apart without damaging something.

It seems like it might be nice to have 3 or 4 hole interconnecting bars. Maybe long strips with a bunch of holes you can cut off to any length.
"One test is worth a thousand opinions"

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emaayan   100 kW

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Re: DIY assembly kit for 18650 without spot welding/Solderin

Post by emaayan » Apr 18 2017 8:58am

hey vruzend
how about these tools for a solution to a "other side popping" problem ?

http://www.irwin.com/tools/clamps/xp600 ... -spreaders
Trek 7.7 fx, 22.5" frame, 38x700c,10 gears.
ecospeed mid drive 1300 watt engine, max speed 45 kph.
battery1: 48v 14 ah, frame mounted battery, range 40km.
battery2(spare) 52v 10ah frame mounted bag, range, 30km.

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Re: DIY assembly kit for 18650 without spot welding/Solderin

Post by 999zip999 » Apr 18 2017 12:52pm

Im interested in how many amps a 20s 4p setup can handle with high quality cells. I see these as mid level options like 40amps. But how about 80amps ? Who going to test the limits ?

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emaayan   100 kW

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Re: DIY assembly kit for 18650 without spot welding/Solderin

Post by emaayan » Apr 18 2017 1:02pm

40 amps on 4p? considering that each conductor can pass up to 3.5 amp maybe 4, how did you arrive to 40? (unless you didn't mean in this case?)
Trek 7.7 fx, 22.5" frame, 38x700c,10 gears.
ecospeed mid drive 1300 watt engine, max speed 45 kph.
battery1: 48v 14 ah, frame mounted battery, range 40km.
battery2(spare) 52v 10ah frame mounted bag, range, 30km.

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parabellum   10 MW

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Re: DIY assembly kit for 18650 without spot welding/Solderin

Post by parabellum » Apr 18 2017 1:15pm

999zip999 wrote:Im interested in how many amps a 20s 4p setup can handle with high quality cells. I see these as mid level options like 40amps. But how about 80amps ? Who going to test the limits ?
I will sacrifice some caps and make them glow, but they are still on the way for now

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Re: DIY assembly kit for 18650 without spot welding/Solderin

Post by tomjasz » Apr 18 2017 4:30pm

fechter wrote:
tomjasz wrote:Will secure with loctite 290 wicking green.
That stuff is incredibly strong. You may not be able to take it apart without damaging something.

It seems like it might be nice to have 3 or 4 hole interconnecting bars. Maybe long strips with a bunch of holes you can cut off to any length.
There are several "green" versions. The 293 and 600 series are all green an are extremely strong. I use the 290 very often and it's not, IME, as strong as the blue. I'm wondering if you could confirm which you had experience with? I will use due diligence and test first. Thanks for the warning.
Thanks Justin_le we're here thanks to you. All the best to the mods for their tireless work keeping it on an even keel.

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Re: DIY assembly kit for 18650 without spot welding/Solderin

Post by hemo » Apr 18 2017 5:45pm

tomjasz wrote:Works for me...
Tomasz out of interest what is the overall dimension of your 7s 3p pack ?

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Re: DIY assembly kit for 18650 without spot welding/Solderin

Post by VRUZEND » Apr 19 2017 2:17pm

999zip999 wrote:Im interested in how many amps a 20s 4p setup can handle with high quality cells. I see these as mid level options like 40amps. But how about 80amps ? Who going to test the limits ?
I had made two packs of 13s4p each. LG HE2 cells. Connected the 2 packs in parallel. That makes it 160 Amps. It worked fine for me.

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Re: DIY assembly kit for 18650 without spot welding/Solderin

Post by VRUZEND » Apr 19 2017 2:20pm

emaayan wrote:hey vruzend
how about these tools for a solution to a "other side popping" problem ?

http://www.irwin.com/tools/clamps/xp600 ... -spreaders
If you could maybe extend its mouth a bit to go all the way inside the pack in between the cells, then yes this thing will work. Else it will just dislodge the caps on the sides.

A wooden stick works just fine though, in my opinion. Have not tried any of this.

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fechter   100 GW

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Re: DIY assembly kit for 18650 without spot welding/Solderin

Post by fechter » Apr 19 2017 2:26pm

tomjasz wrote: I'm wondering if you could confirm which you had experience with? I will use due diligence and test first. Thanks for the warning.
I just checked the bottle. 294 wicking grade.
I call it wicked grade. I've had screws break the heads off after using it.

At test would be the safe thing to do.
"One test is worth a thousand opinions"

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mlt34   100 kW

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Re: DIY assembly kit for 18650 without spot welding/Solderin

Post by mlt34 » Apr 19 2017 6:10pm

emaayan wrote:hey vruzend
how about these tools for a solution to a "other side popping" problem ?

http://www.irwin.com/tools/clamps/xp600 ... -spreaders
The problem with most of these spreaders is that the minimum jaw distance is still pretty big, so I'm not sure it will fit. But I have one of these style spreaders so I'll give it a test.
Are you planning your first electric bicycle conversion? I wrote a book that teaches beginners everything they need to know about building their own ebike.
Then I wrote the book (literally) on building custom lithium batteries.
I also write for EbikeSchool.com, a site that does mainly how-to style articles and other informational write-ups. Check out our youtube channel for great how-to battery building videos.
Lastly, I run www.Vruzend.com, which sells solderless 18650 battery kits, 18650 cells, li-ion chargers, BMSs and more!

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Re: DIY assembly kit for 18650 without spot welding/Solderin

Post by mlt34 » Apr 19 2017 6:11pm

fechter wrote:
tomjasz wrote: I'm wondering if you could confirm which you had experience with? I will use due diligence and test first. Thanks for the warning.
I just checked the bottle. 294 wicking grade.
I call it wicked grade. I've had screws break the heads off after using it.

At test would be the safe thing to do.
I worry a little bit about the effect of the loctite on current carrying capacity. The stainless steel threads in the post and nut are actually transferring current, in addition to the surface of the bus bar. Adding a layer of loctite may increase the resistance. It would be interesting to test this empirically.
Are you planning your first electric bicycle conversion? I wrote a book that teaches beginners everything they need to know about building their own ebike.
Then I wrote the book (literally) on building custom lithium batteries.
I also write for EbikeSchool.com, a site that does mainly how-to style articles and other informational write-ups. Check out our youtube channel for great how-to battery building videos.
Lastly, I run www.Vruzend.com, which sells solderless 18650 battery kits, 18650 cells, li-ion chargers, BMSs and more!

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emaayan   100 kW

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Re: DIY assembly kit for 18650 without spot welding/Solderin

Post by emaayan » Apr 19 2017 11:48pm

mlt34 wrote:
emaayan wrote:hey vruzend
how about these tools for a solution to a "other side popping" problem ?

http://www.irwin.com/tools/clamps/xp600 ... -spreaders
The problem with most of these spreaders is that the minimum jaw distance is still pretty big, so I'm not sure it will fit. But I have one of these style spreaders so I'll give it a test.
not sure we are talking about the same thing here, my aim was the eliminate the possibility that in a big pack if you hammer one side , the other side will pop, if you place 1 or 2 clamps on one side, especially with aluminum board under them, and clamp it to the desk. i don't think it will move.
Trek 7.7 fx, 22.5" frame, 38x700c,10 gears.
ecospeed mid drive 1300 watt engine, max speed 45 kph.
battery1: 48v 14 ah, frame mounted battery, range 40km.
battery2(spare) 52v 10ah frame mounted bag, range, 30km.

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tomjasz   10 GW

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Re: DIY assembly kit for 18650 without spot welding/Solderin

Post by tomjasz » Apr 20 2017 4:33pm

fechter wrote:
tomjasz wrote: I'm wondering if you could confirm which you had experience with? I will use due diligence and test first. Thanks for the warning.
I just checked the bottle. 294 wicking grade.
I call it wicked grade. I've had screws break the heads off after using it.

At test would be the safe thing to do.
290 is what i used and is recommended for electronic parts.while the sheet does say heat for disasembly it is easier than with blue. IME


After nearly an hour of searching I can come up with no values for resistance of conductivity. Only the "Applications include...
fechter wrote:
tomjasz wrote: I'm wondering if you could confirm which you had experience with? I will use due diligence and test first. Thanks for the warning.
I just checked the bottle. 294 wicking grade.
I call it wicked grade. I've had screws break the heads off after using it.

At test would be the safe thing to do.
290 is what i used and is recommended for electronic parts.while the sheet does say heat for disasembly it is easier than with blue. IME

"Applications include ....instrumentation screws, electrical connectors...." Instrumentation screws would lead me to think that it would release without high heat and to much torque given the sensitivity of both, and the likely hood that an electrical connector would have some sort of power? Or is that taking to big of a leap.

"Applications include instrumentation screws, electrical connectors and set screws and also seals porosities in welds and metal parts."
Heat in this context i think is a couple of seconds with a solder iron.
Thanks Justin_le we're here thanks to you. All the best to the mods for their tireless work keeping it on an even keel.

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tomjasz   10 GW

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Re: DIY assembly kit for 18650 without spot welding/Solderin

Post by tomjasz » Apr 20 2017 4:40pm

hemo wrote:
tomjasz wrote:Works for me...
Tomasz out of interest what is the overall dimension of your 7s 3p pack ?
67MM X 157MM
2 19/32 X 6 3/16
Thanks Justin_le we're here thanks to you. All the best to the mods for their tireless work keeping it on an even keel.

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Ptit_Philou   10 mW

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Re: DIY assembly kit for 18650 without spot welding/Solderin

Post by Ptit_Philou » Apr 21 2017 10:43am

I have only one word for this kit : JUGAAD ! :-)
I have a spot welder and I dont need this kit for now but I had a lot of dreams about it before :-)
Nice job Indians, go on ! ;-)

https://en.wikipedia.org/wiki/Jugaad
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Ptit_Philou   10 mW

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Re: DIY assembly kit for 18650 without spot welding/Solderin

Post by Ptit_Philou » Apr 21 2017 11:59am

Please, what is the weight of elements for one cell (2 holders, 1 contact and 1 nut)?
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tomjasz   10 GW

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Re: DIY assembly kit for 18650 without spot welding/Solderin

Post by tomjasz » Apr 21 2017 8:03pm

Ptit_Philou wrote:Please, what is the weight of elements for one cell (2 holders, 1 contact and 1 nut)?
An entire box, cardboard and enought ports for 100 cell just over 700 grams.
Thanks Justin_le we're here thanks to you. All the best to the mods for their tireless work keeping it on an even keel.

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