Looking for some constructive criticism on this modular pack design idea I would like to follow through with my build. If the idea is bad and I've missed something important then please state so.
Some background information. The attached design is a 2x3 format for 1s6p, this is just a quick design, the final intention is packs in 2x10 format for 1s20p. Then they would all be series'd together to form the overall 28s20p pack. Intention is to use VTC6 cells but got offered some VTC5As for a steal. Entire pack will peak at 700A for 10s boost which should be fine. I also intend to individually cell fuse using some fuse wire, size is yet to be decided.
Bike intention use is off-road enduro and so therefore the battery pack won't be pushed to the limits often.
I'll include the pictures now and then an explanation afterwards.
So on the left you have the "holder". On the right you have the copper busbar. The copper busbar will sit inside the holder with the 18650 cells on top.
The busbar is 1mm thick and is always 24mm wide. Reason for this busbar placement and design is to help with structural rigidity and heat dissipation. I've calculated that this busbar should be able to handle 150A continuously with a 30c rise. I may double the busbar thickness to 2mm to essentially double the continuous rating.
This is essentially how the busbar and cells will sit inside, you will have to imagine the same busbar and holder being on the other side of the cells.
Here is the underside. The reason for those empty circles it to leave the spot-welding of the fuse-wire till last as well as to leave it visible to regularly check them.
Things I'm already thinking of changing:
- Doubling busbar thickness to go from 150A to 300A continuous capability.
- Making the holder itself nearly twice as high as it currently is. Currently only holds about 5mm of the cells.
Edit:
Forgot to mention that the end of the copper busbar is essentially the positive/negative terminal in which some busbars would be used to connect all of the modules together in series.
Some background information. The attached design is a 2x3 format for 1s6p, this is just a quick design, the final intention is packs in 2x10 format for 1s20p. Then they would all be series'd together to form the overall 28s20p pack. Intention is to use VTC6 cells but got offered some VTC5As for a steal. Entire pack will peak at 700A for 10s boost which should be fine. I also intend to individually cell fuse using some fuse wire, size is yet to be decided.
Bike intention use is off-road enduro and so therefore the battery pack won't be pushed to the limits often.
I'll include the pictures now and then an explanation afterwards.
So on the left you have the "holder". On the right you have the copper busbar. The copper busbar will sit inside the holder with the 18650 cells on top.
The busbar is 1mm thick and is always 24mm wide. Reason for this busbar placement and design is to help with structural rigidity and heat dissipation. I've calculated that this busbar should be able to handle 150A continuously with a 30c rise. I may double the busbar thickness to 2mm to essentially double the continuous rating.
This is essentially how the busbar and cells will sit inside, you will have to imagine the same busbar and holder being on the other side of the cells.
Here is the underside. The reason for those empty circles it to leave the spot-welding of the fuse-wire till last as well as to leave it visible to regularly check them.
Things I'm already thinking of changing:
- Doubling busbar thickness to go from 150A to 300A continuous capability.
- Making the holder itself nearly twice as high as it currently is. Currently only holds about 5mm of the cells.
Edit:
Forgot to mention that the end of the copper busbar is essentially the positive/negative terminal in which some busbars would be used to connect all of the modules together in series.