Same Batt Channel... Same Batt time...
I've never posted on this forum before! I usually come here to search for info on technical stuff that I need help with.
There are some really smart and helpful guys here... Thank you!
My main build is found on ElMoto.net ... Basically, I am building my 3rd version of an electric motorcycle conversion.
I'm almost done with it. I'm at the most technical, difficult, and important part of the build: the battery pack!
I've searched this forum and can find no real helpful threads on what I'm doing, so I figured I'd start a thread that might help someone else, and maybe in the process get redirected to the thread that my search couldn't find.
I'm going from 11 48aHr Nissan Leaf modules (just under 4.5kW) to 24 Dow Kokam Xalt 75aHr cells (just under 7.5kW)...
As you most likely know, the Nissan Leaf pouches are nice and neatly packed in big sardine cans and really easy to configure and build a pack. The DKX's are bare pouches and need extra attention to configuring/completing the pack build.
My motorcycle has a Motenergy ME1616 water cooled 3 phase axial flux motor mounted to the frame at 3 points. The rear attaches to the swingarm pivot bolt, the bottom on the bottom frame rail, and the front to the Al battery enclosure that is a stressed member of the frame. I just finished fabrication of this and am ready to start assembly of the pouches.
I will post some pics as I go. I will be taking my time with this. I don't want to get fried or start any garage fires! And I definitely don't want to damage any of these expensive cells.
This is my plan, and I hope by posting it here, I can get some helpful suggestions by you more experienced builders.
Since the box is constructed out of Al, I must be sure that there is no arcing to the box. Because of the cell's size and limited space available for them, I had to build the box in 3 compartments of 8 pouches each. This is a ~100v pack of 1p24s. These cells could only be mounted vertically with the tabs facing towards the top. The lids are constructed of nonconducting 1/4" Lexan acrylic. I have some dense 1/4" silicone foam pad to line the box with, to protect the cells from road bumps and vibrations, as well as keeping the Al box electrically isolated. The person I bought the cells from has already stuck 1/4" dense rubber foam tape all around the pouch outside seams on both sides of each pouch. I had originally thought of putting pressure on the cell stack with compressed air by utilizing a modified mountain bike inner tube. The seller of these cells told me that he got them direct from XALT and spoke extensively with the engineer about compressing the stack and temperature management for use in a motorcycle conversion. He came to the conclusion that heat wouldn't be much of an issue and the compression could be easily done with dense foam slightly compressed. I couldn't get a more accurate description of how much pressure was needed than that. So I planned on ditching the compressed air idea in favor of just using dense foam rubber for compression.
The supplier that I bought my motor and Sevcon controller from suggested that I place thin Al sheet in between each pouch to help dissipate heat away from the pack. I have some really thin rubber sheet material that the person included in the sale of the battery cells to me. I'm thinking that since the box is Al, which is an awesome heat sink, and the XALT engineer said heat isn't a real problem with these cells, that I would put a thin Al sheet divider in between each pair of cells, so that each cell will have one side facing and sharing a heat sink with one side of another cell, separated by a piece of the thin rubber, keeping each cell isolated from vibration.
That's my plan in a nutshell!
I've never posted on this forum before! I usually come here to search for info on technical stuff that I need help with.
There are some really smart and helpful guys here... Thank you!
My main build is found on ElMoto.net ... Basically, I am building my 3rd version of an electric motorcycle conversion.
I'm almost done with it. I'm at the most technical, difficult, and important part of the build: the battery pack!
I've searched this forum and can find no real helpful threads on what I'm doing, so I figured I'd start a thread that might help someone else, and maybe in the process get redirected to the thread that my search couldn't find.
I'm going from 11 48aHr Nissan Leaf modules (just under 4.5kW) to 24 Dow Kokam Xalt 75aHr cells (just under 7.5kW)...
As you most likely know, the Nissan Leaf pouches are nice and neatly packed in big sardine cans and really easy to configure and build a pack. The DKX's are bare pouches and need extra attention to configuring/completing the pack build.
My motorcycle has a Motenergy ME1616 water cooled 3 phase axial flux motor mounted to the frame at 3 points. The rear attaches to the swingarm pivot bolt, the bottom on the bottom frame rail, and the front to the Al battery enclosure that is a stressed member of the frame. I just finished fabrication of this and am ready to start assembly of the pouches.
I will post some pics as I go. I will be taking my time with this. I don't want to get fried or start any garage fires! And I definitely don't want to damage any of these expensive cells.
This is my plan, and I hope by posting it here, I can get some helpful suggestions by you more experienced builders.
Since the box is constructed out of Al, I must be sure that there is no arcing to the box. Because of the cell's size and limited space available for them, I had to build the box in 3 compartments of 8 pouches each. This is a ~100v pack of 1p24s. These cells could only be mounted vertically with the tabs facing towards the top. The lids are constructed of nonconducting 1/4" Lexan acrylic. I have some dense 1/4" silicone foam pad to line the box with, to protect the cells from road bumps and vibrations, as well as keeping the Al box electrically isolated. The person I bought the cells from has already stuck 1/4" dense rubber foam tape all around the pouch outside seams on both sides of each pouch. I had originally thought of putting pressure on the cell stack with compressed air by utilizing a modified mountain bike inner tube. The seller of these cells told me that he got them direct from XALT and spoke extensively with the engineer about compressing the stack and temperature management for use in a motorcycle conversion. He came to the conclusion that heat wouldn't be much of an issue and the compression could be easily done with dense foam slightly compressed. I couldn't get a more accurate description of how much pressure was needed than that. So I planned on ditching the compressed air idea in favor of just using dense foam rubber for compression.
The supplier that I bought my motor and Sevcon controller from suggested that I place thin Al sheet in between each pouch to help dissipate heat away from the pack. I have some really thin rubber sheet material that the person included in the sale of the battery cells to me. I'm thinking that since the box is Al, which is an awesome heat sink, and the XALT engineer said heat isn't a real problem with these cells, that I would put a thin Al sheet divider in between each pair of cells, so that each cell will have one side facing and sharing a heat sink with one side of another cell, separated by a piece of the thin rubber, keeping each cell isolated from vibration.
That's my plan in a nutshell!
