PedalingBiped
100 W
I was inspired by Leamcorp's thread "Building Cylindrical battery pack for Dummy!"
http://endless-sphere.com/forums/viewtopic.php?f=14&t=17912
I got a hold Dr Bass and ordered Makita packs.
A week later he bragged on the forum that he ordered A1 batteries.
WHATS UP DOC! (I've always wanted to say that in context :lol: "
So after making many mistakes and taking wrong paths, I am past plan b or even plan z. So here's the end result (almost)
I took 2 straps 12 inches long and put 15 AA clips on each of them.
I worked free hand at first then I made a jig. Screwed the straps loosely on jig, then I laid the cells down. I then tightened the screws down. This is nesearry or else the straps will twist when you tighten the cable ties.
the Jig
A 'flat' made up in the jig
A close up of a 'flat'
I then slid the ends of the flats down the battery pack frame
This is a 12s 15p or 22.5 AH at 48V
I wasn't happy with this pack. It was tall and fell over too easy. Plus I wanted a more elegant way of connecting the levels together. In the picture you can see the bare wire curved in a 's' and screwed in with the strap. I was trying to figure out how to use a mechanical lug.
I am a truck driver and many of the loading docks I back up to don't have lines painted and in the dark and rain I don't have a reference and when I get out and look I'm at a 45 degree angle (embarrassing) I came up with an idea of putting car flood lights on my battery pack and when I swung the trailer doors open, I could turn on the light.
but the pack was unstable and I needed to lay it down and only have 12v.
but then I started thinking about pack laying down and came up with this idea.
Make a box with the straps on the inside and let the batteries touch each other to make a contact.
I made slots in the sides of the box 1/8 inch from the ends and slid the straps down.
This is only 1 layer. 4s 8p When I add another it will be 4s 16p in each box, 3 total for 12 s 16p
A view from the end.
This way is still a work in progress. I left the first battery pack in an unheated detached garage and with this freezing weather, when I first made the boxes and put cells in them, I felt heat.
Started measuring the voltage on every cell. Came away with 15 that were reversed, zero or very low. I hope I didn't shorten the life expectancy of the other cells too.
http://endless-sphere.com/forums/viewtopic.php?f=14&t=17912
I got a hold Dr Bass and ordered Makita packs.
A week later he bragged on the forum that he ordered A1 batteries.
WHATS UP DOC! (I've always wanted to say that in context :lol: "
So after making many mistakes and taking wrong paths, I am past plan b or even plan z. So here's the end result (almost)
I took 2 straps 12 inches long and put 15 AA clips on each of them.
I worked free hand at first then I made a jig. Screwed the straps loosely on jig, then I laid the cells down. I then tightened the screws down. This is nesearry or else the straps will twist when you tighten the cable ties.
the Jig
A 'flat' made up in the jig
A close up of a 'flat'
I then slid the ends of the flats down the battery pack frame
This is a 12s 15p or 22.5 AH at 48V
I wasn't happy with this pack. It was tall and fell over too easy. Plus I wanted a more elegant way of connecting the levels together. In the picture you can see the bare wire curved in a 's' and screwed in with the strap. I was trying to figure out how to use a mechanical lug.
I am a truck driver and many of the loading docks I back up to don't have lines painted and in the dark and rain I don't have a reference and when I get out and look I'm at a 45 degree angle (embarrassing) I came up with an idea of putting car flood lights on my battery pack and when I swung the trailer doors open, I could turn on the light.
but the pack was unstable and I needed to lay it down and only have 12v.
but then I started thinking about pack laying down and came up with this idea.
Make a box with the straps on the inside and let the batteries touch each other to make a contact.
I made slots in the sides of the box 1/8 inch from the ends and slid the straps down.
This is only 1 layer. 4s 8p When I add another it will be 4s 16p in each box, 3 total for 12 s 16p
A view from the end.
This way is still a work in progress. I left the first battery pack in an unheated detached garage and with this freezing weather, when I first made the boxes and put cells in them, I felt heat.
Started measuring the voltage on every cell. Came away with 15 that were reversed, zero or very low. I hope I didn't shorten the life expectancy of the other cells too.
