deVries
100 kW
Since this topic of safety and battery wiring-connection procedures is not thoroughly covered in its own thread, I'm starting this thread using my battery design & reconfiguration problem for charging as an example.
I know there are more sophisticated methods to use diodes, relays, or switches to reconfigure a battery safely, but can it be done simply with plugs and jumper-plugs too? For example, I want to be able to simply reconfigure a 60v 4p8s x 2s A123 battery into a 4p16p 3.6v battery for charging.
Using connection techniques for creating a battery for simple reconfiguration...
Basics:
1) When connecting many parallel packs in series, to create the final battery in the first place, there certainly is a safe series & a safe parallel wiring-connections procedure to do this. What are these safe methods to prevent shorting and other mishaps?
For example, is there a proper sequence for connecting the parallel sub-packs or cell-groups... does one connect all the positives together first before connecting all the negatives together... or is it just the reverse? Or, flip a coin because either way is safe?
What about connecting in series all the parallel packs?
2) Specific example to convert a 60v battery into a charging reconfiguration of 3.6v and back to its original configuration of 60v safely using plugging or plug-jumper techniques:
A newbie problem for any experienced battery maker... Using plugs or jumper-plug techniques to enable a battery to be quickly reconfigured for charging or other voltage-amp packaging. In other words, how does one create a completed battery and wire the series connections safely, in sequence, to connect, for example, to all the 4 celled parallel batteries in 16s (packaged as 4p8s x 2s), and, then have the option, for example, to covert it into a massive 3.6v 64 cell battery of 16-4p-cells in parallel? (In my case I will have 4p8s x 2s sub-packs for the series battery and want to convert it to parallel mode.) AND... I need to make it easy to disconnect & reconnect safely for these two different configurations using plug-in or jumper-plugs for quick reconfiguration that is still safe.
I think I should be able to avoid using switches or relays with some smart plug design techniques for unplugging and/or jumper-plug the series/parallel connections and reconnecting.
Any ideas?
I know there are more sophisticated methods to use diodes, relays, or switches to reconfigure a battery safely, but can it be done simply with plugs and jumper-plugs too? For example, I want to be able to simply reconfigure a 60v 4p8s x 2s A123 battery into a 4p16p 3.6v battery for charging.
Using connection techniques for creating a battery for simple reconfiguration...
Basics:
1) When connecting many parallel packs in series, to create the final battery in the first place, there certainly is a safe series & a safe parallel wiring-connections procedure to do this. What are these safe methods to prevent shorting and other mishaps?
For example, is there a proper sequence for connecting the parallel sub-packs or cell-groups... does one connect all the positives together first before connecting all the negatives together... or is it just the reverse? Or, flip a coin because either way is safe?
What about connecting in series all the parallel packs?2) Specific example to convert a 60v battery into a charging reconfiguration of 3.6v and back to its original configuration of 60v safely using plugging or plug-jumper techniques:
A newbie problem for any experienced battery maker... Using plugs or jumper-plug techniques to enable a battery to be quickly reconfigured for charging or other voltage-amp packaging. In other words, how does one create a completed battery and wire the series connections safely, in sequence, to connect, for example, to all the 4 celled parallel batteries in 16s (packaged as 4p8s x 2s), and, then have the option, for example, to covert it into a massive 3.6v 64 cell battery of 16-4p-cells in parallel? (In my case I will have 4p8s x 2s sub-packs for the series battery and want to convert it to parallel mode.) AND... I need to make it easy to disconnect & reconnect safely for these two different configurations using plug-in or jumper-plugs for quick reconfiguration that is still safe.
I think I should be able to avoid using switches or relays with some smart plug design techniques for unplugging and/or jumper-plug the series/parallel connections and reconnecting.
Any ideas?
