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New Ground Up DIY for Mark

Discussion in 'DIY & Custom Built Boards' started by SkaterBoy58, Dec 11, 2017.

More threads by SkaterBoy58
  1. OP
    SkaterBoy58

    SkaterBoy58 Member

    MJ1 Cells and lots of other stuff has arrived and battery pack construction has commenced :)

    The battery will be a 10S 6P configuration.
    First thing is check voltage of all cells - all are within 3.5Vto 3.6V so all good.

    Has some spare 18650 cell heatshrinks so used that on outside cells in eack pack ( for additional inter-pack insulation).

    Then hot glue 3 cell packs together.

    Then 3 cell cardboard insulators on all +v ends.

    Ready for nickel strips to be added

    MJ1 cells.jpg

    pack.jpg

    cell.jpg
     
    • Like Like x 1
  2. Brucey

    Brucey Member

    Looking the business buddy!
     
  3. OP
    SkaterBoy58

    SkaterBoy58 Member

    Bit of a post on the various bits and bobs needed for this build.

    BATTERY PACK

    Battery Cells 60 x 18650 LG MJ1
    3 cell cardboard stick-on insulators
    Nickel Strip 10 x 0.15mm
    Hot Glue
    Kapton Hi Temp tape
    Fibreglass Tape
    18 awg silicon wire( balance leads)
    30mm x 5mm rubber strips
    Neoprene 2mm foam
    170mm heat shrink
    12 awg silicon wire ( power leads)
    velcrose strips for battery pack to enclosure fixing
    12 pin balance header socket and plug
    5A wire fuses( balance leads)

    CHARGER/BMS BOX

    PVC Enclosure
    10x mini LED voltmeters
    Smart BMS and data cable
    Charger socket
    LCD Combo Voltmeter/ Ammeter
    12 pin weatherproof plug
    terminal block
    18 awg silicon wire
    cable gland

    ENCLOSURE

    Custom ABS Enclosure ( Psychotiller special for double row cells)
    ABS Glue
    12mm x 10mm rubber strip ( for weatherproof sealing enclosure)
    Charger Socket
    Headlight switch
    Strip RGB LED strips ( 2 off)
    mini usb weatherproof sockets ( for VESC data connection)
    XT60 panel socket and fuse plug
    Battery Cell monitor/alarm
    Enclosure deck fixings

    VESC PANEL
    2x VESC HW 4.12
    VESC heatsinks
    14 awg silicon wire ( motor leads)
    MT30 sockets ( motor power leads )
    Adaptor cable for motor Hall effect sensors
    Aluminium plate
    CAN Bus data cable
    Anti-spark switch
    Weatherproof on/off illuminated push button switch
    Photon 2.4 GHz receiver and whip antenna
    RC back-up 2.4 GHz receiver and antenna
    Servo male to male lead
    Photon UART data cable
    42V to 8V step down converter ( for heads lights and RGB LED strips) and 8V fuse
    METR Bluetooth UART module ( for IPhone telemetry)
    Rubber vibration isolation mounts

    GENERAL
    Front LED headlights
    Photon Remote
    RC Remote
    2x Racestar 140 KV 5065 motors
     
    Last edited: Jan 23, 2018
    • Like Like x 1
  4. dannyboyski

    dannyboyski Member

    Wow! Sexy Build! I did consider building one before buying my gtx. Decided I couldn't wait. Maybe number 2 will be a self built....

    Can I ask what sort of range you would expect to get out of 60x 18650's?

    That seems like a lot of battery! Like crazy shed loads of battery....

    Cheers

    Dan
     
    • Like Like x 1
  5. dannyboyski

    dannyboyski Member

    Ignore last message, just saw diagram 2

    Holy Beeeejusus 50km is pretty epic.
     
    • Like Like x 1
  6. OP
    SkaterBoy58

    SkaterBoy58 Member

    First nickel strip layer completed

    Racestar motors fitted

    Few ideas discussed with Mark re enclosure mounting , position of fittings to suit and VESC plate mounting. IMG_3273.JPG

    IMG_3274.JPG
     
    • Like Like x 1
  7. Doug079

    Doug079 Member

    Hats off.. board is stunning :)
     
    • Like Like x 1
  8. OP
    SkaterBoy58

    SkaterBoy58 Member

    Battery pack building continued - photos show:
    • each 6 cell pack wrapped in Kapton hi-temperature tape and then with fibreglass tape
    • mock up of series connection with 2x 12 awg flexible silicon wire and showing current sharing on packs
    • additional insulation for inter-pack cell outer skin insulation
    • packs taped together to form 2 x 5S blocks
    ready for final nickel strip welding and series wire connections
    IMG_3277.JPG IMG_3278.JPG IMG_3279.JPG IMG_3280.JPG IMG_3282.JPG
     
    • Like Like x 1
  9. OP
    SkaterBoy58

    SkaterBoy58 Member

    Started on VESC panel - use Aluminium 2mm sheet as baseplate and heat sink then mount equipment on plate.
    VESCs , anti-spark switch and RC receiver mounted
    Powered up with 42V supply (limited to 0.1A for initial testing) connected to anti-spark switch input
    2.4Gz RC receiver binded OK to remote - and connection to VESCs tested OK. Note that this receiver has a wire antenna which provides a very strong connection signal ( Evolve remotes do not have this)
    No CANBUS connection yet

    Function over Form inside the enclosure for my builds

    IMG_3285.JPG
     
    Last edited: Jan 30, 2018
    • Like Like x 1
  10. OP
    SkaterBoy58

    SkaterBoy58 Member

    Mark's very neat handy-work in BMS enclosure cut-outs charger case.jpg
     
    • Like Like x 1
  11. Brucey

    Brucey Member

    A6560613-F5A9-4DF9-B55A-D68EEEF135DC.jpeg
    Roger has almost finished the battery, now for the test charge followed by a load test. I’m getting a little excited!
     
  12. OP
    SkaterBoy58

    SkaterBoy58 Member

    a few pictures of battery construction -
    series connection between packs are 2 x 12 awg silicon flexible wire (pre-tinned) with two solder points per lead giving four current sharing paths between the series packs.
    Balance leads are soldered on to one of the cross nickel strips and all leads bought out to a header plug

    IMG_3300.JPG

    IMG_3301.JPG

    IMG_3302.JPG

    IMG_3303.JPG

    IMG_3304.JPG

    IMG_3305.JPG

    IMG_3306.JPG

    IMG_3307.JPG

    IMG_3308.JPG
     
  13. OP
    SkaterBoy58

    SkaterBoy58 Member

    First charge was a leisurely 2A directly onto +42V and 0V ( no BMS) . Packs were sitting at 3.65 shipped and all were within range 3.61 to 3.65V . First charge took hours ( a good sign) and the pack was charged to 41.7 V ( with packs sitting between 4.15V and 4.20V ) . Next step is a discharge test using an eight ohm 100W resistor hanging over a fan. This provides approx. 4.5A load ( varies with voltage)
    The discharge test objective is to confirm cell capacity ( Wh and Ah) from full charge to 30V
    Discharge test took four hours with data checked every 30 minutes
    Final readings at discharge test conclusion were
    30.0V
    690Wh
    18.5Ah
    with a cells within 0.1V

    These are slightly better than estimated ( Ah capacity of 18Ah and Wh 648) - so cells are all good.!

    discharge test 1.jpg

    discharge test 2.jpg
     
    Last edited: Feb 14, 2018
  14. OP
    SkaterBoy58

    SkaterBoy58 Member

    Next step is to finish off battery with a 2mm neoprene foam wrapping followed by heat shrink. The foam provides padding for the battery pack and the heat shrink holds it all in place and provides dust/moisture protection. IMG_3314.JPG

    IMG_3315.JPG
     
  15. OP
    SkaterBoy58

    SkaterBoy58 Member

    Recharged battery and its all ready to mount in enclosure
     
  16. Brucey

    Brucey Member

    Battery Tray now mounted and it’s back to Roger for some electronic magic!
    32E33A07-EAD4-4996-8ACA-63C11AF0CB33.jpeg ECB8121F-0035-491D-91E8-B86A9DCBA4F8.jpeg 08F74DE6-4E34-4521-82DB-96048551F73C.jpeg
     
  17. OP
    SkaterBoy58

    SkaterBoy58 Member

    Following on from Mark's handy work on enclosure mounting - time to fit it out with the good stuff.
    First job is to bash some holes in enclosure for the various switches and other stuff.

    Mark had an excellent idea to avoid any mounting bolts heads protruding on bottom of enclosure - basically to stick a rubber strip on bottom of enclosure and have bolts protruding from the strip to hold down the aluminium plate containing electronics.

    After a few trips to Clark Rubber and tries - pinch weld was selected for the enclosure lip and sealing to the rubber strip stuck on bottom of deck. This looks very neat and should be good structurally long term.

    Enc 1.jpg

    Enc 2.jpg

    Enc 3.jpg
     
    Last edited: Feb 19, 2018
    • Like Like x 1
  18. OP
    SkaterBoy58

    SkaterBoy58 Member

    Further work on electronics tray - have fitted heat sink directly to aluminium plate for bottom mosfets and individual heat sinks on top mosfets. Anti-spark switch is small rectangle at top and space for REC is for Photon remote receiver ( still under test at the moment) aa.jpg ac.jpg

    no 1.jpg
     
    • Like Like x 1
  19. OP
    SkaterBoy58

    SkaterBoy58 Member

    Last edited: Feb 19, 2018
    • Like Like x 2
  20. maxbicyclemax

    maxbicyclemax Member

    Looking great guys!!!
     
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