DIY-battery - Revision history

Kopaz: /* Prerequisite software/knowledge */

2023-11-27T04:21:22Z

Prerequisite software/knowledge

← Older revision		Revision as of 04:21, 27 November 2023
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	You will most likely see terminologies that you've never encountered before, this will be explained along the article.		You will most likely see terminologies that you've never encountered before, this will be explained along the article.

			[https://docs.google.com/forms/d/e/1FAIpQLSd-Jee1HL-Nlk5ZMCbuMsobD1qEIL67Lgq1BAB8IZPk3SZLIQ/viewform If you can pass this quiz without using internet for help, you have bare minimum qualification to continue. (You must get everything right)]

	==Safety==		==Safety==

Kopaz: /* Safety */

2023-11-27T04:20:47Z

Safety

← Older revision		Revision as of 04:20, 27 November 2023
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	'''If this is your first electronics project, stop what you're doing. You're most likely to screw something up and burn your house down. If you don't know how to use a soldering iron and doesn't know how to use a multimeter, consider doing some other electronics project (learn from makerspace) then try again later.'''		'''If this is your first electronics project, stop what you're doing. You're most likely to screw something up and burn your house down. If you don't know how to use a soldering iron and doesn't know how to use a multimeter, consider doing some other electronics project (learn from makerspace) then try again later.'''

	[https://docs.google.com/forms/d/e/1FAIpQLSd-Jee1HL-Nlk5ZMCbuMsobD1qEIL67Lgq1BAB8IZPk3SZLIQ/viewform If you can pass this quiz without using internet for help, you have bare minimum qualification to scroll. (You must get everything right)]

	==Equipment requirement==		==Equipment requirement==

Kopaz: /* Safety */ add quiz link

2023-11-27T04:20:14Z

Safety: add quiz link

← Older revision		Revision as of 04:20, 27 November 2023
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	'''If this is your first electronics project, stop what you're doing. You're most likely to screw something up and burn your house down. If you don't know how to use a soldering iron and doesn't know how to use a multimeter, consider doing some other electronics project (learn from makerspace) then try again later.'''		'''If this is your first electronics project, stop what you're doing. You're most likely to screw something up and burn your house down. If you don't know how to use a soldering iron and doesn't know how to use a multimeter, consider doing some other electronics project (learn from makerspace) then try again later.'''

	~~(Reminder~~: ~~add self~~-~~served knowledge assessment~~. ~~- kopaz~~)		[https://docs.google.com/forms/d/e/1FAIpQLSd-Jee1HL-Nlk5ZMCbuMsobD1qEIL67Lgq1BAB8IZPk3SZLIQ/viewform If you can pass this quiz without using internet for help, you have bare minimum qualification to scroll. (You must get everything right)]

	==Equipment requirement==		==Equipment requirement==

Kopaz at 04:18, 27 November 2023

2023-11-27T04:18:36Z

← Older revision		Revision as of 04:18, 27 November 2023
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	*Select cells. You will most likely end up spending some time doing this, if you've never done something like component selection before. In general - Cells are characterized by (to price, cheaper to expensive):		*Select cells. You will most likely end up spending some time doing this, if you've never done something like component selection before. In general - Cells are characterized by (to price, cheaper to expensive):
	Low power density, low max/continuous power output (usually the cheapest - prismatic cells fall into this sort of category, and entry level cells that are commonly found in powerbank packs)		Low power density, low max/continuous power output (usually the cheapest - prismatic cells fall into this sort of category, and entry level cells that are commonly found in powerbank packs)
			Refer to [[Cell selection]] for detailed guide.

	Medium~high power density, low~medium continuous power output (something like LG M50 series linked above falls into this category). Slightly higher than the entry level cells, but still not the best. Example:		Medium~high power density, low~medium continuous power output (something like LG M50 series linked above falls into this category). Slightly higher than the entry level cells, but still not the best. Example:

Kopaz: /* Start-to-Finish cycle */

2023-09-28T14:46:10Z

Start-to-Finish cycle

← Older revision		Revision as of 14:46, 28 September 2023
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	Connect cells in parallel. Depending on dimension/shape, you may not be able to simply line them up (i.e., 1sx amount of p-group, on a line). If you've been following this rundown, you should already have layout of your battery pack. Simply follow that, wire balance leads (V- goes to the V- of first series group, S1 goes to V+ of first series group, and so on, to the last series group). The last series group and V+ should be on a separate junction (series group balance lead should be soldered onto your busbar/nickel plate, other should be on output i.e., V+). Appropriately pad the battery pack to the case and, organize your balance wires so they aren't spaghetti. This might sound funny, but having balance lead that aren't spaghetti will be easier for you to troubleshoot & reduce likelihood of accidental shorts.		Connect cells in parallel. Depending on dimension/shape, you may not be able to simply line them up (i.e., 1sx amount of p-group, on a line). If you've been following this rundown, you should already have layout of your battery pack. Simply follow that, wire balance leads (V- goes to the V- of first series group, S1 goes to V+ of first series group, and so on, to the last series group). The last series group and V+ should be on a separate junction (series group balance lead should be soldered onto your busbar/nickel plate, other should be on output i.e., V+). Appropriately pad the battery pack to the case and, organize your balance wires so they aren't spaghetti. This might sound funny, but having balance lead that aren't spaghetti will be easier for you to troubleshoot & reduce likelihood of accidental shorts.
			For calculating current capacity for your busbars for parallel group, [https://chemandy.com/calculators/rectangular-conductor-resistance-calculator.htm There's a website that calculates resistance for a given sheet metal.] I'm sure you can find others, but that's just 1 example.

	*Place thermistors onto cells wherever appropriate. this will be explained further.		*Place thermistors onto cells wherever appropriate. this will be explained further.

Kopaz: DIY-case link added

2023-09-27T09:54:16Z

DIY-case link added

← Older revision		Revision as of 09:54, 27 September 2023
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	===Battery case===		===Battery case===
	The shape/volume of the case determines how much cell you can fit in the case. You can 3D Print a battery case, and this will be explained further. In general, injection-molded/hardcase plastic battery case (if designed/manufactured well) will be almost always superior to a 3D printed/handmade case. Therefore, the latter cases are for more experimental purpose that market does not provide i.e. very large in dimension, custom mounting/hole for heatsinking, etc.		The shape/volume of the case determines how much cell you can fit in the case. You can 3D Print a battery case, and this will be explained further. In general, injection-molded/hardcase plastic battery case (if designed/manufactured well) will be almost always superior to a 3D printed/handmade case. Therefore, the latter cases are for more experimental purpose that market does not provide i.e. very large in dimension, custom mounting/hole for heatsinking, etc.
			[[DIY-case]] has helpful resources/practices if you are making your own battery case.

	===Spot welder===		===Spot welder===

Kopaz: /* Design */

2023-09-27T09:06:41Z

Design

← Older revision		Revision as of 09:06, 27 September 2023
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	==Design==		==Design==
	You use the simulator to find power requirement of your setup, then you use the peak power consumption as your baseline. Most cells can handle power load above their continuous output for short period of time. Cell datasheets '''should''' have this info.		You use the simulator to find power requirement of your setup, then you use the peak power consumption as your baseline. Most cells can handle power load above their continuous output for short period of time. Cell datasheets '''should''' have this info. '''Do not use cells that does not have reliable datasheet. This also applies for batterypacks as well.'''

	Depending on your design decision/riding habit, this can be flexible to some degree. 10s should be the absolute maximum for "peak" power output of your battery (this will also depend on the cells you are using). Dimension is also fairly simple - Either you find a case that fits on wherever you are placing battery on, or you design a custom case and use that as a baseline.		Depending on your design decision/riding habit, this can be flexible to some degree. 10s should be the absolute maximum for "peak" power output of your battery (this will also depend on the cells you are using). Dimension is also fairly simple - Either you find a case that fits on wherever you are placing battery on, or you design a custom case and use that as a baseline.

Kopaz: /* Safety */

2023-09-18T05:56:18Z

Safety

← Older revision		Revision as of 05:56, 18 September 2023
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	*Do not leave individual cells outside packaging unkept. Store them in a container, if possible.		*Do not leave individual cells outside packaging unkept. Store them in a container, if possible.

			*Do not mix battery packs of different cells (model, chemistry) in parallel, unless if you know what you are doing. Eg: I wire a 36V battery and 48V battery in parallel. Result: House fire.

	*Do not use used cells, if possible. Used cells are not recommended because they will have different internal resistance (IR) and it will be harder for BMS to balance packs with different IR and increase chance of cell failure.		*Do not use used cells, if possible. Used cells are not recommended because they will have different internal resistance (IR) and it will be harder for BMS to balance packs with different IR and increase chance of cell failure.

Kopaz: /* Start-to-Finish cycle */ grammar fix.

2023-09-17T23:39:45Z

Start-to-Finish cycle: grammar fix.

← Older revision		Revision as of 23:39, 17 September 2023
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	*Decide equipment of your choice first. depending on how complicated you want your design to be, CAD software may be recommended, but a simple sketch drawing might also do.		*Decide equipment of your choice first. depending on how complicated you want your design to be, CAD software may be recommended, but a simple sketch drawing might also do.

	*Calculate power & speed requirement of your ebike. Refer to the[[Simulator]]. Hint: Faster ebike usually need a battery of higher voltage, or a motor with high KV rating (how much the motor will spin per volt), with enough power output to sustain this power (usually a peak at startup due to torque requirement, then gradually slopes down).		*Calculate power & speed requirement of your ebike. Refer to the [[Simulator]]. Hint: Faster ebike usually need a battery of higher voltage, or a motor with high KV rating (how much the motor will spin per volt), with enough power output to sustain this power (usually a peak at startup due to torque requirement, then gradually slopes down).

	Plan out what cell sizes you will be using (the most common sizes are 18650 (18mm65.0mm) and 21700 (21mm*70.0mm). I hope you already have a battery case designed/purchased. If not, purchase/design a battery case first to your shape/dimension, make a mockup of your cells, including busbar/nickel strip so you don't mess up and burn your house down. Feel free to ask for help on our [https://discord.gg/ATZ8eet6fy Discord server].		Plan out what cell sizes you will be using (the most common sizes are 18650 (18mm65.0mm) and 21700 (21mm*70.0mm). I hope you already have a battery case designed/purchased. If not, purchase/design a battery case first to your shape/dimension, make a mockup of your cells, including busbar/nickel strip so you don't mess up and burn your house down. Feel free to ask for help on our [https://discord.gg/ATZ8eet6fy Discord server].

Kopaz at 23:37, 17 September 2023

2023-09-17T23:37:06Z

← Older revision		Revision as of 23:37, 17 September 2023
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	*Decide equipment of your choice first. depending on how complicated you want your design to be, CAD software may be recommended, but a simple sketch drawing might also do.		*Decide equipment of your choice first. depending on how complicated you want your design to be, CAD software may be recommended, but a simple sketch drawing might also do.

	*Calculate power & speed requirement of your ebike. Refer to the [~~https://ebikewiki.com/index.php/~~Simulator~~\|Grin simulator~~]. Hint: Faster ebike usually need a battery of higher voltage, or a motor with high KV rating (how much the motor will spin per volt), with enough power output to sustain this power (usually a peak at startup due to torque requirement, then gradually slopes down).		*Calculate power & speed requirement of your ebike. Refer to the[[Simulator]]. Hint: Faster ebike usually need a battery of higher voltage, or a motor with high KV rating (how much the motor will spin per volt), with enough power output to sustain this power (usually a peak at startup due to torque requirement, then gradually slopes down).

	Plan out what cell sizes you will be using (the most common sizes are 18650 (18mm65.0mm) and 21700 (21mm*70.0mm). I hope you already have a battery case designed/purchased. If not, purchase/design a battery case first to your shape/dimension, make a mockup of your cells, including busbar/nickel strip so you don't mess up and burn your house down. Feel free to ask for help on our [https://discord.gg/ATZ8eet6fy Discord server].		Plan out what cell sizes you will be using (the most common sizes are 18650 (18mm65.0mm) and 21700 (21mm*70.0mm). I hope you already have a battery case designed/purchased. If not, purchase/design a battery case first to your shape/dimension, make a mockup of your cells, including busbar/nickel strip so you don't mess up and burn your house down. Feel free to ask for help on our [https://discord.gg/ATZ8eet6fy Discord server].