| Part
7: Installing the new cells |
|
We
use some light wood to support and protect the cells.
|
|
|
A piece
of white coroplast and then the first cell.
|
|
|
The
pack's negative cable is connected. It is tie-wrapped to the board
to keep it from flexing and putting strain on the battery tabs.
The tabs are very thin and will break if flexed or loaded too much.
|
|
|
The
first cell will have three temperature sensors.
|
|
|
Each
sensor will be smeared with heat sink compound and taped in place.
|
|
|
We
place a sensor near the positive tab since Kokam feels this will
be the hottest spot. We also place a sensor at the middle of the
cell and the lower corner to compare.
|
|
|
Then
the next sheet of Coroplast.
|
|
|
The
next cell goes in reversed. Positive to negative. The cells are
in series.
|
|
|
Every
eight cells, the BMS wires are carefully bundled.
|
|
|
The
first 24 cells are in.
|
|
|
The
next 24.
|
|
|
The
other cells go where the passenger seat would be. The only bit of
trickiness is that with 24 cells, the cables come in and go out,
on the same side as in the stack to the right (Blue arrows). By
running 23 cells in the stack on the left, the negative cable for
the rear pack comes in from the left and the positive cable exits
forward to the right (green arrows).
|
|
|
This
allows for a very short connector cable.
With
the installation done, we have saved about 3 feet of cable. Less
weight. Less resistance.
|
|
|
|
|
|
