Thanks, lots of preparation and ordering parts thus far but now that most of the parts have arrived I be starting the real work. Time to build!Very nice project
KTM conversion ELXC
- Thread starter bunya
- Start date
Confirming the battery design with 0.5mm 3040 epoxy glass sheet insulators between cells, thanks @amberwolf
.I've found that most electrical insulation/mechanical padding materials generally have poor thermal conductivity.
I know I'll be dropping the bike when off road and the battery enclosure will likely take some damage being mounted on the sides of the frame. The risk of the aluminium enclosure shorting against the cell terminals or damaging the cells is something that has been on my mind.
To protect against this I've opted to use 2mm thermal pad on each side of the pack to conduct heat away from the cells as well as providing some space to absorb any small dents from damage. I also did some destructive testing of the 3040 epoxy glass sheet to see how it would absorb damage from a cell terminal pressing hard against if that happened in a crash. I expected it to crack like fibreglass but it held up really well to a few solid blows from me hitting it with a hammer. I'll use this above the terminals on the lid of each 14s battery case. I'd recommend this if other members are looking for a strong, thin (0.5mm) insulator.
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I've been testing the compression/immobilisation with some sash clamps and the 0.5mm fibreglass sheet between each cell. The spec sheet I have from the CALB 58Ah NMC states 100kgf, this is more than Iexpected and these 75Ah cells have approximately 50% more side surface area. My compression force may need to be increased to 150kg. I'll check with the manufactured on their requirement.
I'm not sure if others in this forum have experience with compression of prismatic NMC cells so hopefully this will be useful information for others building similar packs.
I've also started making the 26 bus bars from 3mm x 22mm wide copper flat bar.
One milestone for the project was dropping the bike off at Spartan Future for the design, fabrication and engineering approval of the battery cases and motor mounts. This is a requirement for getting the bike's modification approved for road registration.
The fork and shock also came back from a service and were put back into the bike. It feels super plush now!
Next steps are to configure and bench test the battery, BMS and charger including the CANBUS implementation on the display.
I'm not sure if others in this forum have experience with compression of prismatic NMC cells so hopefully this will be useful information for others building similar packs.
I've also started making the 26 bus bars from 3mm x 22mm wide copper flat bar.
One milestone for the project was dropping the bike off at Spartan Future for the design, fabrication and engineering approval of the battery cases and motor mounts. This is a requirement for getting the bike's modification approved for road registration.
The fork and shock also came back from a service and were put back into the bike. It feels super plush now!
Next steps are to configure and bench test the battery, BMS and charger including the CANBUS implementation on the display.
Cali Yang
100 µW
Is there any latest news?