gotgraham
1 mW
- Joined
- Feb 10, 2018
- Messages
- 12
I have started in on an e-dirtbike build based on an 06 Yamaha YZ450F.
- ME1616 motor - 96v, 20-55kw
- Kelly KLS96601-8080IPS Controller. 240a continuous. 550a peak.
For a battery, I purchased 364 Samsung 30T 21700 cells. These are rated at 35a continuous discharge. 3000mAh.
Data sheet - https://www.imrbatteries.com/content/samsung_30T.pdf
My plan is to build a 28s13p pack. Since the Kelly controller has a max dc input voltage of 120v, at full charge (4.2v) I'll be at a 117.6v. I will split this pack up into 3 smaller packs for easier packaging on the bike - 2 x 10s13p and 1 x 8s13p, all connected in series. With 13p, I should be ok for up to 455a continuous. I'm sure I can hit 550a safely for a brief period. 2900mAh nom x 13 * 103.6v nom = 3.9kwh. This should be enough for plenty of riding.
I'll run the Zeva EVMS 3 BMS - one module for each of the 3 packs. I had good luck with this BMS on my EV Delorean.
Now for my questions:
1 - For battery interconnects, what do people recommend for this (high) current pack?
My first thought is to laser cut copper bus "plates" out of 16-18ga copper. These would have approx 12mm holes aligning with the cells. Instead of bonding wires (like tesla), I would use 0.35mm pure nickel strips. While the ampacity of these isn't sufficient for longer runs, I would think a 0.375" run to the copper bus would be more than fine for 35a per cell. I would spot weld the strip to the battery and solder the strip to the bus plate. Thoughts?
2 - A dirtbike is a high vibration / harsh environment for a battery. Do I need to consider fully potting the battery in epoxy? Or build a well padded / shielded housing for the shrink wrapped pack?
I'm sure I'll think of other questions, but that is what I have for now.
Thank you!
- ME1616 motor - 96v, 20-55kw
- Kelly KLS96601-8080IPS Controller. 240a continuous. 550a peak.
For a battery, I purchased 364 Samsung 30T 21700 cells. These are rated at 35a continuous discharge. 3000mAh.
Data sheet - https://www.imrbatteries.com/content/samsung_30T.pdf
My plan is to build a 28s13p pack. Since the Kelly controller has a max dc input voltage of 120v, at full charge (4.2v) I'll be at a 117.6v. I will split this pack up into 3 smaller packs for easier packaging on the bike - 2 x 10s13p and 1 x 8s13p, all connected in series. With 13p, I should be ok for up to 455a continuous. I'm sure I can hit 550a safely for a brief period. 2900mAh nom x 13 * 103.6v nom = 3.9kwh. This should be enough for plenty of riding.
I'll run the Zeva EVMS 3 BMS - one module for each of the 3 packs. I had good luck with this BMS on my EV Delorean.
Now for my questions:
1 - For battery interconnects, what do people recommend for this (high) current pack?
My first thought is to laser cut copper bus "plates" out of 16-18ga copper. These would have approx 12mm holes aligning with the cells. Instead of bonding wires (like tesla), I would use 0.35mm pure nickel strips. While the ampacity of these isn't sufficient for longer runs, I would think a 0.375" run to the copper bus would be more than fine for 35a per cell. I would spot weld the strip to the battery and solder the strip to the bus plate. Thoughts?
2 - A dirtbike is a high vibration / harsh environment for a battery. Do I need to consider fully potting the battery in epoxy? Or build a well padded / shielded housing for the shrink wrapped pack?
I'm sure I'll think of other questions, but that is what I have for now.
Thank you!
