SAVE $$ - LiFePO4 Battery Pack Assembly | Overland Electrical Build.
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- Опубліковано 11 тра 2024
- EP106 - Scroll all the way down for links!
Assembling the LIFEPO4 cells into a whopping big battery pack, to power the Fuso habitat. Using a few simple and easy to acquire parts, and a couple custom designed and 3D printed pieces (which could be left out of you want to build a similar pack) - this assembly will keep everything together, and maintain some restraining force so the cells can’t swell.
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And here I am watching you build a battery bank that is more than 33% larger than both of my Power Queen 300 ah battery outputs (600 AH TTL), but the same dimensions.
You'll like this Bruce. I made a deal with my 14-year-old grandson. I am going to buy a 3D printer like you recommend and he's going to make my parts for me on it. His uncle has already taught him to use his, so this way, I don't have "one more thing" to learn how to use!
I'm 73 after all and still enjoy playing with my tools!😊
That’s Great! Once you guys get comfortable with the printer get him going in Sketchup or one of the other free 3D design software options! Your imagination will be the only limit!!
Wow! Super clean, bud. I saw glue and tape, and thought meh... Glad I watched the rest! Very nicely done.
Thanks Don! Sometimes things can look a mess until they are finished 😎.
Pretty slick, Bruce. My EP4 48v 100ah LiFePo4s are about double that size and weigh over 100# each. I like your HDPE border walls and even more 3D parts.
The power density available these days is getting nuts! Always room for more 3D printed parts!!
We went with truck voltage for our setup too, it just makes life so much easier. We have a 24v LiPo setup and the battery internal BMS has wifi connectivity to a downloadable monitoring app. One of things I like best about that system is when the truck is parked at home we can check battery condition from inside the house if we need to. Our 'shore charger' has wifi connectivity too. Modern technology can make life a lot simpler at times 🙂
Yep, my BMS’s have a Bluetooth connection, and can also be wired to an onboard network, or Wi-Fi. Super handy!
That was very good and very educational. I appreciate that you did not get to where you are without my help and assistance. I sometimes swell up myself but I like the idea of that tape that you use - I might try it and if it does not work I can always try a threaded rod! Anyway are you able to hazard a guess at the saving you would make building a battery bank in lieu of buying ready made batteries. The closest thing I have to that is a piggy bank!
Well, just keep in mind any time you find yourself swelling up, some fiberglass tape, a cutting board and some threaded rod can McGuyver you back into shape for less than the cost of a doctor or therapist! 🤣
That's great... thanks for the advice. I'm delighted that somebody has got my back!
Ah - you make it look so easy, but I can only imagine the time it takes to arrive at the final design. BTW - may be just me - but I'm unconvinced that battery swelling is containable......some very powerful forces at work
I won’t really mind if they swell a little - but hopefully I can constrain them enough to save a bit off the capacity loss. Only time will tell! I don’t plan on having any high C charge or discharge rates, so that should help.
The manufacturers say to do it. I’m guessing that they might still swell in height or change shape in some other way internally.
I’m sure at some level there will be a bit of swelling - but minimal isn’t overly concerning. The reality is you don’t have to constrain them, you just loose some capacity, but I figured it’s pretty easy to at least attempt to do it!
Great explanation 👍 You made it look easy. When you think about would you say you saved around half the cost? Or more....🤔💪💰
Very rough numbers, compared to buying 100aH batteries, yes - my cost was a little more than half the cost.
Very nice. I like the nylon lock nuts on one end. Are you thinking of something like loctite on the other end? (Someone should make nylon lock nut versions of blind nuts. Actually, maybe they do, but they're such a specialty item that they're too $$$)
That reminds me - if you haven't seen them, Misumi makes all sorts of interesting things. Every type of aluminum extrusion nut you can imagine. And nuts and bolts of very imaginable type. Including a reasonable number that are customizable in size. The prices for those can get steep.
(When I am fabulously wealthy, I am going to have to get a Tornos Swiss lathe so that I can get *precisely* the fasteners that I want...)
I considered using loctite on the ends of the threaded rod, but it’s actually much easier to assemble the pack using the nyloc nuts as pseudo bolt heads. I’ll keep and eye on the pack for the first little bit of use, and if they seem to be loosening off I’ll add some loctite. Mini lathe sounds fun… would be much easier to lug around than my old 1947 South Bend 🤣.
@@BruceandKrista actually, since you don’t need that much tension on the bolts, you could 3D print a rectangular piece of plastic to press fit over the nylon lock nut. And add something to the cutting board at that end to stop the rectangle and nut from rotating.
Does that make sense?
Re: lathes, you should look up video of Tornos lathes. I’m pretty sure their “mini” needs 3 phase power. Their larger ones have something like 8 heads so that you can be turning 8 things at once. One of their smaller ones might fit into my post-apocalyptic 50’ trailer RV concept. My current inverter can be configured with up to 12 units, four per phase for 3 phase. 36 kW. So I’ve already started building my setup. :)
Well, ok, I was thinking Mini Being more like desk top LOL. I’ve actually found and downloaded all the files to 3D print a desktop CNC milling machine (light duty!)
@@BruceandKrista It’s quite possible that a much more reasonable lathe would work. The examples I’ve seen of the Tornos ones making beautiful and exotic screws are enchanting.
But my goal right now is to figure out a good way to have my Ender 3 somewhere in my RV so I can 3D print on the road. I’m currently thinking it will go in my Honda Element that we tow. Because then I don’t need to have any fancy fume extraction since we won’t be inside it most of the time.
I have minimal practical experience with metal machining so a mill or lathe are very much on the back burner.
(I was only slightly joking about a 50’ trailer, though. I am pretty sure that my next RV will be something I build on a semi truck chassis. Never again will I be annoyed at slowing down to 30mph on uphill mountain highways…)
12V makes me sad. For that kind of AH I would have recommended 24V. I'm making a two strings Eve 304s with 16 cells for 24V, 14,336 wh.
I did strongly consider 24v, but that’s hard to do with 12 cells… it’s kind of 12V or 36V.