Beginners Guide to Processing 18650 Cells | Cell Database


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All new design with intelligent control
#11
So I am going to try an layout the design requirements and everyone is welcome to add/comment. This is a two part design.

Part 1: Feed power from solar panel directly to a "1P Pack" of 18650's (much more on this later).



Part 2: Redesign 18650 cell holder, busbar, fuses.

i. must be able to easily remove/replace every cell it if/when needed;
-why? if you've ever blown a fuse in the middle of pack and had to tear one down you know it sucks

ii. should be able to expanded battery capacity, without total makeover (i.e add more cells along the way)

iii. must not be made of a conductive material

iv. busbars need to be standardized & easily replicated (i.e. made exactly the same every time)

v. each busbar must handle current in excess of 100A's or 2X the expected load
-a larger surface area will carry more current, not necessarily a thicker wire/ sheet

vi. busbar must be copper

vii. busbar must not cause unintentional short (to cells)

viii. every cell must have a fuse

ix. fuses need to be easily replaceable

x. fuses must maintain a '3C' rating max (datasheet for the cell should be referenced)

xi. design should be comparable in price to currently available solutions ( if not, no one will use it)

xii. design should (will) take less time and be easier to construct than what is currently available

I have a working prototype of the new pack holder design but I am fine tuning it a little more before I release it. Your input is welcome. Please try an keep suggestions inline with the model above. The word MUST indicates something that is mandatory . My current design incorporates everything listed above. I had to learn to melt and pour copper to refine the busbar and standardize them. Still tinkering with fuses and different options.
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#12
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#13
I see a problem. The square header pin isn't like the rest. Electricity wont flow properly and balanced. Tongue


Nice work! Added bonus is the TP4056 also has a temp probe as well. Are you going to utilize it, too, or use the temp probe going to the mcu? Can you share probe readings to both the TP and MCU?
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Proceed with caution. Knowledge is Power! Literally! Cool 
Knowledge is Power; Absolute Knowledge is Absolutely Shocking!
Dollar Shave Club. Best Razor I've ever used
Certified 18650 Cell Reclamation Technician
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#14
It's upside and all the electrons are going to fall out!!! - Dave Jones...EEV Blog Smile
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#15
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#16
quick update:
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#17
I liked this post 10 times. Does that count as 10 requests? Tongue
Proceed with caution. Knowledge is Power! Literally! Cool 
Knowledge is Power; Absolute Knowledge is Absolutely Shocking!
Dollar Shave Club. Best Razor I've ever used
Certified 18650 Cell Reclamation Technician
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#18
(07-25-2017, 11:15 PM)Korishan Wrote: I liked this post 10 times. Does that count as 10 requests?  Tongue

Awesome, for sure man.Maybe I'll make a video and email it instead of doing the YouTube thing. I just don't want to go through the work of filming, editing, etc if no one cares, you know? Mad respect for the YouTube guys, its a hard job to make good videos. Especially when you have 'a face made for radio' and a voice that shatters windows.
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#19
"Especially when you have 'a face made for radio' and a voice that shatters windows." I agree wholeheartedly Tongue
Proceed with caution. Knowledge is Power! Literally! Cool 
Knowledge is Power; Absolute Knowledge is Absolutely Shocking!
Dollar Shave Club. Best Razor I've ever used
Certified 18650 Cell Reclamation Technician
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#20


Temp probes too, every useful.
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