also, i decided to go with custom busbars for my batteries, instead of cable, since they will be VERY inaccessible when installed and it will make me worry a bit less about my crimps
Re: Project VW Cadd-E
Posted: Fri Jun 25, 2021 4:59 pm
by ZooKeeper
Yes, bussbar >>> cables!!!
Re: Project VW Cadd-E
Posted: Fri Jul 02, 2021 2:41 am
by vwbrady
Busbars!
Re: Project VW Cadd-E
Posted: Fri Jul 02, 2021 6:05 am
by RetroZero
Very professional
Re: Project VW Cadd-E
Posted: Mon Jul 19, 2021 10:53 pm
by vwbrady
battery reconfiguration done, and installed under the truck. TDL is still very long.
Again, this is a very modest battery pack, @ ≈7kWh, that I chose for it's low cost and small packaging that gets me to a 96s pack.
Batteries with all BMS leads and busbars installed:
then back in their enclosures:
installed under the truck, not noticeable at all:
My K100 cafe project that's been a fun distraction:
Before a test spin i need the EVBMW Leaf VCU wired up and some HV junction box stuff mocked up. Also HV cables run.
Re: Project VW Cadd-E
Posted: Fri Jul 30, 2021 9:05 am
by RetroZero
You said low cost. May I ask how much for the modules? Might go your route.
Re: Project VW Cadd-E
Posted: Fri Jul 30, 2021 4:48 pm
by vwbrady
RetroZero wrote: ↑Fri Jul 30, 2021 9:05 am
You said low cost. May I ask how much for the modules? Might go your route.
They sold out after a few weeks but they were $100 each. Mercedes L09-1 modules, cells made by Li-Tec in Germany.
At 880Wh new, with the diecast enclosure they come in, I thought it was a good deal. I bought 16 and am only using 8 at first. depending on my range i may add the other 8 in parallel. they did take a decent amount of work to make usable, as you can see in the thread. And when running these in a 96S 1P config each cell tab is carrying full current. So, we'll see how that goes...
Re: Project VW Cadd-E
Posted: Fri Jul 30, 2021 6:52 pm
by RetroZero
Goodnight to know. With the golf/caddy space and weight is critical, and then the cost. Will wait to see what range you get. For now I have mountings to make
Re: Project VW Cadd-E
Posted: Tue Aug 10, 2021 8:44 pm
by vwbrady
made a little more progress before paternity leave ended.
yet again, more laser cut parts from Send Cut Send. Chevy Volt Charger bracket and a bracket for the Leaf acc pedal
Leaf pedal proto and final bracket. GOT to design > proto > test > design > proto > make
installed in truck:
charge bracket mount to Leaf motor:
Installed:
Now I need to get to my High Voltage Junction Box and control system wiring.
HV Junction Box is done, installed, and connected to batteries
VCU is wired to HVJB and leaf inverter.
VCU CAN jumpers from header 1 to 2. to connect the Inverter CAN with ISA Shunt communication to pins on HVJB header where ISA shunt resides. I plan to bring this up in the Leaf VCU support thread. It's my understanding that the ISA Shunt and Leaf Inverter share the same CAN bus. I'll have to look at Damien's code to confirm.
Charge inlet mounting designed and done
12s battery charger/balancer used to check cell voltages
designed and printed a 12v battery tray for a LiFePo4 35Ah
after a bunch of test wiring, then more code review and trouble-shooting, I have a spinning motor!
Precharge works great, Acc pedal calibrated. Next up will be further refinement of the low voltage wiring, and then on to getting my Volt DC-DC and Charger working. Also wiring the Leaf BMS.
changing my BMS strategy. Was intending on using the Nissan Leaf BMS, but have since decided to go the Simp BMS + Tesla route.
You may wonder how, if I'm not using Tesla modules. Well i just bought a bunch of used Model S/X BMS boards off ebay and am going to wire them to my cells. Combining 2 boards get's me the 12S i need for each of my mercedes modules.
Bratitude wrote: ↑Thu Apr 07, 2022 3:01 am
Nice, bought a gen1 volt bms to do the same thing. never found a good price for Tesla slave boards, how much did you get the full set for?
So, i knew there would be a bunch of loose model S/X boards out there because of so many people using aftermarket BMSs +adapter boards for stationary, or other, use cases. StealthEV who makes an adapter board for these modules had hundreds of these in stock, which they sold to me for $25ea.
So for 16 modules, needed for a 400V system, plus the cost of the Simp BMS:
Simp BMS from kitoffgrid (only place that would ship to the US): $578
Model S/X modules from StealthEV: $400
BTW, I'm hoping to get it set up to share my powertrain contactors and ISA shunt.
I compared this to the Orion BMS for a 96s system at $2000.
Here is my first 12s sub-module test setup, contains 2 tesla boards:
They will mount to the side of my batteries like so: