Electric car upgrade part 3 - Cell board installation/wiring

[my73737373]

Where did you get the bms system?

[zaakthecat]

what happens to a conductor in a magnetic field?those bms boards are not only of poor quality but are subject to huge magnetic flux because of the high dc current flow around those batteries.every semiconductor and every copper wire and lump of solder is generating cross currents across your battery terminals under load(charge or discharge).KISS =Keep-It Simple=Safer.

[mynewschannel]

Oh a BMS, I would have a word with Jack Rickard and Brian Noton at EVTV about the problems with those.

[johnshelbyjenkins]

With the quality of those balancers, I hope you discharged tested the cells to see if they're all in good shape.

[DDDarray]

I need to convert my Prius one day. Hopefully you're wearing a safety shield with arc flash protection when working around that battery pack.

[joeyf504327]

i know about half of what you talk about when it comes to making home cameras and other stuff like that it is amazing how much people know about electronics

[joeyf504327]

the rear battery box looks sharp with the yellow batteries against the blue tape

[aredditor]

Too bad you don't have a nice lightweight carbon fiber/aluminum chassis to work with.

[PhattyMo]

Just a safety tip, *ALWAYS* remove *ALL* of your jewelry,etc. when working on live circuits (including batteries). One slip,and it could severely burn you,or worse. Your watch appears to be plastic/rubber,but it is still GOOD PRACTICE to remove it.

Be Safe!

[skonkfactory]

Aren't you a little worried about the high voltages present on the battery pack? I'd be terrified of accidentally kneeling into it...

[tesla500]

@skonkfactory Yes, it is nerve wracking working on this. During installation I had the pack electrically split into 3 sections by not connecting some bus bars, so there's a relatively safe 50V on each section. Once everything is connected, you just have to be careful and plan what you're going to do. Using insulated tools also goes a big way to avoid sparks.

[HDXFH]

Are these AGM Batteries, this system looks quite complex, can't wait to see the end result

[tesla500]

@HDXFH These are Thundersky (Winston battery) lithium ion. The old batteries that I removed were AGM.

[TickyTack23]

I would not have the guts to take on a project like this. I would be worried I would fry something at that moment, or later in the future due to something I over looked.

[douro20]

Don't each of the cell boards have their own microcontroller on them? That's a pretty complex system.

[tesla500]

@douro20 Yes, there's a lot of micros! It seems to be the best way to do it, the alternative is to have 1 wire going to each battery, with a central unit with tons of ADC channels and isolated switches to activate loads on each battery.

[Adventuresofwiiman]

Neat video series, I didn't check the comments on the other videos, but im curious about what kind of car your using, and also the expected range/top speed vs the batteries you were using before.

[tesla500]

@Adventuresofwiiman This is a 1991 Pontaic Firefly. With these batteries, range should be about 40-50km vs 20 with the old batteries. Top speed should be similar, I've had the car up to 110km/h on the lead acid batteries.

[hoppes9]

What a bummer. Those battery minders look like they were assembled in someone's garage using their kids as forced labor. Not Good.

[tesla500]

@hoppes9 Yeah, I was quite appalled by the quality. I expect more for something this expensive.

[TheElectricnoob]

This is a big and ambicious project but i wonder if it in the long run will be any cheaper than just keeping the car stock and run the fuel it left the factory with.

[tesla500]

@TheElectricnoob It'll take a few years to pay off, but in the long run it should be worth it. It's also not all about money, it's a fun project.

[robot797]

mure pleas i am loving it