I think there is a lot for us (esk8) to learn about battery pack construction from the EV industry. Battery pack design is constantly improving and evolving as there are more company’s researching battery construction techniques.
The goal of this thread is to be a place to post pictures and discuss construction techniques being used in production battery packs. Hopefully this can help us improve the design and safety of our bigger packs.
To get started i wanted to post some pictures of a few interesting battery packs or modules that i have found.
looks like newer versions of these cell modules have the negative nickel run to the top front edge of the block and the positive terminal run to the back to facilitate easy connection when stacking.
I think its easier to do on the production line as you can do many welds very quickly without overheating copper probes. Its also much easier to get different weld shapes depending on the mechanical properties needed.
as this is a relatively new technology it doesn’t look like there is a standardized weld pattern yet.
at 90mm high by 200mm wide this aluminium extrusion looks like it could be perfect for top mount battery packs. Keen to find out where we could source extrusions like this if anyone knows.
They even have some brick packs which use a double stack construction method.
I find it surprising how thin the cell holder material is to get enough rigidity to hold the cells in place. I would love to know what material it is they are using for these.
Whilst i cant stand BrunoPOWEEER his video tour of the EM3ev factory is fantastic insight into how ebike packs are produced. Well worth a watch.
This is the LUNA Wolf pack.
They are using custom cell holders with gold plated PCB for series and parallel connections. This pcb also includes balance wires which are routed back to the bms which is mounted on the top.
