The battery builders club

yeah basically. this is why the Mooch ratings are so valuable. just pick the best rated cell that fits your use case.

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The easy way is to use the Wh from mooch’s “E-score”. The whole point is that he does the integrating I talked about for you. That is why labeled capacity doesn’t really matter. If the battery stays at a higher voltage longer it will have more total energy even with the same or possibly less Ah. You can try to integrate under the curves yourself by estimation if you don’t like the 3.2 V cutoff he uses. I’m not actually 100% sure why he chose a 3.2 V cutoff and if that is more for vapes or something. That would be a question for @Battery_Mooch. Anyway if you want to do a better job than using Ah you’d need to integrate or estimate the integral of those curves and use that to calculate range.

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The rated capacity numbers are for when you’re drawing some tiny amount of current, like a phone battery bank would. Thats when you can listen to advertised capacity. While under heavy load, delivered energy down to ___ voltage (usually 3.2v) is what you wanna look at.

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pretty sure this is for safety/datasheet reasons, something to do with cycle life

many in the vaping community will run their cells as low as 2.8V or 2.5V, as will many in the PEV community.

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3.6Wh * 12(serial) * 3(parallel) = 129.6???

i think i have a knot in my brain :sweat_smile:

now multiply that by the number of cells in parallel.

3=Ah

3.6=V

the formula is:

Wh = (S x V) x (Ah x P)

S = Cells in Series
V = Cell Voltage
Ah = Cell Ah
P= Cells in Parallel

so for a 12s3p of 30q cells that would be:

12s x 3.6V x 3Ah x 3p
43.2V x 9Ah
388.8Wh

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that calculation i get

in case of using the Wh measurements of a single cell from Mooch, i don’t get how to add it up to the whole pack

an easy way is just to multiply by the number of cells total in the pack.

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okay, i think i get it
it is off, because we’re only looking at the range till 3.2V in moochs test, therefore leaving some Wh that get calculated in when using the datasheet

This internal layout turned out really clean, I like it!

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the great thing about Mooch’s numbers is that they’re generally pretty conservative. meaning if you do your calculations based off his numbers you’ll always get more than you expected.

it’s much better than building a pack to the maximum specs that can be calculated, and being disappointed when it’s even 5% less than the highest number you calculated.

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I used Velcro. Velcroing the cells down

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Very nice. I hate butyl tape for sealant though. Only good for maybe one or two separations. Window sealant tape is much better imo. Are the series connections directly soldered onto the parallel connection on the cells or is it folded up beforehand?

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@Evwan @tech.shit @BLVDE

It’s a good conservative number for general use as there is typically little charge left in the cells below that to affect any delivered-Wh differences between cells.

The better cell at 3.2V would most likely be the better cell at 2.8V. If there were any changes below 3.2V they would be small since there’s only a short amount of run time left between 3.2V and 2.8V. It just doesn’t matter much.

Just a general side note….
If the lower voltage data is important for a particular application I strongly recommend testing the cells under consideration to those lower voltages. I can only provide a bit of general guidance towards which cells you might consider. :slightly_smiling_face:

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Yeah I remove the bulk of the butyl tape every time I open up the enclosure. And then apply a bead. I stretch it out before I apply it is only 5 wide & maybe 1,5 mm tall.

I solder in between the cells. With added flux and high quality solder & iron it is a 2-4 second job first to add the solder to the nickel then to join the tinned wire to to the pool of solder. The heat transferred to the cell soldering like this is not a factor tbh. I have confirmed with thermal imaging camera as well. Try it if you don’t believe me. The nickel is shit at transferring the heat.

Using two wires between each P-group to distribute the current flow.

The battery box is contoured at the bottom so folding up is not viable. And I would also build in height. As well as increased risks of short. If I rubs against the deck.
Right now I have a air gap of roughly 2mm between the cells and the deck so nothing ever rubs. And the enclosure won’t budge unless you really hit something. And then it is a compression load and there you will dent the can before you wear through the pvc wrapping. And tbh then you have bigger issues as the ground clearance is massive to begin with.

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Does anyone know what is the name of the following tapes?

a.

b.

image
(taken from message 115 here)

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the fiberglass tape?

Yes. How can I find it, and what is speical about it?

Filament tape. It has fibreglass in it and is very strong.

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I got mine from aliexpress, and it’s just very strong tape. You can’t tear it.

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