Battery Box building

Technical discussion on converting internal combustion to electric
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Richo
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Battery Box building

Post by Richo » Wed, 25 Oct 2017, 15:53

So I'm looking to build my battery box soon.
I can get all the parts made to size, Aluminum frame + panels, if required.
But the actual frame and panels will need to be welded together.

Can anyone suggest someone in the Perth metro who would want/can do this?

Also now is the time to put your 2c worth in the overall design.
Either it will be a simple rectangular box shape if the batteries all fit or a short T-Shape like the Volt.
Polycarb inner liner.
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Re: Battery Box building

Post by jonescg » Wed, 25 Oct 2017, 20:11

Richo - how big? Like 1400 mm long sort of thing?
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Re: Battery Box building

Post by Richo » Thu, 26 Oct 2017, 12:53

Well it's most of the width of the car.
It's where the fuel tank used to sit but now wider as the exhaust system is removed.
I guess around 1400 wide, 300 tall, 400 long.
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Re: Battery Box building

Post by Richo » Thu, 26 Oct 2017, 13:17

I was thinking of 1" RHS ali frame all welded together then ali checker plate on the outside except the top.
Then the thickness is filled with something, fire proof, such as rockwool. Or EVA if I cant be bothered.
The inner is then lined with a polcarb box and the top has a sheet of polycarb.
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Re: Battery Box building

Post by Richo » Thu, 26 Oct 2017, 13:20

$417 from superchunk auto 1400L x 515W x 480H is too big...
http://www.supercheapauto.com.au/Produc ... om=1021424
Image
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Re: Battery Box building

Post by Richo » Thu, 26 Oct 2017, 17:56

Richo wrote:
Thu, 26 Oct 2017, 12:53
I guess around 1400 wide, 300 tall, 400 long.
Well it's not even that big.
900W x 250H x 350D from a quick measure.
This will only hold about HALF my pack.
Looking at the original weight distribution I will have to put the other half in the engine bay anyway to get it back near 50/50.
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Re: Battery Box building

Post by goingbush » Fri, 27 Oct 2017, 10:05

I'll be making some battery boxes soon too.
Both these fuel tanks will be replaced with boxes that hold 12 x CALB 180 cells , and I'll need another box holding 21 cells under the bonnet .

Constructing a box & lid is one thing, but I assumed the cells all need to be clamped down somehow, this is the tricky bit. None of the many battery box images across the internet seem to have such clamping arrangments. Are such clamps required or not ??

Image

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Re: Battery Box building

Post by goingbush » Fri, 27 Oct 2017, 10:09

Also what about making battery boxes from Angle & flat plate , then linking with Alloy sheet + some internal insulation. ??

Im thinking same as in this old blog http://adventure-ev.com/?p=386

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Re: Battery Box building

Post by Richo » Fri, 27 Oct 2017, 13:29

Yeah I'm thinking that RHS with an outer plate and inner polycarb liner is over the top.
Plus it takes up a lot of space.
Also the internal gap, which I was thinking of putting rockwool etc would make the box flex with 80kg of battery pushing it around corners.

Angle and flat plate could work.
On the top I would have the angle going out for a mounting flange.
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Re: Battery Box building

Post by Richo » Fri, 27 Oct 2017, 13:33

goingbush wrote:
Fri, 27 Oct 2017, 10:05
Are such clamps required or not ??
The prismatics usually need to be held tight together to prevent from swelling during charge/discharge.
The ones I have seen have used the ratchet straps like for trailers.

Luckily I am using the Leaf cells which have 4 mounting holes that have a rod put through to pull them tight and lock them in place.
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Re: Battery Box building

Post by goingbush » Fri, 27 Oct 2017, 14:10

Ahh Thanks - ratchet straps - I can do that.

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Re: Battery Box building

Post by Richo » Thu, 02 Nov 2017, 12:55

I guess the tried and tested way is best.
This is from Zeva's RX-7
Image
http://www.zeva.com.au/Projects/RX7/?se ... tteryPacks

Ali box, flanged top, polycarb inner, polycarb top and external mounting struts.

Still leaves me with the problem of an ali welder.
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Re: Battery Box building

Post by jonescg » Thu, 02 Nov 2017, 14:34

I reckon this will work pretty well with the Leaf modules. However if you can, try and squeeze them in so there's good contact all the way out to the sides of the enclosure. Then it should be able to soak any heat away. The polycarb lining will limit how effective this is, but you will need something there for electrical isolation too.
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Re: Battery Box building

Post by Richo » Fri, 03 Nov 2017, 12:38

Worst case I'd be pulling 3C for 10secs.
Mostly would be under 0.5C.
I'd be surprised if heat would be an issue in this case.
It's not a performance car - just a general runner.
You know all show - no go :lol:

The polycarb wont add much so I'll keep it thin like 1.5mm.

The BMS has a temp sensor on each cell so I'll know if it goes north so to speak...

I don't know if there are any other materials that would be better.
You know good thermal and good electrical isolator.

The cells will be packed in tight except for the tops due to the BMS, cell interconnects and power cabling to first and last cell.

I was thinking of making a wooden mock-up first just in case there is some obvious problem once mounted in the car.
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