It’s actually the other way around, they created a commercial product using some information obtained on this and other forums.Wow! I just read through this whole thread like a novel. Super interesting and impressive. Thanks everyone who is involved in this.
Before this forum I was looking for ready made upgraded battery packs and I stumbled over this Australian company who seems to have figured it out. Has anyone ever been in contact with them to ask how they solved the range limit?
Hi,Hello,
Please note that piev is the organizer of the traction battery upgrade effort and has consulted with many folks to get to this point. My son and I are now benefiting from piev's efforts. Our car's upgrade is performing as expected and we are very pleased.
My son is working on some documentation on "Pack Removal, Module Rebuild, and Man in the Middle." The first version of "Module Rebuild" is complete and may be found at:
https://5by9.net/prune_batteries/module_rebuild.html
I will post notice of the other sections when they are available.
Our thanks to piev and all the other people who have contributed.
Mike
You are welcome to experiment but I already tried that and this was the best method in my opinion. Mike may have another opinion but it looks as if he chose the same path.Hi,
Just read through your excellent document "Module Rebuild". Forgive me if I make one or 2 observations:
1/ Section 14 - 'Remove ~2mm on each side of the battery cage...'
This shows the full depth of the bottom section of the cage having plastic removed to accommodate the 4mm longer cells. Surely if you have to put 4 x 4mm = 16mm of spacer underneath the cells, you can avoid the need to remove that much plastic? What does that leave to actually remove? 10mm or less? Much less work and the unaltered plastic will mean what remains of the cage will be stronger ...
2/ Section 18: 'Fabricate jumpers to attach the CMU to the batteries'
Rather than reproduce the jumpers tediously from bus bars, would it not be much easier to make them from heavy (to allow heat movement so the CMU PCBs can still sense overheating cell terminals) gauge multi-strand copper wire with a suitably sized eye crimped onto each end? Or use a piece of maybe 0.5mm thick copper flat with suitably sized holes punched in each end and the centre section heatshrink-wrapped for insulation? Punching would be much quicker and neater than drilling... This would be added once the busbars are all connected - and on top of the webbing...? - almost entirely avoiding potential issues of breaking the PCB when tightening the cell terminal nuts. The PCB ends could be attached by first added a suitably long M4 screw and nut through the PCB hole and then the eye of the jumper attached with another nyloc nut. Not using the - quite thick original - jumpers might mean even less plastic removing in section 14.
Sorry if this sounds like ungrateful nit-picking...
Looking forward to the next ones. MW
Good job !Hello,
Please note that piev is the organizer of the traction battery upgrade effort and has consulted with many folks to get to this point. My son and I are now benefiting from piev's efforts. Our car's upgrade is performing as expected and we are very pleased.
My son is working on some documentation on "Pack Removal, Module Rebuild, and Man in the Middle." The first version of "Module Rebuild" is complete and may be found at:
https://5by9.net/prune_batteries/module_rebuild.html
I will post notice of the other sections when they are available.
Our thanks to piev and all the other people who have contributed.
Mike
@phebbler ‘s ‘combined bus bar’ solution2/ Section 18: 'Fabricate jumpers to attach the CMU to the batteries'
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