• Home
  • Shop
  • Videos
  • Technical!
  • Fun Stuff!
  • About Us!
  • More
    • Home
    • Shop
    • Videos
    • Technical!
    • Fun Stuff!
    • About Us!
  • Home
  • Shop
  • Videos
  • Technical!
  • Fun Stuff!
  • About Us!

Build Process

Cell Verification

Cell Verification

Cell Verification

image395

To prevent the mis-fortune of using counterfeit or manufacture discarded cells, batches are capacity and electronic load tested at a constant 15A. Above photo depicts a sample discharge graph of a Samsung 30Q cell which is consistent with manufacture's data sheet. Cells are purchased in bulk in Samsung sealed packaging.

Spot Welding

Cell Verification

Cell Verification

image396

Single layer of 12 mm by 0.15 mm thick nickel strips equates to an 13AWG current carying capacity. This yields 0.03% power loss over 12mm length between cells. This allows for proper current flow with the ability to "blow" incase of a short, acting as a fuse. These welds are electronically timed using capacitive discharge.

Cables

Cell Verification

Packaging

Replacing factory Polyvinyl Chloride (PVC) wires that have a temperature threshold -20 to 105C with

Substituting Polyvinyl Chloride (PVC) insulated wire with a temperature threshold of -20C to 105C for Polytetrafluoroethylene (PTFE) which increases the threshold to 240C and decreases the overall diameter by 40%. PTFE has a much higher resistance to abrasion than PVC. PTFE is costly. 

Packaging

DIY: Installation

Packaging

image397

Epoxy is used on parallel cells to relieve stress from the welds. Plastic strips insulate series cells. PVC heatshrink to seal battery assembly. 

DIY: Installation

DIY: Installation

DIY: Installation

Taking off the BMS from your factory battery, using a heat gun to heat three "solder sleeves", and plugging in the 11-pin BMS harness, completes the installation.

Video Installation!

Dimension and Weight

Bamboo GT Battery

Bamboo GTX Battery

Bamboo GTX Battery

Factory (7aH): 16x135.7x335.3mm @ 1.5kg

40 Cell (12aH): 21.2x141x378 @ 2.01kg 

80 Cell (24aH): 42.2x135x376 @ 4kg 

Bamboo GTX Battery

Bamboo GTX Battery

Bamboo GTX Battery

Factory (10aH): 22.5x134.7x331.9mm @ 2.12kg

40 Cell (12aH): 21.2x141x378 @ 2.01kg
80 Cell (24aH): 42.2x135x376 @ 4kg

Carbon GT Battery

Bamboo GTX Battery

Carbon GT Battery

Factory (10aH): 18.2x135.1x414.1 mm @ 2.15kg

40 Cell (12aH):  20.4x133.4x378.3 mm @ 2.01kg 

50 Cell (15aH): 20.4x133.4x465.5 mm @ 2.43kg

Gen 1 BMS

Gen 1 BMS

Carbon GT Battery

Design flaw - No Heatsink causes over heating

Size: 95x50x8mm

Gen 2 BMS

Gen 1 BMS

Gen 2 BMS

Design flaw - No Heatsink causes over heating

Size: 110x40x6.5mm

Gen 3 BMS

Gen 1 BMS

Gen 2 BMS

Heatsinked

120.5x40.3x10mm 

Thresholds

Samsung 30Q Data Sheet

In house cell verification

Samsung 30Q Data Sheet

Examine Samsung's discharge curve, this is consistent with the performance of over depletion.

Samsung's discharge shows the voltage sag you'll experience over load and cycle life. Street wheels on flat surface on ECO you'll see minimum load. Uphill with AT tires on GT mode you'll see close to maximum .

In house cell verification

Samsung 30Q Data Sheet

Recommended max output per parallel cell 15A
Recommended max charge per parallel cell 4A

Recommended max output per cell: 15A

Recommended max charge per cell: 4A

In house cell verification

In house cell verification

In house cell verification

In house testing shows consistent with Samsung's data sheets.

Electronic load testing verifies constisconsistency with Samsung's data sheet.

Evolve's BMS Data Sheet

Evolve's BMS Data Sheet

In house cell verification

image398

Maximum Charging Current: 6A.

Maximum Output Current: 60A for 10 Sec.


22awg charging cable is another reason not to charge over 5.4A.


Abuse

Evolve's BMS Data Sheet

Abuse

image399

Cells can withstand a lot, nearing 300 degrees Fahrenheit per datasheet. Do not test these limits.

Copyright © 2020 Pelican Bay Innovations - All Rights Reserved.

  • Technical!