Posted on 16 October 2014 at 11:59 pm (CET)
Yesterday and today I've been busy making the wires between the 4 battery packs. First I checked which size I needed to crimp the cable lugs. I just used a small piece of wire for testing. I also have 2 different kinds of cable lugs, one thicker than the other. I can't use the same size for both of them. You can see this here with the wire on the right, this is a thicker cable lug and crimped it with the same size as the thinner cable lug. Because of this you get some extensions on the sides. If a wire like this gets used it can melt or even cause a fire because of the heat build up. The left and middle one are crimped with 2 different sizes and are perfect. So that is how they all should be.
Now I could start with the real wires. First I stripped the wires and crimped the cable lug onto it.
Then I made the wire to size and did the same on the other side. I just placed the cable glands on it first because they don't fit over the cable lugs.
That's how I did all of the wires for the battery packs and they're all done now.
Tomorrow I'll continue with the wires between the whole battery pack and the controller. These are a bit more difficult since there's also a seperate shielding in these wires making them more stiff. Also have to do some other things with these but I'll probably show this tomorrow.
A big update again after a few days of work. I've made cable pass throughs for all of the boxes.
First I completely finished the one for the fuses of the charger and dc-dc converter. Drilled quite a few holes and placed cable glands in them.
This one I could also place on the frame already. Can only connect the cables once everything's on there anyway.
For the next box I didn't use a cable gland, not enough space for it unfortunately. So I just glued a small hose into there. Works pretty good as well.
For the square box I could have placed a cable gland but the space on the inside was very tight then. So I also just glued a small hose into there.
Then the bigger box. Here I was able to use cable glands everywhere.
But the most important is that all of the battery boxes are all done now and finally back in the frame. I just wonder if all of the frames of corner profiles will still fit well since the paint layer is pretty thick but I'll find out soon enough.
Also placed all of the lids on them to see what it'd look like. I'd say it looks pretty nice.
Now I just still have to place those other boxes, then I can start connecting everything. And the top case I still have to get ready as well, probably won't be easy either. But it's really starting to get a move on again.
Posted on 7 October 2014 at 11:44 pm (CET)
Today I finished the other high voltage box. For this one I could make a bottom plate again to screw all of the parts onto. This box is also pretty important, the distribution is made here for the charger (to charge the battery pack) and dc-dc converter (to keep the 12V battery charged). For both there's also a seperate fuse.
Tomorrow I'll have to check what I all need now of connectors and cable glands, then I can hopefully place a few of the boxes in the frame already this weekend.
Tonight I finished the first box with high voltage parts. Had quite some work with this one since the standard mounting points weren't really useful and the box is also too low to make a plate for the bottom. Was also quite tricky to decide where to place everything, still is far from ideal but I can't really think of any better way.
In this are the main contactor (splits the battery pack in two to safely work on it and for emergencies), sensor plate for EV Display (gauge) and the main fuse. The orange cables I still have to connect, will do this once all of the boxes are done and placed in the frame. I did however connect the 12V part already, wasn't really much work for this box.
I also started with the last box already, this one's easier and will probably be finished tomorrow already. Meanwhile 15 of the 24 batteries are also charged already. So this weekend I hope to have them all charged. Then I can finally start placing them in the boxes and in the frame.
Today I finished the second box. It's also completely stuffed now with only relays.
First I made a plate again to which I could attach all of the circuit boards. And with all of those spacers inbetween the circuit boards are stacked together as close as possible.
All wires connected again like in the diagram that I made a while ago. There are quite a few.
It all barely fits in the box. With this one I'll also add a cable gland so all of these wires can go outside. And I'll spray it black myself tomorrow. Wasn't really planning on using this one, that's why it wasn't sprayed together with rest of the boxes.
Meanwhile I'm also busy charging all of the batteries one by one to the same level. Takes about 1,5 hour for each battery so it'll still take me a while.
Now I still have to finish 2 more of these kind of boxes, only after that I'll start with the battery boxes.