Thursday, July 13, 2017

Rear battery box out for review

We have stumbled on the design of the rear battery box for almost a year now.  The configuration has not changed much in that time, just overall size nudges.




The plan is to slide the 6 modules into place and place threaded rods through the pack to hold them in place clamped.  The bus bars can then be installed on them with two wire leads protruding for connection to the 20 pack or the main output relay.  The two 10 packs are on the original Leaf plates and will have the bus bars applied to them again with a couple of leads extending.  The two packs will then be lowered into the box, secured with threaded rods, and the wiring connections completed.  A 5/8" plexiglass plate will be secured and sealed to the opening above the 20 pack.  The entire pack will be flipped upside down with the threaded rods now protruding from the top it will be lifted/the car may be lowered onto it with the rods passing through the floor pan for securing to the pack to the frame.  An independent skid plate will then be installed under the pack for debris protection.

We could use a little help figuring out the best wiring pattern.  I have tried to upload both an excel worksheet we have been using to visualize the wiring in both xlsx and csv format.  They are plain sheets there should be no macros in them.  Anyone know how to upload them here?

This is the rear battery pack for the golf.  There are 26 modules in the pack, 4 stacks of 5, and 3 stacks of 2 as shown in the 3D images.  Note that the shorter stack is inline with the lowest rows in the 5 stacks.  Physical arrangement is FINAL, no moving modules...Each of the 3 boxes represents a connection on each battery module.  The middle connection is for sensing and may not be used for a power connection.  The outer connections represent + and -.  The entire set of 26 must be connected in series, + - + - +-......  Due to space constraints the outer gray set of connections should not be end points for the entire pack or transition to the 6 pack, but should route up or down in the rows of the 20 pack using flat bus bars as shown in the front box pictures.



Suggestions please.

The winning suggestion
This pattern looks like the best option.  It will allow the sections deeper in the box to be pre-connected leaving only one connection to make near the top of the box between the 6 pack and the left 10 pack.  This arrangement requires 13 long bus bar connections.  The original leaf pack only had 10.  So we are short 3.  It is simple enough to make the bus bars, but we would also like to reuse the Leaf orange safety housings like we did on the front boxes.  Anyone in the U.S. have some spare leaf protective covers we may use?

UPDATED:

Requires fewer long bus bars, and therefore we have enough parts.





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