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272Ah Lifepo4 battery with DIYBMS on 3d printed cradle

Hi folks, thanks to the brilliant work by Stuart and plenty of help on here I have my battery built and BMS mounted.

In the end I build a base from aluminium extrusions that has a heater pad built in that holds the 4 cells together. I then designed and 3D printed a cradle for the DIYBMS and relay board that snuggly sits over the top of the cells.

Finally I added a webbing strap that can be used to pick the battery up with.



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Hi Ian,

great work! :grinning:

Lishen cells?

Would you be so kind and share the .stl and .dxf files of the cradle?

Then I could just redesign your idea for my 280 Ah EVE cells in this or other orientation.

Cheers

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Thanks,

Yes the 272Ah Lishen cells. I’ve attached the 2 top cradle STL files. Battery Top Cradle STLs.zip (535.6 KB)

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Looking great!!

I don’t see any clamping force on the sides of the cells.

That’s highly recommend by Eve and Lishen to prevent delamination.

Look at it as a phone book on its side.
That won’t hold long, while together it’s strong enough to stop a bullet.

Many people use plywood or acrylic sheet and threaded rods to compress.

For more information:

If you look carefully at the bottom frame you will see that the long bars are shorter than the cells. I have tapped the ends of these bars so that I have been able to apply torque to the fasteners, which in turn clamp the cells.
After this is done I then tighten up the fish plates on top of the bars to hold it all rigid and lock it down in place. Also the top cap is a ‘snug’ fit, this along with the bolted down busbars will resist the cells ‘opening’ at the top.

he’s not talking about holding the bottom or the top together, he’s talking about the sides.
Think of each plastic encased cell as a rubber balloon which is currently prismatic but when there’s any pressure on the large long sides, such as when charging, each cell wall will push against the next and start to bulge outward. This deforms the laminations internally and weakens the chemical reactions.

So you want to put a piece of 1/2" or 3/4" plywood on each large side and use long bolts to hold them together so they too won’t bulge outward when the cells try to expand.

Good question, thanks. I’ve now been and done some further reading.

It does look like adding some compression could increase the number of available cycles. But I’m not sure how tangible that will be. If can increase the life by 1.6X which sounds a lot, but this is based on higher C rates. And whilst the system is all geared around producing 270A without an issue, I’m not sure that this will happen very often (I’ll have to try and think this through).

So I will look into it, but the cost/benefit of replacing the cells after 10 years rather than 15 years may not be there. Especially since a lot of what I was reading looked at adding spring systems, these soon add up in price.

As far as I have read there any no short term risks with having little/no compression, so this is a gradual thing, like changing the oil on your car after 10000 miles, rather than 7000 miles.