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2024-2026 Battery Procedure

2024-2026 Battery Procedure

image-20260219-012913.png
Horizontal = Multitasking | Vertical = Sequential Tasks

A: Housing (Except Inner-Lid)

B: Individual Segment(s)

C: 8-Segment Assembly + Finish Housing

D: BPS

E: Thermals [UNFINISHED]

A. Housing (Except Inner-Lid)

a. Fix Hirose Panel Mount

  1. Prepare:

    1. cutout pattern

    2. Dremel w/ saw bit

    3. sharpie

    4. 3D-printed Hirose cutout

  2. Use cutout pattern (or 3D-printed Hirose cutout) to trace the outline of where the panel mount sits

  3. Use Dremel to carefully cutout your tracing

image-20260221-002509.png
Hirose pattern w/o tolerancing

b. Preparing Housing Panels

  1. Prepare:

    1. LocTite 120

    2. JB Weld

    3. Popsicle Stick(s)

    4. Paper Plate

    5. C-Clamp(s)

    6. Interior Panels

    7. Exterior Panels

    8. Interior Segment Panels

    9. Outer Lid Latches

    10. Outer Lid Latch Pegs

    11. Interior Panel Inserts

    12. Exterior Panel Inserts

    13. Cell Cover Inserts

    14. Recessed MX150 Mount

  2. Mix together the LocTite 120 using a popsicle stick on a Paper Plate

  3. One at a time, apply mixed LocTite 120 to the inner side of one of the three inserts

  4. Using a C-Clamp, clamp down one of the three different type of inserts into their respective exterior & interior housing walls hole

  5. Wait for 3 hrs for the Loctite to functionally cure

  6. Mix together the JB Weld using a popsicle stick on a Paper Plate

  7. Insert the Outer Lid Latch Pegs into the Outer Lid Latches (You’d rather have the pegs sticking OUT of the enclosure than into the interior of the enclosure)

  8. Apply the mixed JB Weld to the inner side of the Outer Lid Latches bottom

  9. Lineup the Outer Lid Latches onto the top edge of the panels where the peg holes are and firmly press the latch bottoms into the panels

  10. Using a C-Clamp, clamp down the latch bottoms onto the panel

  11. Let sit for 15-24 hours before removing C-Clamps

  12. Mix together more of the LocTite 120 using a popsicle stick on a Paper Plate

  13. Apply the mixed LocTite 120 to the recessed MX150 mount

  14. Using a C-Clamp, clamp down the recessed MX150 mount onto the exterior BPS panel

  15. Wait for 3 hrs for the Loctite to functionally cure to remove the C-Clamp

 

c. Bonding Finished Panels to Base Plate

  1. Prepare:

    1. Cold Plate

    2. Case Corner Jigs

    3. Finished Interior Panels

    4. Finished Exterior Panels

    5. Finished Interior Segment Panels

    6. LocTite 120

    7. Popsicle Stick(s)

    8. Paper Plate

    9. XXXX Caulk

  2. Lay the cold plate down where you plan to let the epoxy sit

  3. Mix together 1/3 of the LocTite 120 using a popsicle stick on a Paper Plate

  4. Apply the mixed LocTite 120 to the red arrows marked intersections and red lines marked cold plate intersections

  5. Wait for 3 hrs for the Loctite to functionally cure

  6. Mix together the next 1/3 of the LocTite 120 using a popsicle stick on a Paper Plate

  7. Apply the mixed LocTite 120 to the orange arrows marked intersections

  8. Wait for 3 hrs for the Loctite to functionally cure

  9. Mix together the final 1/3 of the LocTite 120 using a popsicle stick on a Paper Plate

  10. Apply the mixed LocTite 120 to the green arrows marked intersections and green lines marked cold plate intersections

  11. Wait for 3 hrs for the Loctite to functionally cure

  12. After finishing the mounting the panels to the cold plate, use caulk to cover any of the exposed aluminum

panelBondingProcedurev1-20260220-231212.png
Panel Bonding Order (Red → Orange → Green) [lines are bonds to cold plate]

 

B. Individual Segment(s)

a. Component Preparation

  1. Prepare:

    1. X-Acto Knife

    2. Cells

    3. Cell Delivery Cases

  2. Setup the open box of cells on one side of you with the lid of the delivery case off

  3. Setup the lid of the delivery case to the other side side of you

  4. CAREFULLY remove the wrapping around the cells at the top side of each cell using the X-Acto Knife (There should be a divot near the top end of the cell, use the knife edge to cut in that divot)

  5. Put the partially unwrapped cells upside down onto the lid of the delivery case

  6. When finished unwrapping all the cells from a delivery case, put the base of the delivery case on top of the partially unwrapped cells

  7. Store back into the carboard box back inside the batt cave battery cabinet

 

b. Thermistors

  1. Prepare:

    1. Zip-Ties (x2)

    2. Mold Release

    3. Thermistor Jig

    4. Partially Unwrapped Cells (x4)

    5. Thermal Epoxy 8329TCM

    6. Popsicle Stick

    7. Paper Plate

    8. Tesa Tape

  2. Insert 4 cells into the center 4 slots of the cell carriage

  3. Place one side of the thermistor jig onto the back side of the cells (opposite of where you want the thermistors to be)

  4. Apply mold release to the other side of the thermistor jig

  5. Start a 45 minute timer (5 minute if TFF)

  6. Wait 15-30 minutes to allow the epoxy to become thicker and more tacky (Unnecessary if TFF)

  7. Use a popsicle stick to mix together the thermal epoxy on a Paper Plate

  8. Use a popsicle stick to spread enough mixed thermal epoxy onto the thermistors, with as little epoxy hanging off the edges (Be sure to fully cover the actual thermistors)

  9. Slide the thermistor into the side of the thermistor with mold release that is not on the backside of the cells

  10. When ready, press the side of the thermistor jig with the thermistors against the other side

  11. Use zip-tie’s to clamp the two sides together

  12. Wait for 24 hours (15 minutes if TFF) while the epoxy cures

  13. Cut the zip-tie’s and remove both sides of the thermistor jig

  14. Cover the thermistors with Tesa Tape to securely adhere them to the cells

 

c. Cells + Bus Bars

  1. Prepare:

    1. Partially unwrapped cells (x32)

    2. Carriage WITH thermistors already installed

    3. P Bus Bar

    4. PN Bus Bars (x3)

    5. N Bus Bar

    6. Loctite 120

    7. Popsicle Stick

    8. Paper Plate

    9. Volt Temp PCB Mount

    10. Volt Temp PCB

    11. Bottom terminal collector covers (x2)

    12. Collector Terminal (x2)

    13. Segment Top Plate

    14. Segment Handles (x2)

    15. Press-fit nut (x2)

    16. M3 Screws (x?)

    17. HV Blanket

  2. Insert the one row of the cells into cell carriage through the bottom openings

  3. Spot wield P bus bar to cells

  4. Insert the one row of the cells into cell carriage through the bottom openings (x2)

  5. Spot wield PN bus bar to cells (x3)

  6. Insert the one row of the cells into cell carriage through the bottom openings

  7. Spot wield the N bus bar to cells

  8. Carefully flip the carriage upside down on top of a HV blanket

  9. Use Loctite 120 to epoxy the bottom of cells into cell carriage

  10. Place a heavy plank or a something flat on top of the bottom of the cells (INSULATIVE) (If using something flat and NOT heavy, use a clamp or two to press the cells into the bus bar guide while curing)

  11. Wait for 3 hrs for the Loctite to functionally cure

  12. Mount Segment Top Plate with M3 screws

  13. Mount VoltTemp Mount with M3 screws

  14. Mount VoltTemp PCB with M3 screws

  15. Plug thermistors into VoltTemp PCB

  16. Install bottom terminal covers using M3 Screws

  17. Install press-fit nut

  18. Lay the collector terminal in place atop the bottom terminal covers and press-fit nut

  19. Lay the the P/N bus bar on top of the collector terminal in preparation for segment-to-segment bus bars

  20. Mount both the segment handles using M3 screws

  21. Repeat for each segment

  22. For two segments install full-battery terminals using bolts (And terminal specific bottom terminal covers using M3 Screws)

C. 8-Segment Assembly + Finish Housing

  1. Prepare:

    1. Finished Housing (Beside Inner Lid)

    2. Finished Segments (x8)

    3. Cell Cover Front Lock Mount (x2)

    4. Cell Cover Rear Lock Mount (x2)

    5. Housing Inner Lid

    6. Battery Box Internal Wire Harness

    7. XXXX Screws (x???)

    8. 0.5 in. Hex Bolt (x16)

    9. M3 Screws (x?)

  2. Carefully place each finished segment into a open space in the battery housing, following the pattern of having the opposite polarity busbar touching the same inner panel as the busbar of the segment next to it.

  3. Mount each segment into the 2 interior panel holes using XXXX Screws

  4. Mount each segment into the 1 exterior panel holes using XXXX Screws

  5. Install segment-to-segment bus bars in numbered order shown below using 0.5 in. hex bolts

  6. Install the terminal covers using M3 screws, once you connect a bus bar to a terminal

  7. Use insulation covers to safely cover the bus bars after each bus bar you connect

  8. When finished with ALL segment connections, connect internal wire harness to all the segment VoltTemp PCBs

  9. Install both cell cover front lock mount using M3 screws

  10. Install both cell cover rear lock mount using M3 screws

  11. Install inner lid using M3 screws

segmentConnectionProcedurev1-20260221-000509.png
Segment Connection Order (1->7)

D. Battery Protection System (BPS)

  1. Prepare:

    1. PDM Mounts (1-8)

    2. PDM Base Plate

    3. PDM Precharge Strut (L & R)

    4. PDM Fuses

    5. PDM Bus Bars

    6. PDM Lug Terminals (x8)

    7. PDM Contactors (x?)

    8. Cooling Manifold

    9. Amperes PCB

    10. Active Precharge PCB

    11. Controls Indicator PCB

    12. Scrutineering PCB

    13. BPS Leader PCB

    14. E-Stop

    15. Amphenol Panel mount (x2)

    16. Hirose Panel Mount

    17. LocTite 120

    18. Popsicle Stick

    19. Paper Plate

    20. Press-fit nuts (x?)

    21. M3 Screws (x?)

    22. XXXX Bolts (x?)

  2. Screw in all 8 of the PDM mounts into the PDM base plate

  3. Mix together the LocTite 120 using a popsicle stick on a Paper Plate

  4. Apply the mixed LocTite 120 to the backside of the PDM Mounts using only a drop of epoxy per mount

  5. Place the PDM in place inside of the BPS area (You should have decent tolerance around the BPS area to orient the PDM)

  6. Wait for 3 hrs for the Loctite to functionally cure

  7. Install the press-fit nuts into the PDM base plate

  8. Mount PDM bus bars using M3 bolts

  9. Install PDM bus bar terminals using XXXX bolts

  10. Install PDM fuses using XXXX bolts

  11. Install PDM Contactors using XXXX bolts

  12. Mount cooling manifold using M3 screws

  13. Install BPS PCBs (Amperes, Active P.C., Controls Indicator, Scrut., BPS Leader) using M3 Screws

  14. Install both of the PDM Precharge struts using M3 screws

  15. Install E-Stop using M3 Screws

  16. Install the Hirose and both Amphenol panel mount connectors using M3 Screws

E. Thermal System Assembly

a. Copper Tubing

  1. Prepare:

    1. Cold Plate

    2. Copper Tubing

    3. 150 Grit Sandpaper

    4. Thermal Interface Material

    5. Tube Bending Molds

    6. Quick Disconnect

    7. Cooling Manifold

    8. LocTite 120

    9. XXXX Caulk

    10. M3 Screws (x?)

  2. Clean and prepare the cold plate

    1. Sand down inner surface of the tube recess with 150 grit sandpaper

    2. Wipe down cold plate surfaces with paper towels and isopropyl alcohol to remove dust/grease

    3. Inspect for debris, especially in the tubing track

 

b. ????

  1. Apply thermal interface material to cold plate

  2. Install copper tubing

    1. Bend tubing first using 3D-printed molds

      1. Bend every angle while molds are still clamped

  3. Install tube retention clips

  4. Install manifold with M3 screws onto mount

  5. Install Quick Disconnect

    1. Glue soft tubing onto manifold

    2. Apply adhesive around cup

    3. Caulk the edges of the cup

    4. Repeat for Male QD and Female QD

  6. Install Intake & Outtake

    1. Install intake gasket onto the lid (bolted?) (not finalized)

    2. Secure intake mount using M3 screws

    3. Repeat for outtake mount

  7. Install intake funnel onto intake mount using M3 screws

  8. Install mesh caps onto the mounts using epoxy