Battery packs - no spot welder or solder required

The plastic in use has a slight amount of flex and the cells go in very snugly, I promise you I can not see them coming loose.

The recommendation to not exceed 50 cells is more due to the likelyhood of total pack weight strain on the joints, this can be fixed with a variety of methods.

And of course the stainless steel used in the connectors, bolts & contact tabs are not very current friendly it’s true.

The problem with introducing threadlock is that you can make a barrier using 2 nuts locked together makes more sense?

Looks like something you could 3D print yourself…

1 Like

And yes have seen a million stl files out there, I guess their IP is the bolting system in tandem with dovetails joining, making it fairly simple for… well even me to use.

Has it been done before? Well since I was asked fairly quickly by the Vruzend people who I was after making a post of two on their thread, in reality, <-> username on ES I think they are worried about imitation being the highest form of flattery…I told them my name, I am not a manufacturer of eStuff.

Probably if you search all the sites you will find that it is maybe an amalgamation of derivatives but in combination fairly effective and once you have a patent which I am pretty sure they have, then it doesn’t matter if they got their idea off something else.

But yes you could download a stl of a 18650 cap and modify it to have a top caps with a small hole in it and add your own hardware, there’s no escaping that fact. I just bough two of their kits which were fairly cheap but I would have paid more to not have the shitty steel in them which caused a couple of cuts on removal already in the 2 parallels I’ve made so far.

Here is the comment I read from the creator:

1 Like

That dude Micah Toll is their US distributer, he is very social media savvy and well placed in the ebike market to market their product. And yes it is not a high power application (unless you modify like I am in the process of doing)

Can I ask what mods you are doing to improve them? They do seem like a very good solution if they can be used on a board

I replaced the SS metal spring contacts with 1mm silver plated beryillium-copper wire fashioned into springs, also the SS bolts/nuts were replaced with 3mm brass bolts/nuts with washers on either side of the cap. 12mm pure nickel for the parallel connections and 2mm silver plated copper for the series connections. I’ll use a copper busbar on both terminal ends to complete

Sorry to reseruct… but i have the newest kit and its in now way useful… it keeps decompressing itself and needs to be compressed every few days and causes overvolt faults and makes the vest reset constantly to the point the board is unusable and the 1st couple times it bucked me off going 20+ mph (1st time i flew into a median any time after that i hit the ground running)

Decompressing?

so when u build the pack u snap the end caps on the cells and u need to “compress” the pack, i use a couple short 2x4’s and my vice (not hard or u will kill the cells or break the plastic) well, as you ride they slowly but surely work themselves loose and cause under/over voltage faults… im dealing with that issue now, this time it was over voltage faults

The following faults were registered since start:

Fault : FAULT_CODE_OVER_VOLTAGE Current : -6.2 Current filtered : -9.4 Voltage : 57.45 Duty : 0.240 RPM : 17840.9 Tacho : 316785 Cycles running : 8222 TIM duty : 3394 TIM val samp : 1697 TIM current samp : 8766 TIM top : 14139 Comm step : 1 Temperature : 75.80

Fault : FAULT_CODE_OVER_VOLTAGE Current : -13.5 Current filtered : -11.0 Voltage : 57.73 Duty : 0.167 RPM : 13405.0 Tacho : 528970 Cycles running : 11971 TIM duty : 3059 TIM val samp : 1529 TIM current samp : 10663 TIM top : 18268 Comm step : 2 Temperature : 75.67

Fault : FAULT_CODE_OVER_VOLTAGE Current : -13.5 Current filtered : -22.1 Voltage : 58.13 Duty : 0.135 RPM : 11982.8 Tacho : 531729 Cycles running : 3292 TIM duty : 2837 TIM val samp : 1418 TIM current samp : 11919 TIM top : 21002 Comm step : 1 Temperature : 76.13

Fault : FAULT_CODE_OVER_VOLTAGE Current : -15.2 Current filtered : -15.2 Voltage : 57.70 Duty : 0.133 RPM : 11358.6 Tacho : 533092 Cycles running : 1005 TIM duty : 2820 TIM val samp : 1410 TIM current samp : 12018 TIM top : 21217 Comm step : 2 Temperature : 75.87

Fault : FAULT_CODE_OVER_VOLTAGE Current : -28.8 Current filtered : -24.5 Voltage : 58.37 Duty : 0.090 RPM : 9394.8 Tacho : 535393 Cycles running : 6982 TIM duty : 2395 TIM val samp : 1197 TIM current samp : 14430 TIM top : 26465 Comm step : 5 Temperature : 74.65

Fault : FAULT_CODE_OVER_VOLTAGE Current : -6.9 Current filtered : -3.6 Voltage : 57.39 Duty : 0.306 RPM : 22435.7 Tacho : 670864 Cycles running : 10792 TIM duty : 3589 TIM val samp : 1794 TIM current samp : 7656 TIM top : 11723 Comm step : 2 Temperature : 80.14

Fault : FAULT_CODE_OVER_VOLTAGE Current : -7.4 Current filtered : -6.1 Voltage : 57.23 Duty : 0.289 RPM : 21303.0 Tacho : 672337 Cycles running : 717 TIM duty : 3547 TIM val samp : 1773 TIM current samp : 7900 TIM top : 12253 Comm step : 5 Temperature : 79.64

Fault : FAULT_CODE_OVER_VOLTAGE Current : -19.7 Current filtered : -18.5 Voltage : 58.13 Duty : 0.236 RPM : 17821.2 Tacho : 675390 Cycles running : 10829 TIM duty : 3380 TIM val samp : 1690 TIM current samp : 8841 TIM top : 14302 Comm step : 4 Temperature : 79.42

Fault : FAULT_CODE_OVER_VOLTAGE Current : -24.1 Current filtered : -23.8 Voltage : 58.40 Duty : 0.173 RPM : 14644.5 Tacho : 677196 Cycles running : 4424 TIM duty : 3091 TIM val samp : 1545 TIM current samp : 10482 TIM top : 17874 Comm step : 4 Temperature : 79.28

Fault : FAULT_CODE_OVER_VOLTAGE Current : -3.8 Current filtered : -7.0 Voltage : 57.32 Duty : 0.184 RPM : 13773.5 Tacho : 761773 Cycles running : 22703 TIM duty : 3150 TIM val samp : 1575 TIM current samp : 10148 TIM top : 17146 Comm step : 1 Temperature : 83.72

Fault : FAULT_CODE_OVER_VOLTAGE Current : -19.5 Current filtered : -21.8 Voltage : 58.13 Duty : 0.142 RPM : 12271.8 Tacho : 763249 Cycles running : 5563 TIM duty : 2890 TIM val samp : 1445 TIM current samp : 11623 TIM top : 20356 Comm step : 1 Temperature : 84.21

Fault : FAULT_CODE_OVER_VOLTAGE Current : -20.6 Current filtered : -27.0 Voltage : 58.27 Duty : 0.126 RPM : 11123.0 Tacho : 764499 Cycles running : 3889 TIM duty : 2763 TIM val samp : 1381 TIM current samp : 12341 TIM top : 21920 Comm step : 3 Temperature : 84.86

The following faults were registered since start:

Fault : FAULT_CODE_OVER_VOLTAGE Current : -6.2 Current filtered : -9.4 Voltage : 57.45 Duty : 0.240 RPM : 17840.9 Tacho : 316785 Cycles running : 8222 TIM duty : 3394 TIM val samp : 1697 TIM current samp : 8766 TIM top : 14139 Comm step : 1 Temperature : 75.80

Fault : FAULT_CODE_OVER_VOLTAGE Current : -13.5 Current filtered : -11.0 Voltage : 57.73 Duty : 0.167 RPM : 13405.0 Tacho : 528970 Cycles running : 11971 TIM duty : 3059 TIM val samp : 1529 TIM current samp : 10663 TIM top : 18268 Comm step : 2 Temperature : 75.67

Fault : FAULT_CODE_OVER_VOLTAGE Current : -13.5 Current filtered : -22.1 Voltage : 58.13 Duty : 0.135 RPM : 11982.8 Tacho : 531729 Cycles running : 3292 TIM duty : 2837 TIM val samp : 1418 TIM current samp : 11919 TIM top : 21002 Comm step : 1 Temperature : 76.13

Fault : FAULT_CODE_OVER_VOLTAGE Current : -15.2 Current filtered : -15.2 Voltage : 57.70 Duty : 0.133 RPM : 11358.6 Tacho : 533092 Cycles running : 1005 TIM duty : 2820 TIM val samp : 1410 TIM current samp : 12018 TIM top : 21217 Comm step : 2 Temperature : 75.87

Fault : FAULT_CODE_OVER_VOLTAGE Current : -28.8 Current filtered : -24.5 Voltage : 58.37 Duty : 0.090 RPM : 9394.8 Tacho : 535393 Cycles running : 6982 TIM duty : 2395 TIM val samp : 1197 TIM current samp : 14430 TIM top : 26465 Comm step : 5 Temperature : 74.65

Fault : FAULT_CODE_OVER_VOLTAGE Current : -6.9 Current filtered : -3.6 Voltage : 57.39 Duty : 0.306 RPM : 22435.7 Tacho : 670864 Cycles running : 10792 TIM duty : 3589 TIM val samp : 1794 TIM current samp : 7656 TIM top : 11723 Comm step : 2 Temperature : 80.14

Fault : FAULT_CODE_OVER_VOLTAGE Current : -7.4 Current filtered : -6.1 Voltage : 57.23 Duty : 0.289 RPM : 21303.0 Tacho : 672337 Cycles running : 717 TIM duty : 3547 TIM val samp : 1773 TIM current samp : 7900 TIM top : 12253 Comm step : 5 Temperature : 79.64

Fault : FAULT_CODE_OVER_VOLTAGE Current : -19.7 Current filtered : -18.5 Voltage : 58.13 Duty : 0.236 RPM : 17821.2 Tacho : 675390 Cycles running : 10829 TIM duty : 3380 TIM val samp : 1690 TIM current samp : 8841 TIM top : 14302 Comm step : 4 Temperature : 79.42

Fault : FAULT_CODE_OVER_VOLTAGE Current : -24.1 Current filtered : -23.8 Voltage : 58.40 Duty : 0.173 RPM : 14644.5 Tacho : 677196 Cycles running : 4424 TIM duty : 3091 TIM val samp : 1545 TIM current samp : 10482 TIM top : 17874 Comm step : 4 Temperature : 79.28

Fault : FAULT_CODE_OVER_VOLTAGE Current : -3.8 Current filtered : -7.0 Voltage : 57.32 Duty : 0.184 RPM : 13773.5 Tacho : 761773 Cycles running : 22703 TIM duty : 3150 TIM val samp : 1575 TIM current samp : 10148 TIM top : 17146 Comm step : 1 Temperature : 83.72

Fault : FAULT_CODE_OVER_VOLTAGE Current : -19.5 Current filtered : -21.8 Voltage : 58.13 Duty : 0.142 RPM : 12271.8 Tacho : 763249 Cycles running : 5563 TIM duty : 2890 TIM val samp : 1445 TIM current samp : 11623 TIM top : 20356 Comm step : 1 Temperature : 84.21

Fault : FAULT_CODE_OVER_VOLTAGE Current : -20.6 Current filtered : -27.0 Voltage : 58.27 Duty : 0.126 RPM : 11123.0 Tacho : 764499 Cycles running : 3889 TIM duty : 2763 TIM val samp : 1381 TIM current samp : 12341 TIM top : 21920 Comm step : 3 Temperature : 84.86

all those faults were from this one ride and that was from my house to the corner store >1mile from my house… i went to get some smokes and omw home it started jerking

So you compress it like the video. Then it wiggles loose?

What about zip ties or glue to keep it from spreading?

Messy, Ik, but that’s my vesc, bms, and battery there is 3 layers of foam to isolate all the components and even with those 3 layers to dampen shock it still wiggled itself lose

You could sandwich the cells between two sheets of plastic then zip tie the whole thing

I was thinking about that @E1Allen

1/2" acrylic

1 Like

Yeah. You need to compress it and secure it. Foam isn’t going to stop the vibrations.

1/2" thick? If you have room for it. Something thinner would probably be just as good.

Then ima go with my idea of leaving some over hang and bolting the plastic all the way around until I get a spot welder and a 12s bms… 10s just isn’t doing it for me

1 Like

It won’t budge after you bolt it down

nope and the sad part is… I can only ever go maybe 3 miles if that on a 10s5p pack made with 30Qs

Because it vibrates apart right?