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titleJan 3, 2023 Module Manufacturing

Pre-Meeting Notes:

  • What is the current state of modules?

    • 9 modules manufactured1 aux battery manufactured?

      • series spotwelds first decreases resistance

      • hot glue thermistors to busbar (only top and bottom as they get hottest)

      • each module can have 3 thermistors (on top, easier to manufacture)

      • busbars are good conductors, MS14 had thermistors only on busbars. Busbars are better for catching any cell that heats up

      • 1 on each busbar and 1 on center cell on negative end (closer to jelly roll)

      • difference b/w sum of voltage taps and pack voltage (through multimeter) because of Vdrop from busbars Vtap position

      • Vtap positions on bottom of module are ok (placement is closer to some cells, but prob only ~1mv diff)

      • voltage drop may occur between voltage taps (resistance of busbar)

    • 1 tested w/ forest

      • quick test

      • access to HV room w/ big eload (chroma?)

  • What do we need to do W24?

    • 9 modules + 4 5 spare modules manufactured and validated

    • Test 8 modules

    • 3 aux batteries

      • Testing: basic capacity test (full cycle + IR)

  • Review Module Testing Plan with Micah

    • All modules should be at same SOC when testing IR

    • cannot use multimeter because of method

    • High current testing is most important

    • when making tests, what can we do if it doesn’t pass?

    • wouldn’t do balance test

    • do full discharge for max current test

    • when checking temperature, use temperature rise from ambient rather than absolute temperature

    • first pack test should be as controlled as possible (chroma e-load)

    • Extra test: look at voltage of each individual cell

    • Ideal pack testing

      • take bench outside with pack and array, discharge and watch array charge the pack

    • OR put the whole system together, see vehicle move, watch array charge

  • Review Modules with Micah

    • Does he have any concerns with any choices we made?