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When designing a method for mounting modules to the battery box, we must consider the clearance required to access any fasteners used and electrical safety. For these reasons, we are considering a tool-less compression fit. Our modules would be held in place with a grid high enough to prevent rocking, possibly lined with foam. We can also embed copper busbars in this grid to form the series connections between each module, resulting in minimal exposed copper. For added strength, we can add magnets to keep the modules locked in place. These should be polarized to prevent modules from being placed in reverse.
Inspiration
Original solderless pack design
Layout
An approximately 60kg pack will be difficult to lift. With additional electronics and the added weight of connectors, brackets, and the box itself, we expect the pack to be between 70-80kg total. To make this easier to manage, we are considering splitting the pack into two boxes. Note that we have approximately 40" x 47" x 9" of space to work with.
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