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In order to validate our BMS system at the same time as building our battery, we need to make a board that will give all the same voltages as a 36S battery would. With this, we will be able to connect our AFEs, BMS carrier, and BMS current sense to it and validate the battery system.


We will build a 36S 1P battery system with spare cells in 18650 cell holders. Each of these cells will emulate a module in the actual battery pack.


This test rig should have:

  • 36 cells connected in series with voltage taps on each one
  • A thermistor on each cell to measure the temperature
  • A mount for the current sense resistor and board
  • A fuse to protect the batteries
  • Switch to easily turn on/off the stack
  • Contactor on + and - connections to be consistent with the car implementation


Fuse

Fuse should be rated to around 15-20A, fast blow. Should probably use the same Cooper-Bussman series as we are using for the actual car. Need to find purchase and get the fuses. Ask Joshua Rong for more details on fuses.

Contactors

  1. Charge Input + 
  2. Output (Motor Controller) + 
  3. Common GND Side - 
  4. Secondary contactor to emulate the coil sense contactor, coil wired in parallel with main contactor

For Contactors 1,2,3 I am thinking TE EVC 80 contactors or the solar contactors. Need to check prices and find digikey/mouser links

Switch

We should be able to manually turn the battery on or off. Should be rated for at least 20A, probably more for a  safety factor. Should also be satisfying to turn on - big switches are nice.

Current Sense

Should we have the option of switching in a larger current sense resistor to measure the current more accurately - then we might not have to change current set points when switching code as the reading scales according to the resistor chosen.

Connectors + Cables

  1. 12V Input - Molex Ultrafit, 2 pin, +/- consistent with the rest of the boards, 22AWG
  2. CAN - 2 ports, with BMS carrier in Daisy Chain Config - Molex Duraclik 2 pin, consistent with the rest of the boards, 22AWG
  3. Charge Input - 2-pin Molex MX150L, 14AWG
  4. Power Output - 2-pin Molex MX150L, 14AWG
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