Module Manufacturing Mistakes & Repairs

Module manufacturing ran into some mishaps and there were errors in how they were manufactured. This page exists as not only a set of instructions for how to fix them but also tips for future car generations.

1. Parallel Connections First

THIS IS WRONG! Series connections should have been spot welded before parallel because series first allows for voltage matching. Putting cells in series first allows for cells to balance their voltages before being connected in parallel. Once a parallel connection is made, a shared current travels through the connected cells, meaning that if there are variations between cells capacity and internal resistance, some cells will take more current than others and lead to an imbalanced module.