Connecting the Pack (Learnings)

Owned by Owen Li
Last updated: Mar 30, 2024 by Nicole Choe
2 min read

  • Long busbar for end of pack doesn’t align with all module holes

    • It connected before when Taylor checked so it might only work with certain module

 

 

  • Make sure to tape over all busbar connections to avoid getting shocked

  • Don’t use locknuts (there was a lot of adjusting to do/some modules had to be re-wired and disconnected from the pack)

  • Next time make sure all the 3D prints are done beforehand, there may be some unforeseen interferences with some of thick HV wires

Wiring Modules:

  • Make sure the wires are long enough, if unsure of exact length always make them longer - can always cut them to length

    • Used 50cm for voltage tap connections and 60cm for thermistor connections

  • Use the wire strippers, and use 0 clicks for thermistor soldering and 1 click for any soldered connections to the modules

    • When soldering wires to the the thermistors: cut them so the metal ends are about 1/3rd the length, use the metal clamps to hold the two wires, put flux on the wires and tin them, then soldering the thermistor onto them by positioning the soldering iron below the wire and the thermistor (Forest said = better heat transfer). Add heat shrink to exposed wires by using the heat gun (don’t use the soldering iron)

    • Shove the thermistor so it sits in the middle of the wire (do a guestimate of the measurement)

    • When soldering wires to the modules: add flux to the nickel strips and create a “pool of solder” (makes it a lot easier). While the pool is still there, place the frayed end of the wire in the pool of solder, then remove the soldering iron and let cool. Add more solder if necessary, but in retrospect it probably would have been better to just verify each connection by checking it with a multimeter. Add heat shrink wherever necessary

  • Make sure all the wires are of similar length before crimping and connecting them to the Molex Connector

    • When crimping the wires, make sure the metal latches on to the rubber on the wire (otherwise you need to redo them)

  • Be 100% sure when connecting the Molex connector that it is the correct wire - had to connect the Molex connector in increasing voltage at the pins (0, 3.3V, 5.5V, 7.7V, 11.9ishV, 14.6ish V) - next time, do more checks with the multimeter for the soldered wires to avoid wasted time with screw-ups