Rainbow Prius Hybrid Powered by Lithium!

so, what is the meaning and consequence of the higher resistance? And why does it seem to affect that one block?

 

I lost both my elm327 s I know they're around here somewhere. I've got the app and thanks for all the testing and tweaking JTR

edit: thank god I finally found this thread....
- do the lithium modules swell like the Ni MH modules when fully charged and not compressed in the pack?
do you always number modules starting at the contactor side?

 

Anyone that can provide live test data or is it just going to be 'seat of the pants' thing?

 

I am very lad to see progress on this project. Watching with interest...

 

So excited to be a part of this final testing process before large scale production begins...

 

Seem like we need to find a good price on copper cable and compatible terminals... Anyone know where to best start that search?

 

If we're saying the OEM style cables and safety interlock switch are inadequate, I'm going to have to throw the "BS" penalty flag.....

Looking at the photos, it appears there are terminals only on one side of the module. Is that true? If so, what modifications did you perform to install the disconnect?

 

Jack recently sent me a photo of a slightly different terminal configuration for block #10 module, but am not clear on it until the package arrives...

My buddy who runs his modified Prius at the race track is confident this is an easy trip to the hardware store type fix, but I'm thinking it might require a bit more than that. We'll see...

 

Woohoo... I'm so excited... But I have to go climb up a Cedar tree to prune some branches before I can get started!

 

Don't think I've ever seen a battery temperature that low. Do you recall what your outside ambient temperature is?

 

Module level reconditioning can get expensive. What I believe I'm looking at in PriusCampers pic above are
several chargers, several multimeters and a discharger all very well organized on a dedicated bench. And none of the components look inexpensive. Thinking 28 of each meter and charger and one discharger or two, plus a lot of work during the process.

Has the cell configuration and / or composition been released yet?
I think I know some of what I'm looking at like cell count per block etc and can only imagine the conplexity involved adjusting the traction pack charge and discharge monitoring for the conversion.

 

My primitive hyrbid battery diagnostic rack is for NiMH module work for Toyota & Honda battery packs and doesn't have anything to do with these lithium modules/blocks...

 

A few questions.
There are 13 identical blocks and 1 special block with studs on both sides to allow connecting the safety disconnect? This cable assembly, purchased from Toyota, is very inexpensive.
Do the holes provide access for test points or will they not be there on later versions.?
What are the items on top of the modules? Are they vents?
Do these modules fasten to the case floor using machine screws from underneath? If not..Without those fasteners, it's relying on one nut on the block 1 end and one nut on the block 14 end to keep the pack in place during any 'mechanical agitation' event. (And those nut attachment points are pretty sketchy). That would be an area to look at later.
Do the modules have a positive mechanical interlock with one another? Just wondering about the alignment issue circled below and the visible fastener holes. Are the modules dimensionally different (lengthwise) from the OEM? If no machine screws fastening them to base, and no mechanical interlock, are there any concerns that the modules will move due to normal forces exerted on the car?

This really sounds like it's going to be an interesting battery.

 

Camper,

Are you doing discharge/charge cycles on all the modules to get capacity data? I don't think my chargers have ever been set up for anything other than NiMH, lol.

 

Nope... I mean I'd love to play around with them in terms of getting discharge and charge data but my chargers are for 8.2v modules and not powerful enough for 16.4v blocks. I'm just going to get initial out of the box voltage readings on the spread sheet for now and then I'll add load test data each time I swap the pack between vehicles. For now I'm just trying to find enough time to get it in the first car.

PS: And yes, I was thinking I was finally going to get to explore settings other than NiMH on my chargers, but didn't turn out that way.