Building a fast 18650 DIYPowerwall 80P battery using a KWeld Spotwelder
ฝัง
- เผยแพร่เมื่อ 19 พ.ย. 2019
- Using Battery Hookups new fused nickel strip I think I've built the sexiest battery ever. So clean and fast to build it's just incredible.
The fused nickel I'm using here is the 5p variety ordered for a different project but it comes in sizes 2-5p to suit your project. On it's own it's rated at 20 amps, but by adding the busbars that easily increased to 30-50 amps tho I'll never see those loads in this application.
💥🔋Fused Nickel - bit.ly/FusedNickel - Use "DIYPowerwalls" at the checkout to save 10%. 🔋💥
■▬▬▬▬▬ Links ▬▬▬▬▬■
🏵 Fused nickel strip - bit.ly/fusednickel
🏵 Kweld Spot welder - bit.ly/2OhVCM9
🏵 Kweld Battery - bit.ly/kweldbattery
🏵 Cell Information - bit.ly/2OBeiqm
🏵 iCharger X6 Discharger - bit.ly/iChargerx6
🏵 Thermal camera - bit.ly/35qWwgh
🏵 Batrium BMS - bit.ly/2XyVXyg
🏵 Lug Crimper - bit.ly/2XxFDgZ
🏵 Community Forum - www.secondlifestorage.com
🏵 Community FB - www.diypowerwall.com
🏵 18650 wall mounts - goo.gl/xDUzSV
🏵 Total Project Cost - goo.gl/cfLqZf
💰Save up to 10% at these stores with coupon code ' powerwalls '💰
🔵 BatteryHookup USA - bit.ly/BatteryHookUP
🔵 BigBattery USA - bit.ly/BIGBattery
🔵 Lithium Power - Australia - bit.ly/LithiumPowerAustralia
Second Life Storage Cell Finder -
🔋 Paolo Italy ebay.to/38xPUhT
🔋 Tim De Groot NL ebay.to/2OX9koS
🔋 Power 2 Spare USA ebay.to/2SuJWsr
🔋 Pro-LOX Netherlands ebay.to/2HsyPKr
💻💡DIYPowerwalls Community Facebook Group 💡💻
► / diypowerwalls
Official forum thread with all the extra details to fill all the gaps -
👍 Total Project Cost - goo.gl/cfLqZf
👍 18650 wall mounts - goo.gl/xDUzSV
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Cheap BMS - s.click.aliexpress.com/e/eX4NpXsc
Quality BMS - www.batrium.com
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Learning resources -
🔖 DIY Lithium Batteries- amzn.to/2MC4BaM
🔖 Mobile Solar Power Made Easy - amzn.to/2Tzk6TA
🔖 DIY Solar Power - amzn.to/2IgxfMa
Recommended Gear -
🔵 Clamp AMP Tester -- goo.gl/z8b4uJ
🔵 iCharger X6 - goo.gl/GtBtW9
🔵 Flir Thermal Camera - bit.ly/35qWwgh
Affiliate Stores -
💸 Amazon Store - www.amazon.com/shop/hbpowerwall
💸 eBay - goo.gl/tk6Qdd
💸 Banggood - goo.gl/1PWhni
Social Media -
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Thanks for tuning in as always!
Pete
#diypowerwalls #hbpowerwall #diypowerwall
Use the code 'Powerwalls' at www.batteryhookup.com's checkout to save 10%
Not any more, but have in the past
WTF how cool is that dude! Very nice Job really!
1:50 is it safe to touch that metal sheet say when the power is on?? I swear i see in some videos of people touching that metal or other bits of metal ? what about the big wires that go into a hook end thing and crimped together like what if you touch that as its never covered? i dont get it lol
im such a noob lol
Amaizing! Thak you for sharing!
Thanks for tunning in
This legit couldnt of come at a better time lol, love the new layout :)
Did you pick up a bunch of nickel sheets?
Glad I could help
@@jamess1787 Added to my wishlist :D
That is one awesome setup. You my friend, rule.
Thank-you sir
@@HBPowerwall I have a question. First you are doing a good job explaining, and you have a good channel. back to my question - As far as i can see, your cells are in series in each pack? but how are all the pack's connected together? what voltage do you have on the side with battery pack's ? Do you have a video where you systematic goes thrue your installation ?
What a battary like that worth to build in total cost very interesting
Anywhere from a dollar to a billion dollars - there is to many variables
I like your work mate! - would love some advice at some stage considering lithium cells. My current diy batteries revolve around super caps paired with small solar panels to pulse warm water through my tomato grow beds. But have issues in the morning when the solar charge controller no longer recognises my super cap cell below "X" voltage. Super caps drop volts overnight unfortunately
Awesome, perfect timing. Think I need to get myself some busbars
Let me now when you need the Community Spot Welder :) www.secondlifestorage.com/kweld
@@HBPowerwall thanks man, just need to get me some busbar, where do you forage your cable for making busbars?
Gumtree works really well, some sparkies sell off half rolls
@@HBPowerwall great idea, I am just nickel striping the first 560 this weekend, then my next lot of 560 cells at Xmas, I will make proper 80p packs with busbars like yours.
I ain't going to be drawing more than 30a max currently and the nickel can handle around 60amps without heat.
Awesome setup. Humidity has not affected your outdoor setup at all?
Great video, what info lead you to replacing that bank of batterys, what information comes from your system that caused you to do this or are you pulling cells out and replacing them based on cycle count ect...
Sorry I should have watched the last few minutes before commenting, you did explain some why you chose that cell to replace.
Love the layout and the final look, and how easy is to connect after each battery set with the others. Still, if after a while single 18650 cells are failing and you need to replace them, what to do? Do you break apart the whole set?
you would have to be creative, but it's no different than a timing belt on a car, some are easy some are a pain - you just deal with it and move on. It's really so fast to assemble, doing maintenance and it taking a little longer is an acceptable trade off. That said, is not soldering going to cause even LESS maintenance thus making it even more attractive way of doing it?
GREAT VIDEO MAN!!! THUMBSY👍 With a BOOOOM💥💥💥💥
Thumbsy AND a booooom.. dam dude
I hit the like button thanks for sharing your video I'm here to support your channel as always I can't wait to share my battery build video coming soon with you I will post in the Facebook group
Awesome thanks for the like! can't wait to see it on FB
Love your videos. One question I have with all these diy powerwalls is how do you control discharge of your batteries when connected to the grid? So if you are connected to grid, batteries are fully charge and you want to pull power from your batteries instead of grid is this controlled through your charge controller/inverter? I can't picture how the output of everything is being managed. How do you push only to supply house load vs supplying house and grid? Seems that powerwalls 2 has the gateway that helps manage all that but there's probably a bunch of magic smoke in there. Ha this might be too much for a simple message. Thanks for your time.
My inverters are off grid. They can not power the grid at all - the units blow up instantly. I run 24/7 from my inverters and if the batteries go flat i can flip a transfer switch that totally bypasses the inverters
The copper wires need to be anchored to the plastic holders because they are only relying on the fuse links for location strength. Notice the nickel lift at 3:49
Yes it does, but need to make holes before attaching, i tried to do it after and i had to use come creative editing or start over lol
Hi. I am from Austria and in the next days i will build my new powerwall 4.0 from new chinese 18650 (about 2000€) for 1450 pcs.
I had a powerwall up and running, but i had some issues with the soldering points in the old one. I used 5 amps fusewire and sold it to the batteries. But over the time some of these solderingspoints starts to rust and i think i have lost (a good) connection. So i bought your spotwelder and use your promoted sheet of metal fuses and i still dont know how to connect the connectors. Should i solder them (like in your video) and then use protection paint (teslanol) to prevent corrosion or is there a better way? Please help. Thx Markus
Very nice!!
Only one thing I would do differently.
I would first soldered the copper buses and then spot welding.
This way there is no heat transfer to the batteries :-)
Definitely !!! There is also drilling some holes to ziptie the busbars to the battery & also adding insulator rings to the positive terminals
Hi HB I believe You common in one of your videos The K Weld electrodes get hot before you finish one side to of pack as I have a K weld to I Considering getting an extra pair of electrodes When one gets hot you can Alternate let the other ones cool just have 2 p Pair hooked up all the time lol
All I needed was a small usb fan blowing air across the battery & electrodes , take a little more time placing the electrodes to slow me down and i can do both sides before needing to have a cool down period.
Looks great! I had a concern with the fuses holding the pack together. I have been using zip ties around the buss bars on the conventional packs. Been trying to find a way to also do that on this style.
Also,it should have gone in cell 5s position:)
I have the same concerns - i'll be submitting my thoughts on improvements today - on includes a way of attaching with zipties or double sided tape
@@HBPowerwall I was wondering if a hole punch could be used to widen the existing holes in the sheet so we could use zip ties. Also was going to suggest that we cut the sheets into 4x4 cell sizes. As to aid in removing a bad cell in the future. So we only break 16 fuses getting them out,instead of having to break the whole set
This looks very nice and looks great, now what happens when the cell in the middle needs replaced?
Same as when a clutch goes in your car, you pull it half to bits and fix it ....
Looking to start a cartridge style wall, where do you get your supplies from? Not trying to "poach" any leads in SA or QLD would be appreciated! Medical packs etc etc..
heya so you didn't balance it for 6 or more or more month's but the batrium with the longones does that or not
Nice Pack! Speaking of hitting batteries too hard. How is your HVAC/Heatpump doing? Are ducts in a hot attic? How much space do you have to cool? Does air escape uncontrollably? It could be a video, might even be cheaper to replace something.
They are just mini splits in each room - I love my cold air, I also like fresh air so house is always pulling fresh air from outside. Not efficient but a comfortable comprise.
Hello can you please tell me how many nickel strips in 0.20 you have To accumulate for resistance for 20s10p battery with Samsung 25r cell.
I have a nominal 100A bms 200A pic .
For the power of amps. so that it will hold the shock well knowing if is necessary for example doubled or tripled the nickel strips.
0:51
As repetitive as that task is, I would get a V shaped, non conductive, holder to keep them in optimal position.
I have that, this way is stupid fast! Put the Kweld into auto mode, put a small fan blowing over the workspace to keep electrodes cooler and GO - if it wasn't for filming it would be so much faster again.
Shedporn ❤
😂
Thanks again for the info, I’ll need to search your videos to find content about balancing. My Lipo Remote control cars get balanced, it balances each individual cell in the pack / module. Where you balance modules / packs to each other but not balance each individual cell with in each module. I know stuff all but I heard it was ‘very important’ to always balance each cell with in pack, that would be a lot of wiring I assume. Surely Tesla Power wall doesn’t run 888 balancing wires from each one of its individual 888 cells?
What if one of your cells from the back is 1.5v, do all the other cells now only put out at 1.5v even if they are a higher resting voltage?
Thanks 👍🏻
Edit: I did recently watch a video of yours where you talk about active balancing but I don’t have enough back knowledge to fully understand that video.
That welder looks effortless. My maleletrics welder probe sticks every single time, and the 2 weld never look even. I wonder if its down to the probes or how it's applying the energy
I think i'm going to make another battery and see if i can do it even better again using the 3D printed probe holders
What's the gauge of the busbar
Very interesting. you mention you upcycle laptop batteries. im assuming they're fairly new when you get your hands on them, as all of the ones i've encountered are at the end of their life.. or is there a way to bring them back from the grave?
No none are new all are end of life in their current form.
Surly using the fused nickel strip would mean not needing any bus bar, the load is even true out? Great Video Pete, thanks.
evens out the load accross the battery, increased it's amp capacity & makes it compatible with my powerwall configuration ( and looks sexy)
What do you think about this idea: spot weld a bunch of these packs, then line up the packs in series, and compress them slightly all togehter? At the negative and positive end of the series, do the busbar thing. I think that would be the true value of these nickel plated sheets and the amp rating would go way up because a huge section of the sheets would be in contact with each other.
I did try this and it works, but no real way of knowing how inefficient it is
@@HBPowerwall thermal camera?
Pete how do you make sure your batteries are balanced before you put the nickel on? take a reading of each cell? how big a voltage difference is ok?
I try have them close around the 4v mark typically
Hey just a random question, where is the best place to buy solder?
amazon, ebay, local electronics store. I got my from the hardware store in the plumbing section - not idea but price point was great
Do all aussies good with electronics and off road overlanding??? Or is it just a niche to some. From US
I don't offroad so must be just more bad media lol
I have just started watching your videos and subscribed I wanted to ask a question i have been struggling with configuration of my battery pack for my ev motorcycle. I want to ask four questions :-
1. Can i connect 3 x 72v lithium ion pack in parallel with configuration of 20s 10p to power my 72v 3000w motor controller it supports 50A so does the motor? (I want max range and power)
2. All 3 packs will have BMS so how do i charge it what charger should i use for this purpose and will those BMS work properly if connected in parallel, what amps will it req to charge?
3. Should i make 3 72v packs or should make 6 24v packs and then connect 3s 2p which one is better ?
4. If question 1 and 2 are possible then what wire should i use to run this project?
Please respond its my first time ever commenting on youtube video i hope you can answer my questions
I would love to reply... but unfortunately everything i know i've googled or tubed so probably not the right person to ask i'm sorry. The forum or facebook group linked in the description would be your best bet for help
No time for your ass, he just wants the views and the likes. Then refers you to his FB forum to get clicks on that also. This is why I can't stand this guy. And since I am a better man, I always try to give him another shot but then I end up reading some shit like this again. SMH
Cant calibrate my kweld 🤯 after first use try to use next day and boom overcurrent. Help needed
READ and understand the instructions - don't make things up in your head.
@@HBPowerwall thanks for replay .I did read 10times before I build.all done how its should be done.first run was calibrated all ok did few welds 100j and power off next day ask for calibration and when I try calibrate say overcurrent. I did mange today calibrate but touching electrode ends not sides.very interesting why.cleaned well tips too.
Ps.love your channel 👍
I also recycle cells for e bike battery packs. I hope you might answer a question for me. I have been testing my batteries with b6 hobby chargers and I also bought dischargers online. I just bought a Liitokala 500s charger tester and I’m finding that the mah results it gives me are about 500 mah more than the other dischargers give me. The batteries do get discharged more with the liitokala but not that much more. Can you possibly explain this and which results should I go by.
Buy one make and model and stick with just that one to do the discharge tests - to be honest you're looking for the bad cells not the good. You just need a consistent result for your own tests.
Where did you got all your batteries from?
If i was in the states it would be www.batteryhookup.com (my discount code 'Powerwalls' for 10% off) I'm in Australia so it's schools, computer shops, council offices, hospitals etc
Hey , that tip you have for your soldering iron is it U shaped? If so where did you get it and how many watts is it? Cheers
Just a cheap piece of junk that wore out from being make of chinese beens cans
@@HBPowerwall haha I’m having a hard time soldering the solid 6 to the fused nickel ( I also forgot to solder prior to spot welding the tabs to the cells ) do you have any suggestions? I’m using a weller 650. Cheers
LMAO....why so serious.
cheers man.
I'm almost never serious!
My kweld burns holes through the nickle if I set it over 10 , how does yours work so nicely?
I've used different batteries with different results. Havn't even calibrated to this battery. I've noticed if the voltage of the battery drops below 4v per cell the quality drops fast. But i did 100's of welds of tests. Next on the wish list is a second battery or third and run them all together. That with a fan on the electrodes and it'll be such a fast process i'll sell my soldering irons lol
No problems with the heat in this steel containers?
You mean my sheds? Not yet, South side of my home, have about 2" of insulation on the roof & lucky to get maybe 3 hours of direct sun in the morning then shaded rest of the day. Adding to that my BMS controls fans that turn on and off depending on the air temp inside the sheds
WOOF!!!
Meow?
@@HBPowerwall nah I guess your a dog guy and just loved the low sounding woof woof in the background with the little fast woof!! grafik
I should get my Bartium running soon to make sure its all working. Do I need a computer or is a tablet good enough? Its a wm4
Requires a windows based pc with USB & not RT version of windows so you can install Watchmon ToolKit
@@HBPowerwall so laptop is best then?
Laptop works well
I am building a 7S 80p but I am torn between spot welding with nickel fuse or soldering with fuse wire :( . Any insight is appreciated.
Spotweld... my insight is complete...lol
@@HBPowerwall LOL, thank you
Where they 4s 80p units? Just trying to get my head around some of this as I have around 1100 18650 over 2000 mAH waiting to build a wall.
I tap power of my 48v bank on the wall that's 4S80P ?
@@HBPowerwall so you hook 3 up in series to get 48 Volts?
These are (1S)80P packs. At 3.6/3.7V (nominal), a 14S configuration would yield a "48V" pack. (Actually 50.4V nominal, 58.8V max/35V min.) Pete decided on 80P based on desired system capacity vs. average cell capacity. Your mileage may vary.
How many Lutyens batteries will a 1600 Empire inverter have?
I have no idea...
Do you think these nickel fuses can take 4A continuous without heating up the fuse link itself? Im curious because they would be good for my ebike pack that will max out at 4A a cell. I sent a message about this to alarmhookup a few weeks ago but no response on this subject.
If your local come test the theory at mine.. i have a bit spare :) I think at 4 amps for short periods of time it would be fine, as the nickel plate disperpates heat fairly well. If you were drawing that load for a long time the heat build up would be an issue. I don't think this in it's current form is well suited to a higher amp draw of an ebike. Also unproven in vibration tests. That would concern me more than anything else.
@@HBPowerwall Im not local unfortunately and you make all valid points! Im going to stick to standard nickel strip for my bike packs.
James McCreadie rily
Where can I buy the kwelder?
In the description I have a link for more information on the kweld unit including US & Global sales
how much does a battery bank cost to build?
Depends on how large you go I'm guessing - whats your plans?
Are you stressed out about the heat it could generate when the fuse is about to blow? I saw your video when you tested the nickel fuses and I was feared that it could heat up the cells and start a fire.
It's no worse than my current setup, the whole battery isn't going to fail. One cell might - add a potential amp dump of 200 amps to a single fuse and it won't even get time to glow before the fuse blows. If a case arises where all fuses in one battery needs to blow it'll more likely be along side the rest of the battery - then the amps could be 1000's of amps again instant blowing of all 80 fuses on one battery. The way i tested was dumb, and not how fuses are ment to work. All that said i'm happy to be proven wrong.
what's your total amount of ah ? and how long can u run ur house now without sun ?
I have on paper 40kwh useable & i've run load tests that say around 60 hours MUCH longer if i didn't tried to save power rather than just use it normally. th-cam.com/video/cKMiCQGf6q4/w-d-xo.html
:)) What's the point of still using the copper busbar this time? :))
distribute current flow, increase amp rating & to make it compatible with my current configuration.
@@HBPowerwall Yes, that's really important.
Nickel has much more resistance than copper and the path over the cells is quite long.
Incidentally, looks like the pack could do with some straps or wrapping as it looks like the nickel plates and bus bars are only held on by the fuses!
They are I explored the idea of drilling holes in the nickel strip to put some zipties in but only after applying the nickel bad move on my behalf but I know better and the next itteration shall be better. That said for stationary storage it'll almost never be an issue unless you have a woops moment.
@@HBPowerwall It's the whoops moments that you know will never happen that get you!
Zip ties are a great idea though would have to loop around the bus bar as the nickel would deform.
Large heat shrink sleeves would probably be too expensive and limit maintainability.
I think my favourite would be velcro straps as they're cheap, strong and convenient, and don't leave a mess like duct tape.
I'll do another video - i thought this one would have gone better.. typical youtube crap - so much time and effort and 5k views and 11 bucks income lol might do better in the coming weeks i guess
Woof
Meow?
@@HBPowerwall @5:22 I love it!
How does it go removing a faulty cell
Rip it off start again...
No different to an eBike or prebuilt battery pack.
@@HBPowerwall yeah just thinking of metal fatigue welding and rewelding
Less stress on cell than solder i guess.. either way this is a learning curve and together we will make something that works and is cost effective
1) Cut out the bad cell.
2) Spot weld new nickel strips across the void where the bad cell was removed and to adjacent fuse foil.
3) Install replacement cell.
4) Spot weld new nickel strips across replacement cell and to adjacent fuse foil.
I'd have to give some thought to individual fusing for the replacement cell.
Thoughts anyone?
Elektrikli bisikletime 102 amper olurmu nasıl yapmam lazım
With pure nickel strips - something more suited to high amp draw. Perhaps consider building something like - th-cam.com/video/zmX07eZ10Z4/w-d-xo.html
If I understand correctly, it doesn't calibrate
how you find that much batteries tell me lol :O
I spend a metric shit ton of time and have a youtube channel where some find me lol
@@HBPowerwall I need support to activate the bike which l have made on my channel. That's why l'm asking :( help me please
Why don't you spot weld diagonally rather than side by side. That seems a better way to me ...
Umm... never thought about doing it differently than the way i do it.
@@HBPowerwall It just seemed a more stable way of doing it.
One thing that has been bothering me, before I build my packs. If a cell does fail, it seems that many of the "easy assembly" type frames and connections are going to make replacement difficult. Yeah, I know we all test things well before installation, but shit will happen, yeah?
Yep, shit happens - you either deal with it or not it's up to you..
Not bad moi8
Tnks ma8
Man I was hoping for the whole fog machine, sexy music, shirtless peet experience....
Next video *winkky face*
.
Y did u soldered 4sides enough 1side na. Waste of copper wire
How will one be enough?
@@HBPowerwall k
😲😵 how much Battery you have
would have to be plus 10,000 cells by now.
Hahaha the captions don't even know what the hell you are saying. Lol
HAHAHAH
I think it's sexy.
I think so too lol
SEXY AF!
I agree