卡因 发表于 2021-2-18 21:32:15

自己DIY用宁德时代三元锂铝壳大单体组装72V100AH两轮电动车锂电池组


<i class="pstatus"> 本帖最后由 卡因 于 2021-2-18 22:00 编辑 </i><br>
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<font color="#333333"><font style="background-color:rgb(255, 255, 255)"><font face="arial, sans-serif"><font style="font-size:16px">2020年3月15日,耗时一个星期用240颗东磁18650</font></font></font></font><font style="color:rgb(51,51,51)"><font style="background-color:rgb(255, 255, 255)"><font face="arial, sans-serif"><font style="font-size:16px">三元</font></font></font></font><font color="#333333"><font style="background-color:rgb(255, 255, 255)"><font face="arial, sans-serif"><font style="font-size:16px">锂电池组装的12并20串电池组,因为用的是原装铅酸电池控制器,欠压值较高,电池组电压68V,单体电压到3.3V的时候,</font></font></font></font><font style="color:rgb(51,51,51)"><font style="background-color:rgb(255, 255, 255)"><font face="arial, sans-serif"><font style="font-size:16px">电动车</font></font></font></font><font color="#333333"><font style="background-color:rgb(255, 255, 255)"><font face="arial, sans-serif"><font style="font-size:16px">跑起来就感觉没什么力了,可是电池电量却还剩不少,电池总电量33AH,实际可用电量为25AH。不过这样也有一个好处,就是电池不会经常放电到单体2.8V的保护电压,浅充浅放,有利于延长电池使用寿命。经过多次测试,那组18650锂电池组在野外路况良好的情况下满把全速前进,一直骑行直到电池低压保护,可以骑行大约100公里,时间大约2个半小时。但在市区道路,我开车习惯经常都是满把高速行驶,并且急开急停,时速低于35后虽然还能开挺远,但我一般都忍不了这么慢的速度就不想开了,对于我来说实际续航只有大约六十公里。为了继续增大续航,减少里程忧虑,能毫无顾忌地无视路程地开车,还有就是降低充放电倍率,延长电池使用寿命,我于2020年12月上旬决定对车子进行改装,把铅酸电池组替换为锂电池组,并且与上半年做的18650电池组并联起来使用。</font></font></font></font><br>
<font color="#333333"><font style="background-color:rgb(255, 255, 255)"><font face="arial, sans-serif"><font style="font-size:16px"><strong>下图为车子改装之前的照片</strong></font></font></font></font><br>
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<font color="#333333"><font style="background-color:rgb(255, 255, 255)"><font face="arial, sans-serif"><font style="font-size:16px"><strong>以下是改装后的照片,我更换了部分破损的外壳</strong></font></font></font></font><br>
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<font color="#333333"><font style="background-color:rgb(255, 255, 255)"><font face="arial, sans-serif"><font style="font-size:16px"><strong>一、电池仓改装<br>
</strong><p style="line-height:28px;text-indent:nullem;text-align:left">既然决定全部用锂电池组了,要改就改的彻底一些。原来的电池仓是阶梯状的,俗称阶梯仓,最好是改成一体仓,放的电池更多,也更好做电池组。不过改了一体仓的话,就得把后平叉和后减震也一起换了</p></font></font></font></font>
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<font color="#333333"><font style="background-color:rgb(255, 255, 255)"><font face="arial, sans-serif"><font style="font-size:16px">我找了一个专门改装车子的店帮我改装电池仓,老板很年轻,包工包料550块钱,包括焊接后平叉和电池仓,后减震我自己买。改装后的车子只有边撑,没有大撑了。</font></font></font></font><br>
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<font color="#333333"><font style="background-color:rgb(255, 255, 255)"><font face="arial, sans-serif"><font style="font-size:16px">因为没有大撑,维修不方便,我买了一个维修专用大撑</font></font></font></font><br>
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<font color="#333333"><font style="background-color:rgb(255, 255, 255)"><font face="arial, sans-serif"><font style="font-size:16px"><strong>二、测量计算</strong><p style="line-height:28px;text-indent:nullem;text-align:left">凡事预则立不预则废,测量计算是最基础的一步,包括测量电池仓的大小,电池箱的大小,电芯的大小,计算用哪种型号的电芯,如何才能最大化地利用电池仓的空间,最终达到做出容量最大的电池组。这一步其实还是很让我头疼的,因为各个品牌的铝壳大单体电芯大小不一样,还要多方比对查找,寻找靠谱的品牌和靠谱的货源,还要考虑价格不能太贵,以及思考电芯的排列摆放方式等等,现在想起来依然让我感到头大。过程就不细说了,最终我决定用宁德时代100AH三元锂铝壳大单体电芯,规格如下</p><p style="line-height:28px;text-indent:nullem;text-align:left">
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</p><p style="line-height:28px;text-indent:nullem;text-align:left">电芯不能直接放在电池仓里,那样长时间风吹雨打对电池不好,也容易被偷,需要做一个电池箱,我在闲鱼上找人给我做了一个厚0.8毫米的不锈钢电池箱,花了140块钱。本来开价是120块钱的,卖家说由于是异性仓,费了很多功夫,以后不接这种活了,还发图说做废了两个盖子,我心一软,多给了20块钱辛苦钱。</p><p style="line-height:28px;text-indent:nullem;text-align:left">
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</p><strong>三、材料购买</strong><p style="line-height:28px;text-indent:nullem;text-align:left">材料主要就是电芯、保护板、电池箱、胶带、电线、电烙铁,上次做电池的焊锡还剩下不少,不需要买了。上次做18650电池组用的电线是装修时候用剩下的单股铜线,太硬了,这次我用BVR多股铜线。之所以不用耐高温硅胶线,是因为电芯之间线径足够粗,三四十安培的电流,完全不会产生热量,还有一个原因是多股铜线比耐高温硅胶线存放时间更长。</p><p style="line-height:28px;text-indent:nullem;text-align:left">经过多方对比,比价,在阿里巴巴上一家名叫东莞市富宝新能源科技有限公司的店里买了20块100AH的宁德时代三元锂铝壳大单体,无焊接痕迹,磨码的,184块钱一个,据卖家说是全新B品。唉......囊中羞涩,买不起全新A品。电池极耳是铝的,不方便焊接,我让卖家转镍后发货</p><p style="line-height:28px;text-indent:nullem;text-align:left">
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</p><p style="line-height:28px;text-indent:nullem;text-align:left">经测试,转镍后的内阻大约在0.8毫欧左右。为了焊接更牢固,我用刀在镍片上划了很多划痕</p><p style="line-height:28px;text-indent:nullem;text-align:left">
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</p><p style="line-height:28px;text-indent:nullem;text-align:left">保护板的选择也让我比较头疼,我在联盟社区多方询问、查找,最后决定用睿骡电保护板,可是卖家当时说无货,第四代睿骡电保护板正在设计研发中,需要等半个月。我从12月初等到12月底,卖家终于发货了,可是没几天卖家发公告说保护板有点小问题,我又把板子寄回去换了一块新板,来回又折腾了一个多星期,终于在1月初拿到了板子,前后等了一个月,不容易啊。睿骡电在2021年1月1日起改名为锂享</p><p style="line-height:28px;text-indent:nullem;text-align:left">以下为保护板</p><p style="line-height:28px;text-indent:nullem;text-align:left">
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</p><p style="line-height:28px;text-indent:nullem;text-align:left">PS:本次电池制作很多参考自电动车联盟,电动车联盟曾经是一个论坛,2019年因被人举报关闭了大半年,
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直到2020年4月29日重新开放,改名电动车联盟社区。好不容易找到了组织,我也于4月30日马上注册加入了电动车联盟的大家庭,可是现在不到一年联盟又要关了,我无比伤心难过。
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</p><strong>四、电池组装<br>
</strong><p style="line-height:28px;text-indent:nullem;text-align:left">电池盒是不锈钢做的,为了绝缘我在内部贴满了青稞纸。电芯摆放如下图</p><p style="line-height:28px;text-indent:nullem;text-align:left">
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</p><p style="line-height:28px;text-indent:nullem;text-align:left">电芯之前的连接我用两根4平方的BVR多股铜线,相当于是8平方铜线,焊接方式采用的是锡焊,大致就是先在极耳镍片上和焊接电线上焊上焊锡,俗称挂锡,再把电线融到极耳上。</p><p style="line-height:28px;text-indent:nullem;text-align:left">
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</p><p style="line-height:28px;text-indent:nullem;text-align:left">由于焊接经验不足,烙铁头没有用焊锡养护好,导致烙铁头氧化严重,焊接的时候比较难焊
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</p><p style="line-height:28px;text-indent:nullem;text-align:left">为了给电芯膨胀留有余量,我把电线做成弯曲状,然后焊接。刚开始焊的时候,焊完不牢固,用手稍一用力拉就拽掉了,后来上电动车联盟询问,才知道是温度不够,焊锡没有完全融化。之后焊的时候,通过增加焊接时间,让焊锡完全融化为液态后冷却,就焊得比较劳了,拉不掉。烙铁离开后,用湿<font style="color:rgb(51,51,51)"><font style="background-color:rgb(255, 255, 255)"><font face="arial, sans-serif"><font style="font-size:16px"><a href="https://www.smzdm.com/fenlei/maojin/" target="_blank">毛巾</a></font></font></font></font>让焊锡降温,减少高温时间,避免损伤电芯,我的焊接时间通常在5到10秒之间。焊锡是焊在镍片上的,而镍片是点焊在极耳上的,镍片和极耳的热量传输只有那32个焊点,面积很小,热量传输并没有想象中的快,焊完后极耳的温度变化不大。</p><p style="line-height:28px;text-indent:nullem;text-align:left">
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</p><p style="line-height:28px;text-indent:nullem;text-align:left">保护板采集线用的是0.5平方的多股铜线,连接采用的也是锡焊,先用剥线钳剥掉大约1厘米的线皮,再将焊接部分挂锡,最后将焊锡融化到一起。</p><p style="line-height:28px;text-indent:nullem;text-align:left">
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</p><p style="line-height:28px;text-indent:nullem;text-align:left">为了以后维护的时候方便取出,我在前后两部分分别缠绕了两圈纤维胶带。</p><p style="line-height:28px;text-indent:nullem;text-align:left">
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</p><p style="line-height:28px;text-indent:nullem;text-align:left">电芯用电线连好后用纤维胶带捆绑固定好,电芯和电池盒之间的缝隙部分我用珍珠棉填上作为缓冲,将电芯固定在电池盒里,电池盒的前后尺寸几乎刚刚好</p><p style="line-height:28px;text-indent:nullem;text-align:left">
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</p><strong>五、电池装车</strong><p style="line-height:28px;text-indent:nullem;text-align:left">电池盒盖上盖子后,刚好放进电池仓里,这都得益于前期测量计算准确。</p><p style="line-height:28px;text-indent:nullem;text-align:left">这辆车是一辆<font style="color:rgb(51,51,51)"><a href="https://www.smzdm.com/fenlei/ershouche/" target="_blank">二手车</a></font>,已经开了好多年了,车架有很多地方已经生锈了,好不容易把外壳全都拆开,索性就给车架做一下保养吧。用砂纸把生锈的地方打磨一下,把锈斑尽量磨掉,擦干净后,刷上防锈漆,防锈漆是之前装修的时候用剩下的。</p><p style="line-height:28px;text-indent:nullem;text-align:left">
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</p><p style="line-height:28px;text-indent:nullem;text-align:left">把旧的铅酸电池充电头取下来,换成锂电充电头。其实就是在充电头的正负极上分别焊接一根4平方的电线。焊接方法还是一样,分别在充电头接线处和电线上挂锡,然后焊接到一起。需要注意充电头是塑料做的,焊接的时间不能太长,挂锡和焊接后要立刻用湿毛巾降温。</p><p style="line-height:28px;text-indent:nullem;text-align:left">
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</p><p style="line-height:28px;text-indent:nullem;text-align:left">最后就是接线了,先把18650电池组和大单体电池组充满电,让两组电池的电压尽量接近。我在把两组电池接起来的时候,电压差只有0.7V。连接的时候我采用的是用接线端子拧螺丝压接的方式,由于BVR多股铜线不好压接,我在电线接头部分先用紫铜连接管把多股铜线压紧,再把线塞进接线端子里用螺丝拧紧</p><p style="line-height:28px;text-indent:nullem;text-align:left">
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</p><p style="line-height:28px;text-indent:nullem;text-align:left">最后接好是这样的,因为两组电池组都有保护板,可以保护电池,短路的时候会断电,所以我取消了空气开关。</p><p style="line-height:28px;text-indent:nullem;text-align:left">
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</p><p style="line-height:28px;text-indent:nullem;text-align:left">两组电池都是三元锂电池,放电曲线是一样的,电压一样的话,是可以并联的,并联后容量相加,保守估计总容量应该在130AH左右。以下是保护板手机APP显示</p><p style="line-height:28px;text-indent:nullem;text-align:left">
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</p><p style="line-height:28px;text-indent:nullem;text-align:left">利用下班和休息时间,经过长达一个月的努力,我终于在除夕当天下午将电池和外壳装好。原车控制器是铅酸电池控制器,欠压值是63V,达到欠压值的时候,依然有不少电放不出来,所以过完年后下一步需要换一个欠压值为55V的锂电池控制器,那样才能最大限度发挥锂电池的性能。之前那组18650电池组我用原车控制器,全顺1000瓦电机,多次测试,能跑100公里。本次电池完成后,容量差不多是之前的五倍,更换锂电池控制器后,满把全速开理论上能跑500公里以上,即使冬天大概率不会不低于400公里。</p><p style="line-height:28px;text-indent:nullem;text-align:left">
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</p><p style="line-height:28px;text-indent:nullem;text-align:left">本次电池制作我除了在电动车联盟上学习参考交流外,还参考了西瓜视频上一位叫“神航锂电”的人。</p><p style="line-height:28px;text-indent:nullem;text-align:left">发热问题我觉得不用担心,经过测试,充放电的总电流,大单体电池组占80%,18650电池组占20%,充电电流最大为11安培,其中大单体电池组占80%,也就是8.8安培,18650电池组占20%,也就是2.2安培;放电总电流最大为32安培,大单体电池组占80%,为25.6安培,18650电池组占20%,为6.4安培,这点电流对于这两个电池组来说太小了,几乎不会发热。</p><p style="line-height:28px;text-indent:nullem;text-align:left">大单体电池组最高充电倍率是0.088C,最高放电倍率是0.26C;18650电池组单个圆柱最高充电倍率是0.065C,最高放电倍率是0.19C。这么低的充放电倍率,相信这组电池能用好几年吧。</p><br>
<strong>六、花费明细</strong><p style="line-height:28px;text-indent:nullem;text-align:left">
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搬砖道人 发表于 2021-2-18 21:50:10


<i class="pstatus"> 本帖最后由 jcv3424 于 2021-2-18 21:52 编辑 </i><br>
<br>
<img src="static/image/smiley/default/37.gif" smilieid="55" border="0" alt=""> <img src="static/image/smiley/default/37.gif" smilieid="55" border="0" alt=""> <img src="static/image/smiley/default/37.gif" smilieid="55" border="0" alt=""> <img src="static/image/smiley/default/37.gif" smilieid="55" border="0" alt="">动手能力杠杠的,帖子写的很详细<br>

卡因 发表于 2021-2-18 22:01:16


<div class="quote"><blockquote><font size="2"><a href="/forum.php?mod=redirect&amp;goto=findpost&amp;pid=5606577&amp;ptid=601777" target="_blank"><font color="#999999">jcv3424 发表于 2021-2-18 21:50</font></a></font><br>
动手能力杠杠的,帖子写的很详细</blockquote></div><br>
花了很长时间呢

ct_dev 发表于 2021-2-18 22:11:21


写的真是详细,500km,秒杀好多电动汽车了。

卡因 发表于 2021-2-18 22:20:26


<div class="quote"><blockquote><font size="2"><a href="/forum.php?mod=redirect&amp;goto=findpost&amp;pid=5606581&amp;ptid=601777" target="_blank"><font color="#999999">ct_dev 发表于 2021-2-18 22:11</font></a></font><br>
写的真是详细,500km,秒杀好多电动汽车了。</blockquote></div><br>
可它不能遮风挡雨呀

搬砖道人 发表于 2021-2-18 22:56:49


你这车子极速多少?GPS的真实极速<br>

搬砖道人 发表于 2021-2-18 23:14:04


桂林的来学习了

卡因 发表于 2021-2-18 23:55:24


<div class="quote"><blockquote><font size="2"><a href="/forum.php?mod=redirect&amp;goto=findpost&amp;pid=5606586&amp;ptid=601777" target="_blank"><font color="#999999">qiyif12345 发表于 2021-2-18 22:56</font></a></font><br>
你这车子极速多少?GPS的真实极速</blockquote></div><br>
大概52公里每小时吧

kaivaya8 发表于 2021-2-19 08:11:34


以后再也找不到 电池组装的资料了。

tyuka 发表于 2021-2-19 08:34:30


看了内容,显然楼主在别的地方也发帖了<img id="aimg_DM87N" onclick="zoom(this, this.src, 0, 0, 0)" class="zoom" file="//mobcent//app/data/phiz/default/03.png" onmouseover="img_onmouseoverfunc(this)" lazyloadthumb="1" border="0" alt=""><br>
不过控制器没必要换<br>
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查看完整版本: 自己DIY用宁德时代三元锂铝壳大单体组装72V100AH两轮电动车锂电池组