2 layers260.6 × 134.4 mm
2 layers260 × 260 mm
Easypowerwall
mitchese/easypowerwallA PCB to make 18650 Battery packs easier to assemble and maintain
- Size
- 260 × 260 mm
- Copper layers
- 2
- Thickness
- 1.6 mm
- Parts
- 172
- Nets
- 21
- Pads
- 1,764
- Tracks, vias
- 315, 6
- Routed
- Yes
- KiCad
- KiCad 5 (file 20171130)
- Created
- 21 Mar 2020
- Updated
- 21 Mar 2020
Overview
Easypowerwall is an open-source printed circuit board by mitchese, from the mitchese/easypowerwall repository on GitHub. It is a 2-layer board of 260 × 260 mm with 172 parts on 21 nets, routed with 315 tracks and 6 vias.
Its parts include 7 fuses and 2 connectors. It belongs with the power boards of this library.
README
README.mdeasypowerwall
There are many projects which are building battery packs out of 18650 cells and fusable links. These projects all require massive amounts of labour to solder or weld the packs together. Once built, a dead cell in the pack requires much work to re-build the pack. This project will make an 18650 sandwich, with PCBs on either side taking care of the boring solder work. If a cell dies or the pack must be re-built, then four bolts hold it together and the cells are then replaceable.
The packs are designed around a 13s12p configuration - 13 in series and up to 12 in parallel. This will make a 48v pack. The spacing is designed around these holders:
.
Create a matrix of 13x12 cells, with the rows alternating positive/negative. :warning: Pay attention to the polarity :warning: Then sandwich a PCB on either side of the board and you're done.
Materials Required
Each 48v pack will require:
| Qty | Item | Sample Source |
|---|---|---|
| 2 | PCBs | Upload the Gerbers/.zip to JLCPCB |
| 156 | 18650 Cells | Buy a tesla and recover them from the pack |
| 312 | Battery Springs | https://www.ebay.de/sch/i.html?_from=R40&_nkw=battery+spring&_sacat=0&rt=nc&LH_PrefLoc=2 |
| 4 | M5x90 Nylon Bolts + nuts | TBD |
| 21 | Pin headers | TBD |
| 1 | BMS | Daly 13S LiIon BMS |
| 1 | BMS DIY Cable | |
| 2 | M5 Nuts + Bolts - Metal for poles |
Assembly
Todo once order arrives
BMS DIY Cable
The circuit board is designed such that the top and bottom can be the same board. Because of this, the BMS connector on the bottom borard needs to be connected to the even connectors on the top board. The pinouts are as follows
| BMS Connector bottom | Input top |
|---|---|
| 1 | 2 |
| 3 | 4 |
| 5 | 6 |
| 7 | 8 |
| 9 | 10 |
| 11 | 12 |
| 13 | 14 |
Repairing Fuses
The board has a fuse per cell, as well as one fuse per balancing input from the BMS. If a PCB trace fuse blows, the board can be fixed by soldering a fuse wire inbetween the two pads.
| Fuse | JLCPCB Current 1oz |
|---|---|
| Battery | TODO |
| Balancer | TODO |
TODO: Measure the acutal fuse performance TODO: Add pictures of fuse repair
Parts
172| Qty | Value | Footprint | References |
|---|---|---|---|
| 156 | BatterySpring | Battery:batteryspring | B1, B10, B11, B100, B101, B102, B103, B104, B105, B106, B107, B108, B109, B110, B111, B112 +140 |
| 7 | Fuse | Fuse:pcbfuse_4a | F1, F2, F3, F4, F5, F6, F7 |
| 1 | Conn_01x07 | Connector_PinHeader_2.54mm:PinHeader_1x07_P2.54mm_Vertical | J2 |
| 1 | Conn_01x14 | Connector_PinHeader_2.54mm:PinHeader_1x14_P2.54mm_Vertical | J1 |
The 165 most common of 172 parts.
Questions
How big is the Easypowerwall PCB?
It measures 260 × 260 mm and has 2 copper layers, 1.6 mm thick.
What parts does the Easypowerwall use?
172 parts. The full list of its parts is on this page, with links to each part's symbol and footprint where PCBKit's library has them.
Where can I download the Easypowerwall KiCad files?
From the mitchese/easypowerwall repository on GitHub, at the commit this page was made from: the board is easypowerwall.kicad_pcb. PCBKit opens the board in the browser, with nothing to install.
Can I use the Easypowerwall design in my own project?
Its repository states no licence, so its author keeps all rights: ask mitchese before reusing the design.
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