BEST OF THE 48v 2P16S 32 cell large battery box design discussion

Boondock Saint

Solar Addict
Joined
Apr 8, 2021
Messages
658
I want to build a compression box exactly for this 2P16Sconfiguration. I'm looking for something stationary, easy to manufacture and assemble, disassemble if needed.

This is 2 cells side by side and then 16 of them long @ around 48"

This structure should probably have a bottom, but this would be just to protect the wrapping on the cells. The weight of all the cells alone is appr 355lb. The box will be stationary indoors but could be on locking wheels as feet for movement, and then additionally secured in place.

If one end of the box is greatly secured, then only the other end of the box needs to be the compression variable where the end-plate is being pushed against the bank of cells using bolts, or springs etc. Small hardware.

The long side walls do not need to be hella think and the whole box could be wood, lexan, HDPE, Aluminum etc.

For this box, I'm looking to make something different than the 5 long rods with insulating tubing design. This box will be publicly visible and needs to have a nice aesthetic.

I'm thinking of different kinda of latches, ratcheting, bolting etc with the least amount of extruding and irregular surface areas. (no long bolt of rod ends, least amount of size for adjustment or attachment.

I've searched the forums and seen some good work, some of it was not the final product though and I couldn't find the final pics.

Please offer your ideas for materials, designs, construction, connections and so on. If you have a finished product please post a link to what you did, maybe I missed something clever to repro.

Thanks in advance!
 

Sunnytheskoolie

New Member
Joined
Feb 12, 2021
Messages
25
I want to build a compression box exactly for this 2P16Sconfiguration. I'm looking for something stationary, easy to manufacture and assemble, disassemble if needed.

This is 2 cells side by side and then 16 of them long @ around 48"

This structure should probably have a bottom, but this would be just to protect the wrapping on the cells. The weight of all the cells alone is appr 355lb. The box will be stationary indoors but could be on locking wheels as feet for movement, and then additionally secured in place.

If one end of the box is greatly secured, then only the other end of the box needs to be the compression variable where the end-plate is being pushed against the bank of cells using bolts, or springs etc. Small hardware.

The long side walls do not need to be hella think and the whole box could be wood, lexan, HDPE, Aluminum etc.

For this box, I'm looking to make something different than the 5 long rods with insulating tubing design. This box will be publicly visible and needs to have a nice aesthetic.

I'm thinking of different kinda of latches, ratcheting, bolting etc with the least amount of extruding and irregular surface areas. (no long bolt of rod ends, least amount of size for adjustment or attachment.

I've searched the forums and seen some good work, some of it was not the final product though and I couldn't find the final pics.

Please offer your ideas for materials, designs, construction, connections and so on. If you have a finished product please post a link to what you did, maybe I missed something clever to repro.

Thanks in advance!
Hi, Any luck yet? I am building something similar and would love to see what you came up with. Also, did you decide to go with 2p16s setup or are you going to go with 2x 16s for monitoring purposes ?
 

Boondock Saint

Solar Addict
Joined
Apr 8, 2021
Messages
658
Hell if I know :D I've been through so much churn on all this it's even hard to keep up with.

The 2P gives me 560AH and makes a 16 deep solid bank, which has it's own problems. Are you able to move or relocate as bank that weighs 380lbs? Do you want to try and make all the connections from the BMS while laying on your stomach or on your knees?

Where I want to put this bank is beside the bed pedestal in my RV. This config is appr 16" wide and 46" length, varying according to box design.

It's 2:30 PM up in the mountains and at this moment it seems like I need to build the "box" or platform in 2 pc, in order to move into place. The platforms will then be cinched together binding the 2 halves and applying some compression.

I envision a long rectangular flat bottom with a 1" lip around three edges where the batteries will fit snugly down in to. This bottom will be cut in two and will hold 16 cells ea. The ends of the compression (not box) box will be held pulled and together with the threaded rod but otherwise open to allow for cooling.

The first platform will be pushed into place with the threaded rods attached and locked down. Then the second platform pushed into place while running the threaded rod through the holes. Once everything is properly aligned the flange nuts will be tightened equally applying pressure and making this one physical piece. The connecting busbars will be added making this one electrical bank. This 380lb of physical battery will be secured to the floor.

Ask me again after happy hour and I might have another scheme in mind.
 

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