That is why you need a mad electronic tech. Since you would not be switching on the fly (under load) it should not be a big issue with current interruption.
no, but whatever you switch would need to be able to handle the full current output on a contentious basis... so 100amps? 200amps? Basically the switch element would become the bus bar... in some places it would need to make a choice of 3, so now you have to bus bar to each "on" position and have it fail with things open so it is safe. If the battery goes dead how do you wake it up? How much drain is it going to take while it is just sitting there.
Latching contactors would be the ideal things... those are just a bit over $120 each --
You need 2 contactors or a bistable set at the junction of 4 & 5 and again at the junction of 12 and 13... and you would need 2 at junction 8 & 9 ...
A little chatgpt help to get the logic table
Takes - 4 bistable latching contactors - so they don't consume power except to switch them --- and the rest hurt my head to think about ... but if you study the stuff below it makes sense -
Cost would be an extra $600 to $1500 per battery + the minor logic circuits to control things....
And it would be something you might switch once in the life of the battery unless you also used it with a shunt-trip to disconnect it instead of a fuse...
AND NOW YOU HAVE MADE MY HEAD HURT ---- DONT DO THAT
Here is a detailed logic table showing the connections for each
post of the 4 DPDT bistable latching contactors in all three configurations (
4s4p,
8s2p, and
16s). Each contactor has six terminals: two poles (
Pole A and
Pole B) and four throws (two for each pole, for the two states).
Contactor Terminal Legend:
- C1: Contactor for junction 4&5.
- C2-A: First DPDT contactor for junction 8&9 (parallel/series switching for cells 8 and 9).
- C2-B: Second DPDT contactor for junction 8&9 (direction of 8&9 connection to other cells).
- C3: Contactor for junction 12&13.
- Terminals are denoted as:
- A1, A2: Pole A throws (e.g., connected when in state 1 or 2).
- B1, B2: Pole B throws.
Logic Table for Each Configuration
Contactor | Terminal | 4s4p Connection | 8s2p Connection | 16s Connection |
---|
C1 (4&5) | A1 | Cell 4 positive ↔ Cell 5 positive | Cell 4 negative → Cell 5 positive | Cell 4 negative → Cell 5 positive |
| A2 | Cell 4 negative ↔ Cell 5 negative | Not connected | Not connected |
| B1 | Not connected | Not connected | Not connected |
| B2 | Not connected | Not connected | Not connected |
C2-A (8&9 Parallel/Series) | A1 | Cell 8 positive ↔ Cell 9 positive | Cell 8 positive → Cell 9 negative | Cell 8 positive → Cell 9 negative |
| A2 | Cell 8 negative ↔ Cell 9 negative | Not connected | Not connected |
| B1 | Not connected | Not connected | Not connected |
| B2 | Not connected | Not connected | Not connected |
C2-B (8&9 Direction) | A1 | 8&9 parallel positive → Cell 1 positive | 8 positive → Cell 7 positive | 8 positive → Cell 7 positive |
| A2 | 8&9 parallel negative → Cell 16 negative | 9 negative → Cell 10 negative | 9 negative → Cell 10 negative |
| B1 | Not connected | Not connected | Not connected |
| B2 | Not connected | Not connected | Not connected |
C3 (12&13) | A1 | Cell 12 positive ↔ Cell 13 positive | Cell 12 negative → Cell 13 positive | Cell 12 negative → Cell 13 positive |
| A2 | Cell 12 negative ↔ Cell 13 negative | Not connected | Not connected |
| B1 | Not connected | Not connected | Not connected |
| B2 | Not connected | Not connected | Not connected |
Detailed Notes on Connections:
- C1 (4&5):
- 4s4p: Both poles (A1 and A2) connect cell 4 positive/negative to cell 5 positive/negative for parallel operation.
- 8s2p/16s: Only Pole A connects cell 4 negative to cell 5 positive for series operation.
- C2-A (8&9 Parallel/Series):
- 4s4p: Both poles (A1 and A2) connect cell 8 positive/negative to cell 9 positive/negative for parallel operation.
- 8s2p/16s: Only Pole A connects cell 8 positive to cell 9 negative for series operation.
- C2-B (8&9 Direction):
- 4s4p: Parallel pair of cells 8&9 is connected to both cell 1 (positive) and cell 16 (negative).
- 8s2p/16s:
- 8s2p: Series connection established between 7 → 8 → 9 → 10.
- 16s: Series connection extends from cell 7 → 8 → 9 → 10.
- C3 (12&13):
- 4s4p: Both poles (A1 and A2) connect cell 12 positive/negative to cell 13 positive/negative for parallel operation.
- 8s2p/16s: Only Pole A connects cell 12 negative to cell 13 positive for series operation.
And a cost estimate
To implement the battery configurations (
4s4p,
8s2p, and
16s) using
4 DPDT bistable latching contactors, you can consider the following options:
- Albright SW88-102L:
- Specifications: 24V coil voltage, 80A continuous current rating, DPDT configuration.
- Pricing: Approximately $354.16 per unit. citeturn0search2
- TE Connectivity KUL-11D15D-24:
- Specifications: 24V DC coil voltage, 10A current rating, DPDT configuration, dual coil latching.
- Pricing: Approximately $108.21 per unit. citeturn0search0
- TE Connectivity RT424F24:
- Specifications: 24V DC coil voltage, 8A current rating, DPDT configuration, dual coil latching.
- Pricing: Approximately $7.02 per unit. citeturn0search0
Total Cost Estimates:
- Using Albright SW88-102L: 4 units × $354.16/unit = $1,416.64.
- Using TE Connectivity KUL-11D15D-24: 4 units × $108.21/unit = $432.84. *takes both this and the next*
- Using TE Connectivity RT424F24: 4 units × $7.02/unit = $28.08.
Considerations:
- Current Rating: Ensure the contactor's current rating meets or exceeds your system's requirements.
- Voltage Compatibility: Match the coil voltage with your control circuit's voltage.
- Physical Size and Mounting: Verify that the contactors fit within your design's spatial constraints.
The Albright SW88-102L offers a higher current rating, suitable for more demanding applications, but at a higher cost. The TE Connectivity options are more cost-effective but have lower current ratings. Choose based on your specific application's electrical requirements and budget.
And for 200amps
To accommodate a continuous current of
200 amps, you'll need
4 DPDT (Double Pole Double Throw) bistable latching contactors rated for at least 200A. Here are some suitable options:
- Albright SW200 Series:
- Specifications: Designed for direct current loads, including motors used in electric vehicles.
- Pricing: Approximately $218.25 per unit.
- Source: Cloud Electric
- Electric Car Parts Co. 200A DPDT Contactor:
- Specifications: Available with coil voltages of 12V, 24V, 48V, 60V, 72V, 96V, or 120V DC; includes magnetic blowouts and UL listing.
- Pricing: Approximately $91.00 per unit.
- Source: Electric Car Parts Co.
Total Cost Estimates:
- Albright SW200 Series: 4 units × $218.25/unit = $873.00
- Electric Car Parts Co. 200A DPDT Contactor: 4 units × $91.00/unit = $364.00
Considerations:
- Current Rating: Ensure the contactor's current rating meets or exceeds your system's requirements.
- Voltage Compatibility: Match the coil voltage with your control circuit's voltage.
- Physical Size and Mounting: Verify that the contactors fit within your design's spatial constraints.
The Albright SW200 Series offers a higher current rating, suitable for more demanding applications, but at a higher cost. The Electric Car Parts Co. option is more cost-effective but has a lower current rating. Choose based on your specific application's electrical requirements and budget.