How to DIY 48V 400AH Lithium Battery
Description
DIY a 48V 400AH lithium battery requires a certain amount of professional knowledge and skills, the following are the general production steps:
1.Prepare materials and tools
1.1 Material
400AH Lithium battery cell: Choose the appropriate lithium iron phosphate or ternary lithium battery cell, 48V voltage is usually composed of 15 series of lithium battery cells in series to achieve the nominal voltage,the capacity of 400AH requires parallel combination according to the capacity of the selected battery cell,for example, if we use 200AH cell, two groups are required in parallel.
48V 400Ah Lithium Battery Management system (BMS) :Select the appropriate BMS according to the voltage, capacity and application requirements of the battery pack,here, 48V 300AH or 400AH is recommended. It can overcharge, overdischarge, overcurrent, short circuit protection and balanced charging of the battery pack to ensure the safety and performance of the battery pack.
Connection line: Select the appropriate specifications of the copper cable to ensure that it can withstand the high current when the battery pack is charged and discharged, the general requirement of the current carrying capacity of the cable is greater than the maximum charge and discharge current of the battery pack, so we need to choose a 1C discharge current greater than 400AH.
Protection plate: Used to fix and protect the battery cell to prevent the battery from being damaged by external forces such as extrusion and collision.
400AH Lithium Battery Box: Select a strong, insulating, and fireproof housing material, such as ABS plastic or aluminum alloy housing, to protect the internal structure of the battery pack, and play a role in heat dissipation and safety protection.
1.2 Tool
Electric soldering iron: Used to weld the connection lines between battery cells.
Multimeter: Used to measure battery voltage and current.
Spot welding machine: If conditions permit, the use of spot welding machine can better connect the battery cell to ensure the reliability and conductivity of the connection.
Assembly tools, such as screwdrivers and wrenches: Used to assemble battery pack covers and secure internal components.
2. Production procedure
2.1 Battery cell detection and screening
Use a multimeter to check the voltage and internal resistance of each battery cell to ensure the consistency of the battery cell. Select battery cells with similar parameters to form a battery pack to avoid performance degradation or safety problems caused by excessive differences in battery cells.
2.2 Battery cells are connected in series and parallel
According to the design requirements, the lithium battery cell is first connected in series to achieve the required 48V voltage,then, the connected battery pack is connected in parallel to meet the capacity requirements of 400AH,in the connection process, ensure that the connection line is firmly connected, avoid virtual connection, and use electric soldering iron or spot welding machine for welding, to ensure the electrical conductivity and reliability of the connection,at the same time, during the welding process, attention should be paid to controlling the welding time and temperature to prevent overheating from damaging the battery cell.
2.3 Install a Battery Management System (48V 400AH Lithium BMS)
Connect each connection wire of the BMS to the corresponding position of the battery pack according to the instructions,the positive and negative terminals of the BMS are respectively connected to the total and total negative terminals of the battery pack, and the sampling lines of the BMS are respectively connected to the positive and negative terminals of each string of battery cells, so that the BMS can monitor the voltage, current and other parameters of each string of battery cells in real time. After the installation is complete, check whether the connection cable is properly connected and whether there is loose or short circuit.
2.4 Install the protection plate and battery box
Put the assembled 400AH lithium battery pack into the protection plate to ensure that the battery pack is firmly fixed and will not shake or collide during use,then, place the protective plate and battery pack into the box, and install the housing fixing screws or clasps to ensure that the housing is well sealed and can protect the Lithium battery pack.
2.5 Whole 48V 400AH Lithium Battery Test
Use a multimeter and other tools to conduct a comprehensive test of the prepared 400AH lithium battery pack, including measuring the total voltage of the battery pack, charge and discharge current, and whether the functions of the BMS are normal,during the test, pay attention to the working status of the 400AH battery pack and BMS, if there is an abnormal situation, it should be timely troubleshooting and repair.
3.Conclusion
The above are the basic steps for making 48V 400AH lithium batteries. It should be noted that the production of lithium batteries involves high voltage and chemical energy, which has a certain risk, if you do not have relevant professional knowledge and experience, it is recommended to seek the help of professionals or purchase finished lithium batteries.