Sheet/brick order

[twiersum]

For future reference the sheets & brick numbering starts from negative contactor side and counts up towards positive contactor side.

1 to 11 & 1 to 99

 

[petergrub]

For those who prefer visuals. X-axis are the 11 sheets; Y-axis are the 9 bricks in each sheet.

—	1	2	3	4	5	6	7	8	9	10	11
1	1	10	19	28	37	46	55	64	73	82	91

[TR1][TD=] 2 [/TD][TD=]2[/TD][TD]11[/TD][TD]20[/TD][TD]29[/TD][TD]38[/TD][TD]47[/TD][TD]56[/TD][TD]65[/TD][TD]74[/TD][TD]83[/TD][TD]92[/TD][/TR1]
[TR2][TD=] 3 [/TD][TD]3[/TD][TD]12[/TD][TD]21[/TD][TD]30[/TD][TD]39[/TD][TD]48[/TD][TD]57[/TD][TD]66[/TD][TD]75[/TD][TD]84[/TD][TD]93[/TD][/TR2]
[TR1][TD=] 4 [/TD][TD]4[/TD][TD]13[/TD][TD]22[/TD][TD]31[/TD][TD]40[/TD][TD]49[/TD][TD]58[/TD][TD]67[/TD][TD]76[/TD][TD]85[/TD][TD]94[/TD][/TR1]
[TR2][TD=] 5 [/TD][TD]5[/TD][TD]14[/TD][TD]23[/TD][TD]32[/TD][TD]41[/TD][TD]50[/TD][TD]59[/TD][TD]68[/TD][TD]77[/TD][TD]86[/TD][TD]95[/TD][/TR2]
[TR1][TD=] 6 [/TD][TD]6[/TD][TD]15[/TD][TD]24[/TD][TD]33[/TD][TD]42[/TD][TD]51[/TD][TD]60[/TD][TD]69[/TD][TD]78[/TD][TD]87[/TD][TD]96[/TD][/TR1]
[TR2][TD=] 7 [/TD][TD]7[/TD][TD]16[/TD][TD]25[/TD][TD]34[/TD][TD]43[/TD][TD]52[/TD][TD]61[/TD][TD]70[/TD][TD]79[/TD][TD]88[/TD][TD]97[/TD][/TR2]
[TR1][TD=] 8 [/TD][TD]8[/TD][TD]17[/TD][TD]26[/TD][TD]35[/TD][TD]44[/TD][TD]53[/TD][TD]62[/TD][TD]71[/TD][TD]80[/TD][TD]89[/TD][TD]98[/TD][/TR1]
[TR2][TD=] 9 [/TD][TD]9[/TD][TD]18[/TD][TD]27[/TD][TD]36[/TD][TD]45[/TD][TD]54[/TD][TD]63[/TD][TD]72[/TD][TD]81[/TD][TD]90[/TD][TD]99[/TD][/TR2]

 

[hcsharp]

Where are the bricks located within each sheet? For example, are bricks 1,10,19... located at the bottom (perhaps along with 2,11,20...) and they work their way up until 9,18,27... are on top?

 

[petergrub]

Where are the bricks located within each sheet? For example, are bricks 1,10,19... located at the bottom (perhaps along with 2,11,20...) and they work their way up until 9,18,27... are on top?

Not quite bottom to top or visa versa. They are numbered sequentially from negative to positive. Start at the negative terminal of the sheet and follow the collector plate to the negative side of the cells. Go to the positive side of the cells on the other side of the sheet and follow the collector plate to the negative side of next brick group; rinse and repeat. They follow a sort of C shape around the sheet with a break in the middle with either a fuse or a bus bar.

Also, below is a picture for reference. This is an unfused sheet; you can tell by the bus bar below the coolant inlet/outlet.

 

[nick]

How are the punched tabs connected to the cells?

I would have guessed spot weld except I understand Gruber can find and replace individual bad cells.

 

[petergrub]

How are the punched tabs connected to the cells?

I would have guessed spot weld except I understand Gruber can find and replace individual bad cells.

The areas that look like punch tabs are in fact recessed areas where a thin aluminum bond wire is ultrasonically welded from the recessed area to the anode/cathode of the cell.

The individual cell replacement would be a huge task as the Sytcast between the cells and the cooling pipes would need to be removed without breaking anything.

 

[X.l.r.8]

Thinking aloud, if you pulled the sheets off, replaced the cells with newer ones, and replaced the cooling tubes from say a model S, then used nickel to remake the sheets, what would happen, I mean I know the 3.0 has the PEM upgraded but if the bms treats the cells as the lower capacity ones. would it just make it a new 2.0 pack. I mean 2400 cells can be had for as little as $1 each and complete model S packs are changing hands for $12k. I wonder what would happen if you had a bricked pack and swapped the cells out and added the water circulation from a model S and kept it in the same format.

 

[petergrub]

and replaced the cooling tubes from say a model S, then used nickel to remake the sheets

Why use the Model S cooling tubes and nickel? Is the nickel for the collector plates?

 

[X.l.r.8]

Because the model S cooling tubes are easy to use, the nickel would be to replace the aluminium sheets forming the bricks. I know my welder will do nickel and cooper, so I thought I could make wide strips for the parallel connections and smaller ones for the series. It seemed to me using the removable model s coolant tubes would overcome the disaster of pulling the roadster pack apart, it would keep the same form factor and become a replaceable unit. But what would the PEM do, treat it as a stock unit?