18650 Battery Module Build, A Recap of Episode 34’s for the Electric Samba

Today’s Video: I want to dig in to a video from one of my favorite YouTube channels. In Episode 34 of the “Electric Summer Project,” Jehu Garcia returns to working on his custom 18650 battery modules after previously having fun with his Samba VW Bus on a racetrack. He focuses on the second battery module, distinct from the first because of its Tesla-style cell level fuses. This fuse wire was tested to slowly burn up at 6 amps, a bit more than each cell’s regular operational amperage. The concern raised was about whether there was sufficient headroom, but calculations suggest there should be around 200 amps of headroom in events that only last a few seconds.

Jehu continues by finishing his second module’s cathode side, where the fuses have mostly been installed. The anode side doesn’t use fuses. Instead, it employs strips of copper to gather the current from the cell fuses, leading to larger copper bus bars that act as the battery terminal.

Then the video shifts to the JAG35 offices, where Jehu has setup a work area for the battery project. He discusses completing the second module with Tesla-style fuses and demonstrates soldering techniques for the anode side. Finishing up, he’ll charge the module using RC charger and monitors the charge rate.

After charging, he’ll install the module and go for a test drive, particularly interested in monitoring for voltage sag. Jehu drives to a dog park with his two dogs, taking advantage of a steep hill to challenge the battery module.

The video concludes with Jehu reminding viewers to tune in for the next episode of “Electric Samba Adventures” and urging them to comment, like, and subscribe to his YouTube channel for feedback and thanking them for their support.

Jehu has been doing an excellent job with helping DIYers for years. On his YouTube channel @jehugarcia he teaches us what he has leaned and he also develops of some pretty cool products. He has engineered his own EV Volkswagen Bus. Now, the world of electrical engineering, especially when it relates to automobiles, is rapidly expanding. As the push for sustainable energy grows, the need for effective and efficient batteries is paramount. So, how do the experts design these marvels of engineering, and what do these designs teach us about the future of transportation? Well, sit tight, and prepare for a journey in Episode 34 of the “Electric Summer Project.” By the end of this article, you’ll have a thorough understanding of custom 18650 battery modules, their design intricacies, and the essential takeaway from this particular video episode.

Table of Contents

  1. Return to Battery Modules
  2. Significance of Tesla-Style Fuses
  3. Importance of Headroom in Electrical Design
  4. A Trip to Jag35 Offices: The Practical Application
  5. Testing the Battery in Real-World Conditions
  6. Final Thoughts

In this episode Jehu returns to the 18650 Battery Modules

While previous episodes Jehu captivated viewers with his racetrack escapades, Episode 34 symbolizes a return to roots—going back to the drawing board, and delving into the nitty-gritty of EV mechanics. This redirection underscores the importance of continuous improvement, reminding us that innovation is an iterative process. Even after testing a product in high-adrenaline scenarios, like a racetrack, returning to refine its core components is pivotal.

The Significance of Custom 18650 Battery Modules

The 18650 battery, named for its dimensions (18mm x 65mm), is not a new entrant in the power landscape. Originally popularized by laptops and flashlights, it has found new life and renewed importance in the realm of electric vehicles. These batteries boast of high energy density, making them attractive for EVs, where space and weight considerations are paramount.

But it isn’t just about using an 18650 battery; it’s about customizing it to the specific needs of the vehicle, optimizing its performance, durability, and safety. By focusing on custom 18650 battery modules, the “Electric Summer Project” emphasizes the importance of tailoring solutions to suit specific needs, rather than adopting a one-size-fits-all approach.

Illustration of 18650 Battery Module Build Tesla Style Fuse

Significance of Tesla-Style Fuses

Traditional batteries often use a single or a few fuses for the entire battery pack, which acts as a safety mechanism to prevent overcurrent situations that can lead to fires or other hazardous conditions. However, Tesla’s approach is different, implementing a fuse on each individual cell within the battery pack. This provides an unprecedented level of protection, ensuring that if one cell fails or acts erratically, it won’t jeopardize the entire battery system.

Safety First

Imagine having a net with wide gaps versus a net with ultra-fine mesh. While both can catch larger objects, the fine-meshed net can also trap smaller items, offering a much more detailed level of protection. Tesla’s cell-level fusing works on a similar principle. By safeguarding at the minutest level, it drastically reduces the risk of catastrophic failures. This is especially crucial in electric vehicles, where battery failures can result in serious safety concerns.

Optimizing Performance

Beyond just safety, this meticulous approach to fusing also offers performance advantages. In scenarios where a single cell might be underperforming or malfunctioning, Tesla’s design ensures that the entire battery pack’s performance doesn’t take a hit. By isolating issues at the cellular level, the overall efficiency and longevity of the battery pack are enhanced.

Setting Industry Standards

Tesla’s approach to battery safety and performance with its unique fusing mechanism has set new industry standards. While many automotive companies are playing catch-up, the incorporation of such fuses in Episode 34 of the “Electric Summer Project” underscores their significance in modern EV design. It serves as a testament to the evolving nature of vehicle safety and performance standards, influenced by trailblazing pioneers like Tesla.

Illustration of 18650 Battery Module Build Headroom

Importance of Headroom in Electrical Design

At its core, headroom is a safety margin. It represents the difference between the typical operating point of a system and its maximum limit. In simpler terms, if you imagine a bridge that can safely bear up to 100 tons but generally only carries 70 tons, the 30-ton difference is its “headroom.” In electrical design, headroom ensures that devices operate safely and efficiently, even when faced with conditions that push them beyond their typical parameters.

A Cushion Against Surges

Electrical systems, especially those in dynamic environments like EVs, can experience surges or unexpected spikes in demand. Without adequate headroom, these surges can push components beyond their limits, leading to failures, reduced efficiency, or even potential hazards. With the right headroom, however, systems can handle these spikes gracefully, ensuring longevity and safety.

Optimizing Performance and Longevity

While it might seem counterintuitive, operating components constantly at or near their maximum limits can significantly reduce their lifespan. Think of it like continuously revving a car engine at its redline – it’s not sustainable in the long run. By designing systems with ample headroom, you ensure that components operate in a more relaxed zone, promoting efficiency and extending their useful life.

Balancing Cost and Safety

There’s a catch, though. Increasing headroom often means investing in more robust, and therefore more expensive, components. This is where the expertise of electrical designers comes into play. They must strike a balance, ensuring that systems have enough headroom to handle unexpected conditions, while also keeping costs in check. It’s an intricate dance between safety, performance, and budget constraints.

Real-Life Relevance in EV Design

Episode 34 of the “Electric Summer Project” beautifully illustrated this concept of headroom. The potential concern that the 6-amp fuse wire might not provide enough headroom for the battery module underscores the importance of meticulous planning. Too little headroom, and you risk the module’s safety and efficiency during peak demands. Too much, and you might be overdesigning (and overspending).

Illustration of 18650 Battery Module Build Jag35 Office

A Trip to JAG35 Offices: The Practical Application

At JAG35 offices, viewers get a front-row seat to the module’s final steps, including soldering techniques and charging procedures.

The newly constructed battery module is connected to a charger. It’s a pivotal moment, embodying the anticipation every designer feels when their creation undergoes its first real-world test. Observing the charging rates, assessing efficiency, and ensuring the module’s safety are all part of this crucial phase.

Illustration of 18650 Battery Module Build Charge Illustration of 18650 Battery Module Build Install Illustration of 18650 Battery Module Build Test Drive

Testing the Battery in Real-World Conditions

True success is gauged when that module faces the open road, with all its uncertainties. Will it perform as expected when subjected to varying temperatures, road conditions, or unexpected demands? This is the crux of real-world testing.

The EV Samba Ride: A Perfect Test Vehicle

The vehicle for this experimental run is Jehu’s EV Samba. This Samba’s trip was a ride to the dog park, a 15-mile round trip, not just a casual drive—it’s a rigorous testbed. During the journey, several crucial parameters to monitor for:

  1. Voltage Sag: A critical indicator of the battery’s ability to maintain power levels under demand. Voltage sag can be an early warning sign of a battery’s inefficiencies or potential shortcomings.
  2. Peak Demand Performance: The drive features a long, steep hill—this is a perfect scenario to push the battery module to its limits.
  3. Consistent Performance: Beyond the peaks and troughs, how does the battery perform under regular driving conditions? Is its delivery consistent, or are there unexpected drops or surges?

A Holistic View

Real-world testing also offers insights into the user experience. How does the battery module impact the Samba’s overall driving experience? Are there noticeable changes in performance, sound, or even vehicle behavior?

Frequently Asked Questions

The "Electric Summer Project" is a series that covers various aspects of electrical design, with a specific focus on electric vehicle battery modules. Episode 34, which this article reviews, delves into the construction and testing of custom 18650 battery modules.
Tesla-style cell fuses provide an added layer of safety by ensuring that each individual cell operates within its safe current limit. In the episode, this design choice was emphasized because of its importance in preventing cell overheating and potential hazards.
Headroom refers to the buffer or margin of safety built into electrical designs, ensuring that devices operate safely below their maximum specified limits. In the context of the episode, the headroom is related to the amperage each cell can handle without overloading.
The Jag35 office is where the theoretical design of the battery module is put into practice. It acts as the workstation and testing ground, bridging the gap between conceptual design and tangible, functional prototypes.
The drive to the dog park provided a real-world scenario, simulating both everyday driving conditions and peak demands on the battery. It was a practical way to test the battery module's performance outside of controlled lab conditions.
Voltage sag refers to the drop in voltage experienced when a battery is under load. Monitoring voltage sag is crucial as it can indicate inefficiencies or potential issues in a battery module. In the context of an electric vehicle, excessive voltage sag can impact the vehicle's performance.
Beyond just the technical parameters, real-world testing offers insights into the overall user experience. It helps understand the battery module's impact on driving performance, vehicle behavior, and other nuanced observations.
For direct video content and further insights into the project, it's recommended to visit the creator's official YouTube channel. The details and link to the specific episode or series might be provided in the sources section of articles or reviews.

Final Thoughts

Diving into Episode 34 of the “Electric Summer Project” Jehu Garcia offers a look into his 18650 Battery Module design. The episode underscores the importance of headroom considerations. The biggest takeaway? As electric vehicles become more mainstream, understanding the battery module—becomes ever more crucial.