Thursday, July 25, 2013

New battery layout

In the past few months, although I have not done a lot of building on the Jeep, I've done a lot of thinking.  I've figured out the exact battery layout I need - using the existing racks.  Here is the schematic layout:

There are 30 cells in the front rack, 3 in each of the under-seat boxes, 26 in the upper rear, and 34 in the lower rear.  This totals 96 cells - a little less than the 98 I was originally going for, but not enough to make a significant difference.

The front box sits in the original front rack, with some room to spare:

The lower rear rack is nearly filled with its 34 cells.  It will need some plastic inserts to retain the batteries in their positions:

Under each rear seat, there is not enough room to put the BMS on top, so it goes on a separate plastic insert/retainer on the side:

And the upper rear rack's 26 cells fit in the original rear rack with room to spare - which will allow for some extra components, such as a mid-pack fuse, the BMS controller, the amp-hour counter/sender.  It will also allow all cabling to be inside the boxes, which will eliminate high-voltage cabling from inside the passenger compartment:

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