Electric Scooter Extended Range Battery Pack

Last crawled date: 1 year, 11 months ago

This is a CAD model of my newly designed scooter battery packs. I will be using two of these packs and a custom controller for my brushless 3-phase hub-motor based scooter. Each battery pack is setup in a 8s6p configuration (8 series, 6 parallel), for 48 cells in total. Every 26650 cell has a capacity of ~2.5ah each, with a 3.3v nominal voltage. 26.4v*15ah=396wh, making each pack 396wh. The 2 packs will be in series, giving an overall scooter battery capacity of 16s6p, or 792wh.
The top & bottom plates are clear acrylic, the black cell holder is polycarbonate plastic, the standoffs are plastic, and the hardware is plastic. This is a lot of energy, so care was taken to use non-conductive materials whenever possible. Silicon was used between the cell terminals and the clear acrylic outer sheet. I used Anderson SB50 connectors in the final iteration of the battery wiring design, and surrounded the battery in 1/8in rubber sheet.

The CAD for the nuts and bolts are from mcmastercarr:
https://www.mcmaster.com/#96367a671/=16l2r8t
https://www.mcmaster.com/#90387A332

Let me know what you think of it. I hope you enjoy it!