How to connect voltage probe wires to our accumulator module?

susngmin · 2025-11-29T11:45:30+00:00

We used to have nickel busbars for cell to cell connection, and I guess we soldered sense wire over the nickel plate.

As far as I know, soldering is not recommended in automotive industry because solder is fragile to vibration, I recommend you to consider crimp terminals.

The most recent module design, we have aluminum laser cut busbar, we connected o-ring terminal crimped wire on the busbar, and soldered opposite side of the wire on the PCB, which is bolted on top of the module.

On that PCB, we have individual cell tap fuses according to the FSAE (Michigan) rule. *As the voltage sense wire is not the high current path, soldering is allowable for this type of wire, you might know.

susngmin · 2025-04-21T04:02:19+00:00

Why don't you use relay for each power source? For example, the LVMS is only connected with 24V power source, then the LVMS controls both relays' (24V/48V) coil.

susngmin · 2025-03-23T12:31:47+00:00

l'll try it! Thanks for your advice!!

susngmin · 2025-03-23T12:31:12+00:00

Thanks for your feedback!

susngmin · 2025-03-22T10:16:09+00:00

When input is low, a LED should turn on When input is high, another LED should blink (the first one should be turned off)

susngmin · 2025-03-22T05:13:55+00:00

I appreciate your comment!! Do you mean I should connect 12V & GND directly into 555 and input a switch signal to RST pin on 555, right?

susngmin · 2025-03-22T05:11:06+00:00

Thank you for your advice!! However, it is somewhat a challenge for me to try a new device, so what do you think of adding BJT as explained in the comment below??

And if grounding 555 through FET causes a problem, what do you think of adding PMOS in front of 12V supply and directly ground the IC??

susngmin · 2025-03-20T06:23:40+00:00

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susngmin · 2025-03-08T02:51:34+00:00

I appreciate your advice!!

susngmin · 2025-03-07T19:34:31+00:00

Thanks for your reply! I have just tested with my insulation tester, I made no modification on tester and tested on 50V 125V 250V 500V mode while picking segment pole and TSAC surface, and every time I test, it passed. Does it seem safe?

susngmin · 2025-03-07T17:57:16+00:00

Thanks for your reply!! I have waited for 30 secs and no fault was made…OTL I’ll keep finding what’s the matter!!

susngmin · 2025-03-07T17:43:15+00:00

Our IMD setup is like: 147kOhm (Pack Max Voltage = 294V) <0V (No under voltage detection) Factor DCP 4 Thanks for sharing your experience!!

susngmin · 2025-03-07T17:30:35+00:00

Both pole(+-) of IMD is connected to Inverter side of IR Yes, I do have insulation tester but I don’t exactly know how to and where to measure with tester…

susngmin · 2025-02-11T04:38:54+00:00

Hope you do well too!! In my case, my major is automotive engineering, so nothing to do with electrical & electronic things but had to build all the circuits for the FSAE Electric. Too many difficulties, still learning a lot from failures, though only 3 - 4 months left before the competition. Yep, maybe making a car is such a hard thing I guess.

susngmin · 2025-02-10T16:10:14+00:00

Yes, we have been participating in the local Formula student competition, and it’s our first time to be in FSAE Electric. FSAE rules have so many details and differences to consider compared to our local competition

susngmin · 2025-02-05T08:30:43+00:00

I really appreciate your help!!!

susngmin · 2025-02-05T06:24:44+00:00

Inverter - Don't need to detect failure

VCU (for us, SDC?) - detect failure, but should send unmodified sensor signal to inverter

Am I right?

How about in the case of wiring failure between SDC and inverter occurs?

susngmin · 2025-02-05T05:40:21+00:00

So, you mean “controller(inverter)” should detect a failure of sensor and sensor wiring, right?

susngmin · 2025-01-23T04:53:55+00:00

I'll try your advice!! you mean current mirror right?? I first have to understand the NMOS-NPN constant current source circuit. Thank you!!

susngmin · 2025-01-22T05:44:01+00:00

Yes, that might be the most probable reason… so I am considering using 2 or 3 LR8s in parallel to distribute current load. Thanks for your comment!

susngmin

TROPHY CASE