Solar Power: Wind Power: Hydro Power: Hydrogen Power: What Will You Use to Store the Power?

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Have you ever wanted to become energy independent?

Have you ever wanted to install Solar Panels on your house or barn?

What about creating Hydrogen Generation Fuel Cells?

Or maybe you have even considered installing a waterwheel on a small Creek or Stream?

Well that is very ambitious, and highly commendable of you.

But my question to you is how are you going to store all that great power you have created.

Are you going to use heavy Lead Acid Batteries? Do you realize that these can explode! Or you could be Chemically Burned from the Acid! (Considered the most Dangerous).

NiCd batteries, are the next favorite battery to use. Not dangerous unless the seal of the battery is broken.

Lithium Ion Battery is the battery of choice. Even the Car Manufacture Tesla uses Lithium Ion Batteries, for his automobile. By using 16,444, 18650 Lithium Ion Batteries.

So with that information in hand; Many enthusiasts have used this battery as their battery of choice.

Now we will see how you can do this, on a large scale; But with the ability of disassembling the power cells, with out any great difficulty!

Step 1: Power Packs - 18650 Lithium-Ion Battery Module.

18650 (18mm by 65mm) battery is a size classification of lithium-ion batteries. They are slightly larger than a normal AA Battery.

As you can see by the pictures provided, each module can be stacked to increase the power output. By using ohms law we can calculate each modules power.

Step 2: Battery Calculations

Each battery is equivalent to: 18650 VTC6 3000MAH = 3AH; 3.7V IMR Battery / Here is a website that explains the math in calculating batteries in parallel and in series.

Each Module is capable of producing a verity of current ratings. Depending on the output current of the batteries used. But in this case we are using a 3amp battery which will produce 3Ah per board.

Once you start stacking the modules on top of each other you are now putting them in parallel and the calculation is now. Amps + Amps = 2A or 3a + 3a = 6 amps

Each Module is capable of providing 25.9vdc at 3000mah (if that's the battery used) and if we start stacking the modules one on top of the other, the math looks like this.

25.9v / 3000mah + 3000mah + 3000mah+ ect...

A single 10 tier battery bank would be capable of 25.9v @ 30ah /// 3000mah * 10 = 30,000mah / or 30ah

By stacking battery pack after battery pack; all in parallel. your voltage stays at 25.9 vdc @ 30ah per battery bank.

Step 3: PCB 18650 Lithium Battery Power Module

Are you interested in creating a 18650 Lithium Battery Power-Pack.

I want to make this perfectly clear ""I did not come up with this idea"" "" I Acquired this design from the internet "" I am only sharing this information with you.

Now we are only going to deal with a single 7 cell Module. (You can stack these up to 7 to 10 Modules high.)

But we are only going to make a 7 cell battery power module in this Instructable.

This cell will consist of 9 different items.

1 = PCB Circuit Board Gerber Files

1 = 18650 Battery Case Holder, 4 Slots x 3.7V DIY Battery Storage Box, in Parallel Black Plastic Batteries Case with Pin For Soldering 4 x 18650

1 = 18650 Battery Case Holder, 3 Slots x 3.7V DIY Battery Storage Box, in Parallel Black Plastic Batteries Case with Pin For Soldering 3 x 18650

1 = 8 Pin Female tall stackable Header Connector socket for Arduino Shield

1 = Pairs XT60 Male Female Connector for High-Amp Lipo Batteries

1 = Plastic Shell Fuses Holder Socket for SMD 1808 Fuse

1 = HQ 4A 125V 1808 SMD Ceramic Fuse Surface mount

1 = HQ 10A 125V 1808 SMD Ceramic Fuse Surface mount

4 = M4 x 6mm Phillips Pan Head Machine Screws, Brass, Metric, Full Thread, Right Hand,

4 = 4mm Thread Inner Diameter Brass Hex Nut Solid Brass Nut Copper Hexagonal Nut (M4)

You can search eBay / Amazon / and the Internet to find all the parts for the very lowest price, but your going to have to buy in very large quantity's, to get the very best prices.

Step 4: PCB Custom Made Board

This board was custom designed and created at a considerable cost. If you buy in small quantities this board will cost you up to \$8.00 or more a piece. As you buy in larger and larger quantities the price drops accordingly. But your order cost rises.

I will provide you links to Amazon to find the parts used. (I do not guarantee that the links will work.) they are some times deleted due to vendor stock depletion's.

Step 5: Parts List

Battery Storage Box Holder Cases

Description: Takes standard size 18650 batteries side by side to form a compact battery of 3.7V Keep your batteries organized and protected Lightweight Convenient to carry easy to install This battery box holder with pin connector, fit for 3.7V 18650 batteries. With weld leg design, you can easily to put the battery in it. Easy installation Battery is not included here. Battery Model: 18650 Battery Number of batteries: Size: 77.98X78.84X21.54mm Material: ABS polystyrene Color: Black Output: 3.7V DC Specifications: Keep your batteries organized and protected Lightweight Convenient to carry Easy to install This battery box holder with pin connector, fit for 3.7V 18650 batteries. With weld leg design, you can easily to put the battery in it.

Hardware Needed

This is the Hardware contents we will include
5. M4 x 6mm Phillips Pan Head Machine Screws, Brass, Metric, Full Thread, Right Hand,
(This item is not be included)

Step 6: Soldering Electronic Connections

I have provided 2 Video's and 2 Photos

Soldering is a skill that anyone that wants to work with electronics should acquire.

It takes time and effort, and a steady hand to solder correctly.

So watch the videos. and practice on a spare perforated board.

Practice PCB Soldering Boards

Step 7: Assembly

Step 7

Lay out your parts so you can make sure all parts are present.

Step 7a

Orient the battery boxes so that the + side of the boxes are in alignment to the board. You can look inside of the battery boxes and see there are + sings on the bottom of the box and place it so the plus sign is on the top.

You can see on the PCB board a + sign at the top left corner, this orients the parts correctly. Each battery box will only fit on the board in the correct order, (But unfortunately I photographed it in the wrong position; The three battery box should be first then the four place battery box should be second.)

Step 8: Soldering the Battery Boxes.

Step 8 Once the boxes are oriented correctly flip the board over and prepare to solder them in, Always make sure your soldering iron is HOT and melting solder before you start soldering on the board. Always use rosin-core solder on electronics. And use a wet sponge to clean the tip of your iron off before you solder, a clean tip is a must. Heat up the pad and component together, once it is hot the solder will flow freely.

Step 9: Soldering the Fuse Holder

Step 9 Use some type of clamp to hold the fuse box in the correct orientation on the split solder pad. solder one side, then remove the clamp and make sure it has not moved and solder the second side.

Step 10: Soldering the Header Pin

Step 10 It does not matter on what side of the board you solder the header pin in. Just make sure that once you have decided, you do all the boards the same.

Step 11: Soldering the XT60 Connector

Step 11 Make sure you heat it up properly and apply plenty of solder. this is a big connector.

Your project should at lest resemble the pictures above.

Step 13: Power Wall

As you can see this is the way a power distribution center should look like.

Step 14: If You Have Any Questions or Comments

I am more than willing to answer your questions. As to where you can obtain the parts listed here in this Instructable.

Step 16: FAIR USE NOTIFCATION

material; the use of which has not always been specifically authorized by the copyright owner. We are making this material available in an effort to advance the understanding of environmental, political, human rights, economic, democracy, scientific, and “fair use” of any such copyrighted material as provided for in section 107 of the US Copyright Laws. In accordance with the Title 17 U.S.C. Section 107, the material in this “Work” has been distributed without profit to those who has expressed an interest in receiving the included information for research and educational purposes.

Fair Use is a use permitted by copyright statues that might otherwise be infringing, Non-Profit, Educational, or personal use tips the balance in favor of “Fair Use”.

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5 Discussions

Hi nice instructable bud why you didn't add gerberfiles for that PCB if it is opensource ?

I do not own the rights to them. But if you use the email address (Second to Last Picture) at the end of the article I will email you a web address where you can down load it.

I'm also willing to take orders, so as to make a Group Buy so you can lower the cost per board. as of right now the last purchase I made I paid around \$1.57 each, that's with shipping to me, But you would also have to have shipping to you added in too.

i know where to find gerbers but others don't

without any informations where to get PCBs looks this instructable litle bit pointless to me if you have links to all componnents needed except main part
did you try to contact owner and ask him if you can add links to his page with gerbers ?

I don't consider it point less, others can create their own
boards, I can provide them the web address, or we all can get together and make
a large order at the same time. Since I did not have his permission to use his
videos, I did not provide them, in the instructable.

I tried in his comments to make contact with him months ago, no go.

As I stated in the instructable, I did not Create it, Design
it, the boards. In addition, since I did not own the board, I did not list it
on this Instructable. However, But I did provide an Email address at the end of
the instructable so anyone can contact me and I am willing to provide the web
address to obtain the Gerber Files. Alternatively, if anyone is willing I will
take orders to generate a large order of 500 boards or more, to get the price
down for everyone. I have the 4 different versions of the boards Gerber's files.
He provided it, I used It. In addition, if he contacts me; I am will to acknowledge he created this. Moreover, I will make a supplement to the instructable and enter that information. You have my permission to pass it on to him.