LiBSU - Redesigning the "Battery Support Unit" to Support Lithium

It's crazy that TE makes "wire-to-board" connector housings (1473143-1) that they don't also sell mating headers for. In other words, a company that solely manufactures mechanical connector systems expects me to design my own header to mate with their connector housing. OK, seriously?

Looks like I'll end up cutting off the OEM temp sensor terminals (1123343-1) and replacing them with another connector system. Another thought is to kludge a 0.100" 2p shrouded header to work with their 1473143-1 connector housing.

 

Daily PCB layout update:

Notes:
-HVDC section 100% placed.
-Connectors 100% placed.
-Should have all remaining parts placed tomorrow.
-Almost certainly a 2 layer board... almost every signal routes on bottom layer.
-Planning to order PCB Monday.

 

There are several ways to retrieve debug info from LiBSU:
1: The most verbose output is via USB. Here's the existing method for my Honda Insight product. Note that while I'm using Arduino's IDE in the video, any standard serial putty terminal will work... LiBSU isn't running Arduino code, but that platform is the easiest for computer novices to use.
2: LiBSU will report all OEM parameters to the hybrid computer, which are readable via OBDII. This will only narrow the failing cell down to QTY4 cell segments. You would need to use USB to narrow down to a single cell.
3: The (optional) 4x20 LCD displays the following parameters:
KEYON_SECONDS
VPACK_ACTUAL
VPACK_SPOOFED
BMS_ERROR_FLAG
CELL_VOLTAGE_HI
CELL_VOLTAGE_LO
CELL_DELTA
POWER_kW
CELL_MAX_SINCE_KEYON
CELL_MIN_SINCE_KEYON
SoC
PACK_CURRENT
TEMP_BATTERY
FAN_STATUS
CHARGER_STATUS
HEATER_STATUS
CELL_BALANCE_STATUS
WATT_HOURS_SINCE_KEYON_ASSIST
WATT_HOURS_SINCE_KEYON_REGEN

As I mentioned previously, no wireless options are available. The FCC certification is expensive and annoying, and I just don't plan to do it. If someone wants wireless, they'll need to develop an expansion module that plugs into LiBSU. Some of my Honda Insight customers use an Android phone with USB OTG for wireless comms.