Shark Attack! Breaking Down BYD’s Battery Pack

hello everybody Welcome to Monro live I'm Al Styer vice president of Technology uh today we're going to look at the uh byd shark Hybrid battery pack which is setting off here to my side um

what I'd like to do is I'm going to start with the cover because I found this to be rather interesting you see it's got a couple of ports down here but this is on top of the battery which is the top side and then when you look at

this side you can see all the channels it's actually AC cooled uh I've have seen a couple AC cooled batteries in the past it was uh predominantly on BMW uh but the interesting part is it's on the

top and not the bottom everybody else cools from the bottom uh you do get like the Tesla that does uh the channels between the cells but it's definitely a little something a little different that

we've than what we typically see so as you come over here uh they're using What's called the blade cell uh they're long thin cells about a/4 inch maybe a little more than a/4 38 of an inch wide

uh and they just kind of run in series so I've got a positive connection over here and I have a negative connection over here and so the battery power what it does is it runs down the length of

the the module it comes across at the back and then it comes back down here to exit out inside this area is your BMS your contactors uh we haven't it opened it up but I would imagine there's

probably a fuse or some sort of pyro charge inside here as well um um on top of the batteries you can see this grid so what they're doing is you know with batteries you got not only do they have to be cooled but they also have to be

heated and what they've done is they put an electric grid on top of the batteries to heat them up oh this there's another interesting that green ceiling compound or adhesive you see uh is all around the

whole perimeter of the pack and even across the center um actually if you zoom in on this cover the other interesting thing we found which is very rather unusual but

you can see where the Fasteners were and you can actually see they encapsulated the Fastener around the edge of the Fastener to prevent leakage and they did that all the way around all the the Threaded Fasteners on

this so the other thing that's kind of odd on this is they actually have a foam uh pad adhere to the P the module the pack itself all the way around uh one of the other things you notice there's a

vent there's two of them one on this side one on the other side and then if we move to the front I mentioned the AC so what was nice is

the cover has the ports in it and they just engaged it just press into this block right here and this is your AC manifold and then it looks like we have a couple high voltage connections and

probably a uh it looks like another one here for DC all right welcome back day two here uh you can see the shark battery packs

upside down um just kind of recap yesterday we uh you know we disconnected the uh bus bar cars we got the communication wires out of the way so it was ready to pull out uh we tried doing

some wedging on it trying to get it to move inside the battery pack and as you can see we were not successful so today uh we know where the where the battery

sits inside and what we did is I end up scribing some lines down and we got a nice good old uh skill saw here with a metal cutting blade and we're hoping we

can just follow the lines and when we'll get done we'll cut through it and the battery pack will fall out the bottom or off the top [Music]

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all right welcome to day three of uh Monroe live and uh the uh byd shark battery pack tear down what you see in my hand is uh results of three days

worth of work this is the blade battery cell um it's a lithian ion phosphate uh there's basically uh 114 of them in this

module uh between the two modules 57 per around 30 kilowatts 365 volts DC 81 amp hours uh it was a little bit challenging uh

just to get this out uh it basically it was glued down inside of here they got some adhesive so we basically had to pry down but was the last step before we

could get to that step we had to remove a whole bunch of uh bus bars so this is the connection between cells and as you look down the length of this battery pack you can see a number of them are

still in here uh they're basically laser welded to each of the batteries so you go from the positive of one to the negative of the other go crosses over on the other side comes back to connect

them all in series down through uh they do have this plastic plate on here so it kind of covers over everything so we had to remove that on each side of that uh

the plastic plate serves as a couple functions one is it actually closes out the cells here so you really can't touch it so it's like an insulator uh the the

second purpose of it is I get it out of the bag there's what's called a BMS board so this BMS board is attached on the ends

down here and there's a number of tabs that connected it to the battery cells and what it's doing is it's monitoring each cell's voltages and it's trying to balance it so if you're trying to if you

got all the volts all the cells are at 3 volts and one it's at 2.9 it's going to try to discharge the rest of those cells to get them equal so they always want to keep the cells as close as possible

together um the interesting there you know a lot of people they'll take and have a wires running out to a BMS but what they did is they just had tabs that went from one cell to the other um to

get from one side of the battery to the other they took an interesting approach on that as well so down the length of this side of the

battery they had this Flex circuit um it's not connected to anything it's just uh basically connecting from here to here and what they did is they connected it from one side here and what and then

over here there's a little bar a little tab here that tab actually connects to the other side of the battery so they're actually running the current back through the battery somehow we haven't pulled a cell apart to see how it

actually works but a little bit different approach most people will have Flex circuit on both side interconnecting they've actually done it through the battery itself something that we've never seen so something that

caught her eyes I could tell you I hate this glue this stuff is hard it does not come off uh so to get the batteries out I think we talked about it yesterday so

it's literally glued in the walls of the the hous a come up through here you have no access to anything so we literally had to cut the plate out at the bottom of the battery box and the battery box

is over here and you can see it's now empty you can see we had to get pretty close to the walls uh this one we did this one was a little better than this one had a little bit sticking out but we

only have about that much room between the battery and where we're cutting so we had like couple millimeters for a margin of error and we uh successfully removed them without uh arcing and

shorting anything out other than that I think that kind of sums up what we've done over the last couple of days so anyways I'd like to thank everybody for watching I hope you enjoyed the video uh

feel free to subscribe to our site and uh looking forward to the next one n [Music]