[Charles] Tears Into a Ford Fusion Battery


Any time we hear from [Charles Z. Guan], we know it’s going to be a good feature. When he’s linking us to a blog post with phrases like “If you touch the wrong spots, you will commit suicide instantly”, we know it will be a really good feature. [Charles] is no stranger to Hackaday – we’ve featured his GoKarts, Quadcopters, and scooters before. He was even generous enough to let a couple of Hackaday writers test drive ChibiKart around Maker Faire New York last year.

This time around, [Charles] is working on a power system for chibi-Mikuvan, his proposed entry of the Power Racing Series. He’s decided to go with a used battery from a hybrid vehicle. As these vehicles get older, the batteries are finally becoming available on the used market. [Charles] was able to pick up a 2010 Ford Fusion NiMh battery for only $300. These are not small batteries. At 20” wide by 48” long, and weighing in at 150 pounds, you’ll need 2 or 3 people to move one. They also pack quite a punch: 2.1kWh at 275V. It can’t be understated, taking apart batteries such as these gives access to un-fused lethal voltages. Electrocution, arcs, vaporized metal, fire, and worse are all possibilities. If you do decide to work with an EV or hybrid battery, don’t say we (and [Charles]) didn’t warn you.

As [Charles] began taking apart the battery, he found it was one of the most well thought out designs he’d ever seen. From the battery management computers to the hydrogen filled contactors, to the cooling fan controller, everything was easy to work on. The trick to disassembly was to pull the last module out first. Since all the modules are wired in series, removing the last module effectively splits the pack in half, making it much safer to work on. The battery itself is comprised of 28 modules. Each module contains two 4.8V strings of “D” cell sized NiMh batteries. The battery’s capacity rating is 8000 mAh, and [Charles] found they still took a full charge. Since he doesn’t need the pack just yet, [Charles] removed the final bus bars, rendering it relatively safe. Now that he has a power source, we’re waiting to see [Charles'] next stop on the road to chibi-Mikuvan.


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