Re: Historic Size of Battery
 

The document that Tristan has linked to is part of the references I have used in the past. The current battery is an AGM style battery so the electrolyte is absorbed in a mat but can become fluid under certain conditions. I recommend charging upright so that any fluid that might be present doesn't cover the pressure valves. Should pressure build to the point of venting, loss of fluid is inevitable. For the students handling batteries, if we make it a normal procedure to charge upright, then should they be in position where they are charging some other types, the vents will likely be facing up. If the battery experiences some failure during charging, then all venting will take place where pit crews can see it and react ASAP. We are not sure at this point what failures may have occurred, but a small number of teams have experienced battery failures over the last two years. Some have occurred during charging and the rest appear to be physical damage. Since the battery stores a large amount of energy, physical damage can cause internal heat. The domino effect causes venting, external heat, and leaking fluid. Please instruct your students to never handle the battery by the wiring, always carry with two hands and in the event of a drop, be sure to put the battery on the side until you (or another mentor) can determine if it has internal damage. A few hour test with a load tester like the West Mountain Radio CBA II will show if one or more of the cells have a reduced capacity indicating internal damage.

Re: Historic Size of Battery
 

Thank you to all who responded so quickly and thoroughly in the answers. We were in the middle of finalizing the design tonight and the students wanted to understand why the batteries can not be charged sitting on its side.

Our original design would have the batteries laying on its side with the top facing out when charging in the pit. At other places where space is not a constraint, we will lay the battery cart down on the back which is on wheels so all batteries will be upright.

Now at the pit, we can either lay it on the back and put it under the table or take the batteries out of the holder that carries two batteries and set it upright without the holder in the battery cart. Either way we are going to charge it upright. It may be hard for others to understand what I am talking about. We did manage to finish the CAD model tonight. We are going to tweak it a little, put in the details where the holes are to run the charger wires, power strips etc. We will post it here for you to see at a later date. It is really cool.