Lawrence Rhodes wrote:
OK so I don't know spot welders. How about pigtails and soldering to drilled
copper or brass plates? Seems it would be more reliable than spot welding but
take longer. Lawrence Rhodes.....
Good equipment helps, but the skill and experience of the user makes a
lot more difference. An expert can get good results, even with cheap
tools. A beginner will get bad results, no matter what he spends on tools.
Big companies that build a lot of packs will have an expensive, highly
automated spot welder, with enough automation so even a moron on the
assembly line can get good results (all he does is push the buttons).
But some expert carefully set up and fine-tuned that setup to get
consistent results. This setup can easily build a reliable pack with
100-plus cells.
Every "Batteries Plus" store has an inexpensive spot welder, for
building up packs to repair various cordless devices. Some of their
employees are experienced and well-trained. They do good work despite
the simple welder (like 999 good out of 1000 welds). Others are just
stumbling around, and are lucky if 9 out of 10 of the welds they make
are good. If the latter tries to make a 1000-cell pack, there will be
hundreds of bad welds.
So, if you are really committed to do this, either find someone with the
skill and equipment to do if for you. Or, buy the equipment yourself and
*practice* and *test* enough to BECOME an expert. Expect to waste a lot
of time, and destroy a lot of cells before you get it "right".
--
A designer knows he has achieved perfection not when there is
nothing left to add, but when there is nothing left to take away.
-- Antoine de Saint Exupery
--
Lee A. Hart, http://www.sunrise-ev.com/LeesEVs.htm
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