Martin WINLOW via EV wrote:
What, as a matter of interest, is an acceptable amount of resistance in a 
battery or cell terminal connection?  MW

It depends on the current, how long it has to carry it, and how large and effective the terminals are at radiating the heat produced.

But in general, the resistance had better be a small fraction of the internal resistance of the cell or battery itself; otherwise, most of your energy will be thrown away as heat before it ever gets to your load!

Most EV-size cells and batteries have an internal resistance of a few milliohms. As a rule of thumb, you want your inter-battery connection resistance to be under 10% of this. For example, if your cell is 3 milliohms, that means 0.3 milliohms cell-to-cell.

--
You never change things by fighting the existing reality. To change
something, build a new model that makes the existing model obsolete.
        -- R. Buckminster Fuller
--
Lee Hart's EV projects are at http://www.sunrise-ev.com/LeesEVs.htm
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