Mr. Sharkey via EV wrote:
In an EV, we usually only get a single bolt and a flat mating surface the diameter of a nickle to make a successful connection. In building battery packs, we get to repeat that a hundred times over. Seems unfair, but I think I said it previously, we got to work with what we are given.
Yes, it's a poor situation for making a good connection. But one we are stuck with on cheap Chinese prismatic cells. I don't think they know or care about making reliable high-current connections.
Industrial batteries always have welded inter-cell jumpers. My old friend Bob Rice used to weld his connections, too. He figured the only time they will ever have to be disturbed is if the battery fails; and then there's no problem in cutting it off the dead cell.
His technique was to use a very hot torch, wrap a wet rag around the outside of the terminal, and then quickly weld to the top of the post. If you can do it in a second or two, the post and terminal have enough thermal mass to keep the heat from spreading and damaging the seal.
It is possible to weld aluminum. I've often wondered if an experienced welder with the right equipment could weld the inter-cell jumpers to a lithium cell without damaging the seal. It seems like it's such a massive slug of aluminum that a spot welder might be able to do it.
Lee Hart -- There is a computer disease that anybody who works with computers knows about. It's very serious, and interferes completely with your work. The trouble with computers is that you 'play' with them! (Richard Feynman) -- Lee Hart, 814 8th Ave N, Sartell MN 56377, www.sunrise-ev.com _______________________________________________ UNSUBSCRIBE: http://www.evdl.org/help/index.html#usub ARCHIVE: http://www.evdl.org/archive/index.html INFO: http://lists.evdl.org/listinfo.cgi/ev-evdl.org Please discuss EV drag racing at NEDRA (http://groups.yahoo.com/group/NEDRA)
