What do you think should be the minimum bus bar thickness for 24V- 7s80p system?
I'm hoping this is a typo. Did you mean 7s instead?? Because 7p would mean each cell is having to output 14A to meet the 100A peak.I think I will assume max 100 Amp for the whole battery -7p
Not really - a given wire size can handle xxx amps for yyy temp rise & this doesn't really change with length.The shorter the wire, the more current it can handle before heating up. This is because there's less resistance in the wire.
I tried that calculator & I think it has a bug or two!According to this calculator: https://www.omnicalculator.com/physics/dc-wire-size
Yes that's true but it doesn't change the current carrying capacity rating.The longer the wire, the more the resistance. This is why length matters. All wire-size/amp charts include length as a measurement.