SPIM08HP Busbar

Announcement - Help us fight the BOTS! Please report all spam including stuff in your inbox!

FarmerJ

New member
Joined
Apr 13, 2021
Messages
19
I have finally tested all the SPIM08HP pouch cells for my golf cart battery and have the 10s16p repacker configuration to build the battery but now I need to consider the busbar to connect all the cells for the high amp load the golf cart can draw.
I started out by cutting 8mmx8mmx97mm aluminum bars to fit the cell holders and drilling and tapping the holes to align with the cell tabs. That takes care of the bottom of the parallel cell connections between two cells but now I need the top busbar that will connect the 8 pairs of cells in parallel and then to series and I’m debating between 2mmx95mm copper sheet which would have a amp rating of about 228amps or 1/8”x3.75” aluminum flat bar stock which would also have an amp rating of about 240amps. I need 10ft of total length as 8 parallel 2p cell holder configuration is 6”, so that’s 5ft on each side with a small gap between the series of 10mm which I have HDPE dividers cut to insulate between series connections. A 2mmx100mmx200mm (7.87”) sheet of copper is $13.65 on Amazon so that would be around $260 vs 1/8”x4”x72” 6061 aluminum bar stock being $23.32 at my local Grainger and 1/4”x4”x72” 6061 is only $5 more and would have around 480amps maximum.

So I guess the question is, is it worth it to go to copper for the price? My local scrap yard occasionally has 1/8” and 1/4” copper bar stock/bus bars that come in and the yard worker there holds it behind the bin for me to buy at current scrap cost per/lb so I could try and wait it out and get the copper over time. They also have tons of 4/0 clean stripped copper wire that is always available and often in 1-2ft lengths but I don’t know how I would connect that to the cell tabs in an efficient manner which was why I went with the flat bar configurations. Am I missing anything if I use Aluminum instead of copper for this purpose?
 

Attachments

  • F2578958-688D-4A35-81FC-6A873B4FBC4D.jpeg
    F2578958-688D-4A35-81FC-6A873B4FBC4D.jpeg
    1.9 MB · Views: 27
  • 42386EC9-4E23-458D-B31E-683551EFDA89.jpeg
    42386EC9-4E23-458D-B31E-683551EFDA89.jpeg
    1.4 MB · Views: 26
  • C33C9629-F051-4AC5-A718-1BE157CF900A.jpeg
    C33C9629-F051-4AC5-A718-1BE157CF900A.jpeg
    1.3 MB · Views: 29
Last edited:

FarmerJ

New member
Joined
Apr 13, 2021
Messages
19
One added question is, could I use a thinner copper sheet with an aluminum bar on top of it to dissipate heat and get the 200amp current safely by layering them? I know from the current shunt and monitoring that the golf cart motor/controller can pull up to 250amps at startup load and on hills but then it drops down to a much more reasonable 30-50amp range cruising.
 
Top