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Battery Hookup's Nickel Fuses
#1
Been on a learning curve (burning nickel is hot...) with BatteryHookups new nickel fuses.

So far I'm so impressed with the speed and ease they can be attached. They look clean & it's easy to see when a fuse has failed. The only thing they lack is the ease of maintenance. 

My testing methods so far have been less than 'professional' but I'm enjoying the curve as well as sharing what I've learned. 



The first video basically trying to figure out current flow via the thermal camera, kinda failed due to the size of the battery and the nickel sheet does a great job of dispersing heat. 



Second Video
Me trying to 'test shit' didn't exactly go to plan BUT did learn so I guess that's a win. 

Korishan likes this post
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#2
I saw Avg Joe talking about these and thought they were definitely worth checking out. Since I'm mostly ebikes and cars my worry is about cell replacement being a hassle.
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#3
If Alarmhookup could make the circular cut-outs larger - large enough to push cells thru - then you could cut the spring/fuse and pull out out of the way and perhaps hack it back on (mabye solder) or just cut it off and straighten use it as a fuse wire.
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#4
If the cutout were to be made large enough to fit a cell through, there would not be enough material left to carry much current.
I think it's already pushing the limit, certainly for a 100+P pack. Might be a good idea to reinforce with a copper busbar down the center.
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#5
I guess the issue is if you make the cut out larger it will make the fuse even longer & reduce the current-carrying ability even further? Definitely a design trade off
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#6
The fuse can be tapered so thats not a problem. You can even run the fuse in another angle.

Its important to remind that this is not the holy grail that save you from fuckups or low draining cells. Its a simple way to incorporate fuses for dead shorts or high current and makes life so much easier to assemble larger packs Smile
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#7
The glowing fuses photo is a nice money shot.

Just to confirm, these are nickel plated steel, not 100% nickel?

Pretty clean way to go about doing this, but I still like the idea of those glass axial fuses. Considering I am not spot welding (yet), it certainly limits my options.
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#8
Yes nickel-plated, someone on facebook shared a photo of the glass fuses acting as a lightbulb for half an hour so with the right conditions any photo looks like a money shot lol
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#9
Just about all fuses will glow nicely for an extended period of time in the "sweet spot".

I did test the glass axial ones and they do get hot, got enough that I did melt the plastic on my wire grabbing meter leads when I clamped too close to the glass. I do prefer the blow element being contained, but the design of these fuse sheets are clever.

Just an old video, of the glow.
https://youtu.be/190HebfiQ78
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#10
I can't believe Batteryhookup went nickel-plated steel for this design. As someone who has taken apart a thousand generic packs or more, I expect nickel-plated steel from China, but not from an American company that claims to be helping the DIY community. Not only is nickel-plated steel much higher in resistance to pure nickel, it is also subject to rusting that can cause cells to rust. Even the tiniest scratch and light humidity can make the steel underneath rust. A spot-weld is enough to burn off the nickel plating and expose the steel underneath. I've attached a picture of two strips, the one on the left is nickel-plated steel and the one on the right is pure nickel. You can see the rust underneath the nickel plating that was leaching onto the positive terminal of the cell I was extracting. The strip on the right came from a pack of rusty cells, but the nickel held its integrity. I wouldn't buy this, but that's just me. Hopefully you all have better luck with nickel-plated steel!

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