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Battery Hookup's Nickel Fuses
#11
The issue is stamping pure nickel, it's just too soft. Credit where it is due, Tom always disclosed this fact (unlike the chinese)
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#12
Surely plating thickness would also play a part in how the end result works over time?
If so, there would be better and worse standards of nickel plated steel products?
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#13
I would assume Oz
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#14
The more I used this product the more I like it, agree it's not perfect but it's 100x better than soldering packs. 


ajw22 and chuckp like this post
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#15
Looks like you have self discharging cell(s) in packs #41 and #48, possibly others? The process of finding those in "traditional" packs can range of easy (visual inspection) to tedious, but not difficult (desolder all fuses). Faulty cells can be replaced in less than 10 mins?

How is it with the new nickel fuse pack? Obviously some major disassembly is required... or can you slice off just one section? Is it enough to do one side? Can the whole sheet be peeled off all in one go without shearing? How often can cells be re-spotwelded?

Perhaps a mid-road approach of using 10 pieces of 2x4 nickel fuse sheets, and soldering them individually to the bus bar is a good balance of speed, performance and serviceability?
Modular PowerShelf using 3D printed packs.  40kWh and growing.
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#16
Maintenance is always going to be an issue - with the speed this product can be put on and the fact the cells aren't un-naturally stressed by the soldering process you can reasonably expect that the cells will have an even longer serviceable life requiring less maintenance. (one would hope)

I like your approach of just cutting off half, that would work well and would be more cost-effective, a different approach could be using 2p strips I guess making it more serviceable.

But if I should be honest making the pack better in the first place (don't do what I did and build shit batteries for the tubes) will reduce the maintenance issues greatly. Thus this is no different to replacing the pistons in a car engine. You deal with it when it happens and accept its part of car ownership
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#17
Does it worry anyone else that the section that burns out is quite long, and in the videos, during a short between both sides, there is a fair amount of glowing red metal for quite a while before the fuse section blows?
Pete, it might be too much to ask, but are you interested in doing a comparison test with your old process (one strand of wire for fusing per cell) and/or with the new method of spot welding on a few cells, then fuse wire to the bus bar?
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#18
(11-22-2019, 12:30 AM)Oz18650 Wrote: Does it worry anyone else that the section that burns out is quite long, and in the videos, during a short between both sides, there is a fair amount of glowing red metal for quite a while before the fuse section blows?
Pete, it might be too much to ask, but are you interested in doing a comparison test with your old process (one strand of wire for fusing per cell) and/or with the new method of spot welding on a few cells, then fuse wire to the bus bar?
@Oz18650,

Yes it has always worried me to have an open air fuse just glowing away till it blows splattering its liquid molten metal everywhere. Especially on the positive side sliding down the pos terminal and shorting it to neg.

But I think there is a solution.There are a ton of different size insulators for the pos end of a 18650 cell. Cheap too!

Install insulation before spot welding and enjoy.
You could also go very radical and cover the positive side with silicone which would encapsulate the wire/fuse. 
Make replacing the cell a bit of a hassle though.

Wolf
If 18 X 650 = 2200+mAh then we have power! 
May all your Cells have an IR of 75mΩ or less Smile
Last count as of 8/7/2019
Total Number of Cells Recorded and processed                 6149
Total Cells required for PowIRwall                                   2856
Total Cells ≥2200mAh, ≥80%, ≥35mΩ, ≤75mΩ, ≥4.12V   2760
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#19
That test is without a doubt worst-case scenario, most times it's only one cell that fails & in that case its dam near instant blowing of the fuse. I have so many of those cell insulators from www.18650shrink.com I should have used them but without thinking and the many takes it took to get the panning spot welding shot right I just kept getting premade packs i had on the wall without busbars. Sad  But the good thing that comes from these conversations is I'll do it again and apologize for not remembering this conversation lol 

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