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E-Go Kart 18650 Pack - Cell fuses or nickel strips?
#11
As a thought, why has nobody come up with spot welded nickel strip fuses ?

Stamp out a pattern with the two pads each end and then a thin section to act as the fuse... would make pack setup a lot more easier and less damage to the cells internally, via soldering.

Pattern : O-O
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#12
They are made. I've seen them before, but I can't remember where I saw them now. Nor what they are called. A little googling might turn something up.

They kind of look like a bandage that you'd put across your nose, or like an exaggerated " I " shape.
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#13
That is a pretty cool idea.  I keep debating (with myself) on whether I should 1) Stick with pure nickel strips and a spot welder or 2) go the “Tesla route” and use individually fused cells (also spot welded)
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#14
After a bit of reading it may be due to the melting point. The nickel strip will heat up a lot more and stay conductive in a small overload situation, fire risk... fuse wire has a lot lower melting point and better for smaller overloads. Shorting protection - nickel would work but a prolonged overload no. Learnt something new...

Interesting one... "A123 sizes their fuses to be 3.6 mm wide and .007" thick nickel sheet. They rate there fuses to blow at 2100amps in .1 seconds." http://mit-evt.blogspot.co.uk/2009/06/
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#15
Thanks for the ideas. This forum is awesome
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#16
Remember, you can show your gratitude by donating 18650 cells Wink
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#17
(04-15-2018, 12:13 PM)Korishan Wrote: Remember, you can show your gratitude by donating 18650 cells   Wink

Well I was about to send you $1000 check but since you only prefer used 18640 cellswith two volts each I can send that instead Tongue
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#18
hahah Tongue
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#19
OK this may be a dumb question but how would I replace a cell that has a blown fuse if I have a large battery pack? For example if I have a 20 S 10 P configuration and one of the cells in the middle has a blown fuse how do I replace that particular cell when the rest of the pack is connected with those Cell holders such as this?

YEHAM 4x5 Cell Spacer 18650 Lithium Battery Plastic Holder Bracket (10pc) https://www.amazon.com/dp/B06XHHM28S/ref...2AbCSFVMH2

Maybe I’m missing something obvious but it seems like I would have to disconnect the fuses on all of the cells, pull off the brackets, and then refuse each of the cells.
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#20
Desolder all connections to that cell, break the little dog ears that hold the cell in the holder, slide it out, slide new one in, resolder the connections adding new fuse wire.

This is why I plan on going with solderless cell holders. That way I can just pop a cell out without needing to de/re-solder anything
Proceed with caution. Knowledge is Power! Literally! Cool 
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