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E-Go Kart 18650 Pack - Cell fuses or nickel strips?
#21
Thank you again sir. That is very helpful. I actually will use a spot welder to connect the individual fuse wires however I can easily disconnect them just pulling them off. Thanks again

By the way what did you mean by solderless holders?
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#22
4x 18650 Battery Holder Case

[Image: s-l1600.jpg]
garolittle likes this post
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#23
Now that is interesting. Would it handle a max of 300 amps for my 20S20P configuration? I did not see any discussion of max amps in the description (although I have been known to miss things). Cool idea Sir.
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#24
Well, they'd be able to handle about 2A per cell. So, you could get 8A out of 1 4x holder. I haven't tested to see if they could handle more than that. But I'm sure they could handle 2A easily.
garolittle likes this post
Proceed with caution. Knowledge is Power! Literally! Cool 
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#25
Good info. Thanks.
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#26
Garolittle ....have you come to a final decision on your pack design.  Your hybrid of spot welded nickle strips/copper bus bar and soldered fuses is something I actually contemplated last night.
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#27
Hello Sir. I am still giving it some thought. I am torn between the relative ease of spot welding pure nickel strips to brand new 18650 cells and the possible safety benefits of using individual cell fuses. So many people have provided good arguments for both options. Right now I am leaning towards the use of individual cell fuses since I can always spot weld nickel strips at a later date. The fuses in the attached picture look so easy and simple even though it will take some time for me to fuse 400 cells individually. Do you have an up ideas?  Tell me about your project. I am always looking for suggestion
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#28
Spot welding fuses just has a little more of a learning curve than strips. The tip needs to have a slight notch in it to hold the wire during welding. Pete demonstrated this on one of his videos. Then you can have the best of both. Fuses and spot welding Wink
Headrc likes this post
Proceed with caution. Knowledge is Power! Literally! Cool 
Knowledge is Power; Absolute Knowledge is Absolutely Shocking!
Certified 18650 Cell Reclamation Technician

Please come join in general chit-chat and randomness at https://discord.gg/c7gJ5uA
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#29
So once again, the wisdom of Korishan beckons me to follow.  It does appear that spot welding individual cell fuses is the "best of both worlds".  For example, the following video is really cool.  

https://youtu.be/H_b3OJuQpEE  (Credits to [b]daromer)[/b]

Since I will be pulling a max of 300 amps (probably around 50 on a constant basis), I guess it all comes down to a few basic questions: 

Is the risk of thermal runaway significant reduced when compared to spot welding nickel strips (even though I will be using brand new 18650 cells from a reputable dealer?)

Are there any disadvantages to spot welding individual fuses (ie. does it increase resistance thereby increasing heat?)

Thanks again for everyone's help.  

Gary
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#30
Soldering vs Spot Welding isn't what causes or leads to thermal runaway. So neither one will really increase or decrease the chances of such.

The reason for Spot Welding over Soldering is that heat breaks down a cell. Too much heat, and the life cycles of that cell are diminished. That's why some have decided to go with Spot Welding. Less likely the cells are damaged. The other reason is it's a lot faster. You can probably solder a cell every 5 seconds or so. Spot welding can probably be every 3. Especially after you've gotten the hang of it. (note, that 5 seconds is not spent 'on' the cell)

Disadvantages is that it's a lot harder to replace the fuse if it breaks (if it blows, there's a reason and should be investigated). Resistance isn't added or removed, really. I suppose if anything, it might be slightly (ever so slightly) removed as solder has a bit of resistance too (but, there is usually so much of it that this is negated)

(I think I have answered correctly. Please wait for others to chime in to agree or disagree Wink )
garolittle likes this post
Proceed with caution. Knowledge is Power! Literally! Cool 
Knowledge is Power; Absolute Knowledge is Absolutely Shocking!
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Please come join in general chit-chat and randomness at https://discord.gg/c7gJ5uA
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