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E-Go Kart 18650 Pack - Cell fuses or nickel strips?
#31
I actually had success building a spot welder out of a 12 volt battery, car solenoid, welding cable and a digital timer this past week.  On a pack I plan to build I am thinking about pursuing spot welding fuses to the batteries and then soldering the other end to a bus bar.  If I have trouble spot welding the fuses directly another approach might be to solder them to a nickel strip and then spot weld that to the cell.
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#32
(05-01-2018, 01:16 AM)Headrc Wrote: I actually had success building a spot welder out of a 12 volt battery, car solenoid, welding cable and a digital timer this past week.  On a pack I plan to build I am thinking about pursuing spot welding fuses to the batteries and then soldering the other end to a bus bar.  If I have trouble spot welding the fuses directly another approach might be to solder them to a nickel strip and then spot weld that to the cell.

 I may just build a small prototype (7S 7P) just to test out the individually fused cells under “load”. I can use it on a very small go kart just to see how it works.   I really appreciate all the great ideas. You guys are awesome.
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#33
    So I just had an idea that I wanted to share with the forum. Rather than having to 2 separate 36V battery packs connected in series (one on each side of the go cart seat), why not have 3 separate 24V battery packs as depicted in the drawing. Please forgive my drawing abilities. The 24V battery packs could be connected in series which would allow me to achieve the necessary 72V.  The risk of thermal runaway over at a large single or double battery pack is reduced simply because there would multiple smaller packs. Also, this provides a “modular approach”  which would allow me to use the individual 24V battery packs for other purposes when not attached to the go kart.   My plan would be to connect each of the 24 V battery packs using 4-AWG since I could pull a maximum of 300 amps (50-60 Amps Constant Current).  I could still spot weld the individual cell fuses as discussed but I wanted to see what the forum experts thought about this battery configuration. Thanks again for all the great ideas and support.
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#34
I forgot to mention that each 24 V battery module would have a 4S20P configuration. Thanks for any suggestions or ideas anyone may have.

Gary
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#35
post a picture of your go kart
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#36
How are you getting 24v out of 4s?
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#37
I apologize for the incorrect battery configuration. It would actually be 7S20P.  I will post pictures tonight. Right now we just have the frame without a motor charge controller or battery pack.
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#38
7s 20 p, assuming 2.500 A per cell that will give you 50 amps or 1200 watts. It that enough?
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#39
Thanks for your question. Based on the drawing above, it would be three separate 24v packs (7S20P) connected in series which would result in 72V. Assuming 2.5 amp hours per cell, this would result in a total “Watt Hour” calculation as follows: Total # of cells: 420 mutlpied by 3.7 nominal voltage per cell and then multiplied by 2.5 amp hours per cell. This would be approximately 3,800 Watt hours for the entire 72v pack.
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#40
(05-04-2018, 04:31 PM)Jason Morris Wrote: post a picture of your go kart

As requested. Thanks again for all of the suggestions.


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