Its took a while to get this done, a few hours of thinking and soldering, in amongst weeks of an average time poor lifestyle
Its mainly the concept which i think is extremely simple in itself.
There are 2x2 sets of busbar style contacts back to back on a centralised insulating rocker area.
Ive shown 2x2 for simplicity the fourth contact is for signalling and/or control purposes and could be in essence any number of small switching points for ancillary requirements.
The setup could be a manual switch or made as a relay.
With a manual switch, suitable thermoplastic enclosure would have to be designed.
The phase connection points dont have to be welded/soldered bar, they could be extensions of the busbar coming out sideways of the mid section or braids, connected pretty much anywhere on the bars, for greater long term flexibility of the connections.
The assembly could be made spring loaded to the star position, for start and held over to delta position with suitable strong permanent magnet/s, when switched.
A membrane type clear cover could waterproof the finished external moving part of the switch.
For a relay switch, springs and powerful permanent magnets both sides and opposing series wired electromagnet coils could create a strong latching bi state relay, pulsed by say a 12V or more supply.
Besides this star/delta scheme, Ive noticed the ev world appears to have a distinct lack of purpose made, heavy duty electrical switching hardware for areas like battery series/ parallel charge/run schemes and individual battery isolation etc.
I hope to get time to finish some further research, get some drawings together and knock out some prototypes on a laser cutter and 3D printer.
Iron Horse SGS Pro DH.
72V 16AH lipo. 3kW charging system.
Modded Crystalyte 72V/50A, regen, 3 stage overcurrent.
4060 ☆/\, 20mm cover holes.
Hyena supplied motor (much appreciated Onya mate)
Gokart A123 20Ah, 72V, PM72301, Mars motor.