spinningmagnets
100 TW
I wondered how those "fuse wires" that connect the individual Panasonic cells to the bus bars are connected. I supposed that they could have been spot-welded in some custom way, but apparently the wire is pushed against the surface to be bonded, then the wire is vibrated at 60 kilo hertz (60,000 cycles per second?) for 100 milliseconds (1/10th of a second?). It is a "friction weld" process.
Its a "clean" process that requires no cleanup after, and also a "cold" process that cannot damage the cells' internal chemicals. Any heat generated is "just enough" and it is very localized on the skin of the outer surface. Is there any way for use to do this in a garage for ebikes?
https://chargedevs.com/features/a-closer-look-at-wire-bonding/
Greenpower using aluminum buses and aluminum fuse wire, two fuse-wires per cell.
https://www.linkedin.com/pulse/battery-pack-same-tesla-welding-process-jess-chang
Its a "clean" process that requires no cleanup after, and also a "cold" process that cannot damage the cells' internal chemicals. Any heat generated is "just enough" and it is very localized on the skin of the outer surface. Is there any way for use to do this in a garage for ebikes?
https://chargedevs.com/features/a-closer-look-at-wire-bonding/
Greenpower using aluminum buses and aluminum fuse wire, two fuse-wires per cell.
https://www.linkedin.com/pulse/battery-pack-same-tesla-welding-process-jess-chang