Willow wrote: ↑
Jul 06, 2018 6:53 pm
In the search for low resistance, safe battery construction techniques for high power output, this seems to be neither low resistance or robust enough for e-bike/go-kart application. Heat will be an issue because of the resistance of the fuse wire... and I wouldn't trust the wires to maintain contact with the cells. Spot welding may make the wire brittle enough to simply snap the wire off - remember there is going to be significant heating and cooling through these connections, which equates to the wires expanding and contracting accordingly, adding to the mechanical stress of the connections.
Do you have experience with fusible wire? Where are these claims coming from?
Of course you need to select the correct wire size for your application, so that the wire is not heating significantly during operation.
You can see from the pictures I shared how good the contact is between the wire and the cell. These connections are not brittle - I've practiced with junk cells and I've tried to rip the wires off the cells after welding them. The wire is what breaks, not the connection to the cell.
For the 30 AWG wire I'm using, a 2cm piece would have a resistance of 6.77mOhm. I would assume I have a 2cm piece connected to the top and bottom of each cell, so that's 13.5mOhm. This is low enough for the packs I'm using it on. For higher current per cell, I would choose a larger wire gauge.