A123 AMP20M1HD-A Battery pack kit

Hi. Some news. I have met with new manufacturer today and it looks like technologically it's hard to work with brass. I am stuck with few sheets. I have sourced new supplier for 7th series aluminium alloy which is OK to tap and the threads are holding pretty good. Next week this will wil be sorted i hope.
Just need to get those blocks done and as soon as i get them i can start shipping out the kits.
Thanks for taking interest
 
Sounds good to me!
otherDoc
edit: I just ordered a tube of NO-OX to help with the contact surfaces. Seems like it may be a good idea under any circumstances to use this stuff!
 
I guess it is bump time to prevent this thread from rolling off the edge of the first page!
otherDoc
 
docnjoj said:
edit: I just ordered a tube of NO-OX to help with the contact surfaces. Seems like it may be a good idea under any circumstances to use this stuff!
Click to expand...
One thing I read in some tech paper is to use a high-temp "no ox" type product that won't drip/leak once heated. They recommended high-temp petroleum jelly. :idea:
 
Thanks deVries. The stuff that I got is supposed to be rubbed off just leaving a really thin coating. Supposedly it "works its way into the metal". We will see. I am only going to be running 40 amps max, usually around 20 or so.
otherDoc
 
Sorry guys not coming back so often these days, wedding Saturday coming... Anyhow, got replay from manufacturer, at the moment all is good. Will be arranging materials to be delivered to manufacturer on Monday, and then is up to manufacturer regarding completion time. Will try to push them a little.
Cheers for support
 
agniusm said:
Sorry guys not coming back so often these days, wedding Saturday coming... Anyhow, got replay from manufacturer, at the moment all is good. Will be arranging materials to be delivered to manufacturer on Monday, and then is up to manufacturer regarding completion time. Will try to push them a little.
Cheers for support
Click to expand...
Peace and love man! Weddings take precidence over all else!
otherDoc
 
Just another bump to keep this from rolling of the front page!
otherDoc
 
Hi. Was missing there for some time. All is done with wedding, married and all, back on track. Ordered material for blocks. Tomorrow will confirm delivery times to manufacturer.
From the wedding :D
DSC_4929.JPG
 
You really do make a handsome couple! Welcome back.
otherDoc
 
Congrats!!!!
you need a tandem e-bike-- with a just married sign on the back :)
 
agniusm said:
Here is the 6kW tester for end terminals i knocked up today. Possible testing at 45A; 90A; 135A; 180A; 225A; 270A:

IMG_20120426_221400.jpg
Click to expand...

Any names yet, thinking instant tan equipment or make up mirror light for the seriously vision imparied, ecolighting.
For the James Bond theme, only really Moonraker and Goldmember, i can think, had like a death laser thingamy
and with a decent dish yep it would be visible from the moon :D :.

Congrats and also Congrats on your excellent battery system, well thought out.

Just some thoughts on the aluminium connection set ups, led to believe that NOX is really for ac connections as a dielectric grease, like a petrol jelly, zinc suspension. i've used a similar type at work on HV a.c. terminations called Alminox.
Some of the A123 cells, also believe have an Al tab for one and a nickel plated (copper ?) for the other and some cells have nickel coated copper for both, so galvanic issues could crop up with the dissimilars and dampness.
There is some research on the subject, but most of what i've found relates to a.c.
In saying that though, quite a bit of it is also relevant to dc connections also.
View attachment vol3-3.pdf
Think a dry connection might work better even though the Al is oxidised.
The greases,might be better used as a moisture barrier which could be recommended if the batteries are out in humid/damp situations where you'd get those galvanic corrosion issues, lightly coating the outer of the whole plates.
 
Hey megacycle
This is the stuff I got. It looks like it should help.

NO-OX-ID "A-SPECIAL" is the electrical contact grease of choice in new electrical installations and maintenance because of its excellent performance in keeping metals free from corrosion. This rust preventitive has been used for over 50 years to preventing corrosion in electrical connectors from low micro-power electronics to high voltage switchgear. NO-OX-ID A-Special prevents the formation of oxides, sulfides and other corrosion deposits on copper and aluminum surfaces and conductors can be prevented with its use. ------------>>>

otherDoc
 
We are tailking about a coated aliu & copper connections. This zinc and or tin aolly coating my be made just for the connection so as drilling holes my help the corrision process exposing the copper and alium contact ? Or just the heat of a laser or spot welder? ect. What the best connection as for corrision ? I think we all like to be able to swap out cells. Thinker's yes you. I think it all started when you open up that first flashlight and looked in of course the batteries came out, then you unscrewed the bulb. If it worked again after that you were on your way.Agaiusm she has that LOOK in her eye's. Good Luck.
 
Hi. thanx for the info. I am using 6082 T6 alloy which has good corosion resistivity properties yet is strong. Manufacturer got aluminium today, will let you know when they will be ready. I have developed few other toys as an option to help build the pack but this is just a glimpse and will reveal when i will have some viable info from mfr. I want to work on a tripple hole punch so it would be easy to do large amounts of cells in fraction of time, maybe sample for my self at first :)
 
docnjoj said:
Hey megacycle
This is the stuff I got. It looks like it should help.

NO-OX-ID "A-SPECIAL" is the electrical contact grease of choice in new electrical installations and maintenance because of its excellent performance in keeping metals free from corrosion. This rust preventitive has been used for over 50 years to preventing corrosion in electrical connectors from low micro-power electronics to high voltage switchgear. NO-OX-ID A-Special prevents the formation of oxides, sulfides and other corrosion deposits on copper and aluminum surfaces and conductors can be prevented with its use. ------------>>>

otherDoc
Click to expand...

It's not been proved to improve electrical conductivity with dc, only worsen it even though it has metal in suspension,
i'll try and find that paper.
with a.c. i've done we coat the item and scrub the crap out of it before we say crimp a lug on, we test for microhms and sometimes they fail the standard.
There are bimetal connecting plates for this type of connection but :oops: it's getting beyond, though there are A123 packs using these.
I suppose what i am saying is it's a good idea to research the connection methods so there's no problems later,
as a pendantic electrician the reliability of connections is bread and butter.
 
NO-OX-ID Special A does not have any metal in suspension that I'm aware of, it's not NOALOX. NO-OX-ID is supposed to be rubbed onto the contact surfaces as a very thin film, not glopped on. I used it to lubricate my terminal bolt threads on my CALB prismatic pack as well as on the copper connecting straps. Three years so far and no issues.
 
I'm also puting together an a123 20ahr 48v nom pack, I've got copper and aluminium tabs ( korean cells ),
should I use 16 or 17 cells?
I was thinking of just folding the aluminium tab over a copper wire and trying to find some sort of plastic clip to hold it tightly together, there are some strong plastic clips that might suit are used to keep opened chip packets sealed available from supermarkets.
this is the type of clip I was thinking of but not sure if it will work
clip.jpg
plastic hair clip perhaps
hair clip.jpg
 
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