diy solar

diy solar

Compress or not, flexible busbar or not

If not twice as much, then how much? Please show your work. Conjecture and hypothecation aren't enough.

Hey bud I don’t have all those book smarts but I got heaps of common sense and as I said no college but I have pushed a lot of cars and I can guarantee if someone helps by pushing on your back it helps. All be it just slightly but it helps and there’s more force same as there would be with more people or more cells put against each other, ofcourse arms can only handle slightly more force than you yourself can apply before they break but cells of a battery can withstand the force of their buddies
 
So your saying 28.53psi is fine to subject our cells in our packs to? I have to strongly disagree. That might be the maximum a cell will see under there normal operating conditions (tests they put the cell thru) in a rigid/fixed rig like the data sheet, but that does absolutely not mean that is ok to do to our cells.. and how you come up with they are implying that is fine pressures for our cells,, I can’t understand
You may be absolutely correct about this, but the implication in the datasheet is that the force grows as the cells age. They specify the force to be less than 30kN at the end of the cell's life (which they now define as 70% of the original capacity, not 80%).

30kN = 6,744 pounds -> 112.3 PSI.

You still have not answered where you got the 17 PSI maximum number from. Please tell me since I remember seeing it but can't find it.
 
You may be absolutely correct about this, but the implication in the datasheet is that the force grows as the cells age. They specify the force to be less than 30kN at the end of the cell's life (which they now define as 70% of the original capacity, not 80%).

30kN = 6,744 pounds -> 112.3 PSI.

You still have not answered where you got the 17 PSI maximum number from. Please tell me since I remember seeing it but can't find it.
Not “may be correct” I am correct. To much is being assumed and said to be implied by how a data sheet shows a cell tested.. if you and @noenegdod went outside and tried to push a car with one of you pushing on the others back then you both would see that’s im also correct about that..
I would hope it’s less than 112.3psi...
that 17psi came from 2 different things i read, yes one was from what ghostwriter found out with her special connections and the other was from someone who emailed EVE or CATL I think.. the 17psi definitely seems reasonable to me for a cutoff, applying 12 to 17psi would be enough to keep compression
 
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Honestly, you keep asking us to do the work. Grab two bathroom scales and a buddy and come back and tell us the results.
Honestly, in the nicest way possible, I have to do the common sense work by not implying things regarding this data sheet that don’t make sense to imply so that others reading this are not led astray.... I’ve done many real world physics tests.. I’ve already pushed many cars and several times have had people push on my back to get a car moving that I couldn’t move myself and it definitely helps some.. yes it would have helped a lot more if they would have pushed aside of me.. it’s simple really. More mass pushing equals more force even if that mass isn’t next to you.. if you don’t think that’s true then you need to do the test yourself that I have already done several times..
 
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So anyways, at this point for me from all these lovely conversations and info. I’m under the impression that using springs and flexible busbars is the best way to go when having 19cells in a row. Might even be the best option for 16 cells in a row. 8 cells in a row and under is probably fine to use a rigid fixture and poron foam and still not exceed the max 17psi.. everyone is of course welcome to their opinions..
 
Well no that’s not my only concern as I explained other concerns in the original post. Thanks to Rays youtube channel I know that If using wire then I would need 1/0 to have close to the same resistance as a tin plated copper busbar that comes with these cells. With 1/0 it is no longer flexible..The braided from what I am reading/seeing on YouTube) do not flex barely at all in the direction they need to flex and have a much greater resistance than the copper busbars..
Multiple 10 gauge wires crimped into lugs seem like the best flexible busbar option to actually be flexible but idk, just seems wrong using 4+ 10 gauge wires crimped into into lugs
I have put over 10,000 hi-way and off-pavement miles on this configuration. It works without issue.
 
Totally agree with the force excerted by 1x hydraulic ram or 2x hydraulic rams or 1x or 100x lifepo4 cells in series is the same kgf /psi as 1x, what changes is the amount of linear movement. This to be fair is fairly basic physics.
Hence why I'm happy I have multiple springs in series - not to increase force, but to limit linear force of multiple cells and subsequent increases in force.
I did have a look at the Poron foam data sheet, I would say with the correct density/depth of this material it could be used to keep the kgf within spec, for myself this would be far dearer than £15 of springs I already have purchased.
 
I have put over 10,000 hi-way and off-pavement miles on this configuration. It works without issue.
Looks good! Yes with only a 4 cell pack it seems that expansion/compression isn’t a huge deal.
 
Totally agree with the force excerted by 1x hydraulic ram or 2x hydraulic rams or 1x or 100x lifepo4 cells in series is the same kgf /psi as 1x, what changes is the amount of linear movement. This to be fair is fairly basic physics.
Hence why I'm happy I have multiple springs in series - not to increase force, but to limit linear force of multiple cells and subsequent increases in force.
I did have a look at the Poron foam data sheet, I would say with the correct density/depth of this material it could be used to keep the kgf within spec, for myself this would be far dearer than £15 of springs I already have purchased.

Right, that’s what im trying to say. There is more linear force with multiple cells compared to one cell. The battery packs we are discussing are horizontal/linear not vertical.

In regards to the 1x or 100x cells or 1x or 2x rams.. if the rams were looked at as being cells, and there was 8 rams against each other in a linear fashion, each trying to press on each other with the same amount of force, I would assume it would take more linear force to stop all of those 8 rams from expanding/pressing the other than it would to stop 1 ram..
same if there was 2 people standing behind each other pushing on the others back instead of just one. It would be harder (more linear force needed) for 1 person to push those two people..
another example. If there’s 4 cells trying to expand in a rig with springs and end plates,, and 2 cells in another rig with springs and end plates, but the springs on both rigs apply the same amount of force on both rigs just to keep the end plates snug at low SOC. As SOC rises, the group of 4 cells would depress their springs more than the group of 2 cells.. this means that the 4 cells are applying more linear force.. yes if 12 psi was applied to rigid end plates without springs then that might be enough to contain the expansion of both rigs.. but the rigid endplates of the 4 cell rig would be working harder or have more linear force applied to them from the extra cells than the 2 cell rigs endplates experience. The psi in the 4 cell rig would be higher than in the 2 cell rig at high SOC.. this is the reasoning for using springs that can apply a more constant psi that doesn’t rise above 17psi to allow for some slight very minimal expansion but still keep the psi below 17 in the rig.
 
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Right, that’s what im trying to say. Linear force increases as the amount of cells in the pack increases. The battery packs we are discussing are horizontal/linear not vertical.

You're both *not* saying the same thing.

I'm afraid you're incorrect that more cells = more force/pressure. I understand why you think so, but the examples being used (e.g. two people "in series" pushing on a car) do not accurately reflect what's happening with multiple cells in a pack (because the people are individually pushing against the road with their feet; if they were lying down and one person was pushing off a wall and the other person was pushing off the other's shoulders (this is a more accurate analogy), the force against the car would NOT be the sum of their individual force. Half the force goes into pushing against the friend and half the force against the car). The force will always divide, not add. If they're allowed to expand, the distance will add -- yes -- but the force will remain the same in the fixture. This is Newton's third law.

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You're both *not* saying the same thing.

I'm afraid you're incorrect that more cells = more force/pressure. I understand why you think so, but the examples being used (e.g. two people "in series" pushing on a car) do not accurately reflect what's happening with multiple cells in a pack (because the people are individually pushing against the road with their feet; if they were lying down and one person was pushing off a wall and the other person was pushing off the other's shoulders (this is a more accurate analogy), the force against the car would NOT be the sum of their individual force. Half the force goes into pushing against the friend and half the force against the car). The force will always divide, not add. If they're allowed to expand, the distance will add -- yes -- but the force will remain the same in the fixture. This is Newton's third law.

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Yes I understand that it would not be the sum of both individuals force. Just slightly more force than one person themselves could exert..if the people were lying down then gravity is put into the equation which isn’t in the battery packs.. I was also thinking about the pushing against the road.. but isn’t that similar (for our reasoning) to the expansion that happens on its own within each cell due to the chemical reactions within the cells.. the (each) cell is creating its own force from within which is contained by the end plates.. the chemical reactions is where the extra force comes from which is the same (for our reasoning) as pushing against the road with our feet to create force . in your example the two people are not contained by two end plates/walls or floors to push against

I mean in your own rig you are seeing a lot of expansion (compression ofyour springs) with 16 cells, far more than you would see with 4 cells. If you were applying the same force with the same springs to a 4 cell pack then there wouldn’t be nowhere near the expansion/compression of those springs.. this would appear to me that those 4 cells are not exerting as much linear force as the 16 cells. Yes you could loosen up the springs on the 4 cell pack and see similar expansion to the 16cell pack but then there’s not as much force/psi on the 4 cell pack. Yes you could get stronger springs and really tighten down the 16cell pack to have less expansion to closer resemble the expansion of the 4 cell pack but then you are applying more force to the 16cell pack to achieve the same expansion..
 
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Well if that’s what you think the EVE document implies than that’s your opinion. I do not agreee that it implies a fixed/rigid fixture is fine for our DIY packs. All I think the data sheet shows is how they tested one cell. That doesn’t make it correct for multiple cells long term or even for one cell long term or short term for that matter. It is simply how that cell was tested. The pressures that cell experience being in a rigid fixture might not be optimal for long battery life and might be overcompressing the cell and shortening its life..
Manufacturers in general put tips and explanations (like fixture drawings) in their datasheets to assist the customer in proper application of the product, not to mislead them.
 
Manufacturers in general put tips and explanations (like fixture drawings) in their datasheets to assist the customer in proper application of the product, not to mislead them.
That fixture drawing is nothing more than how they tested one cell. To imply otherwise or to imply that’s how we should build packs with many cells can lead people in the wrong direction. If you read thru this thread you should be able to understand why it is incorrect to imply much at all from how EVE tested one cell.. there are facts on the new data sheet.. implication is not what should be done.. I know we all want concrete information from over seas regarding these batteries. But implying in this way can be very misleading.
 
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If they're allowed to expand, the distance will add -- yes -- but the force will remain the same in the fixture.
I guess this is the part I’m having an issue with.. to me it seems the force is more the more cells added, not compounding but still more for each cell added.. the psi experienced by each cell will remain relatively the same only rising by a few psi as the SOC increases due to expansion force.. but the psi rising slightly more so in a 16cell rigid/fixed pack vs a 4 cell pack..
if 16 cells expand and the spring deflect by x amount, then there’s that amount of force from expansion that made the spring deflect x amount. Now if you add another cell, so 17 cells and those 17 cells expand then the same spring will deflect slightly more due to more cells expanding.. that means there’s more force on the spring, which created more pressure at the end plates to make the springs deflect further.

Yes once x amount of psi is applied to the end plates then expansion of16 cells can be all but stopped, but that doesn’t stop the fact that there’s more force applied to the end plates to prevent the expansion in a rigid fixture than if there was only 4 cells.
With springs the springs would have to be stronger or tightened further to stop the expansion force in a 16 cell setup apposed to a 4 cell setup.. and I think you are seeing that with your 16 cells in a row. At the pounds of force you are using you are still seeing quite a bit of expansion, but I’d guarantee if you used that same pounds of force on a 4 cell pack there wouldn’t be nowhere near the expansion PER CELL. Because that amount of pounds of force can keep 4 cells from expanding but can’t be enough to stop 16 cells expansion force.. yes as You and I and others have said it’s not 4 times more force but 16 cells have more expanding force than 4 cells.. or at least so far I haven’t been convinced otherwise.

Yes if the same x amount of psi could be kept in a 16 cell rig as a 4 cell rig then yes the expansion of each cell would stay the same. However my understanding is that it will take more force from springs or heavier duty rigid inclosure to keep that same psi within the rig in a 16 cell pack vs a 4 cell or 1 cell pack.
I think that’s true for the same reasons that a longer piece of threaded rod would stretch more than a shorter piece. There’s more expansion force from more cells... yes the threaded rid is stretching simply because the rod it longer but it wouldn’t stretch more than I shorter rod without it trying to hold together more cells.

If all of this isn’t true then why do you use springs and why does anyone use springs. Why doesn’t everyone just compress the hell outa 16 cells just like they do one cell in the data sheet. I mean I’ll do it. I won’t use the springs and rigid/fix 19cells like it’s one cell in the data sheet.. but I just can’t see how anyone would think that’s ok to do. How anyone’s thinks that 4 cells only exert as much linear expansion force as 16+ cells.. common logic says to me that I could keep one cell compressed (if possible) in my hands easier than 2 cells and 2 cells easier than 3 cells etc etc... yeah it wouldn’t be twice as hard or 3 times as hard but still harder to do with each cell added...

When someone is thinking about compress or not,, are they really supposed to think they only need to account for the expansion force of one cell even if they have say 100cells in a row?
 
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I think it is easier to petition EVE to update their datasheet to include multiple cells!!!
 
Yes I understand that it would not be the sum of both individuals force. Just slightly more force than one person themselves could exert..if the people were lying down then gravity is put into the equation which isn’t in the battery packs.. I was also thinking about the pushing against the road.. but isn’t that similar (for our reasoning) to the expansion that happens on its own within each cell due to the chemical reactions within the cells.. the (each) cell is creating its own force from within which is contained by the end plates.. the chemical reactions is where the extra force comes from which is the same (for our reasoning) as pushing against the road with our feet to create force . in your example the two people are not contained by two end plates/walls or floors to push against

Gravity is irrelevant in the example I'm trying to paint; it can be ignored for the purposes of this discussion and doesn't change the outcome.
In my example, person #1 is pushing against an immovable surface (wall) with their feet and person #2's feet. Person #2's feet is pushing against person #1's shoulders and the car. Let's assume the car doesn't move. That's the same setup as a solid fixture. That's the example I'm trying to convey. If person 1 can do 100 pounds and person 2 can do 200 pounds, the max they can push together is 100 pounds. A similar phenomenon is happening inside a rigid enclosure. A better analogy would be replacing the people with springs. Each spring will push outward with equal amounts of force. If spring 2 COULD push harder (it can't, but let's pretend), it would expand until it was pushing just as hard as spring 1. The forces remain divided/shared and one is longer than the other, but the forces are the same.

I mean in your own rig you are seeing a lot of expansion (compression ofyour springs) with 16 cells, far more than you would see with 4 cells. If you were applying the same force with the same springs to a 4 cell pack then there wouldn’t be nowhere near the expansion/compression of those springs.. this would appear to me that those 4 cells are not exerting as much linear force as the 16 cells. Yes you could loosen up the springs on the 4 cell pack and see similar expansion to the 16cell pack but then there’s not as much force/psi on the 4 cell pack. Yes you could get stronger springs and really tighten down the 16cell pack to have less expansion to closer resemble the expansion of the 4 cell pack but then you are applying more force to the 16cell pack to achieve the same expansion..

You're falling into the trap of combining distance and force. They're unrelated. A sufficiently long spring would exert the same force for a 4-cell pack as a 16-cell pack regardless of their SoC. It's a cheap way to apply a relatively fixed amount of force against an object that changes dimensions.

The springs are used to keep the PSI below 17 (or whatever) by allowing them to physically expand without significantly increasing the force that the springs are applying. And the amount of expansion (NOT FORCE!) depends on the # of cells.

However, EVE is now stating this is not necessary. Just set the kgf to 300 at 30% SoC in a rigid fixture. When at 100% SoC, the kgf will be a lot higher, but the # of cells does not affect that upper number.

I hope that helps. I know this is wicked confusing and hard to wrap one's head around. It's obviously even more difficult to describe in words alone, as you can see by the length of this thread :LOL:
 
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