This material is approximately the same as 4/0 cable. Can handle around 270AI purchased these for creating busbars. I plan to attend to bend/form these for use in the module.
View attachment 164657
I will create one for the 16s, that leaves 4 prismatic cells left in the pack. Therefore I will create an additional busbar for these units.
With 4 left from each pack I can create another 16s battery back, electrically.
Great! I measured the existing busbars and this is what is already in use.This material is approximately the same as 4/0 cable. Can handle around 270A
The coating is there for oxidization protection.Great! I measured the existing busbars and this is what is already in use.
The Exception was they have a sliver coating and polished at the connection points. I plan to polish and use Belleville washers.
Thank you for sharing the video! I only found two videos of these cells (modules), this one and David’s.Check out this guy who did exactly what you’re trying to accomplish
As pretty as your bars are, and we'll laid out as well... unless you nickel plate them, they will corrode and fail very quickly... you cannot let aluminum and copper come in contact.Ok I think I have figured out how to complete the 16S of the 20S module.
Here is a semi-mock-up of it.
View attachment 166912
View attachment 166922
View attachment 166923
View attachment 166924
View attachment 166925
The module is in 20S configuration. Above is the plan for 16S. I have a pretty good idea as well on a 4S configuration for easy wiring in the near future.
Since I have 4 modules, when I split 4S from each module, I will then have created 5x280 Ah 48V batteries.
I have ordered these insulated bussbar standoffs. I will use these for the central busbar in the pictures.
View attachment 166927
This brings me back to my pc water cooling days. I completely forgot about that! Good point. Luckily for OP, nickel plating is not difficult to do via electroplating.As pretty as your bars are, and we'll laid out as well... unless you nickel plate them, they will corrode and fail very quickly... you cannot let aluminum and copper come in contact.