Flexible busbar with the cross section area of 1/0

[bestconcreteblock]

Video in action:

https://photos.app.goo.gl/5m5yxY7AfSxDmVHW7

 

[740GLE]

How’s does that equal 1/0?

Also it’s only flexing at the first joints.

 

[Skypower]

Man that took a long time to mill those little slots in gummy copper. Production would be better served by water jet.

 

[bestconcreteblock]

How’s does that equal 1/0?

Also it’s only flexing at the first joints.

Each flex beam is .073in wide x .125in thick. .073in x .125in = .00913in^2. There are 9 of them. .00913in^2 x 9 = .0821in^2.

1/0 has a solid diameter of .325in. Divide that by two gives a radius of .163in. Square that and multiply by pie gives us .0830in^2.

Each flex beam is flexing the same amount, you just don't notice it because they stay parallel.

 

[bestconcreteblock]

Man that took a long time to mill those little slots in gummy copper. Production would be better served by water jet.

For sure, use what you got though right? Cycle time is about 14min, but if optimized and higher spindle speed(machine only has 6000rpm) I could see that it down to 4-5 mins. I only have to make 8.

 

[Skypower]

For sure, use what you got though right? Cycle time is about 14min, but if optimized and higher spindle speed(machine only has 6000rpm) I could see that it down to 4-5 mins. I only have to make 8.

The crazy thing is how abrasive that copper is , even on carbide. Gets a little dull, stops throwing chips, packs the flutes and click?

 

[bestconcreteblock]

The crazy thing is how abrasive that copper is , even on carbide. Gets a little dull, stops throwing chips, packs the flutes and click?

Yeah as long as the chips are being ejected, you're golden. 1/16" EM is only running about 100 SFM at 6000 max rpm spindle. .0004" chip load per tooth feed. .02" depth per pass full slot.

I thought about stacking parts and Wire-EDMing the slots, but it seemed overkill.

 

[740GLE]

Each flex beam is .073in wide x .125in thick. .073in x .125in = .00913in^2. There are 9 of them. .00913in^2 x 9 = .0821in^2.

1/0 has a solid diameter of .325in. Divide that by two gives a radius of .163in. Square that and multiply by pie gives us .0830in^2.

Each flex beam is flexing the same amount, you just don't notice it because they stay parallel.

Love to see how the current is shared with each beam under load with a thermal imager.

How much force did it take for full deflection?

Cool idea

 

[bestconcreteblock]

I need all this flexibility because the thermal transfer pads between my cells and heatsinks are fairly thick and I expected movement over time with vibration and constant compression force.

I was able to cut all eight without loosing an endmill.

These busbars make these 60AH cells look tiny:

 

[Aridom82]

This concept looks to me quite expensive and inefficient. There is a lot of material that is doing nothing and it takes a lot to make them.
My take on this would be to buy some 0,2-0,4mm thick copper belt, cut strips, put a bend on them and stack them on each other.
It would be much faster, cheaper and effective in my opinion

 

[400bird]

copper belt

I've never heard of copper belt.

 

[Aridom82]

I've never heard of copper belt.

English is not my first language so maybe i am missing the keyword for it.
They sell thin strip sheet copper in coils. You can choose the thickness and how wide you want it and buy by the meter.
You can find it in aliexpress.

https://www.aliexpress.com/item/1005004330878961.html

 

[Skypower]

My favorite part is when I get to tin copper?

 

[Skypower]

English is not my first language so maybe i am missing the keyword for it.
They sell thin strip sheet copper in coils. You can choose the thickness and how wide you want it and buy by the meter.
You can find it in aliexpress.

https://www.aliexpress.com/item/1005004330878961.html

Unfortunately when you carry a lot of amps through thin laminated copper the ends (bolt area) must be resistance welded together(make solid) or the first layers can bast away. This is what’s done to quality flexible buss bars

 

[Aridom82]

My favorite part is when I get to tin copper?View attachment 162485View attachment 162486View attachment 162489

this looks quite nice

 

[Aridom82]

Unfortunately when you carry a lot of amps through thin laminated copper the ends (bolt area) must be resistance welded together(make solid) or the first layers can bast away. This is what’s done to quality flexible buss bars

i bet you can sandwich the ends of the laminated bunch with two thicker pieces just at the ends and bolt it all together all it will be fine.

 

[Skypower]

i bet you can sandwich the ends of the laminated bunch with two thicker pieces just at the ends and bolt it all together all it will be fine.

You could if the two plates are very flat and you could really tighten it, but most terminals are only 6mm with 4Nm torque. You could probably get away with it, but I’m the guy that never has that kind of luck. If it can go wrong the karma gremlins will find me so I don’t tempt fate.

 

[400bird]

English is not my first language so maybe i am missing the keyword for it.
They sell thin strip sheet copper in coils. You can choose the thickness and how wide you want it and buy by the meter.
You can find it in aliexpress.

https://www.aliexpress.com/item/1005004330878961.html

Wow, that's a product I didn't know even existed. I was thinking of regular sheet metal, but I've never seen it anywhere near as thin as you mentioned.

 

[Sam Cho TX]

what does this hair comb thing do actually?

 

[Aridom82]

what does this hair comb thing do actually?

i think is his take on a flexible busbar