Busbars, styles - designs - success - failures

So the whole busbar design is evolving slowly with Jehu's design as one of the earlier solder jobs so to speak.


Altho there were many others feel free to add to this list

I would like to compileall the different types of busbar designs mine as we all know were well based on Jehu's design one busbars between two cells with a fuse on the positive end and regular copper wire on the negative end. Link below has a list of parts he used.

List of parts used to make this project:
Laptop Batterieshttp://j35.us/Ebay-Laptop-Battery-Lot
18650 Holdershttp://j35.us/18650-spacer-clips
Copper buss barshttp://j35.us/1NGpBo4
Brass stripshttp://j35.us/Small-Brass-Strips
Cell Fuse wirehttp://j35.us/1k-Ohm-resistor
Nickel stripshttp://j35.us/1PRIreE

My version is below and even that has evolved some what.

Then there is Mike who released his first video the other day with his process.
https://youtu.be/xNa5DsXhRso[/video]

Or even no busbars
https://youtu.be/EWxTjFMw42s[/video]

15 seconds of fame did soldered nickle strip
https://youtu.be/5EE4TsuzD_Q?t=8m34s[/video]

Damian Rene - does epic packs, however more E-Bike related. Spot welded Nickle Strip
Link to whole channel rather than a specific one definitelyup there with Jehu's videos when I first started.
https://www.youtube.com/user/DamianBSS/videos

Then - THEN there is what I consider the current standard

https://youtu.be/TedqvvDatMk[/video]

UK DIY Powerwall - one of the earliest running setups I've seen even before mine !
https://youtu.be/rhX02FeNLoM[/video]



This list will grow as I get time but any newbies out there - above video is how to do it in my opinion !

Feel free to add to this list links or photos of your busbar designs it'll definitely help others moving forward with these projects..

AND Make sure it's not just the good.. you learn faster from mistakes in my opinion

https://youtu.be/sR1vTqAq0cU[/video]

Design flaw using copper to bind the busbars together was the issue with Rohan's packs. Simply fixed by using zipties.

Here's my style of bus bars. Copper is 12awg and has been working perfectly. Been in production now for 3 months with no problems.

Glubux's amazing projecthttp://secondlifestorage.com/t-Glubux-s-Powerwall

Nicks Powerwall idea with four cells deep - making great use of the single cell holders that's for sure.

Paul Boxer's design - looks pretty neat!

Vladislav Haltof version (mounts available from thingspace I think)

2* 10S24P (36V) = 4kWh ready. This two sets are connecter parallely to easy balancing

Joo Luis Martins, version of busbars

Hi!

I probably missed something about the busbar material. Is there a specific reason why most of you do not use the nickelstrips on a roll as busbars?

I learned it good because of the low internal resistance, but isn't corrosion an issue with the copper wires? Did i miss something concerning Amperage?

If thats the wrong place to ask .. i'll move the question .

Many thanks and best,
Christian

crud said:

Hi!

I probably missed something about the busbar material. Is there a specific reason why most of you do not use the nickelstrips on a roll as busbars?

I learned it good because of the low internal resistance, but isn't corrosion an issue with the copper wires? Did i miss something concerning Amperage?

If thats the wrong place to ask .. i'll move the question .

Many thanks and best,
Christian

Click to expand...

Most are fusing each individual cell with a Tesla style fuse. If you use nickel strip you can't fuse them individually. That's one reason. Another is that true nickel strip is expensive. I hope that helps.
Alec

Hi Alec,

thanks for the reply! Concerning the nickel strip, i actually wasn't thinking about attaching them directly on top of the cells like in the spotwelded versions but rather as a real busbar in between the cells and using that as the main bus and still solder the fuses to it. Do you think this may be a wrong appliance of the nickel strip? I see the width of the nickel strip might be an issue, too. Concerning the pricing, i see the point. I was really wondering if there is a main electrical disadvantage concerning amps or else.

Best,
Chris

Real nickel strip is heaps more expensive and less accessible than twisted mains wire..

Ok, roger that So i'll probably go with the nickel as i have a couple around. I just wasn't sure about that . Thanks for the clarification.

Wish I had some nickel just laying around. Oh wait, I have a jar full of nickels?.

Ok, just to clarify i double checked. Its actually Hilumin and the other is 99,5>Nickel, so those are actually those none pure nickel, i guess.

@korishan: Thats a good one

Ok, so i'll stop here. Don't want to interrupt with Peter's Thread.

Best,
Christian

Inverted18650 said:

Click to expand...

Hello Nice Busbar setup. What size is that pack?

looks pretty neat!

Copper is a better conductor is it not? easier to nick from construction bins.

Yep. Until super conductors come around, copper will be the prime choice for main connections for everything.

Nickel strips in commercial packs/battery packs are mainly used for ease of connection for cell interconnections.

Average Joe's latest upload is worth adding to this list