Re: [EVDL] Banding Winston/Thundersky Batteries
This is a great idea! I used (very large) all-thread to clamp the batts
down to the frame, but did not think of using the all-thread for horizontal
clamping as well. I think this is a much better idea than turn-buckles.
[quote] Bill Dennis <xxx@xxx.xxx> wrote:
> I've got string of 13 CALB 100Ah cells bounded by an aluminum plate on each
> end. The plates fit snugly between the end cells and the aluminum battery
> box itself. Holes drilled in the battery box allow 4 36-inch lengths of
> all-thread to protrude through the sides of the battery box where they are
> bolted in place from the outside, making the box sides themselves also part
> of the clamping. Haven't had any trouble in 2 years. Plus, the 1/4-inch
> all-threads act as battery restraints in case of a crash. I've got three
> rows of cells in the front battery box fitted tightly that way, with the
> all-thread running down the grooves between the cells. I think you could
> turn the box upside down and the cells wouldn't fall out.
>
> Bill
>
> -----Original Message-----
> From: xxx@xxx.xxx.edu [mailto:xxx@xxx.xxx.edu] On
> Behalf
> Of Martin WINLOW
> Sent: Friday, July 27, 2012 9:41 AM
> To: Electric Vehicle Discussion List
> Subject: Re: [EVDL] Banding Winston/Thundersky Batteries
>
> George,
>
> I don't think the Jubilee (as we call them over here in the UK) or worm
> gear-type clips will exert enough tension - unless you use a lot of them...
> one per cell case groove maybe.
>
> Marcus' cables would be better but I don't know exactly which product he is
> referring to. Plastic strapping is easy and cheap and has the advantage of
> being quite elastic (obviously at considerable tension) and therefore is
> unlikely to cause any damage due to over-tensioning, unlike a steel system.
> My strapping can be seen here...
> http://www.winlow.co.uk/wychwood.co.uk/EV_Conversion_-_Part_2.html
>
> As for BMS', I gather Willie McKemie has some considerable experience of
> that particular product - good and not so, I gather.
>
> Tho I have not tried it, the Elithion's 'Lithiumate Lite' would be my
> choice
> but it would be somewhat more expensive than the MiniBMS - but much more
> useful in terms of cell monitoring/logging etc.
>
> Sure, between sub-packs, you would have to use braided connects or lengths
> of cable.
>
> Regards, Martin Winlow
> Herts, UK
> http://www.evalbum.com/2092
> www.winlow.co.uk
>
>
> On 27 Jul 2012, at 14:21, George Wagner wrote:
>
> > My battery configuration is 12 under the hatch; 12 under the rear seat
> > (this is where the gas tank was in my Pontiac Vibe, so no exhaust,
> > brake, or electical lines ran under the full-span of the seat); and 10
> > under the hood for a total of 34 (pack voltage 120 V).
> >
> > For the two sets of 12, I was planning using the orginal metal bands
> > used for banding (up to groups of six) but joining them with
> > stainless-steel "worm-gear" hose clamps of the same width. The
> > batteries would then be placed one-by-one into the jigs already in the
> > battery box, the bands added, and the hose clamps tightened to
> > compress the batteries between the end jigs into the 12-pack. So I
> > won't actually need to physically lift the twelve-battery packs at
> > all; they will be assembled directly into each battery box.
> >
> > I appreciate the great idea of inserting a couple of square dowels
> > between each battery in the pack to keep them from shifting
> > side-to-side. Winston Battery provided solid-copper straps for
> > terminal connections between batteries in a pack. The straps are not
> > long enough to reach over jigs to adjacent packs, so this way I will
> > have to fabricate fewer terminal connections than if smaller-size packs
> were used.
> >
> > For the ten batteries under the hood, I'll probably join the two
> > current five-packs into a single ten-pack, space permitting (I won't
> > know for sure until I get the electric motor/tranny in the car).
> >
> > Also good to know that battery-heating in use should not be an issue.
> > I'm using the MiniBMS system to keep the batteries in the proper charge
> range.
> >
>
>
>
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--
Marcus Reddish
*North Valley Systems LLC*
Stevensville, Montana
406-360-8628
northvalleyev.com
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