Re: [EVDL] Banding Winston/Thundersky Batteries
Here is a link to photobucket showing a picture of the top turn-buckle (4
Are they strong enough? I haven't seen anybody else do this, so time will
tell. I would have rather had steel, but the hardware store only had
aluminum. The cable is steel. They can be tightened till they sing like a
guitar string. I very much considered the super-heavy-duty zip-ties but
thought the cables would provide more tension and look better. I am not
sure if you can have TOO much tension. The Thundersky manual shows a
compression jig to fix a bloated cell. It is beyond extreme compression.
Have yet to hear of damage from over-compression.
As for which bms? I think it depends on your interest in data-logging and
such. Many controllers do that as well. I have a hard time paying several
grand for a bms. Regardless of the configuration, I believe over/under
voltage events MUST be prevented at a cell level. If it does that it will
be fine. Everything else is icing on the cake.
[quote] Martin WINLOW <email@example.com> wrote:
> 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...
> 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
> On 27 Jul 2012, at 14:21, George Wagner wrote:
> > My battery configuration is 12 under the hatch; 12 under the rear seat
> > 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
> > 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
> > and the hose clamps tightened to compress the batteries between the end
> > 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
> > each battery in the pack to keep them from shifting side-to-side.
> > Battery provided solid-copper straps for terminal connections between
> > batteries in a pack. The straps are not long enough to reach over jigs
> > 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
> > until I get the electric motor/tranny in the car).
> > Also good to know that battery-heating in use should not be an issue.
> > using the MiniBMS system to keep the batteries in the proper charge
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