Add more power

[guerney]

Kapton one can use what ever width one wants to, I tend to use 20mm for most of my builds.
The laying of the sense wire across is a bit crap, but I suspect the interconnector material may be a bit below par and is getting quite warm with higher current.

Those interconnectors are not copper, that's for sure, bog standard nickel? Well, at least this battery has MH1 cells, hopefully not ruptured and ready to explode.

 

[guerney]

Yes FR4.

Thanks nealh. I'll order both FR4 and kapton tape, to reduce the heating of those wires. There were a lot of hot days this year, must have been toasty in there.

 

[guerney]

Yes FR4.

I might try to source a kevlar battery cover, in case of an explosion. Or perhaps my aluminium battery box for the rear rack wasn't a such bad idea after all, it might contain the blast? On the other hand, the explosion could burn my a*se with flaming aluminium shrapnel and lithium.

 

[guerney]

I'll give this battery pack a very thorough visual inspection, when the kapton tape arrives.

 

[AndyBike]

 

[guerney]

View attachment 45471

Not since we got married

 

[guerney]

Ebike batteries could be temperature controlled using Peltier plates, powered by the ebike battery, separate battery, or dynamo? Fans outside the case might not be required, could get away with using large waterproof heatsinks?

Thermoelectric cooling - Wikipedia

en.wikipedia.org

Thermoelectric Peltier Refrigeration Cooling System Kit Semiconductor Cooler Large Radiator Cold Conduction Module Double Fans

IN STOCK: best prices on Thermoelectric Peltier Refrigeration Cooling System Kit Semiconductor Cooler Large Radiator Cold Conduction Module Double Fans, E1950.

www.manomano.co.uk

 

[Fordulike]

Whilst we've slightly gone off topic and are discussing battery safety, I thought I'd mention some of the safest battery packs available at the moment. There's also a recently started thread on battery fires here: https://www.pedelecs.co.uk/forum/threads/e-bike-fires.42720/#post-641215

Most established forum members will have definitely heard of EM3ev.
Their battery packs are some of the safest packs around, with multiple safety features for peace of mind when charging, discharging and storing.

I bought mine directly from them in China, but a UK based company also supply EM3ev packs.
They are also a good company to buy from and here's the link for them: https://eclipsebikes.com/lithium-ion-c-1_8/jumbo-shark-52v-17ah-ebike-battery-samsung-35e-cells-p-275.html

BTW, I am not affiliated with either company.

 

[guerney]

Whilst we've slightly gone off topic and are discussing battery safety, I thought I'd mention some of the safest battery packs available at the moment. There's also a recently started thread on battery fires here: https://www.pedelecs.co.uk/forum/threads/e-bike-fires.42720/#post-641215

Most established forum members will have definitely heard of EM3ev.
Their battery packs are some of the safest packs around, with multiple safety features for peace of mind when charging, discharging and storing.

I bought mine directly from them in China, but a UK based company also supply EM3ev packs.
They are also a good company to buy from and here's the link for them: https://eclipsebikes.com/lithium-ion-c-1_8/jumbo-shark-52v-17ah-ebike-battery-samsung-35e-cells-p-275.html

BTW, I am not affiliated with either company.

EM3ev: Those look like copper interconnects, less heat

I'll protect those hot wires using fr4 and kapton, add cushioning, but my next battery will be built much better than this first ebike battery that I've ever bought.