Spot welding fuse wire with the kWeld Spotwelder
ฝัง
- เผยแพร่เมื่อ 10 ส.ค. 2020
- My process for attaching the fuse wire to the nickel strip on my 18650 battery.
I'm using the kWeld, kCap & kSupply spot welder combo
kWeld from KeenLabs - bit.ly/kweld_spotwelder
35awg fuse wire I use - ebay.to/3ag1a4a
Solder/Fuse wire holder - ebay.to/2PND4Es
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Pete
#diypowerwalls #hbpowerwall #18650ed #diypowerwall
![Fc ครับ ขอแนะนำให้รู้จักกับ "น้องเปียโน" l [Nickynachat]](http://i.ytimg.com/vi/HQU6Q_IYTLo/mqdefault.jpg)
Peter its awesome how your process evolved in the last 4 to 5 year. Keep it up you always inspire me.
Thanks, will do!
Mate. Super tidy. I started watching you vid's a few years back and am finally getting around to building something. Just about finished cycling my first batch of batteries. Still heaps to learn. Love you dedication to community. I feel a 'K-Weld' fathers day present coming up. ⚡️
I just got my Kweld and I'm about to finish with first batch of batteries
Same here watched a lot back in 2018/19 then life happened. Just found a box of cells I processed and tested a few feb 2018 was 4.17 and just checked it now 4.04 so guess they passed the 30 day test ;).
Yeh, love the look of this battery and fast enough to make with only one fuze between 2-3 cells, i actually started this battery build about 2 years ago lol
LOVE the wire feed! My wire flops around an occasionally shorts on the bottom side of the pack - burning my finger!
Yep, it happens lol Great little wake up call. Never got it on camera tho.. Might be good in slowmow shot to stage :)
Your all works is clean and nice . I really enjoy from watching your videos. Goodluck bro)
8 minute's that was Super fast smart job Sir! 🙂👍 well non of them get fuse out!
That was really slow, last try on camera was 5min but kept hitting the camera lol
@3:40 😱Jezus H Christ. If you're wearing headphones like I am... I almost shit my pants from the volume change 😂
Woops i'm sorry (i edit with heaphones? ) again i'm sorry
That Kweld is a freaking beast
No denying that!
G'day mate. Great vid. Pretty slick way of getting the job done.
Glad you enjoyed it
Yess, just the video I was waiting for!
Count me in Josh. LOL
Whoo-hoo it was worth filming then lol I often if people think i'm creating content for contents sake
@@HBPowerwall talking about contents is the Honeybees things. 😂
Bees are because i really want to share ! My passion :)
Great job!
Thank you! Cheers!
Hey Pete. I see the pack design has changed (I missed the video obviously lol) I see now the cells are grouped together and each group gets connected to the bus bar by 1 fuse wire instead of each cell individually fused to the bus bar. Is this better? What happens if there's a problem with a individual cell going bad in a group, won't it blow the group fuse but short the other cells in the group since they are connected with nickel to each other? Hope that makes sense. I'm about to build my packs next month so not sure what you reccomend, stick with individual cell fusing or goup cells and fuse the groups?
i have a 13kw powerwall and had enough of soldering.Have you put the wire straight to the cell.i like the strip but i would have thought wire strait to cells less spot welding.Keepup the good work.
da work is neat
if i have 4 x 12V batteries and want to do a 24V system, is it better to hook them up into:
2 in series + 2 in series and those in paralel or
2 parallel + 2 parallel and those in series ?
as allways there are folks that say the first is better and other say the latter is better ...
Excellent!👍 💥💥💥💥
Thank you! Cheers!
Hi Peter, thanks for shared your new process solder fuses, very interesting and efficient work, just a question, you don't solder the fuse to the bus bar copper ?
Thanks bud, no I solder the fuse wire to the busbar - tried to spotweld but the copper is too conductive
ur the best!
I agree...
Would 26 g. Nickel wire (U-shaped piece, 2 spot welds) work as a sorta-fuse?
Actually, this is intended mostly to connect the individual cells to the sheet-copper bus bars.
Nickel strips are there to connect parallel connection still why fusing is required since it's not there any series connection
Hi Pete, have you tried to spot weld the fuse wire to the copper busbar, may need to put a couple of spots on?
Yeh, doesn't work
Nice what are you doing it ..Plus you don’t have to waste all the Solder 👍
Yes, you are right - not having to suck solder fumes is a huge win.. well less fumes still have to attach to busbars
HBPowerwall Yes I hear you on that one specially after I did my battery billed for my E bike I went through so much Soldering 👨🏭 Definitely investing in spot Welder 👨🏭 What do you think about the 35 $40 one the cheap one looks like it does good what’s your thoughts on it ?
you can just use textolite/pcb material for bussbar, its 0,8 mm thickness there
How do you connect the fuses to the bus-bar? Are they just held down by the spot welds? or will it need to be soldered ?
But awesome job! looks great.
They will be soldered just have to wait for a bigger soldering iron to arrive
Really appreciate for this video, video quality is good ...
Can we use only fuse instead of Nikel strips in parallel connections...? Or we have to/need to use only series connection..?
Pls reply
you can just use on fuse per cell that works really well too
@@HBPowerwall but I believe if you remember me I am still waiting for your E-car project
Thanks for the all useful information. Although where i can buy this nickel wire?
amzn.to/3rwVJGa that link should start you in the right direction.
what's the size of your inverter? how many of those in series?
😂 this is what you did but we have to find our own settings. Nice disclaimer there
well I used my 120c Lipo and it was 9J so it was a thing lol
Is your preference this method or the cell level with nickel? You have a few different designs on your videos
This way is strong, like really strong! Fused nickel is FAST! Soldering is dead to me!
I'm doing a DIY of 21700, battery bank of 60V 100ah for my Ebike. Using 1500W BLDC Motor 25A Continuous Discharge. I will be doing 17S25P. I'm confused how to do cell fusing, what should be the fuse wire size ? Should I fuse individual cells or the series connections ? Please guide me.
Can you weld it right to your copper bussbars aswell
Nar, its too conductive
What's your thought on doing the cell groupings smaller packs? like 80p. make any sense to do 40 pairs and then fuse the pairs to the bus bars? I had planned to still do individual. Was just curious on the cell groupings vs individual fused cells.
Bigger is better in my experience. Small is expensive to add a BMS too & harder to keep balanced. Single fuses are better but this seems to work well with my tests over the past 14 months
@@HBPowerwall i have around 2000 cells sitting here tested and ready for packs. Time to decide what size to put them in :)
Bigger the better.
4:50 How are the fuse wires junctioned with the bus bar?
I can't see any welding or spot welding.
Thank you very much for your answer.
Best regards.
Think he said at the end of the video that he was waiting for a soldering iron to solder them on.
Yep, will be soldered as soon as i get a new iron - they they are off to their new home
hello! Nice video! as I see, you do not make cell-level fuse here but only fuse the serial connections - am I correct? How does it help in case there is a shorted cell? It cannot get all current from all packs - that I understand - but you have large packs which can cause problem alone - can you help me understand your structure? Thanx!
Just means I loose 2-3 cells rather than just one. It's a calculated risk tests have shown it to work well so far but only have one production battery in this format for the past 14 months so have not got enough data
I think it's 3.9v or 4.2v battery pack, there is no series connection, it's just for more amps with 3.9 or 4.2 v
Please correct me if I'm wrong
heya oke so those wire are fuse wires still have to learn a lot thanks
Yes they are
Are you running power through those tiny wires or are those bms sensor wires?
little black and red ones YES...
Please make a video how to install the Ksupply, Kcap and Kweld with AC. Have now all items bute no Plain :) thank you first, Best videos
I have considered it, just rather short on time latley.
@@HBPowerwall Thanks for answer. Now all is gone;) thanks
Do you have any book where I can read and get all that knowledge? For now I’m jus making some BAteries for my RC planes but I want to build a power wall.
Should be some links to books on amazon in the description buddy.
what diameter fuse wire should I use for 42a molicell 21700 batteries? Rated for 45A continuous. Would 16awg be good? And tinned copper or is there anything better? I am so lost. Need some help
What did you end up using for your fuses on the molicell?
So just making sure what your doing with this pack, I see 160 Negative sides all bonded together? for a 3.7volt pack with 160 batteries? are you doing multiple 3.7 volt packs in series to make 48volts? 54.6 volts fully charged (4.2v) with 13 battery packs total?
it's for a series of tests
@@HBPowerwall
Understood, I'm just trying to figure out what maybe a new configuration that has worked in your opinion before I go to configure my battery packs
Can you please share the the cell configuration wire size and amp hours of pack
Can I use that batt to storage solar energy?
That is basicly my whole channel :P
Hey man... Im just about to assemble a 4s 80p setup 12v(finally got battery's) i dont know what bms i should get, id love a batrium setup but cant afford to do that at the moment, my solar can put in 80amps at 12v ,but bit confused on if i just need a cell balancer or bms(would like a PC link to monitor) any help Cheers
Go with batrium if you can afford it. If not go with cheaper bms from aliexpress, just make sure it can take in 80 Amps.
Wouldn't go Batrium for 12v hard to justify unless your planing on going 48v down the road. I've never successfully used cheap BMS tho..
@@HBPowerwall cheers man yes i will be adding 3 more packs later mmm dont no what to do i guess wait for another 6 months for more batts..love ya vids keep it up!!
2:07 It looks like you have some rusty cells in there?!
This battery has been laying around for a long time lol
How do those battery bank react to a magnetic field?
Any magnetic object will to some degree
You said it's better and quicker than the old (solder joint) way. I see it being quicker. How is it better?
No solder fumes and quicker..
True, from a potential health impact perspective if you don't ridg-up a vaccum exhaust knozel (like AveRage Joe's). How is it functionally as a current transference contact as-opposed-to a solder joint?
Wow nice. So how do you calculate current when it's coming from 3 cella and runs to one bus bar?
I guessed & it's the same 5ish amp fuse wire I've always used - this battery is one I've been building with scrap cells for the past 18 months
@@HBPowerwall it has a nice look. I am glad I saw this. I'm making a 4s40p soon and I cant decide on a design, but I have plastic holders, copper, nickel, and 200 glass fuses
Not a fan of glass fuses - but i have a bunch here should I do another video trying to weld glass fuses?
@@HBPowerwall I think the kweld can tackle anything. Prob not necessary. Especially if you dont like them :)
I think i want to try it now.... you know ... learning and all might also be good to go direct to cell rather than nickel strip
I haven't been able to keep up but your not using the Battery Hookup Nickel Fuse?
That stuff was overpriced garbage. It was nickel-plated steel, and it still needed an additional busbar soldered on to handle any real current. What Pete is doing here is the best method - 3P pure nickel strip tied to the busbar with 32 gauge tinned copper wire with at least an inch of gap between the busbar and the fuse wire spot weld.
Rendus4 so your saying cancel my order.
You are free to do what you want. I was just saying what was the best practice. The BH ones do work, but they are overpriced for what they do, and you still need to modify them. My hunch is that Pete was using them to promote his affiliate link, but once that was over, he went with what actually works.
Rendus4 I was joking about canceling the order. I only have 100 150 batteries I believe that are good so I thought it was a quick easy trial of doing things. But would be cool for Pete to jump in this message for further thoughts.
I would used BH fused nickel over this in a heartbeat, It's plated nickel but so is this. Pure nickel is expensive and over kill for this application. This is because i could not because I should :) Kinda a side project i've been working on for better part of 18 months
Can the Kweld weld copper wire to copper busbar?
No but i plan on trying too :P
that one weld was right on the edge of the positive, why not move it a bit closer to the center?
I could i guess - but it's lost now with all the others i completed trying to get these shots :)
you have some sort of breakout board connected to server power supply? can you share the link to that?
Is this the one you are referring too? www.keenlab.de/index.php/product/ksupply/
@@HBPowerwall Thank you
Guess i was right lol
Hey Pete...I'm in Canada and looking to go fulltime RV'ing sometime soon. Plans are to upgrade to a 40' - 45' diesel pusher motorhome. I'm going to fill the roof with solar and install a DIY lithium battery in the 400 - 600 AH @24v range. Up until discovering your channel I have always been looking at larger EV cells (in the 100AH plus range) but building a powerwall style battery would be 1/2 the price. Is there a reason I do not see many folks using these style batteries in their RV's?
STOP - DO NOT DIY a battery for an EV or non stationary storage.. vibrations alone make this a SUPER stupid idea - get Tesla battery, and it will out last the RV....
@@HBPowerwall Easy there...I was just asking why it was not done!!!
Sorry lol these cell holders & fuses are not up to vibrations, they break very quickly. Once the fuses start to break the battery can become very unbalanced very quickly & the BMS will at some point not be able to keep the battery in check.
@@HBPowerwall Thanks for the added info. What BMS would you recommend for the Tesla's. I would be looking at 3 Tesla's coupled to 2 x Victron 24v - 3000 watt Multiplus in split phase configuration.
Longer fuse wire - smaller current needed to burn it. Do you remember that?
So long fuse wires probably no well idea. I'd weld to nearest cell, as we do when weld the wire to each single cell. In this case the fuse is ~10mm long.
Average Joe did extensive tests for that, do you remember?
Don't want smaller current i'm running more than one cell. Yes i remember ...
@@HBPowerwall that's why I pay attention! currently it might be under-sizing of fuse.
Help! 0.15MM X 10mm and 8mm Nickel strip can you let me know a decent source or two , where I am zero available , am using the kweld after watching it in action here many thanks
depends where you live and if you need purenickel strip or nickel plated steel
@@HBPowerwall live in South Africa, pure nickel would be best unless you have some words of wisdom to share as the price is going to be different so advice / comment appreciated
Do you weld it to the copper also?
no it wont - neat if it could .
HBPowerwall I saw later in your video that you had soldered it to the copper.
so the fuse wire will blow if something goes wrong?
You'd hope so!
Hello are you selling those batteries i love to have that power source
no not selling sorry - just for me to learn and play with
Hello, what is the fuse wire for?
In case one of the cells goes bad and starts self discharging or dead shorting
Which spot welder would you recommend for a starter? Just getting into building 18650 packs
Kweld is the best.
@@marcelmeijer2509 I'm not from the states so it would be hard to get one of those
@@diy-bj2ed I live in The Netherlands. Take a look at website: www.keenlab.de/index.php/product/kweld-complete-kit/
www.diypowerwalls.com/kweld - you don't need to be in the states to get a Kweld
@@HBPowerwall thanks
Hello sir, what parameters does your super cap bank has?
Not sure but you buy it here - www.keenlab.de/index.php/product/kweld-ultracapacitor-module/ perhaps the info you seek is on that page.
@@HBPowerwall thanks for quick reply
Sir how many 18650 batteries I can attach on 25A 12v BMS?
No idea depends on the cells
@@HBPowerwall I have 50 NCR18650B batteries that has the capacity of 3350mah per cell i want to have 3 series connection how many parralle connection I can made of?
At the end you said the wire was a fuse (could've said it up front), but please explain what you are fusing & why.
Cells are fused incase of an issue with the cell - one would hope the fuse blows before taking out the rest of the battery
@@HBPowerwall I''m a newbie to this and think I am still missing something. Do you go along later and solder the fuse wire to the bus?
@@meetim2931 yes
can you weld two copper cables like that between them?
copper is too conductive
@@HBPowerwall what about those cables are not copper %100 those cheap cables?
are you referring to the 'fuse' wire? the tiny stuff is nickel plated copper wire.
@@HBPowerwall (CCAW or CCA) is an electrical conductor composed of an inner aluminium core and outer copper cladding.
What size of ur copper busbar?
It's 10mm earth cable
whats the output from ksupply ? Volts ?
I think its 12v, Is on loan at the moment & don't have access to the manual
@@HBPowerwall Hello thank you. Yes thats have all 12v. But you can choosedown to 8,1V Now my question, ther comes 8,1V oor 12V ? =) You can ajust it on the Ksupply. thank you first
Is this expensive and productive at the same time?
Cheap n Productive..
@@HBPowerwall Thanks for the frank answer شكرا
How many amps before this fuse wire blows?
Give or take 5 amps
@@HBPowerwall Thanks! - I wonder what search terms to use to find this in europe. With the search terms you linked on eBay, only US suppliers appear and shipping will be expensive as hell.
So nickel strip fuse is dead as well?
NOoooo just order a few feet of that :P Fused nickel is fast, cheap and AWESOME for my builds so far very happy with it.. BUT this way works when you need to get it finished
Hello, I want a link to buy spot welding
link will be in description
@@HBPowerwall Thank you. You are creative
What size of copper is ur busbar?
I use 10mm earth cable - ebay.to/30PK3D5
HBPowerwall also the fuse how many amper pls? Thanks
the fuse wire is 32awg - link is in the description
If you first tin the whole busbar you maybe could spot-weld the fuse wires to the busbar as well. Would save a lot of heat transfer to the cells.
I understand why 32 Gauge wire is used to act as a fuse, but doesnt using such small wire increase the resistance significantly, robbing Watt hours from your pack?
It does yes, balance between power and safety.
@@HBPowerwall Thank you! would love to see a video investigating this quantitatively
@@GaiusGarage Assuming a Pack Voltage of 3.75v and 40 Amps = 150 Watts discharge, I calculate the fuses are dissipating ~0.38 Watts Total. If you had one fuse wire per cell and fused only one side then the fuses would dissipate about ~0.095 Watts, which is 1/4th of ~0.38 Watts.
Damn cabbage patch kids advancing to fast
It only takes time, money & permission from the Mother Cabbage patch kid..
HBPowerwall #TheCabbagePatchHeirarchy
😁 ✌🖖👌👍😎
😆👍😉😇😅
If. You didnt need to spot weld you would have so much more time to create other great things
Busy doing that now.. funny enough it involves redoing several thousand spotwelds :P
Wrap up the bus bar saves alot of headache. 1 strip of tape on the leads coming out of the pack will help about.
hello could you
Could you ?> insert nudie run here
I am afraid you wasting half of your time and material - you need fuse only on one side.
I agree..