No Solder, No welding 48v 20Ah. Cheap battery Pack

General Discussion about electric vehicles.
Post Reply
bik-e-bik-e   100 µW

100 µW
Posts: 9
Joined: Jan 09 2018 6:13am
Location: CHE, TN, INDIA

No Solder, No welding 48v 20Ah. Cheap battery Pack

Post by bik-e-bik-e » Dec 02 2019 6:45am

Please find the new design here in video. Please comment on the design.
https://www.youtube.com/watch?v=_ZgndwUQ4Eo
Last edited by bik-e-bik-e on Dec 04 2019 1:32am, edited 3 times in total.

john61ct   100 GW

100 GW
Posts: 5412
Joined: Dec 18 2018 2:06pm

Re: No Solder, No welding 48v 20Ah. Cheap battery Pack

Post by john61ct » Dec 02 2019 1:55pm

Video I find a waste of time.

Please post text version with diagrams, photos.

User avatar
fechter   100 GW

100 GW
Posts: 14790
Joined: Dec 31 2006 3:23pm
Location: California Bay Area, USA

Re: No Solder, No welding 48v 20Ah. Cheap battery Pack

Post by fechter » Dec 02 2019 2:34pm

Obviously the scooter worked, so it was a success. I'm sure the scooter runs much better than it did with lead-acid batteries.

I can't see from the video exactly how the screws holding the cells are arranged. There will be a tendency for the contacts to go bad over time or when you hit a bump in the road.

Used laptop cells are inexpensive, but you run an increased risk of fire when charging. Charge outdoors in a place where a fire won't do any damage.
"One test is worth a thousand opinions"

bik-e-bik-e   100 µW

100 µW
Posts: 9
Joined: Jan 09 2018 6:13am
Location: CHE, TN, INDIA

Re: No Solder, No welding 48v 20Ah. Cheap battery Pack

Post by bik-e-bik-e » Dec 02 2019 11:30pm

Actually the screws are rolled with copper sheet contacts to act as a bumper. I would try to post a detailed image.

bik-e-bik-e   100 µW

100 µW
Posts: 9
Joined: Jan 09 2018 6:13am
Location: CHE, TN, INDIA

Re: No Solder, No welding 48v 20Ah. Cheap battery Pack

Post by bik-e-bik-e » Dec 02 2019 11:40pm

CopperConts.jpg
Hope This helps a little
CopperConts.jpg (223.55 KiB) Viewed 2562 times

bik-e-bik-e   100 µW

100 µW
Posts: 9
Joined: Jan 09 2018 6:13am
Location: CHE, TN, INDIA

Re: No Solder, No welding 48v 20Ah. Cheap battery Pack

Post by bik-e-bik-e » Dec 02 2019 11:57pm

WhatsApp Image 2019-12-03 at 10.23.17 AM.jpeg
Another Image with full assembly
WhatsApp Image 2019-12-03 at 10.23.17 AM.jpeg (92.23 KiB) Viewed 2555 times

User avatar
MAXIMUM_AMPS   10 mW

10 mW
Posts: 33
Joined: Nov 13 2019 9:11pm

Re: No Solder, No welding 48v 20Ah. Cheap battery Pack

Post by MAXIMUM_AMPS » Dec 05 2019 5:08pm

Wow, very substantial bus-bars.

How is the voltage drop under load? Judging only by the pics, I would think that the interface between the cell and the bars would impede the performance a bit.

User avatar
Matador   10 kW

10 kW
Posts: 913
Joined: Jun 29 2016 10:00pm

Re: No Solder, No welding 48v 20Ah. Cheap battery Pack

Post by Matador » Dec 05 2019 10:12pm

Don't drop a metal wrench in that trunk with the battery inside... :shock: :warn: :flame: :kff:
Your build reminds me my first solderless battery attemps with plexiglass, copper bussbars, brass nuts and bolts and contact springs:
viewtopic.php?f=31&t=87434&start=25#p1277444

bik-e-bik-e   100 µW

100 µW
Posts: 9
Joined: Jan 09 2018 6:13am
Location: CHE, TN, INDIA

Re: No Solder, No welding 48v 20Ah. Cheap battery Pack

Post by bik-e-bik-e » Dec 06 2019 12:57am

In fact my design got inspiration from yours Matador. I am improving my design now with a top cover. and a more compact one. will keep you posted on it.

bik-e-bik-e   100 µW

100 µW
Posts: 9
Joined: Jan 09 2018 6:13am
Location: CHE, TN, INDIA

Re: No Solder, No welding 48v 20Ah. Cheap battery Pack

Post by bik-e-bik-e » Dec 06 2019 1:08am

NewDesign1.jpg
Hope these views helps..
NewDesign1.jpg (247.24 KiB) Viewed 2208 times

User avatar
MAXIMUM_AMPS   10 mW

10 mW
Posts: 33
Joined: Nov 13 2019 9:11pm

Re: No Solder, No welding 48v 20Ah. Cheap battery Pack

Post by MAXIMUM_AMPS » Dec 06 2019 1:12pm

bik-e-bik-e wrote:
Dec 06 2019 1:08am
NewDesign1.jpg
Looks like a clever design! I take it those "pillars" provide the necessary clamping force to get a solid connection?

bik-e-bik-e   100 µW

100 µW
Posts: 9
Joined: Jan 09 2018 6:13am
Location: CHE, TN, INDIA

Re: No Solder, No welding 48v 20Ah. Cheap battery Pack

Post by bik-e-bik-e » Dec 08 2019 10:52pm

MAXIMUM_AMPS wrote:
Dec 06 2019 1:12pm
bik-e-bik-e wrote:
Dec 06 2019 1:08am
NewDesign1.jpg
Looks like a clever design! I take it those "pillars" provide the necessary clamping force to get a solid connection?
Of course those are 10mm PVC Rods. They should hold it firm. I am in process of building it. Will update once done.

frenchie   1 mW

1 mW
Posts: 14
Joined: Dec 24 2019 1:22pm
Location: France, cos UK sucks 8-)

Re: No Solder, No welding 48v 20Ah. Cheap battery Pack

Post by frenchie » Dec 24 2019 1:32pm

How much does it weigh??
Weight is everything in cycling to my mind (and to my body lol) :wink:
I want to come to India and buy a motorbike but I can't own one as a foreigner :(
SO maybe I can come over, kit out an electric cycle and try and make it back to Europe :lowbatt:

Post Reply