Here are some things I'd do differently on the next pack
- The pack needs structure, the wrap is good, but not enough to really give it strength. It needs something to hold it together. I really like the plastic cell spacers... yeah the pack is bigger but much stiffer
- I don't think the pack will stand up well to flight vibrations in a few areas, mostly has to do with the fuse being so small and while they are strong, they can't handle pack loads and vibration. Where the packs join, it's a real weak spot. Each sub-pack needs a strong less stressed bus bar... I shouldn't have joined them just using fused links.
- For the parallel bus bars, I want to use nickel strips next time, not copper, less soldering is better. Welding is much stronger, faster, and simpler.
- Thicker shrink wrapping
Building larger packs than 200 cells is going to be very cumbersome (and heavy to handle). I need to re-think some of the logistics of assembling the batteries going into the wings. They are 480 cells spread out over a meter long on the entire wing, and likely be a bit over 35kg (77lbs).
My plans to build the wing battery as actually 20 serial sub-packs of 24 parallel batteries which can be assembled as they go into the wing are unchanged. Each sub-pack would (3x8) half-width. I just think it will need to be wired as it goes into the wing or it needs a way to be inserted smoothly.
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