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Unread 21-01-2012, 10:07
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Re: Battery connections

Thanks everyone for all the suggestions. My team has decided to use a compression lug (bluedie374) COVERED WITH heatshrink tubing. The full pole connection will have to be isolated. Then we'll validate the electrical resistance (should not exceed milliohms), and then we'll do a pull strength test. The tool used for compression is taken from HomeDepot.
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Unread 21-01-2012, 10:14
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Re: Battery connections

I've used this crimper with good results. The dies are not perfect and their sizes are weird and it flattens the hex a little and puts "wings" on the sides of the crimp, but it goes make a good solid connection.
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  #18   Spotlight this post!  
Unread 21-01-2012, 19:25
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That? That was in the CAD.
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Re: Battery connections

Crimp, solder with a blowtorch, repeat.
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Unread 21-01-2012, 19:45
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Re: Battery connections

Quote:
Originally Posted by Mr. Rogers View Post
Crimp, solder with a blowtorch, repeat.
A proper crimp does not need solder; indeed, the 'right' crimp is made worse with solder.

That being said, a 'pretyty close' crimp can be improved with solder.

We have used the crimping die on these pliers with great success. Two students squeeze it shut, it does take some effort.
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Unread 22-01-2012, 01:57
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Re: Battery connections

Quote:
Originally Posted by slijin View Post
JW, is there any particular method that you've developed to use this? I usually lever a screwdriver in and then use a second screwdriver to pop it off the spring (if you can call it a spring), and I find it an incredibly tedious and annoying process.
I use a very small screwdriver or awl from the "contact" side of the connector to push/pull the spring out of the way, then pull the wire and pin out the other side. It's easy. I even used a paper clip once.
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