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Suggestion: Assigning someone to High Voltage Distribution who deals with:
Contacts
Fuses - look into cell-level fusing
MS12 did not think current-draw will be high enough
cell-level fusing is the last-level result for over-current and for any safety concern (any shorts throughout the pack, crash incident, etc.) irreversible
Pyros - activates via an external-signal, can be used to disconnect a busbar
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Thermistors - what is the error-rate for the thermistors? (+/-1 degree celcius)
We do not have the data to justify why we need or do not need a component
Q&A:
Modules having too many components - the simpler you make a system, the easier it is for everyone
6 standoffs for each module
Using red loctite
Reduce the number of bolts used, standoffs used, etc.
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Sizing a Busbar
Main Considerations temperature
Current draw (short, long)
Material of busbar (Resistivity)
Cross-sectional area - keep cross-sectional area the same to reduce unique components in pack
Ambient temperature
Length
Constant Current - have to figure out what the maximum temperature you can have, and the minimum cross-sectional area required to not over-temp
Check the joint-resistance
Spotwelding - most accessible (find a company that can spotweld the SigmaClad for you)
Concerned about vibrations in the car
Switched to nickel due to spot-welder not being able to spotweld SigmaClad
How to test welds in-cells
Pull Test - determine amount of force is applied to the cell
Make sure pull-test leaves a nugget ensuring all the welds are attached properly
Vibe Test Table
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