Archive for July, 2011

Why build when you can buy?

Thursday, July 28th, 2011

There are times when it is faster *and* cheaper to buy parts.  Good examples are the motor, controller and stuff like that.  Another example is battery interconnects.  I had earlier posted that I need to have flexible battery interconnects, and that I was going to build them.  Well, my mechanical skills are not so good, and the resulting interconnects are not very good.

So, I ended up buying most of them.  From Australia.  I have trouble believing that you cannot find these parts in North America….but I can’t find them here.

http://www.evworks.com.au/index.php?product=BAT-EVW-BCI-80-8

Good people at Evworks, I’ve bought from them before.

Google Translate is My New Friend

Tuesday, July 19th, 2011

Wow.  I was going through the email that my friend in Shenzen was forward to me with some translation, and I FINALLY realized that I could also translate using Google.  Well.  Color me surprised.  Yes, it was literally translated properly, but no, it wasn’t correctly translated.  So, I’m trying to use Google Translate to do both english and chinese to the factory to make sure I’ve got it all correct with the controller.

For those following the saga at home, the 16-pin connector has a bunch of extra lines out.  Those lines out (9-15) are options that can be programmed at the factory – meaning they do nothing for me.  Now I just need to figure out how the potbox connects and whether I really need -12 and +12 or just +12 and ground.  Details, details. 🙂

Bitterly Drinking a Large Cup of “I Told You So”

Monday, July 4th, 2011

Well, remember the nice solid copper battery interconnects I hand-made?  And how some people said I needed to use braided cable?  Well, after doing Yet More Research, they were right.  The problem is that batteries move – all the time – even if you have them strapped.  Mine aren’t strapped.  So if batteries move, and the interconnects don’t, the batteries eventually get damaged.

So, in an effort to build some new ones, I tried two techniques:  wrapping copper plate around the cable, and crimping copper pipe to the cable.  As you can see from picture, the pipe does a lot better job.  The pipe crimps nicely to the cable, and doesn’t leave much sticking up (unlike the plate).

So – only 106 more connectors to build.

Copper plate on left side, copper pipe on right side