Wanted: short busbar standoffs

Technical discussion on converting internal combustion to electric
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jonescg
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Wanted: short busbar standoffs

Post by jonescg » Sun, 14 Apr 2013, 01:22

Image

Is exactly what I need, however these are 35 mm tall. I need one which is 15 mm tall. Any chance I can find or at worst, make something like this to suit my battery box?

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Wanted: short busbar standoffs

Post by Bryce » Sun, 14 Apr 2013, 16:21

Hi there - specialist electrical switchboard component wholesalers stock them - however my supplier in Melb is probably not a lot of use to you where you are in Perth! Netec brand site does list their distributors. (http://www.netec.com.au/). However have not seen less than 25mm in my travels - Netec for example start at 25mm up.

How solid you you need them? Perhaps you could use nylon PCB standoffs? Or threading some nylon cylinder material? Or perhaps using nylon bolts?

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jonescg
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Wanted: short busbar standoffs

Post by jonescg » Sun, 14 Apr 2013, 18:19

Thanks Bryce,
Yes even 25 mm is too tall. It's not impossible, but the natural lay of the cable is to sit lower. Besides, most of the 25 mm high ones seem to stop at M5.

Image

Image

Essentially these 50 mm2 cable lugs will connect to the battery terminals, which are forked busbars bent at 90 degrees. The fork straddles the M8 bolt and the nut (or bolt) tightens down over both. I don't want to have to get underneath it with an open ended spanner - that's asking for trouble.

I like the idea of threaded nylon, or perhaps simply setting a stainless steel threaded rod into some glass reinforced plastic. A copper washer should see that there is even tension and that I don't strip the stud.

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zeva
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Wanted: short busbar standoffs

Post by zeva » Sun, 14 Apr 2013, 18:30

Doesn't look like something that'd be too hard to make. Here's a piece of copper stock that might do the trick?

http://www.ebay.com.au/itm/Copper-Bar-3 ... 500wt_1057

Edit: Or, get one of those 35mm ones and cut it in half?
Last edited by zeva on Sun, 14 Apr 2013, 08:31, edited 1 time in total.
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jonescg
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Wanted: short busbar standoffs

Post by jonescg » Sun, 14 Apr 2013, 18:38

I did think about cutting it in half, but I would then need to find a way of fixing it to the polycarbonate floor such that it wouldn't twist out of its thread. I will work on the threaded stud idea and see how far I get.

The box came up pretty nice I reckon. All up the pack will weigh a shade over 80 kg. Not bad for 9 kWh and potentially >200 kW electrical output.
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Wanted: short busbar standoffs

Post by jonescg » Mon, 15 Apr 2013, 00:11

http://netec.com.au/catalogue/index.php ... uct_id=346

I have come around to 30 mm. It's a bit high, but I can make the battery terminals go on top of the cable lug.

Ultimately I just don't want to be sticking a spanner down there to hold the nut while I tighten. I might need to epoxy/locktight it to the floor or something. The M8 stud can only be screwed into the polycarbonate 4.5 mm before it's through to the other side, free to scuff the cells!
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Wanted: short busbar standoffs

Post by jonescg » Mon, 15 Apr 2013, 05:09

A solution has been found! Danny Sailer has offered to machine some acetal blocks with a hexagonal recess to press-fit a nut. I can use these either as thread-up nut-down for tension, or thread down and nut on the bottom. In any case they will work ideally as they can be fixed to the false floor with countersunk M4 screws.

Poifect :)
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