Attach Wires to NMH Batteries Without Soldering

"William Sommerwanker = TROLL "

"For battery packs subjected to high discharge rates, soldering
produces reliable, low resistance connections and spot welding does not."

** Different words & with a different meaning.

Ya could fooled me.

** Anyone could fool a tenth witted, ASD fucked cunt like you.
 
On Thu, 20 Dec 2012 12:44:09 -0800, mike <ham789@netzero.net> wrote:
Soldering directly to cells is a bad idea.
(...)
Did I mention that soldering directly to cells is a bad idea.
Agreed. Over the years, I would solder to cells. Most worked for a
little while, but soon crapped out. I did MUCH better with a
cazapitor discharge spot welder.
<http://www.ebay.com/sch/i.html?_trksid=p5197.m570.l1313&_nkw=spot+welder+battery>
<http://www.youtube.com/watch?v=G7LKhhyokbQ>
or you can build you own:
<http://ledhacks.com/power/battery_tab_welder.htm>
<http://ledhacks.com/power/tab_welder%20ii.htm>

--
Jeff Liebermann jeffl@cruzio.com
150 Felker St #D http://www.LearnByDestroying.com
Santa Cruz CA 95060 http://802.11junk.com
Skype: JeffLiebermann AE6KS 831-336-2558
 
On Sat, 22 Dec 2012 06:14:53 -0800, "William Sommerwerck"
<grizzledgeezer@comcast.net> wrote:

I have a 200/260W Weller solder gun and when I gave it some thought,
when someone spot welds a tab onto the battery, it creates a momentary
hot spot on the battery. The Weller gun can't to worse than a spot weld
as long as the time is short and proper preparation is made.

Oh, yes it can. A spot weld takes a fraction of a second, and the heat appears
over a small area.
A bit more than a fraction of second. See video at:
<http://www.youtube.com/watch?v=G7LKhhyokbQ>
starting at 0:50. I would guess(tm) about 1/2 second for the spot
weld. I would also guess(tm) that the heat affected zone on the
battery is much larger with the high wattage Weller because of the
longer dwell time and larger thermal contact area. When I was
soldering batteries, the cell was noticably warm after soldering. When
doing the same with a CD welder, it was stone cold.

By golly, I had no trouble at all and the results turned out great!
I test my battery packs with a West Mountain Radio CBA-II.
<http://www.westmountainradio.com/product_info.php?products_id=cba4>
If there's a problem, it will be obvious on the graphs.

I hope so. I've seen connections of this sort fail * with the solder blob
simply falling off the battery.
Not if you sandpaper the base metal. When I solder to a battery, the
solder will wet to the edge of the sandpaper zone, but not into the
non-sandpapered area. That implies that there's some manner of
coating on the battery case that should be removed with an abrasive
before soldering.

* as do spot welds, of course
The real problems are in high current applications, where the weld
turns into a fuse. Power tools are a good example. I did a lousy job
of replacing NiMH cells in a Makita 18V driver. After about 4 hrs of
use, the pack went to open. An autopsy showed that my welds had fused
open. I went to 4 spots instead of 2 spots per terminal, and it was
fine.


--
Jeff Liebermann jeffl@cruzio.com
150 Felker St #D http://www.LearnByDestroying.com
Santa Cruz CA 95060 http://802.11junk.com
Skype: JeffLiebermann AE6KS 831-336-2558
 
"William Sommerwerck" <grizzledgeezer@comcast.net> wrote in message
news:kb4f91$rh3$1@dont-email.me...
I have a 200/260W Weller solder gun and when I gave it some thought,
when someone spot welds a tab onto the battery, it creates a momentary
hot spot on the battery. The Weller gun can't to worse than a spot weld
as long as the time is short and proper preparation is made.

Oh, yes it can. A spot weld takes a fraction of a second, and the heat
appears over a small area.


By golly, I had no trouble at all and the results turned out great!

I hope so. I've seen connections of this sort fail * with the solder blob
simply falling off the battery.
But not if it is done properly in the way that has been carefully detailed,
and by someone who can solder properly in the first place. For a number of
years, I repaired 1st and 2nd generation cordless phones, and used to make
up my own battery packs at the rate of a couple a day. These repairs were
done for a two local phone shops, and for a travelling CB and accessory
salesman who called at many shops around the country, picking up the repairs
one week, and dropping them back the next. The batteries that I was joining
by soldering were of course NiCds back then, but I never had any problems
with exploding ones, or rapid failures, and trust me, if early failures had
been an issue, the shops would soon have been throwing them back at me ...

Arfa

* as do spot welds, of course
 
Phil Allison wrote:
"William Sommerwanker = TROLL "

"For battery packs subjected to high discharge rates, soldering
produces reliable, low resistance connections and spot welding does not."

** Different words & with a different meaning.

Ya could fooled me.

** Anyone could fool a tenth witted, ASD fucked cunt like you.

You still clinging to those worthless fantasies, I see. Tell me about
all your work for Australia's space program...
 
"Michael A. Terrell" wrote in message
news:Le2dnaxriNhnEUvNnZ2dnUVZ_vadnZ2d@earthlink.com...
Phil Allison wrote:

** Anyone could fool a tenth witted, ASD fucked cunt like you.

You still clinging to those worthless fantasies, I see. Tell me about
all your work for Australia's space program...
I know you're speaking to Phil, but I worked on the American space program in
Australia, installing and tuning a new klystron at the Orroral Valley site.

With respect to the American space programl... While working for RCA, I nearly
destroyed one of the TIROS satellites. I don't remember whether it was 6 or
7...
 
William Sommerwerck wrote:
"Michael A. Terrell" wrote in message
news:Le2dnaxriNhnEUvNnZ2dnUVZ_vadnZ2d@earthlink.com...
Phil Allison wrote:

** Anyone could fool a tenth witted, ASD fucked cunt like you.

You still clinging to those worthless fantasies, I see. Tell me about
all your work for Australia's space program...

I know you're speaking to Phil, but I worked on the American space program in
Australia, installing and tuning a new klystron at the Orroral Valley site.

Do you remember how many watts it handled? The largest I've worked
with were a trio of 45 KW made by EEV. The band it operated on? A
friend of mine who passed away a few years ago worked at Cape Canaveral
in the early days, installing cabling & electronics for their first
telemetry & communications systems.


With respect to the American space programl... While working for RCA, I nearly
destroyed one of the TIROS satellites. I don't remember whether it was 6 or
7...

Not on purpose, I'm sure. :)

Phil constantly accuses people of his own shortcomings, and in
general lowers the quality of any newsgroup he intrudes into. He needs
help. If he throws one of these fits in real life, someone my think
they are in danger and hurt or kill him. It's his life he's throwing
away, not yours or mine. I'm sitting here in pain, and having another
day where I'd let them take my leg so a whiny jerk like Phil doesn't
bother me. He needs new insults, though. That cut & paste crap of his
is quite stale.
 
I know you're speaking to Phil, but I worked on the American space program
in Australia, installing and tuning a new klystron at the Orroral Valley
site.

Do you remember how many watts it handled?
I believe the maximum output was 20kW. They were built by Varian whose chief
engineer was one Mr Goldfinger. Really. He gave me the clue I needed to figure
out why we couldn't tune the klystrons.
 
"William Sommerwerck" <grizzledgeezer@comcast.net> wrote:
I know you're speaking to Phil, but I worked on the American space program
in Australia, installing and tuning a new klystron at the Orroral Valley >> site.

Do you remember how many watts it handled?

I believe the maximum output was 20kW. They were built by Varian whose
chief engineer was one Mr Goldfinger. Really. He gave me the clue I
needed to figure out why we couldn't tune the klystrons.
Some guys could fiddle with those forever. I thought it was 10kw but might
be wrong.

Greg
 
William Sommerwerck wrote:


With respect to the American space programl... While working for RCA, I
nearly destroyed one of the TIROS satellites. I don't remember whether it
was 6 or 7...
Well, that sounds like it could be one of those "tales from the cube"
stories on the back page of EDN. Tell us more, if you can!

I have a few small tidbits from the sun angle computer from the TIROS
ground station.

Jon
 
"Jon Elson" wrote in message
news:JOqdnbdu4LY-j3vNnZ2dnUVZ_oidnZ2d@giganews.com...
William Sommerwerck wrote:

With respect to the American space program... While working
for RCA, I nearly destroyed one of the TIROS satellites. I don't
remember whether it was 6 or 7...

Well, that sounds like it could be one of those "tales from the cube"
stories on the back page of EDN. Tell us more, if you can!
Both satellites used dual, identical computers, with one backing up the other.
The software was periodically modified or updated, and I was assigned to write
the step-by-step instructions for a change.

Although my work was checked by other people, they made the same mistake I
did. I assumed that, because one of the satellites did not perform a checksum
on that section of program memory, neither did the other one. But it did.

The result was that, shortly after the update, the checksum was performed,
wasn't correct, and the computer shut down. For reasons I never understood,
the backup computer also shut down. (This was an intentional part of the
design.)

I quickly figured out what was going on, and my boss complimented me (which he
shouldn't have -- he should have chewed me out). No one was fired, or even
reprimanded. I suspect this sort of mistake was not uncommon.

The satellite was "fixed" by sending commands to reload and restart the
computers.
 
On 1/4/2013 1:53 PM, William Sommerwerck wrote:
"Jon Elson" wrote in message
news:JOqdnbdu4LY-j3vNnZ2dnUVZ_oidnZ2d@giganews.com...
William Sommerwerck wrote:

With respect to the American space program... While working
for RCA, I nearly destroyed one of the TIROS satellites. I don't
remember whether it was 6 or 7...

Well, that sounds like it could be one of those "tales from the cube"
stories on the back page of EDN. Tell us more, if you can!

Both satellites used dual, identical computers, with one backing up the
other. The software was periodically modified or updated, and I was
assigned to write the step-by-step instructions for a change.

Although my work was checked by other people, they made the same mistake
I did. I assumed that, because one of the satellites did not perform a
checksum on that section of program memory, neither did the other one.
But it did.

The result was that, shortly after the update, the checksum was
performed, wasn't correct, and the computer shut down. For reasons I
never understood, the backup computer also shut down. (This was an
intentional part of the design.)

I quickly figured out what was going on, and my boss complimented me
(which he shouldn't have -- he should have chewed me out). No one was
fired, or even reprimanded. I suspect this sort of mistake was not
uncommon.

The satellite was "fixed" by sending commands to reload and restart the
computers.
You never tested your code in a real setup?
 
The satellite was "fixed" by sending commands to reload
and restart the computers.

You never tested your code in a real setup?
The satellites were the "real" setup. There was no TIROS simulator.
 

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