Laser Welding Machine

Was this discussion prompted by my earlier mention of breaking the cap of a Calb cell? That incident was entirely my oversight. My batteries were designed to maintain a consistent configuration, with components within an approximate tolerance of 1/8 to 1/4 inch. During the assembly of my second battery, I attempted to connect a thick 4/0 cable to the fuse block while it was still attached to the cell, which proved problematic due to the tight tolerances. As a result, applying too much pressure caused the welds to fail. In contrast, my first battery assembled effortlessly like a hand fitting into a glove.

From that experience, I've learned the importance of utilizing a vise and a ratchet wire bender attachment during the assembly process of subsequent batteries. Furthermore, I now ensure to attach the wire to the fuse block (or shunt) first before connecting it to the cell.

It's worth noting that having the ability to repair such instances would be incredibly beneficial. For example, it could greatly assist in maintaining a trolling motor battery if needed.

Edit: Upon reflection, it appears that I broke the positive wire connecting to the contactor and cell 16 in the accompanying photo.

Edit 2: The arrangement I used for the batteries was simply to accommodate eight of them within the cabinet.

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