Quick Connects

I've revised my quick disconnects from my original plan. I was going to use those really cool Anderson disconnect blocks, but the total price for connectors (not including cable) would have been $240! Instead, I bought 25 15 amp Powerpole connectors that are going to hook straight up to each battery (limiting maximum current draw to 150 amps at 56 volts, which is 8,400 Watts). I'm going to use the existing leads (18 gauge), which is more than fine for 15 amps on a 2" lead. From here, I'm going to drop down to 14 gauge leads and up to 30A connectors (to accommodate the gauge) that are going to travel between 8 and 20 inches from each battery up to a central 120 Amp connector (limiting power to 6,720 Watts). The left side of the bike is going to contain 10 banks of cells, all tied in parallel and will comprise the 0-28V bank. The right side of the bike is going to contain the same number of cells but will be connected in series with the left side to obtain 28-56V. The connection between the two sides will be 6 gauge, as will the connections to the motor controller. I'm only using a 75 Amp connector here (4,200 Watts) because the controller should only pull 50A max; I'm using 120A connectors previously so that I can physically crimp the 10 14 gauge connectors into the housing. This is because the cross-sectional area of a 2 gauge wire is about 32mm^2 and the cross-sectional area of 14 gauge is about 2mm^2. I'll heat shrink 10 cables in parallel, stick them into this connector and then crimp the heck out of it:

I think I'll drop down to 10 gauge (maybe 8?) for the motor controller to motor segment. I'll feel that one out as it comes along.

Here's a cross-section of an Anderson connector:

gotta love that contact area!

:)