Originally Posted by Frankly
Might want to take a look at what one mfg suggests.
Just made a new set of battery cables for Cbreeze. Used crimped tinned copper battery post clamps. Drilled a small hole in the end of both the lugs (for the switch end) and the battery clamps. Finished them off with solder until the end cavity and hole were filled. Sealed with heat shrink.
Don't think typical vibration issues with soldered connections apply to battery cable size connections in any reasonable set up.
That's really not some of Trojan's best work. It almost seems like an intern put that one together. "White papers" would typically employ scientific methodology and include such things as details
.. They are also usually written in a scientific peer-review structure & format.
What is "a high rate discharge" ?
How many amps?
What crimp tool?
What brand and model terminal?
What gauge wire?
Was the terminal designed/sized for that gauge wire?
How long was the high rate discharge applied?
Was the duration of "high rate discharge" equal in each thermal image?
Did they start from the same baseline temp for each test?
Had the lugs and battery stabilized at ambient room temp all yielding similar temp references
on the thermal imaging camera
before the load was applied?
What type of wire?
What type of stranding?
What were the terminals torqued to?
Were the lug holes the same diameter as the battery stud?
Were they copper terminals or aluminum
Was there a control tool
use as a baseline gold standard
Were the crimps tested to any standard such as UL486A or Mil-T-7928?
Were the tools properly calibrated before the testing?
If they are going to offer advice, as a large public company, they really need to do a much better job. The list above just scratching the surface of what a scientific
white paper would include.
I too own a thermal imaging camera
and none of my crimped connections exhibit that type of heat but I use a crimp tool from the same manufacturer as the terminals. My tool also exceeds Mil-T-7928 as is confirmed & tested with a digital load cell yearly for 2GA through 4/0.
With use of the correct tools,
and I can almost guarantee those crimps were not made to any UL, SAE, or Mil-Spec standard, as they should be, the thermal images
do not look like that.
I've run my Flir on cheap
Chinese crimp tool crimped lugs, hammer crimps and those made by my FTZ battery lug compression
crimp tool and there is a wide variation in performance.
That said the average hacked-together
lugs I see on boats, hammer crimps, pliers, and Chinese Harbor Freight quality crimps probably do look like that under a Flir and solder may help.