Battery teardown to get at the cells inside

Most of what people call batteries are actually cells. All of the common disposable alkaline batteries from AAA to D are single cells. The exception is the 9v battery which actually has six smaller cells inside of it. [Tom] took a look inside three different batteries to see what cells they’re hiding. Since he no longer uses the batteries for their intended purposes the individual cells may find a new life inside of one of his upcoming projects.

The six volt lantern battery on the left has four cells inside of it. This is no surprise since each zinc-carbon cell is rated for 1.5V. There’s not much that can be done with the internals since each cell is made of a carbon rod and zinc electrolyte ooze (rather than being sealed in their own packages).

Moving on to the rechargeable PP3 battery in the middle he finds the 8.4V unit is made up of seven 1.2V nickel-metal hydride cells. Many of them were shot, but we’d love to see one of the intact cells powering something small like a bristlebot.

The final component is an old laptop battery. Inside are an octet of Lithium Ion cells. The majority register 0V, but a few have 0.4V left on them. This is not surprising. We’ve seen power tool packs that have a few bad cells spoil the battery. It’s possible to resurrect a battery by combining good cells from two or more dead units.

Welding with over a hundred A123 Lithium cells

a123-cell-powered-welder

[Doctor Bass] needed to do some welding on his electric bicycle. The problem is that he’s never welded before and doesn’t have any tools for it. As you can see, that didn’t stop him. He used a bicycle battery made from reclaimed DeWalt A123 cells to power his diy welding rig.

He has a huge adjustable resistor which is responsible for limiting the current. 80 Amps seems to work the best with the welding rods he’s chosen. It is worth noting that when he shows off each part of the welder (see the clip after the break) the color of the wire used for positive and negative leads is opposite of convention. His positive wiring is black while his ground connection is red.

To get the welding under way he connects a jumper-cable-like clamp to his work piece which serves as the positive electrode. To hold the welding rod he drilled a hole in a pair of vice grip pliers and bolted on the negative lead. This way the end of the welding rod can be clamped in the vice grips while his other hand guides the tip. So far he’s still practicing, but it looks like he’s nearly ready to take on the job at hand.

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LiPo internal resistance measurement tool

lipo-internal-resistance-meter

This is a scratch-build meter for measuring the internal resistance of Lithium Polymer cells. [Bleuer Csaba] uses the LiPo cells for RC vehicles and thet take quite a beating from the motors  they’re supplying. This means that he only gets about 100-200 cycles out of each cell. To figure out where one is in its life cycle you can measure the internal resistance where a rising resistance indicates greater age. [Bleuer] mentions that you can buy a meter to do this for you, but what fun is that?

Since he’s rolling his own tool he defined his own parameters for the readings. After experimenting with different loads driven for different test periods he was able to extrapolate an equation that estimates the resistance measurement. As you can see in the clip after the break, this happens very fast. All he has to do is connect the cell and press one button. The measurements are made and various data points are displayed on the quartet of 7-segment displays.

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Open source capactive charger resurrects an electric skateboard

mikey-sklar-on-electric-skateboard

Here’s [Mikey Sklar] posing on his new electric skateboard. Well, it’s new to him at any rate. He bought it used on eBay for $250. That may not sound like much of a deal, but these will run more like $800 retail. The savings comes because the thing would no longer charge. But it took him just an hour and a half with his capacitive charger to resurrect the flat lithium cells.

The first thing he did in trouble shooting the situation was to measure the voltage of the battery pack. It registered 5V, which is a far cry from the 36V it should supply. The built-in charger does nothing, as it’s circuitry isn’t designed to work in a situation like this one. But [Mikey] has a tool perfect for this purpose. Da Pimp is a capacitive charger which we’ve seen before. It succeeds where the other failed because it is able to adapt itself to the internal resistance of the battery, no matter what voltage level it starts at.

[Mikey] shows off the use of his charger in the clip after the break. His first test run was more than two miles without issue.

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Testing 30 brands of batteries

Batteries come packaged in bright blister packs emblazoned with vague guarantees such as “45% more pictures” and “five times longer lasting.” During his internship at BitBox this summer, [Thomas] decided to put those statements to the test. He tested thirty brands of batteries on a homebrew rig to find the batteries with the most power and the most bang for your buck.

The hardware [Thomas] used an STM32 microcontroller to perform two different tests: a high drain and a low drain condition. For the high drain, 1000 mA were sucked out of the batteries until the voltage reached 0.8 V. For the low drain, 200 mA were used. Data including milliwatt-hours, milliamp-hours, joules, voltage, current, power, and effective load resistance were all logged for both conditions for all 30 batteries.

Generalizing the results for both low and high drain conditions, lithium batteries were better than alkaline, which were both better than zinc AA cells. Perhaps unsurprisingly, batteries marketed as ‘long life’ and ‘extended power’ were the worst batteries for the money, but a brand-name battery – the Kodak Xtralife cells – were actually the best value for the money.

Passion Fruit acquire laser defenses

Apparently being overrun by ripe Passion Fruit is a problem if you live in Hawaii. [Ryan K’s] solution to the situation was to use his extra fruit to power a laser. In an experiment that would make [Walter White] proud, [Ryan] gathered everyday supplies to form a battery based on the fruit.

He used some galvanized bolts as the source of zinc. It forms one pole of each cell, with a thin copper tube as the other pole. Each cell is rather weak, but when combined with others it makes a respectable battery. We’ve seen acidic fruit used to power LEDs, but [Ryan] wanted to do a little more. He built a circuit that would store electricity until he had enough potential to power an LED diode. After the break you can see a four second clip of the fruit wielding its new laser defense system.

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Recycle lithium cells by building custom flashlights

This isn’t a brightest flashlight in the world type of hack (but it does manage to push about 1000 lumens). [Stephen Webb] is finding a use for leftover parts by building his own simple LED flashlights. As you can see, he uses PVC parts available at any hardware or home store. These are a good choice; they’re cheap, light weight, resilient, designed to be water tight, they easily thread together and have connectors that reduce the diameter of the fittings.

The electronics use standard size cylindrical Lithium cells. These are found in many types of Laptop and Power Tool batteries. Often when one of those battery packs bites the dust it’s an issue of one or more bad cells. [Stephen] desolders the cells, and reuses the good ones in this project.

We didn’t see any mention of a recharging technique. Does anyone have any advice on how to top these cells off if they’re not in their original power pack form?