Toddler EV Gets Big Boy Battery Upgrade

July 29, 2022 by Ryan Flowers 13 Comments

No matter the type of vehicle we drive, it has a battery. Those batteries wear out over time. Even high end EV’s have batteries with a finite life. But when your EV uses Lead Acid batteries, that life is measured on a much shorter scale. This is especially true when the EV is driven by a driver that takes up scarcely more space in their EV than a stuffed tiger toy! Thankfully, the little girl in question has a mechanic:

A 3d printed adapter sends go-juice to the DC-DC converter

Her daddy, [Brian Lough], who documented the swift conversion of his daughter’s toy truck from Lead Acid to Li-Ion in the video which you can see below the break.

Facing challenges similar to that of actual road worthy passenger vehicles, [Brian] teamed up with [bitluni] to solve them. The 12 V SLA battery was being replaced with a 20 V Li-Ion pack from a power tool. A 3d printed adapter was enlisted to break out the power pins on the pack. The excessive voltage was handled with a DC-to-DC converter that, after a bit of tweaking, was putting out a solid 12 V.

What we love about the hack is that it’s one anybody can do, and it gives an inkling of what type of engineering goes into even larger projects. And be sure to watch the video to the end for the adorable and giggly results!

Speaking of larger projects, check out the reverse engineering required in this Lead Acid to Li-Ion conversion we covered in 2016.

Continue reading “Toddler EV Gets Big Boy Battery Upgrade” →

The charging station on the table, with twelve powerbanks plugged into it, charging. A small meter on the front panel shows 4.73 volts and 4.38 amps.

A Simple Charging Station For Twelve Powerbanks

July 25, 2022 by Arya Voronova 13 Comments

[jasonwinfieldnz] uses twelve small powerbanks day to day – powering LED strips around his trampoline, presumably, to avoid the mess of wires and make the assembly easily portable. However, if you have twelve powerbanks, you’ll find yourself hogging all the household’s microUSB cables every so often, as they eventually discharge. This was not good enough for our hacker, and he decided to build a charging station to refill them all at once.

If you need 5 volts and many amps, an ATX PSU isn’t your worst bet. From there, he only had to add twelve microUSB connectors to – and condensed the entire contraption into a beautiful charging station. For the microUSB part, he hacked some microUSB cable ends off and embedded them into the case. An embedded voltage and current module is of big help – letting you see at a glance when charging has really finished. Using copper tape as bus bars and banana plugs for charging input, this project is easy to build and solves the problem well.

The 3D printing files and cutting templates are right there on the project page, so if any of us hackers has a problem that twelve powerbanks could help with, [Jason]’s project is quite repeatable. If your devices are more diverse, you could use a pegboard to build a stylish charging station for them! If, on the other hand, you have a single device you need to plug multiple cords into, moldable plastic is there to help.

Adding A Battery To Extend Speaker Life

July 23, 2022 by Bryan Cockfield 14 Comments

Perhaps the weakest point in modern electronics when it comes to user servicability is the lifecycle of the batteries included from the manufacturer. Without easily replaceable batteries, many consumer goods end up in the landfill when they’re otherwise working perfectly. If you’d like to get more out of your devices than the manufacturer intends, you might have to go to great lengths like [Théo] did with his JBL speaker.

This was a Bluetooth device produced by JBL nearly a decade ago, and while the original device boasted several hours of battery life, after so many years of service, it was lucky to get a half hour before the battery died. To replace it, [Théo] removed the original battery and extended the case to be able to hold a larger cell phone battery. He also decided to use the original battery management circuit from the speaker with the new battery after verifying the voltage and chemistry were close enough to the original.

Since the phone battery is a proprietary Samsung device, [Théo] also decided to build a version that uses standard 18650 cells instead, although he prefers the slimmer design with the phone battery for his use case. Straightforward as this build may be, it does go a long way to demonstrate the principle that if you can’t fix your devices, you don’t really own them.

Mouse Charging Mod Shows Even Simple Hacks Can End Up Complex

June 9, 2022 by Donald Papp 16 Comments

Hardware hacks have something in common with renovations that involve taking down a wall: until one actually gets started and opens things up, there’s no telling what kind of complications might be lurking. [voussoir] has a project that demonstrates this nicely: modifying a rechargeable mouse to use USB-C instead of micro-B turned out to have quite a few little glitches in the process. In fact, changing the actual receptacle was the simplest part!

On one hand, the mouse in question seems like a perfect candidate for easy modification. The enclosure isn’t too hard to open, there is ample space inside, and USB is used only for recharging the battery. So what was the problem? The trouble is something familiar to anyone who has worked on modifying an existing piece of hardware: existing parts are boundaries to hacking work, and some are less easily modified than others. Continue reading “Mouse Charging Mod Shows Even Simple Hacks Can End Up Complex” →

Fighting Back Against Dodgy Dyson Batteries

May 23, 2022 by Tom Nardi 64 Comments

If you’ve ever worked with multi-cell rechargeable battery packs, you know that the individual cells will eventually become imbalanced. To keep the pack working optimally, each cell needs to be analyzed and charged individually — which is why RC style battery packs have a dedicated balance connector. So if you know it, and we know it, why doesn’t Dyson know it?

It’s that question which inspired [tinfever] to start work on the FU-Dyson-BMS project. As you might have surmised from the name, [tinfever] believes that Dyson has intentionally engineered their V6 and V7 batteries to fail by not using the cell balancing function of the onboard ISL94208 battery management IC. What’s worse, once the cells get as little as 300 mV out of balance, the controller considers the entire pack to be shot and will no longer allow it to be charged.

These missing resistors deserve justice.

Or at least, that’s what used to happen. With the replacement firmware [tinfever] has developed, the pack’s battery management system (BMS) will ignore imbalanced cells so you can continue to use the pack (albeit at a reduced capacity). Of course the ideal solution would have been to enable cell balancing on the ISL94208, but unfortunately Dyson didn’t include the necessary resistors on the PCB. Though it’s worth noting that earlier versions of the board did have unpopulated spots for them, lending some credence to the idea that their omission was intentional on Dyson’s part.

But not everyone is onboard with the conspiracy theory. Over on the EEVBlog forums, some users pointed out that a poorly implemented cell balancing routine can be more problematic than not having one at all. It’s possible that Dyson had some bad experiences with the technology in earlier packs, and decided to move away from it and try to compensate by using higher-quality cells. That said, at least one person in the thread was able to revive their own “dead” battery pack by installing this unofficial firmware, so whether intentional or not, it seems there’s little debate that usable batteries are indeed being prematurely marked as defective.

Proper cell balancing is key even in DIY projects, so we do have to agree that it seems more than a little unusual that Dyson would intentionally turn off this important feature in their packs. But the jury is still out on whether or not Sir James is trying to pull a fast one on his customers — as Hanlon’s Razor states, “never attribute to malice that which is adequately explained by stupidity”.

Continue reading “Fighting Back Against Dodgy Dyson Batteries” →

A Beginner’s Guide To Lithium Rechargeable Batteries

June 11, 2020 by Lewin Day 42 Comments

Batteries were once heavy, awkward things, delivering only a limp amount of current for their size and weight. Thankfully, over time, technology has improved, and in 2020, we’re blessed with capable, high-power lithium polymer batteries that can provide all the power your mobile project could possibly need. There are some considerations one must make in their use however, so read on for a primer on how to properly use LiPos in your project!

So Many Types!

With the first commercial lithium-ion battery entering the market in 1991, the (nearly) 30 years since have seen rapid development. This has led to a proliferation of different technologies and types of battery, depending on construction and materials used. In order to treat your batteries properly, it’s important to know what you’ve got, so paying attention to this is critical. Continue reading “A Beginner’s Guide To Lithium Rechargeable Batteries” →

Safely Creating A Li-Ion Pack From Phone Cells

June 2, 2016 by Jenny List 47 Comments

[Glen], at Maker Space Newcastle Upon Tyne, is refreshingly honest. As he puts it, he’s too cheap to buy a proper battery.

He needed a 1AH battery pack to power his quadcopter controller and FPV headset, and since inadequate discharge warnings had led him to damage lithium polymer cells with these devices, he wanted his pack to use lithium-ion cells. His requirements were that the cells be as cheap, lightweight, and small as possible, so to satisfy them he turned to a stack of mobile phone cells. Nokia BL-4U cells could be had for under a pound ($1.46) including delivery, so they certainly satisfied his requirement for cheapness.

It might seem a simple procedure, to put together a battery pack, and in terms of physical wiring it certainly is. But lithium-ion cells are not simply connected together in the way dry cells are, to avoid a significant fire risk they need to have the voltage of each individual cell monitored with a special balanced charger. Thus each cell junction needs to be brought out to another connector to the charger.

[Glen]’s write-up takes the reader through all the requirements of safe lithium-ion pack construction and charging, and is a useful read for any lithium-ion newbies. If nothing else it serves as a useful reminder that mobile phone cells can be surprisingly cheap.

Lithium cells have captured our attention before here at Hackaday. Our recent Hackaday Dictionary piece provides a comprehensive primer, we’ve featured another multi-cell build, and an interesting app note from Maxim for a battery manager chip.