Battery Hacks

104 Articles

Tesla’s Plug Moves Another Step Closer To Dominance

December 21, 2023 by 46 Comments

Charging an EV currently means making sure you find a station with the right plug. SAE International has now published what could be the end to the mishmash of standards in North America with the J3400 North American Charging Standard.

The SAE J3400TM North American Charging Standard (NACS) Electric Vehicle Coupler Technical Information Report (TIR), which just rolls off the tongue, details the standard formerly only available on Tesla vehicles. We previously talked about the avalanche of support from other automakers this year for the connector, and now that the independent SAE standard has come through, the only major holdout is Stellantis.

Among the advantages of the NACS standard over the Combined Charging System (CCS) or CHAdeMO is a smaller number of conductors given the plug’s ability to carry DC or AC over the same wires. Another benefit is the standard using 277 V which means that three separate Level 2 chargers can be placed on a single 3-phase commercial line with no additional step down required. Street parkers can also rejoice, as the standard includes provisions for lampost-based charger installations with a charge receptacle plug instead of the attached cable required by J1772 which leads to maintenance, clutter, and ADA concerns.

Now that J3400/NACS is no longer under the purview of a single company, the Federal Highway Administration has announced that it will be looking into amending the requirements for federal charger installation subsidies. Current rules require CCS plugs be part of the installation to qualify for funds from the Bipartisan Infrastructure Bill.

If you want to see how to spice up charging an EV at home, how about this charging robot or maybe try fast charging an e-bike from an electric car plug?

Recycling Batteries With Bacteria

December 18, 2023 by 6 Comments

Vehicle battery recycling is going to be a big deal with all the electric cars hitting the roads. What if you could do it more effectively with the power of microbes? (via Electrek)

“Li-ion” vehicle batteries can be any of a number of different chemistries, with more complex cathode makeups, like NCM (LiNixMnyCo1-x-yO2), being understandably more complex to separate into their original constituents. Researchers and companies in the industry are hoping to find economically-viable ways to get these metals back for both the environmental and economic benefits a closed loop system could provide.

Researchers in the UK developed a method using two species of bacteria to precipitate Ni, Mn, and Co from the liquid leached from cathodes. Li remained in the liquid where it could be processed separately like that obtained in Li brine. Mn was precipitated first by S. oneidensis MR-1, and a following step removed Ni and Co with D. alaskensis G20. The researchers report that Ni and Co show promise for further separation via biological methods, but more research is required for this step.

If you’re looking for some more interesting ways bacteria can be harnessed for the energy system, checkout this microbial fuel cell, another using soil, and an enzyme derived from bacteria that can pull electricity from thin air.

Second Life UPS Mark II: A UPS For Low-Voltage DC Applications

December 17, 2023 by 17 Comments

When you have a whole stack of devices and appliances that all have an AC to DC adapter and which you’d like to put on an uninterruptable power supply (UPS), you could do the obvious thing and get an off-the-shelf UPS with myriad AC outputs. In the case of a 19″ rack this means wrangling a power strip or two and any combination of differently sized AC/DC adapters into the rack, with questionable efficiency and waste heat dumped into the rack. This is where a DC-only UPS like [Maciej Grela]’s Second Life UPS Mark II provides an interesting alternative.

At its core it’s a pretty simple concept: A single 400Watt power supply handles the AC/DC conversion from mains to 24 VDC, which feeds the battery charger as well as the outputs. These outputs include 5 VDC, 12 VDC and Vrail, with the latter being either the output from the PSU, or the battery voltage. In case of AC power failure, an LT4416 dual power path controller handles the switch-over from the PSU output to the internal batteries. In the article, [Maciej] covers how the buck modules for the 12 & 5 VDC rails were sized, along with the conversion of an old rack-mounted network switch into a UPS. Continue reading “Second Life UPS Mark II: A UPS For Low-Voltage DC Applications” →

Mods Turn Junk UPS Into A Long-Endurance Beast

December 15, 2023 by 36 Comments

If you’ve got a so-called uninterruptible power supply (UPS) on your system, you’re probably painfully aware that the “uninterruptible” part has some pretty serious limits. Most consumer units are designed to provide power during a black out only long enough to gracefully shut down your system. But with a few hacks like these, you can stretch that time out and turn it into a long-endurance UPS.

As many good stories do, this one starts in the trash, where [MetaphysicalEngineer] spotted an APC home office-style UPS. It was clearly labeled “broken,” but that just turned out to be a dead battery. While he could have simply replaced it with a 12-volt sealed lead-acid battery, [Meta] knew that his computer setup would quickly deplete the standard battery. A little testing showed him that a car battery would extend the run time significantly, especially if he threw in some extra cooling for the onboard inverter.

His final design uses a marine deep-cycle battery in a plastic battery box with the UPS mounted on top. The vacated battery compartment made a great place to add a cooling fan, along with a clever circuit to turn it on only when the beeper on the UPS sounds, with a bonus volume control for the annoying sound. He also added accessories to the battery box top, including a voltmeter, a USB charger, and a switched 12-volt power outlet. And kudos for the liberal use of fuses in the build; things could get spicy otherwise. The video below shows the entire build along with all the testing. [MetaphysicalEngineer] managed to triple the estimated runtime for the load he’s trying to power, so it seems like a win to us.

If your needs run more toward keeping your networking gear running through a blackout, you might want to check out this inverter-less DC UPS.

Continue reading “Mods Turn Junk UPS Into A Long-Endurance Beast” →

An illustration of a powerplant, solar panel, and two wind turbines is in the bottom left across from an image of three cartoon people holding up a giant battery above their heads. Along the top of the image are the words, "Emergency Battery Network Toolkit." Below in a white bubble on the yellow background, it says, "How to share energy resources with your community in times of need." In the space between the people and the power plant, it says, "A Partnership of Shareable and People Power Battery Collective."

Sneakernet Power Transmission

December 14, 2023 by 29 Comments

Power outages in the face of natural disasters or more mundane grid failures can range from a mild inconvenience to a matter of life or death if you depend on electrical medical equipment. [Shareable] and [People Power Battery Collective] have partnered to develop a toolkit for communities looking to share power with each other in these situations.

Battery backup power isn’t exactly a new concept, so the real meat of this guide is how to build a network in your community so these relatively simple devices can be deployed effectively in the event of an emergency. We know that you can already handle your own backup power needs, but it pays to be a good neighbor, especially when those neighbors are deciding what to do when you’re releasing the factory-sealed smoke from your latest build on the community sidewalk.

For those who aren’t as technically-inclined as you, dear reader, there is also a handy Battery Basics (PDF) guide to help in selecting a battery backup solution. It is somewhat simplified, but it covers what most people would need to know. A note on fire safety regarding Li-ion batteries would probably be warranted in the Battery Basics document to balance the information on the risks of topping up lead-acid cells, but it otherwise seems pretty solid.

If you’re not quite ready to bug your neighbors, how about you build a backup battery first? How about repurposing an e-bike battery or this backup power solution for keeping a gas water heater working during a power outage?

Disposable Vape Batteries Turned USB Power Bank

December 14, 2023 by 31 Comments

It’s another one of those fun quirks about our increasingly cyberpunk world — instead of cigarette butts littering our streets, you’re more likely to find disposable vaporizers that have run out of juice. Unfortunately, while the relatively harmless paper remnants of a cig would eventually just fall apart when exposed to the elements, these futuristic caltrops are not only potentially explosive thanks to their internal lithium-ion battery but aren’t going anywhere without some human intervention.

So do the environment and your parts bin a favor: pick them up and salvage their internal cells. As [N-Ender_3] shows with this build, it’s cheap and easy to turn the remnants of a few vapes into a useful USB power bank. In this case, the enclosure is 3D printed, which makes it particularly form-fitting, but you could just as easily pack the cells into something else if you’re not a fan of extruded plastic.

Continue reading “Disposable Vape Batteries Turned USB Power Bank” →

A 48 Volt Battery Pack With Carefully Balanced Cells

November 28, 2023 by 60 Comments

Many readers will have at some time or another built their own lithium-ion battery packs, whether they are using tiny cells or the huge ones found in automotive packs. A popular choice it to salvage ubiquitous 18650 cylindrical cells, as [limpkin] has with this 48 volt pack. It’s based around an off-the-shelf kit aimed at the e-bike market, but it’s much more than a simple assembly job.

Faced with a hundred salvaged cells of unknown provenance, the first thing to do was ensure that they were all balanced and showed the same voltage. Some might do this the inefficient way by hooking each one up to a charger and a programmable load, but in this case a much more radical route was taken. A huge PCB was designed with sockets for all hundred cells, connected in parallel through individual series resistors. This allowed them to balance to a common voltage before being discharged to a safe voltage for assembly. Their individual ESRs were the measured, and the best performing examples were then spot-welded into the final 13s-6p final pack.

We all use lithium-ion batteries, but how many of us know how they work?