What Happened To Duracell PowerCheck?

October 9, 2024 by Al Williams 83 Comments

Remember Duracell’s PowerCheck? The idea was that a strip built into the battery would show if the battery was good or not. Sure, you could always get a meter or a dedicated battery tester — but PowerCheck put the tester right in the battery. [Technology Connections] has an interesting video on how these worked and why you don’t see them today. You can see it below.

Duracell didn’t invent the technology. The patent belonged to Kodak, and there were some patent issues, too, but the ones on the Duracell batteries used the Kodak system. In practice, you pushed two dots on the battery, and you could see a color strip that showed how much capacity the battery had left. It did this by measuring the voltage and assuming that the cell’s voltage would track its health. It also assumed — as is clearly printed on the battery — that you were testing at 70 degrees F.

The temperature was important because the secret to the PowerCheck is a liquid crystal that turns color as it gets hot. When you press the dots, the label connects a little resistor, causing the crystals to get warm. The video shows the label taken apart so you can see what’s inside of it. The resistor isn’t linear so that’s how it changes only part of the bar to change color when the battery is weak but not dead.

It is a genius design that is simple enough to print on a label for an extremely low cost and has virtually no components. PowerCheck vanished from batteries almost as suddenly as it appeared. Some of it was due to patent disputes. But the video purports that normal people don’t really test batteries.

Watch out for old batteries in gear. Of course, if you want to really test batteries, you are going to need more equipment.

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Need High-Power Li-Ion Charging? How About 100 W

October 4, 2024 by Arya Voronova 21 Comments

Ever want a seriously powerful PCB for charging a Li-Ion pack? Whatever you want it for, [Redherring32] has got it — it’s a board bearing the TPS25750D and BQ25713 chips, that lets you push up to 100 W into your 1S Li-Ion pack through the magic of USB Power Delivery (USB-PD).

Why do you need so much power? Well, when you put together a large amount of Li-Ion cells, this is how you charge it all at once – an average laptop might charge the internal battery at 30 W, and it’s not uncommon for laptop batteries to be dwarfed by hackers’-built packs.

A 4-layer creation peppered with vias, this board’s a hefty one — it’s not often that you see a Li-Ion charger designed to push as much current as possible into a cell, and the chips are smart enough for that. As far as the onboard chips’ capabilities go, the board could handle pack configurations from 1S to 4S, and even act as a USB-PD source — check the IC configuration before you expect to use it for any specific purpose.

Want a simpler charger, even if it’s less powerful? Remember, you can use PPS-capable PD chargers for topping up Li-Ion packs, with barely any extra hardware required.

Lithium-Ion Battery Hotswapping, Polarity, Holders

September 11, 2024 by Arya Voronova 28 Comments

Everyone loves, and should respect, lithium-ion batteries. They pack a ton of power and can make our projects work better. I’ve gathered a number of tips and tricks about using them over the years, based on my own hacking and also lessons I’ve learned from others.

This installment includes a grab-bag of LiIon tricks that will help you supercharge your battery use, avoid some mistakes, and make your circuits even safer. Plus, I have a wonderful project that I just have to share.

Hot-swapping Cells

When your device runs out of juice, you might not always want to chain yourself to a wall charger. Wouldn’t it be cool if you could just hot-swap cells? Indeed it is, I’ve been doing it for years, it’s dead simple to support, but you can also do it wrong. Let me show you how to do it right!

Recently, a new handheld has hit the hacker markets – the Hackberry Pi. With a Blackberry keyboard and a colour screen, it’s a pretty standard entry into the trend of handheld Pi Zero-backed computers with Blackberry keyboards. It’s not open-source and the author does not plan to open-source its hardware, so I want to make it absolutely clear I don’t consider it hacker-friendly or worth promoting. It did publish schematics, though, and these helped me find a dangerous mistake that the first revision made when trying to implement LiIon battery hot-swap. Continue reading “Lithium-Ion Battery Hotswapping, Polarity, Holders” →

The Trashiest Of Mains Inverters

August 31, 2024 by Jenny List 21 Comments

Switch-mode technology has made inverters which take a low DC voltage and turn it into a usable mains voltage within the reach of everybody. But still, there might be moments when a mains supply is needed and you’re not lucky enough to have AliExpress at your fingertips, and for that, here’s [Rulof] with a mains inverter that is simultaneously awful and awesome. He’s made a rotary converter, from trash and off the shelf parts.

While a switch-mode converter operates using PWM at many times the output frequency for efficiency, we’re guessing that most readers will be familiar enough with how AC works to see how a low frequency converter turns DC into AC. A set of switches repeatedly flip the polarity, and the resulting square wave is fed into a transformer to step up to the final voltage. The switches can be mechanical as with old-style converters that used vibrating reeds or rotary armatures, or they can be electronic using power transistors. In this case they are a set of microswitches actuated by a set of cams on a shaft driven by a small motor, and the transformer comes from a surplus UPS.

We’re guessing that the frequency will be only a few Hz and the microswitches will suffer from switching such an inductive load, but as you can see in the video below the break it does light a mains bulb, and we’re guessing it would be enough to activate most wall-wart switching power supplies. We’re not so sure though about his use of the IEC sockets from the UPS to carry 12 volts, as the current may be a little much for them.

Meanwhile if you thirst for more of this kind of thing, we have you covered.

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Universal Power Bank Customized To Your Liking

August 31, 2024 by Bryan Cockfield 10 Comments

One of the most troubling trends of almost every modern consumer product that uses electricity is that the software that controls the product is likely to be proprietary and closed-source, which could be doing (or not doing) any number of things that its owner has no control over. Whether it’s a computer, kitchen appliance, or even a device that handles the electricity directly, it’s fairly rare to find something with software that’s open and customizable. That’s why [Traditional-Code9728] is working on a power bank with an open-source firmware.

From a hardware perspective the power bank is fairly open as well, with a number of options for connecting this device to anything else that might need power. It sports a bidirectional USB-C port as well as a DC barrel plug, either of which can either charge other devices or receive energy to charge its own battery. These ports can also accept energy from a solar panel and have MPPT built in. There’s also dual USB-A ports which can provide anywhere from five to 12 volts at 25 watts, and a color screen which shows the current status of the device.

While this is a prototype device, it’s still actively being worked on. Some future planned upgrades to the power bank include a slimmer design, charge limiting features to improve battery life, and more fine-tuned control of the output voltage and current on the USB-C port. With all of the software being open-source, as well as the circuit diagram and 3D printing files, it could find itself in plenty of applications as well. This power bank also stays under the energy limits for flying on most commercial airlines as well, but if you don’t plan on taking your power bank on an airplane then you might want to try out this 2000-watt monster instead.

Hardware Reuse: The PMG001 Integrated Power Management Module

August 27, 2024 by Dave Rowntree 15 Comments

Battery management is a tedious but necessary problem that becomes more of a hassle with lithium-ion technology. As we’re all very aware, such batteries need a bit of care to be utilized safely, and as such, a huge plethora of ICs are available to perform the relevant duties. Hackaday.IO user [Erik] clearly spent some time dropping down the same old set of ICs to manage a battery in their applications, so they created a drop-in castellated PCB to manage all this.

Continue reading “Hardware Reuse: The PMG001 Integrated Power Management Module” →

Maker [Dala] showing powerwall statistics

From Vehicle-to-Grid To DIY Home Powerwalls

August 13, 2024 by Heidi Ulrich 46 Comments

As battery-to-grid and vehicle-to-home technologies become increasingly mainstream, the potential for repurposing electric vehicle (EV) batteries has grown significantly. No longer just a niche pursuit, using retired EV batteries for home energy storage has become more accessible and appealing, especially as advancements in DIY solutions continue to emerge. Last year, this project by [Dala] showcased how to repurpose Nissan Leaf and Tesla Model 3 battery packs for home energy storage using a LilyGO ESP32, simplifying the process by eliminating the need for battery disassembly.

In the past few months, this project has seen remarkable progress. It now supports over 20 different solar inverter brands and more than 25 EV battery models. The most exciting development, however, is the newly developed method for chaining two EV packs together to create a single large super-battery. This breakthrough enables the combination of, for example, two 100kWh Tesla packs into a massive 200kWh storage system. This new capability offers an accessible and affordable way to build large-scale DIY home powerwalls, providing performance that rivals commercial systems at a fraction of the cost.

With these advancements, the possibilities for creating powerful, cost-effective energy storage solutions have expanded significantly. We do however stress to put safety first at all times.

Hungry for more home powerbanks? We’ve been there before.

Continue reading “From Vehicle-to-Grid To DIY Home Powerwalls” →