battery

416 Articles

Squeezing The Juice Out Of Some AA Batteries

February 27, 2012 by 75 Comments

[Ray’s] breadboard power supply lets you drain the last traces of power from ‘dead’ AA batteries. Electronics that are powered off of disposable alkaline batteries have a cutoff voltage that usually leaves a fair amount of potential within. Since many municipal recycling programs don’t take the disposables (you’re just supposed to throw them in the trash!) we love the idea of squeezing them for prototyping use.

His design uses just one IC, the MCP1640, along with a handful of passive components. The chip is a boost converter with a startup voltage of just 0.65V, which means the batteries themselves – normally starting life above 1.5V – can be used until they drop to about 0.3V each.

Above you can see the kit he is selling. But it’s an open source project and the circuit is so simple we’re sure you can build your own. Add that boost converter chip to your next parts order for around $0.40.

[Ray] made a nice demo video for the device which you can see embedded after the break.

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Hackaday Links: February 1, 2012

February 1, 2012 by 9 Comments

The only thing he needs now is a micro and RTC

For [Dino]’s 44th Hack A Week extravaganza, he made powered window blinds in five minutes. It’s a simple build with a small gear motor and a bit of tubing to adapt the shaft to the control rod of the blinds. Good job [Dino].

BecauseCamelCaseWillKillYourPinkieFinger

The wonderful [Lizzie] over at LUSTlab realized that typing meta keys really slows down the development process. The result? Foot pedals for the Shift and Command keys. No build log for this one, but it’s just a set of old racing pedals and a disused keyboard.

So much cooler than a potato

[mdevaev] out of Russia built a fully articulated GLaDOS replica. Here’s the build album and the relevant MLP forum post. This GLaDOS is tiny – probably less than a foot long, but it moves around and speaks (Russian, which is weird). Somebody get us a couple of motorcycle fenders so we can build the 1:1 scale version.

Visualizing a plane of fog

[greg] was looking for a way to visualize the chaotic turbulence of air. He mounted a laser on a computer fan and held some dry ice above the beam. The result looks like it could make for an interesting photography project, but check out the video if you don’t believe us.

We were asking for it

We asked for battery charging circuits that don’t use specialized parts. [Petr] found this one that only uses few transistors, a MOSFET and a voltage regulator. In one of the Hackaday comments, [atomsoft] had the idea of putting a USB plug on the traces to save a bit in component costs. [mohonri] said he designed one, but we have yet to see it. Perhaps next links post…

LiPo Charging Circuit Tutorial

January 28, 2012 by 86 Comments

As far as battery technology goes, Lithium Polymer cells are the bee’s knees. They’re powerful enough to handle very demanding applications and come in a multitude of sizes for any conceivable application. There’s a problem with LiPos, though – they have the tendency to explode when charged incorrectly. Luckily, [Paul] sent in a great tutorial on building a LiPo charger that works over USB.

In the original design of [Paul]’s board, he chose a Maxim MAX1551 Lithium battery charger. Confounded by the expense and/or unavailability of this IC (although Sparkfun has a few), he moved onto the similar Microchip MCP7813. This IC supports charging from a power source from 3.5 to 6 Volts as would be found in a USB hub.

The board [Paul] came up with is incredibly small – just barely larger than the USB plug itself. The layout is fairly simple as well. We’re thinking this could be a highly useful application of some home board fabrication. If you have a simpler way to charge LiPos that don’t require a specialized chip, send it into the tip line.

Reviewing The Numbers From One Month Of Solar Harvesting

January 23, 2012 by 19 Comments

[Mathieu] just finished analyzing the numbers from a month of solar energy harvesting. You may remember that he was curious to see what kind of energy can be collected from small solar cells used indoors. He built several copies of a test platform which collected data between December 16th and January 16th.

First of all, it’s not shocking to find out that rooms with no sunlight produced negligible energy during that time. When you think about it, if they had been gathering a statistically significant amount wouldn’t that mean the lighting used in those rooms was incredibly inefficient? In other words, there’s no way you need to be making that much light.

But he did find that proper positioning in rooms that catch sunlight during the day can result in usable energy for small loads. He established that a 0.5 Watt panel harvested just a bit more than half of what a 1 Watt panel did. But perhaps the most useful discovery was that it’s quite a bit more efficient to have a charging circuit store energy in a battery rather than directly powering a fixed load.

It will take us a few more viewings to really decide what we can take away from the experiment for our own projects. But we appreciate [Mathieu’s] quest for knowledge and his decision to put this information out there so that others can learn from it.

From The Readers: Low Battery Cutoff Solutions

December 1, 2011 by 26 Comments

We got a lot of really great feedback about low battery cutoff options in the comments section of Monday’s replacement battery post. To refresh your memory, some power tool batteries were replaced by Lithium Polymer units which can be damaged if drained too low before recharging. We had thought that many Lithium cells had cutoff circuitry these days. The consensus is that these batteries didn’t because they’re for RC applications where weight is an issue. But we did get a ton of people sending in commercially available drop-in solutions, mostly from RC hobby outlets, so search around for those if you’re interested.

[Christopher] sent us a link to the cutoff circuit he built for his bike light. You can see the schematic for it above (direct link). He sourced an ATtiny45 to drive a MOSFET which disconnects the battery when it gets too low. This would be easy to adapt to other uses, but note that there’s a voltage regulator involved as well as a few other passives… not a difficult solution but also not all that simple.

This same concept can be adapted. A few commentors mentioned using a transistor (or MOSFET) with the base driven by a voltage divider including a zener diode. This way the voltage rating of the diode would effectively shut off the gate when that threshold was reached.

We also enjoyed reading about [Bill’s] human-controlled cutoff circuit. It also uses a zener diode, but this time in series with a resistor and and LED patched into the trigger of the tool. The LED will shine brightly when the battery is in good shape. It will dim near the end, and fail to light when the critical limit has been reached. Just make sure you’re paying attention and you’re in good shape.

Pros And Cons Of Replacing Tool Batteries With Lithium Polymer

November 29, 2011 by 38 Comments

[HammyDude] was tired of buying replacement batteries for his power tools. He had some Lithium Polymer batteries on hand and decided to take one of his dead drills and swap out the dead power pack.

The orange battery pack you see above has a deans connector on it for use with RC vehicles. By opening up the drill housing, [HammyDude] was able to add the mating deans connector. Now the replacement easily plugs into the drill, and it even fits inside the handle body.

This battery is made up of several cells, and an inexpensive charger is capable of topping off each individually for a balanced charge. In the video after the break [HammyDude] points out that the Makita charger applies voltage to all of the cells in series. It’s incapable of balance charging so when one cell dies the battery is toast. We’ve encountered this problem with Makita tools before.

One drawback to take note of in the end of the video: this replacement doesn’t have any low voltage cut-off. Running this battery pack down too low will permanently damage it. There must be a simple circuit that could be added as a safety measure. If you know of one, drop us a tip.

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Replacing Solder Tab Batteries

November 26, 2011 by 40 Comments

There’s a ton of devices out there that have batteries in them but most people never think about it. That’s because they use rechargeables that are sealed inside and topped off with external chargers. [Todd Harrison] has a couple of them, including a cordless shaver and a Christmas light timer. He’s had these for years and the batteries have gone south. They’re not meant to be consumer-replaceable, but that did stop him from cracking them open and swapping out the solder-tab batteries himself.

The batteries themselves won’t be all that hard to source. The shaver just takes a NiMH AA cell. But since they’re not meant to be replaced [Todd] needed to do some soldering. Here you can see he’s using a solder gun to make the connection between the new battery and one of the solder tabs. He uses the gun instead of an iron because he needs to heat the joint quickly, and must avoid heating the rest of the cell which could rupture. As a safety precaution he’s wearing gloves and a full face-shield.

Check out the video after the break to see this, as well as the coin cell replacement in the lighting controller.

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