A Deep Dive On Battery Life

July 28, 2023 by Bryan Cockfield 12 Comments

There are all kinds of old wives’ tales surrounding proper battery use floating around in the popular culture. Things like needing to fully discharge a battery every so often, unplugging devices when they’re fully charged, or keeping batteries in the fridge are all examples that have some kernel of truth to them but often are improperly applied. If you really want to know the truth about a specific battery, its behavior, and its features, it helps to dig in and actually take some measurements directly like [Tyler] has done with a vast array of embedded batteries in IoT devices.

[Tyler] is a firmware engineer by trade, so he is deeply familiar with this type of small battery. Battery performance can change dramatically under all kinds of scenarios, most important among them being temperature. But even the same type of battery can behave differently to others that are otherwise identical, which is why it’s important to have metrics for the batteries themselves and be able to measure them to identify behaviors and possible problems. [Tyler] has a system of best practices in place for monitoring battery performance, especially after things like firmware upgrades since small software changes can often have a decent impact on battery performance.

While working with huge fleets of devices, [Tyler] outlines plenty of methods for working with batteries, deploying them, and making sure they’re working well for customers. A lot of it is extremely useful for other engineers looking to develop large-scale products like this but it’s also good knowledge to have for those of us rolling out our own one-off projects that will operate under battery power. After all, not caring for one’s lithium batteries can have disastrous consequences.

Miners Vs NASA: It’s A Nevada Showdown

July 6, 2023 by Lewin Day 74 Comments

Mining projects are approved or disapproved based on all kinds of reasons. There are economic concerns, logistical matters, and environmental considerations to be made. Mining operations can be highly polluting, or they can have outsized effects on a given area by sheer virtue of the material they remove or the byproducts they leave behind.

For a proposed lithium mining operation north of Las Vegas, though, an altogether stranger objection has arisen. NASA has been using the plot of land as a calibration tool, and it doesn’t want any upstart miners messing with its work.

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Harvesting Rechargeable Batteries From Single-Use Devices

June 7, 2023 by Bryan Cockfield 63 Comments

The price of lithium batteries has plummeted in recent years as various manufacturers scale up production and other construction and process improvements are found. This is a good thing if you’re an EV manufacturer, but can be problematic if you’re managing something like a landfill and find that the price has fallen so low that rechargeable lithium batteries are showing up in the waste stream in single-use devices. Unlike alkaline batteries, these batteries can explode if not handled properly, meaning that steps to make sure they’re disposed of properly are much more important. [Becky] found these batteries in single-use disposable vape pens and so set about putting them to better use rather than simply throwing them away.

While she doesn’t use the devices herself, she was able to source a bunch of used ones locally from various buy-nothing groups. Disassembling the small vape pens is fairly straightforward, but care needed to be taken to avoid contacting some of the chemical residue inside of the devices. After cleaning the batteries, most of the rest of the device is discarded. The batteries are small but capable and made of various lithium chemistries, which means that most need support from a charging circuit before being used in any other projects. Some of the larger units do have charging circuitry, though, but often it’s little more than a few transistors which means that it might be best for peace-of-mind to deploy a trusted charging solution anyway.

While we have seen projects repurposing 18650 cells from various battery packs like power tools and older laptops, it’s not too far of a leap to find out that the same theory can be applied to these smaller cells. The only truly surprising thing is that these batteries are included in single-use devices at all, and perhaps also that there are few or no regulations limiting the sale of devices with lithium batteries that are clearly intended to be thrown away when they really should be getting recycled.

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Morse Code Clock For Training Hams

March 1, 2023 by Bryan Cockfield 13 Comments

It might seem antiquated, but Morse code still has a number of advantages compared to other modes of communication, especially over radio waves. It’s low bandwidth compared to voice or even text, and can be discerned against background noise even at extremely low signal strengths. Not every regulatory agency requires amateur operators to learn Morse any more, but for those that do it can be a challenge, so [Cristiano Monteiro] built this clock to help get some practice.

The project is based around his favorite microcontroller, the PIC16F1827, and uses a DS1307 to keep track of time. A single RGB LED at the top of the project enclosure flashes the codes for hours in blue and minutes in red at the beginning of every minute, and in between flashes green for each second.

Another design goal of this build was to have it operate with as little power as possible, so with a TP4056 control board, single lithium 18650 battery, and some code optimization, [Cristiano] believes he can get around 60 days of operation between charges.

For a project to help an aspiring radio operator learn Morse, a simple build like this can go a long way. For anyone else looking to build something similar we’d note that the DS1307 has a tendency to drift fairly quickly, and something like a DS3231 or even this similar Morse code clock which uses NTP would go a long way to keeping more accurate time.

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Researchers Find “Inert” Components In Batteries Lead To Cell Self-Discharge

February 6, 2023 by Donald Papp 11 Comments

When it comes to portable power, lithium-ion batteries are where it’s at. Unsurprisingly, there’s a lot of work being done to better understand how to maximize battery life and usable capacity.

Red electrolytic solution, which should normally be clear.

While engaged in such work, [Dr. Michael Metzger] and his colleagues at Dalhousie University opened up a number of lithium-ion cells that had been subjected to a variety of temperatures and found something surprising: the electrolytic solution within was a bright red when it was expected to be clear.

It turns out that PET — commonly used as an inert polymer in cell assembly — releases a molecule that leads to self-discharge of the cells when it breaks down, and this molecule was responsible for the color change. The molecule is called a redox shuttle, because it travels back and forth between the cathode and the anode. This is how an electrochemical cell works, but the problem is this happens all the time, even when the battery isn’t connected to anything, causing self-discharge.

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Hackaday Links: February 5, 2023

February 5, 2023 by Dan Maloney 33 Comments

Well, this week’s Links article is likely to prove a bit on the spicy side, thanks in no small part to the Chinese balloon that spent the better part of the week meandering across the United States. Putting aside the politics of the whole thing — which we’ll admit is hard to do, given the state of the world today — there are some interesting technical aspects to this story, which the popular press has predictably ignored. Like the size of this thing — it’s enormous. This is not even remotely on the same scale as the hundreds of radiosonde-carrying balloons sent aloft every day, at least if the back-of-the-envelope math thoughtfully sent to us by [Dr_T] holds up. If the “the size of three buses” description given in most media reports is accurate, that means a diameter of about 40 meters, for a volume of 33,500 cubic meters. If it’s filled with helium — a pretty safe bet — that makes its lifting capacity something like three metric tons. So maybe it was a good idea to wait until it was off the Carolinas to shoot it down.

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Copy And Paste Lithium Battery Protection

February 2, 2023 by Bryan Cockfield 40 Comments

Lithium batteries have, nearly single-handedly, ushered in the era of the electric car, as well as battery energy storage of grid power and plenty of other technological advances not possible with older battery chemistries. There’s just one major downside: these lithium cells can be extremely finicky. If you’re adding one to your own project you’ll have to be extremely careful to treat them exactly how they are designed to be treated using something like this boilerplate battery protection circuit created by [DIY GUY Chris].

The circuit is based around the TP4056 integrated circuit, which handles the charging of a single lithium cell — in this design using supplied power from a USB port. The circuit is able to charge a cell based on the cell’s current charge state, temperature, and a model of the cell. It’s also paired with a DW01A chip which protects the cell from various undesirable conditions such as over-current, overcharge, and over-voltage.

The best thing about this design isn’t the design itself, but that [DIY GUY Chris] built the circuit schematic specifically to be easily copied into PCB designs for other projects, which means that lithium batteries can more easily be integrated directly into his other builds. Be sure to check out our primer on how to deal with lithium batteries before trying one of your own designs, though.

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