Battery Pack Q's

Magicthyse

Golden Member
Aug 15, 2001
1,095
0
0
I've tried making a battery pack for a Firewire HDD (fitting on a VAIO - you may know they i.Link doesn't output 5v). It works great so far... No burning smells :D I've had about an hours worth of use so far, now doing a Scandisk on a 30Gb disk to check how long it'll actually last). It works with 8 1700mah AA NiMh cells, on a 4-serial x 2-in-parallel layout. Theoretically speaking, I should get about 4 hours of use out of the thing as the enclosure is rated for 1A with the drive, but is probably drawing about 500-750ma altogether in operation.

However, I've realized that the finished article is nearly as big as, and quite possibly heavier than, the Firewire HDD!

To be honest, I can live with it - but I was wondering if it was possible to use Li-Ion cells to reduce weight and size. Is it possible? How would you go about making a 5V Li-Ion cell which can pack around 3000mah?

Other questions are about a battery meter and an 'in-situ' recharger.

As things are now, I'll have to take the AA batteries out to recharge them. It is possible to charge the batteries fixed in the above configuration? What kind of circuit would I have to make (with overcharging protection?)?

And it'd be mighty handy to rig up a battery capacity meter to tell me how much juice there is left - something like a 4-segment LED bar display or something - can someone hook me up with some circuit designs?
 

Mark R

Diamond Member
Oct 9, 1999
8,513
16
81
Li-ion cells are difficult to find on their own - they are solely aimed for OEM use. The other thing is the voltage, Li-ion cells are 3.6 V - you'll need a voltage regulator to provide 5V.

The other problem is charging Li-ion - you must use a Li-ion charge controller chip, and you need to provide it with appropriate temperature sensors. For home-made stuff you are best off with NiMH.

If you trickle charge NiMH (14-16 hours for full charge), then the only overcharge protection you need is a 24 hour cut-off. If you want to charge in less than that, then you need a dedicated charge controller chip, if you want to charge in less than 4 hours then you need temperature monitoring as well.

It situ-charging is very easy if you can ensure that the drive is powered off when you charge - many power sockets have a switch that is triggered by inserting the plug. If you want to be able to charge with the drive on, then that is more tricky, but not too difficult - the key is ensuring that you don't allow more than 5V to the drive (a simple low-dropout linear regulator will do nicely).

PM me if you want me to draw out a circuit diagram for you.
 

Mark R

Diamond Member
Oct 9, 1999
8,513
16
81
Li-ion and NiMH are much the same in terms of volume - potentially Li-ion may offer higher performance. Li-polymer maybe slighty better again.