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Lithium Ion Battery capacity increase help?

jerseykat1

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Not sure if this is the wrong section or not or maybe even just the wrong Forum all together. But You guys are smart as hell so im hoping someone can help me out here. The video explains it all.

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TheEquineFencer

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Right off the top of my head, I'd try a zener diode with the right voltage zener and see if you got the voltage you need out of the 20V L-Ion battery. You have what looks like an O-scope to check the output. It's been awhile since working with electronics, but that's what comes to mind.
 

theoldwizard1

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This could be easy or it could be hard.

If what you replace it with has to fit into the exact same size whole it might be difficult. What you have is 2 (or possibly 4) good sized lithium ion polymer (LiPo) cells. (Polymer refers to the fact that the battery is actually inside of a plastic POLYMER bag.) Finding an exact size replacement, with more capacity, will be difficult because there are no standardized sizes.

I could not tell if the charging electronics were inside that thing you were holding.

The only "standard" cell size is an 18650 (18mm X 65.0mm; slightly larger diameter and length of a AA battery). Each cell is 3.7V when it is fully charged and top quality cells are >3000mAh, so 4 (2 series, 2 parallel, 2s2p) would give you 6000 mAh, 50% more than what you have.

If you don't understand what I just wrote, then you don't want to be messing around with this stuff ! Hooked up wrong, it could explode/catch fire !!

Best place to buy your cells is eBay. Stick with Panasonic, LG, Samsung or Sony. Only buy from Japan, Hong Kong or US supplier. 4 should $30. If you have the space, make a 2s3p pack and get 9000mAh ! There are places that will build you what you want but of course it will cost you.
 
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jkeyser14

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This could be easy or it could be hard.

If what you replace it with has to fit into the exact same size whole it might be difficult. What you have is 2 (or possibly 4) good sized lithium ion polymer (LiPo) cells. (Polymer refers to the fact that the battery is actually inside of a plastic POLYMER bag.) Finding an exact size replacement, with more capacity, will be difficult because there are no standardized sizes.

I could not tell if the charging electronics were inside that thing you were holding.

The only "standard" cell size is an 18650 (18mm X 65.0mm; slightly larger diameter and length of a AA battery). Each cell is 3.7V when it is fully charged and top quality cells are >3000mAh, so 4 (2 series, 2 parallel, 2s2p) would give you 6000 mAh, 50% more than what you have.

If you don't understand what I just wrote, then you don't want to be messing around with this stuff ! Hooked up wrong, it could explode/catch fire !!

Best place to buy your cells is eBay. Stick with Panasonic, LG, Samsung or Sony. Only buy from Japan, Hong Kong or US supplier.

You have some misinformation... 18650's are 4.2v full charged, 3.7v @ nominal charge, and the low voltage cutoff is model dependent, but is generally between 2.8v-3.2v. Currently best available capacity in a commercially available cell is 3500 mah.

I agree with you on how dangerous this is. To anyone who is thinking about trying to make a pack on your own, this is very dangerous. You need a properly engineered battery management system to control the charge and dischage rates and provide protection. Failure to do so will most likely result in an extremely dangerous fire with gases violently venting from the cells at 1500+ degrees farenheight.
 

dogdog

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..... some how I feel like baited... (the chump have an oscilloscope and ask this question)
short answer is NO.... long answer maybe .... probably some better way if you just get a dc-dc converter from ebay to charge your existing LiPo battery... convert it down to 8.4v to charge them.... or what ever volt needed to run your oscilloscope. ALl you have to do is come up with a base to house your Dewalt battery or what ever battery..

I think other than the battery chemistry is different LIPO and LI=Ion...the one in your oscilloscope have 2 cells each of 3.7-ishv have it's own charge controller ( that little circuit board).... if you hack out the power tool the cells are usually 18650, usually they don't have charge controller and arranged in either series for 5 cell or series-parallel for higher capacity modules. Probably for that 5AH battery a 2x 2500mah cells are in parallel then 5 set of that in series.... to get a 5AH capacity....

Even if you hack it out and rearrange it for yours 5x in parallel and 2x of that set in series to get that 7.4v, you'll still have to find a 2 cell charge controller (the one in your dewalt battery pack is a 5 cell charge controller).... some newer 18650 cells comes with a build in charge controller,... but mostly likely not the cells from the power tools you scavenge.

http://batteryuniversity.com/learn/article/confusion_with_voltages


http://www.all-battery.com/protectivepcbsforli-ionandli-polymerbatterypacks.aspx

and yea disclaimers, read those other ppl's warning....
 
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jerseykat1

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This could be easy or it could be hard.

If what you replace it with has to fit into the exact same size whole it might be difficult. What you have is 2 (or possibly 4) good sized lithium ion polymer (LiPo) cells. (Polymer refers to the fact that the battery is actually inside of a plastic POLYMER bag.) Finding an exact size replacement, with more capacity, will be difficult because there are no standardized sizes.

I could not tell if the charging electronics were inside that thing you were holding.

The only "standard" cell size is an 18650 (18mm X 65.0mm; slightly larger diameter and length of a AA battery). Each cell is 3.7V when it is fully charged and top quality cells are >3000mAh, so 4 (2 series, 2 parallel, 2s2p) would give you 6000 mAh, 50% more than what you have.

If you don't understand what I just wrote, then you don't want to be messing around with this stuff ! Hooked up wrong, it could explode/catch fire !!

Best place to buy your cells is eBay. Stick with Panasonic, LG, Samsung or Sony. Only buy from Japan, Hong Kong or US supplier. 4 should $30. If you have the space, make a 2s3p pack and get 9000mAh ! There are places that will build you what you want but of course it will cost you.

i understand fully what your saying. the off brand dewalt battery has the controller electronics inside the pack. i believe i can fit 5 batteries in that same space..

Now its just a matter of finding a controller or a way to charge them safely??

I can probably put an external port on the battery housing and buy a charger that would handle my hack job battery pack.
 
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jerseykat1

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..... some how I feel like baited... (the chump have an oscilloscope and ask this question)
short answer is NO.... long answer maybe .... probably some better way if you just get a dc-dc converter from ebay to charge your existing LiPo battery... convert it down to 8.4v to charge them.... or what ever volt needed to run your oscilloscope. ALl you have to do is come up with a base to house your Dewalt battery or what ever battery..

I think other than the battery chemistry is different LIPO and LI=Ion...the one in your oscilloscope have 2 cells each of 3.7-ishv have it's own charge controller ( that little circuit board).... if you hack out the power tool the cells are usually 18650, usually they don't have charge controller and arranged in either series for 5 cell or series-parallel for higher capacity modules. Probably for that 5AH battery a 2x 2500mah cells are in parallel then 5 set of that in series.... to get a 5AH capacity....

Even if you hack it out and rearrange it for yours 5x in parallel and 2x of that set in series to get that 7.4v, you'll still have to find a 2 cell charge controller (the one in your dewalt battery pack is a 5 cell charge controller).... some newer 18650 cells comes with a build in charge controller,... but mostly likely not the cells from the power tools you scavenge.

http://batteryuniversity.com/learn/article/confusion_with_voltages


http://www.all-battery.com/protectivepcbsforli-ionandli-polymerbatterypacks.aspx

and yea disclaimers, read those other ppl's warning....

great information.thank you.
 
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jerseykat1

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You have some misinformation... 18650's are 4.2v full charged, 3.7v @ nominal charge, and the low voltage cutoff is model dependent, but is generally between 2.8v-3.2v. Currently best available capacity in a commercially available cell is 3500 mah.

I agree with you on how dangerous this is. To anyone who is thinking about trying to make a pack on your own, this is very dangerous. You need a properly engineered battery management system to control the charge and dischage rates and provide protection. Failure to do so will most likely result in an extremely dangerous fire with gases violently venting from the cells at 1500+ degrees farenheight.

building the pack isnt the dangerous part??? unless i directly short the pack im assuming.

It's the incorrectly charging part that can cause the damage?
 
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jerseykat1

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so it looks like i can squeeze 7 of those 18650 batteries into the housing.

Will my O-scope be able to keep track of the charge level of the battery? provided i find a charging solution for the pack.
 

theoldwizard1

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You have some misinformation... 18650's are 4.2v full charged, 3.7v @ nominal charge, and the low voltage cutoff is model dependent, but is generally between 2.8v-3.2v. Currently best available capacity in a commercially available cell is 3500 mah.
So do you think the LiPo cells in the original battery pack use some "other" magic chemistry and don't have the same voltages ? 2 cells in series would give 7.4V. The pack clearly says 7.4V.


The only "other" lithium chemistry is lithium iron phosphate (LiFePO4; aka LiFe) which has a nominal voltage of 3.2V. They are NOT interchangeable with either Li-Ion or LiPo.
 

theoldwizard1

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i understand fully what your saying. the off brand dewalt battery has the controller electronics inside the pack. i believe i can fit 5 batteries in that same space.
You need to use cells in pairs to get the proper voltage.

Now its just a matter of finding a controller or a way to charge them safely??

I can probably put an external port on the battery housing and buy a charger that would handle my hack job battery pack.
I assume there is a charger either built in to the device or external, Why not "use what you got" ?

"Adding on" to the existing pack (external parallel) will just cause that external pack to be sucked dry continuously trying to recharge the old original.

Do some more exploration of that original pack. Let's see what else is inside without destroying it.

A 4 cell 3500mAh would cost <$30 assuming you can solder it up. A 4 cell "flat" pack would measure 65mm thick X 260mm wide X 65mm high.

I am willing to bet, that DeWalt pack uses 18650 cells.



Gave up on your Amazon Fire/Lab Nation scope ? For that to be a real winner, you need the 10" version of the Fire $$$ and for LabNation to speed up the sample rate (250-500MS/s) and double or quadruple the stored waveforms
 
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jerseykat1

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You need to use cells in pairs to get the proper voltage.


I assume there is a charger either built in to the device or external, Why not "use what you got" ?

"Adding on" to the existing pack (external parallel) will just cause that external pack to be sucked dry continuously trying to recharge the old original.

Do some more exploration of that original pack. Let's see what else is inside without destroying it.

A 4 cell 3500mAh would cost <$30 assuming you can solder it up. A 4 cell "flat" pack would measure 65mm thick X 260mm wide X 65mm high.

I am willing to bet, that DeWalt pack uses 18650 cells.



Gave up on your Amazon Fire/Lab Nation scope ? For that to be a real winner, you need the 10" version of the Fire $$$ and for LabNation to speed up the sample rate (250-500MS/s) and double or quadruple the stored waveforms

Im sorry i didnt make myself very clear after i read what i wrote.

I already took apart the dewalt pack and yes it has 18650 cells, 10 of them to be exact.

I can fit 7 of those 18650 cells into the original housing of the oscilloscope battery pack.

The original O-scope battery pack has 2 flat lipo cells and what looks like a controller. i will post some pictures in the next post of the original battery packs electronics....

So what your saying is that i can use the electronics from the original battery pack with the 7 18650 cells that i took from the dewalt pack and charging will work the same way it's always worked on the o-scope. no need for another charging solution?
 

theoldwizard1

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so it looks like i can squeeze 7 of those 18650 batteries into the housing.
Forget odd numbers ! Too much pain.

Will my O-scope be able to keep track of the charge level of the battery? provided i find a charging solution for the pack.
The "best" chargers charge each cell (or cell wired in parallel) individually. There are good generic chargers out there (SKYRC 6BAC) that meet the requirement but they are >$50.
 
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theoldwizard1

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So what your saying is that i can use the electronics from the original battery pack with the 7 18650 cells that i took from the dewalt pack and charging will work the same way it's always worked on the o-scope. no need for another charging solution?

NO ! Forget odd numbers. Cut the batteries apart and solder them back together, 2 at a time in series. That will give you 7.4V. Now take as many if those pairs as will fit into the space of the original LiPo and wire them in parallel.

You can reuse the original charger (controller board).

Will you have a net longer run time time (more power). Maybe. Any marking on the DeWalt cells ? What was the mAh rating of that pack ?

I keep recommending new cells because the Li-Ion battery technology has made HUGE GAINS in the past 5 years or so. Typical 18650 cells have gone from <2000mAh to >3500mAh without significant cost increase.
 
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jerseykat1

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Gave up on your Amazon Fire/Lab Nation scope ? For that to be a real winner, you need the 10" version of the Fire $$$ and for LabNation to speed up the sample rate (250-500MS/s) and double or quadruple the stored waveforms

i still have it, and i have a competent tablet now. But they wont add the ability to use inductive current clamp probes into the probe list. For my needs i believe the speed of the scope will do. But my OWON has the ability to customize the settings for using current probes. They realize that people actually use current measuring probes and allow you to plug in your probes settings and save them.

Labnation thinks you only meaure voltage or that you want to constantly be trying to do the math of converting the voltage readings to amperage (current clamps produce xxmv = xamp).. I cant imagine it would be very difficult to do since it's just a matter of software changes. Im not a coder though so i could be wrong.. If they make that adjustment to there software i would have no problem using there scope the software and touch UI is pretty good just lacking some features.

Anyhow i like the OWON a lot because it gives good detail and the knobs are super easy to get things dialed in (see what i did there lol).. Just wish the battery lasted a longer.
 
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jerseykat1

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NO ! Forget odd numbers. Cut the batteries apart and solder them back together, 2 at a time in series. That will give you 7.4V. Now take as many if those pairs as will fit into the space of the original LiPo and wire them in parallel.

You can reuse the original charger (controller board).

Will you have a net longer run time time (more power). Maybe. Any marking on the DeWalt cells ? What was the mAh rating of that pack ?

I keep recommending new cells because the Li-Ion battery technology has made HUGE GAINS in the past 5 years or so. Typical 18650 cells have gone from <2000mAh to >3500mAh without significant cost increase.

the entire 20v dewalt pack is rated at 5 amp hours.

from the 18650 cell "li-ion 18650HP-C 16E 3.7v"

I dont see anywhere that lists the amperage rating on the individual cell. ill try googling it.
 
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jerseykat1

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so in theory lets just say i have really crappy 18650 cells that only have 1500mah each 6 of them should net me 9000mah vs the stock 4000mah battery pack. but if i purchased some newer higher capacity 18650 cells i could get 21000mah of capacity?

that would be Amazing.
 

jkeyser14

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building the pack isnt the dangerous part??? unless i directly short the pack im assuming.

It's the incorrectly charging part that can cause the damage?

Quality brand name cells have built in PTC's which kill the output completely if you accidentally short them. As long as you use a proper tab welder and don't try to hand solder them you will likely not harm anything putting together a low voltage pack. Where the batteries tend to fail catastrophically is from improper charging or repeatedly discharging at a rate higher than their manufacturer's rating.

Edit: I also forgot to mention that all of the cells need to be balanced before building your pack. If they are not, you can send hundreds of amps from one cell to another the second you connect them to each other.
 
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jkeyser14

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Im sorry i didnt make myself very clear after i read what i wrote.

I already took apart the dewalt pack and yes it has 18650 cells, 10 of them to be exact.

So what your saying is that i can use the electronics from the original battery pack with the 7 18650 cells that i took from the dewalt pack and charging will work the same way it's always worked on the o-scope. no need for another charging solution?

No, the electronics in the Dewalt pack are meant to charge and balance 10 cells in a certain series/parallel connection. The second you go with a different number of cells or different series parallel connection the electronics will no longer be compatible.
 

theoldwizard1

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so in theory lets just say i have really crappy 18650 cells that only have 1500mah each 6 of them should net me 9000mah vs the stock 4000mah battery pack. but if i purchased some newer higher capacity 18650 cells i could get 21000mah of capacity?

Battery pack "capacity" is not straight "addition". First you have to get up to your "nominal" working voltage (7.4V) by hooking batteries in series. BATTERIES IN SERIES DO NOT INCREASE THE CAPACITY OF THE PACK !

A 2s3p (2 in series, the 3 of those pairs in parallel) would give you a 7.4V @ (assuming 2500 mAh/cell) 7.5Ah.

I hope I am making sense.
 

theoldwizard1

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No, the electronics in the Dewalt pack are meant to charge and balance 10 cells in a certain series/parallel connection. The second you go with a different number of cells or different series parallel connection the electronics will no longer be compatible.

True. But is the charge balancing circuitry in the DeWalt battery pack or in the charger ?

On an M12 packeacj individual cell positive connector is brought out so the the "smarts" in the charger can balance them.
 

theoldwizard1

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Labnation thinks you only measure voltage or that you want to constantly be trying to do the math of converting the voltage readings to amperage (current clamps produce xxmv = xamp).. I cant imagine it would be very difficult to do since it's just a matter of software changes.
I really want to see someone come in and KICK PICO'S **** !

The Pico Auto Scope uses ancient, slow hardware. Yes the software looks (including ranging for the various inputs) is nice, but not that nice ! And theie probes and add-ons are ridiculous.

LabNation clearly does not see the automotive marketplace.
 
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jerseykat1

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I really want to see someone come in and KICK PICO'S **** !

The Pico Auto Scope uses ancient, slow hardware. Yes the software looks (including ranging for the various inputs) is nice, but not that nice ! And theie probes and add-ons are ridiculous.

LabNation clearly does not see the automotive marketplace.

I just need something that is convenient and portable. Pico is nice and i do agree it is way overpriced from a hardware standpoint. But i think they are more so selling you on the software, with the free updates for life, but at the same time there addons as you mention are very expensive.

There really isnt an option that provides everything at a reasonable price.
 
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jerseykat1

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The operation was a success. It's charging now. Hopefully it doesn't blow up.. Lol.. I did as suggested by theoldwizard1. put 3 cells in parallel, 3 more in parallel, then put the 2 banks of 3 cells in series to get my 7.4v... Hooked up the original electronics the same way it was connected on the original battery.

Thanks for the help. Very much appreciated.

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6PTsocket

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You have some misinformation... 18650's are 4.2v full charged, 3.7v @ nominal charge, and the low voltage cutoff is model dependent, but is generally between 2.8v-3.2v. Currently best available capacity in a commercially available cell is 3500 mah.

I agree with you on how dangerous this is. To anyone who is thinking about trying to make a pack on your own, this is very dangerous. You need a properly engineered battery management system to control the charge and dischage rates and provide protection. Failure to do so will most likely result in an extremely dangerous fire with gases violently venting from the cells at 1500+ degrees farenheight.
If you look at the discharge curve, it comes off that 4.2 volt peak charge really quick so they are normally sold as 3.7 volt cells, where the voltage stays through most of the discharge. However it has not stopped tool manufacturers from using it to exaggerate their battery voltage. When I got a Bosch compact impact driver it had a 10.9 volt battery Under pressure from competitors they had to start selling the same battery as 12 volts, like the other guys. In Europe, with stricter regulations, it is still 10.9 volts.

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