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Self made simple battery discharge instrument

Author: Yang Jinliang

Electronic enthusiasts often need to use false loads when debugging equipment or repairing batteries. This discharge device can input a voltage of 3 to 60V, with a maximum discharge current of 10A. Due to the small number of components, debugging is easy, and it is suitable for beginners to choose.

Required materials: one piece of iron sheet, one D412-5 meter head, one 2KW electric furnace disc and one electric furnace wire each, one 10A switch, one 2-speed single pole conversion switch, one 60V indicator light, one 1-megaohm adjustable resistor, three crocodile clamps (two in red and one in black), and two meters of 2.5 square sheath wire (one in red and one in black).

Production: Connect according to the diagram below. The tap sizes for electric furnace wires are 1.2, 2.4, 3.6, 4.8, 5.2, 10, and 12 ohms, respectively. The splitter can be wrapped with 1 square millimeter enameled wire on its own, and its required length is determined by the actual current measured with a multimeter and the position of the meter head swing. The voltage indication is not accurate, and the 1 megaohm resistor can be adjusted.

First, remove the battery, solder down the connecting wire, and wipe it clean with a cloth. Next, open the cover. Each battery has an exhaust hole, which is usually located on the edge of the cover. If you see a gap, it is for exhaust. Align the flat screwdriver with the gap, tap the screwdriver with your hand, and let the screwdriver head enter the exhaust hole. Then, tilt it upwards, Then continue to take photos inside (the small battery should be taken in the middle of the upper cover because the opening inside is on both sides of the exhaust hole, but the electric motorcycle battery needs to be taken photos in the middle because the opening inside is in the middle, so as not to damage the rubber cap inside), then lift it up a few more times, and the battery cover can be lifted down, don't be too rough.

Method and steps for adding distilled water to electric vehicle batteries

After opening the lid, you will find 6 hats, but at this point, there may be a few rubber hats flying off with a "bouncing" sound. Therefore, when opening the lid, do not take it off at once, slowly remove it, and cover it with your hand to prevent the rubber caps from flying off, because there may be a high pressure inside the battery at this time. Be careful to remove the rubber cap. The white one is absorbent cotton, so you can leave it on.

Next, you can add 7ml of water to each hole (12ml for the electric motorcycle battery). (If you don't have any replenishment solution, buy a bottle of distilled water from the supermarket and remember it's not electrolyte) Follow the order to avoid any mistakes.

After adding water, you can cover it with a rubber cap. The absorbent cotton should also be restored to its original state. Once it is done, you can cover it with a rubber cap. However, wait and see the next step.

After adding water, you can cover it with a rubber cap. The absorbent cotton should also be restored to its original state. Once it is done, you can cover it with a rubber cap. However, wait and see the next step.

Dip a small screwdriver in some PVC glue, apply a few drops of glue on the lid and battery, and then you can cover it. Don't use too much glue, so it won't be difficult to open next time, and if too much, it may flow onto the rubber cap. This seals the rubber cap, which is supposed to vent but cannot be vented.

After adding water, it is best to let it stand still for 24 hours before charging. If you are in a hurry to use the car the next morning, you can also charge it immediately. If you are not in a hurry to use the car, then wait for one night before charging. This can better absorb the water, and the electrolyte concentration in various positions inside the battery is consistent

The battery is under warranty, or it can automatically turn green when charging. It is not recommended to add water

What I am sharing here is a generator made using an electric scooter motor. As long as you love to use your brain and hands, making it is a very simple thing. The rear wheel of an electric scooter is the generator.

How to use electric scooter motors to make generators

I will first share the production process in the form of a model. The actual production is also similar. Replace the bracket with a wooden frame. As shown in the figure, make two fulcrums with wooden boards that are larger than the radius of the tire, and then connect the two wooden boards with a board of the same thickness as the wheel.

Saw a groove in the middle position of the wooden board bracket. Then place the rear wheel of the electric scooter in the groove.

Then use two angle irons, one on top and one on bottom, and connect them with screws. Two angle irons hold the wheel axle tightly.

Fix the lower angle iron with screws again to prevent any changes in the position of the shaft.

Turning the wheel by hand allows for flexible rotation. And the bracket should be stable and sturdy.

Electric vehicle batteries are the source of power for electric vehicles. The vast majority of electric vehicles nowadays are equipped with lead-acid batteries, which have low costs and high cost-effectiveness. Because this type of battery can be charged and reused, it is called a "lead-acid battery".

In 1860, France's Prandtl invented a battery using lead as the electrode, which was the predecessor of lead-acid batteries.

There are four types of power batteries that can be used by electric bicycles, namely valve regulated lead-acid maintenance free batteries, colloidal lead-acid batteries, nickel hydrogen batteries, and lithium-ion batteries.

lead-acid battery

Lead acid batteries are widely adopted and researched by various electric vehicles in various countries due to their low price, abundant material sources, high specific power, mature technology and manufacturing process, and high resource recovery rate. Electric bicycles, as labor-saving, convenient, fast, comfortable, affordable, and zero emission personal transportation tools, have been widely accepted and valued by relevant national departments. The research group on the development strategy of the light electric vehicle industry, participated by the Development Research Center of the State Council, the National Development and Reform Commission, the Ministry of Construction, the Ministry of Science and Technology, and other ministries, has proposed a report on the development strategy of the light electric vehicle industry. The national ownership of electric bicycles has exceeded 30 million. More than 95% of electric bicycles use valve regulated lead-acid batteries. [1]

The vast majority of commercialized electric bicycles use sealed lead-acid batteries, which do not require frequent water replenishment during use and are maintenance free. The main chemical reaction is: PbO2+2H2SO4+Pb ← charging and discharging → 2PbSO4+2H2O

When a lead-acid battery is charged, the sponge like lead that turns into the anode and cathode of lead sulfate releases the sulfuric acid components fixed in it into the electrolyte, respectively becoming sponge like lead and lead oxide. The concentration of sulfuric acid in the electrolyte continuously increases; On the contrary, during discharge, the lead oxide in the anode and the sponge like lead on the cathode plate react with sulfuric acid in the electrolyte to form lead sulfate, while the concentration of sulfuric acid in the electrolyte continuously decreases. When the lead-acid battery is not fully charged, the lead sulfate in the anode and cathode plates cannot be completely converted into sponge like lead and lead oxide. If the charging is insufficient for a long time, it will cause lead sulfate crystallization, causing the plates to vulcanize and the battery quality to deteriorate; On the contrary, if the battery is overcharged, the amount of oxygen produced by the anode is greater than the adsorption capacity of the cathode, which increases the internal pressure of the battery, causes gas leakage, reduces the electrolyte, and may also lead to the softening or detachment of active substances, greatly shortening the battery life.

Significant improvement in overall performance

In the past decade, the comprehensive performance of valve regulated lead-acid batteries for electric bicycles has greatly improved. Taking the 6-DZM-10 battery as an example. In 1997, this type of battery had insufficient capacity, with a 2-hour rate (5A) discharge capacity of less than 10Ah; Low specific energy, with a 2-hour rate of less than 30Wh/kg specific energy; Short lifespan, with a cycle life of only 50-60 cycles at 100% discharge depth (capacity reduced to before 8Ah; the same below), and a service life of only 3-5 months.

By 2003, the 2-hour rate (5A) discharge capacity had reached 11-13Ah; The specific energy of the 2-hour rate reaches 33-36Wh/kg; The cycle life of 100% discharge depth can reach 250-300 times, and the service life can reach more than 12 months. The problems with valve regulated lead-acid batteries for electric bicycles have been basically solved.

The deep cycle life performance of this type of battery has made new and breakthrough progress. The main performance is that the initial discharge capacity reaches 14Ah at a 2-hour rate (5A); The specific energy of the 2-hour rate reaches 38Wh/kg; The cycle life of 100% discharge depth exceeds 400 times, with a total discharge capacity of 4500Ah and a corresponding cumulative driving distance of about 18000km (calculated as 4km/Ah, the same below). The highest deep cycle life exceeds 600 cycles, with a total capacity of 6151Ah and a corresponding cumulative driving distance of approximately 24600km. If the capacity is less than 7Ah as the end of life mark, the deep cycle life is 943 cycles, and the total released capacity is 8710Ah, with a corresponding cumulative driving distance of about 34800km. If the battery pack has a deep cycle life of 250 cycles or a total capacity of 2250Ah and a corresponding cumulative driving distance of 9000km, it can be guaranteed to be used for 1 year. [1]

Pay attention to matching with chargers

Over the years of practical use, both vehicle manufacturers and battery manufacturers of electric bicycles have gradually recognized the importance of matching batteries with equipment related to electric drive systems, especially with chargers. Manufacturing quality is a prerequisite for the quality of batteries, but only when used in conjunction with a matching charger can high-quality batteries achieve their expected superior performance. Otherwise, high-quality batteries cannot fully utilize their potential superior performance. [1]

The appropriate charging parameters for batteries from different manufacturers vary due to differences in formula, structure, acid concentration, and other aspects. For example, in our research, we found that the charging parameters of batteries from different manufacturers can differ by 1.5-2.0V during the constant voltage stage (for 36V battery packs). The basic requirement for appropriate charging parameters is to ensure that the battery can be fully charged and will not experience abnormal capacity degradation due to under charging; It is also necessary to ensure that the battery does not experience severe dehydration and thermal runaway due to overcharging throughout its entire lifespan. [1]

Lead acid batteries for pure electric vehicles

The open-end lead-acid batteries used in early pure electric vehicles adopted research results from the "Eighth Five Year Plan" period, and have achieved successful experience in 19 months (120000 kilometers) of use. The key is to accumulate work experience and meticulous maintenance experience in controlling the charging method, discharging depth, timely water replenishment, and other system matching. In recent years, the development of four wheeled micro electric vehicles (including tour buses, patrol cars, golf carts, short distance road vehicles, etc.) has been rapid, and most of the vehicles are equipped with open-ended lead-acid batteries. The corresponding model of battery is favored by battery manufacturers. [1]

The electric vehicle adopts a new product of valve controlled sealed lead-acid battery, which has the following performance: 3-hour rate capacity of 55Ah; The specific energy at a 3-hour rate is 33Wh/kg and 84Wh/L; The cycle life of 75% discharge depth reaches over 400 times. I believe that the successful experience of valve regulated lead acid batteries used in electric bicycles can be extended to valve regulated lead acid batteries used in pure electric vehicles, and their performance will be further improved. [1]

Lead acid batteries for hybrid electric vehicles

Nowadays, hybrid electric vehicles are basically divided into three categories: mild hybrid (i.e. the electric system is mainly used for starting and recovering braking energy, and the 42V electric system that will be promoted in all vehicles belongs to this type), moderate hybrid (i.e. the electric system is used for starting, recovering braking energy, and medium to short distance driving), and heavy hybrid (i.e. the electric system is used for starting, recovering braking energy, and long-distance driving, also known as "Plug in"). [1]

It has been clearly stated in domestic and foreign literature that valve regulated lead-acid batteries have advantages in mild hybrid electric vehicles, mainly due to their low cost, mature technology, and reliable performance; ALABC (Advanced Lead Acid Battery Consortium) is organizing research and development to compete with MH-Ni batteries for the market of medium hybrid electric vehicles. It has launched and conducted in vehicle testing of coiled bipolar ear batteries and TMF (Metal Thin Film) batteries; In the field of heavy-duty hybrid electric vehicles, lead-acid batteries have low specific energy and cannot meet the requirements of electric systems for long-distance driving. [1]

Colloidal battery

It is an improvement on ordinary lead-acid batteries with liquid electrolytes. It adopts gel shaped electrolyte, and there is no free liquid inside. Under the same volume, the electrolyte has large capacity, large heat capacity, and strong heat dissipation ability, which can avoid the thermal runaway phenomenon easily produced by ordinary batteries; Low electrolyte concentration leads to weak corrosion of the electrode plate; The concentration is uniform and there is no phenomenon of acid stratification.

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