16 Cell 18650 Charger/Discharger Board Module

nz_lifer

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3 Days from China to New Zealand, WTH! :ninja:
More info to follow.
 

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nz_lifer

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Aug 26, 2020
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Resolved a few PCB mistakes. 10x so far.
Nothing some drilling and jumper wire didn't fix :)

I2C MUX and ADC tested ok.
Shift registers ok.

20210207_161646.jpg

Next to populate and test further.
I am sure there will be some more minor fixes required before completion.

I will change the resistors on the green LEDs.
They are about double the brightness of the red and yellow. A little bit distracting.

Add a few more LEDs to indicate power and data activity.
 

nz_lifer

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Aug 26, 2020
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Revised code enough to verify sensors.
Voltage and temperature looks good.
Voltage does not seem to be jumping around like before, +-3mV. Maybe that will change once I get some live cells in there.
Current measurement is mostly good.
Slots 1-8 match up with what the meter says. 2.2mV across sense resistor at 50mA.
Slots 9-16 read 2.8-3.6mV. They do all measure the same with multimeter.
Can not see anything obvious issues with the track layout. But then again I am no EE :(
 

Oleksii

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Mar 18, 2020
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Advise - implement possibility to "per slot" software adjustment of readings, where user can set +-%.
 

nz_lifer

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Aug 26, 2020
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Advise - implement possibility to "per slot" software adjustment of readings, where user can set +-%.
As long as the offset is liner across the range this would work.
Would still be nice to get to the bottom of the issue.
We could just be hitting the noise floor of the Analog MUX?
 
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Bubba

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May 9, 2018
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292
Revised code enough to verify sensors.
Voltage and temperature looks good.
Voltage does not seem to be jumping around like before, +-3mV. Maybe that will change once I get some live cells in there.
Current measurement is mostly good.
Slots 1-8 match up with what the meter says. 2.2mV across sense resistor at 50mA.
Slots 9-16 read 2.8-3.6mV. They do all measure the same with multimeter.
Can not see anything obvious issues with the track layout. But then again I am no EE :(
Are the distances of the leads all the same? Do you have a 4-Wire IR tester? Check the connections between the chips to be sure that that's not contributing. Using a MUX could certainly introduce the variance. I haven't used them much. You could short each mux pin and apply the same voltage to determine how each input responds and check it's linearity.
 

sigdigits

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Feb 20, 2021
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Found myself with the need to discharge/capacity test a lot of cells. Definitely interested in this, and wondering about costs/availability.
 

nz_lifer

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Aug 26, 2020
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Are the distances of the leads all the same? Do you have a 4-Wire IR tester? Check the connections between the chips to be sure that that's not contributing. Using a MUX could certainly introduce the variance. I haven't used them much. You could short each mux pin and apply the same voltage to determine how each input responds and check it's linearity.
Distances are not all equal.
Voltages across the sense resistors are the same. So it is a loss across the pcb traces.
Which I was hoping was not going to happen as it should be a no load path back to the adc. EE fail :(
Maybe I need to add a resistor to make sure it is a no load path?
I do have a 4wire tester but do not want to scrape the solder mask to enable testing at this stage.

I checked mux input and output and it seems to not affect the signal.
I will do further testing across the range and see if this offset is linear.
If it is we can adjust for it in software.

I would like to migrate to using a ESP8266 for the controller.

Testing is ongoing, getting close to going live.
First run will be a charge only so the cells can rest.
Give us time to tune the discharge programming

I think I have caught 90% of the hardware bugs.

20210221_144647.jpg

Found myself with the need to discharge/capacity test a lot of cells. Definitely interested in this, and wondering about costs/availability.

Cost.
Depends on your choice of cell holders and power supply.
Let's assume if you are going this route you want as many slots as you can.
JLCPCB has a minimum 5 board order, giving you 80 slots.
Note not all of the ordered PCB need to be populated so you can save a few dollars by having only 4 boards with components on them.
But the major cost is setup and shipping so not really worth it to not populate all boards.

Costing below for least labour intensive smd holder option.
us$
18 Controller. Arduino Mega as code is not currently not optimised.
189 5x populated boards (153 order + 36 shipping)
40 80 x single smd holders
40 80 x tp5100
30 160 x 5w resistors. Use two to keep them below 50% of their rating. Less accidental burn risk.
----
317

Allow for a 400w (12v 34A) power supply. 5w * 80.
A few hours to put everything together.
.Solder on cell holders
.wire board data interlinks.
.wire board power interlinks

For comparison a MCC currently goes for us$180 + shipping.



Availability
The hardware is open source. Current posted revision has some bugs.
Can order your own set from JLCPCB.
My software will be open source too. Although someone else might write a better closed source software for it.
 

nz_lifer

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Aug 26, 2020
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Some juicy data to look at.

Starting charge voltage 3.6v
Reported voltage from sense resistor x100 to get on same area.
Charge terminated at 2.32 mV, 58mA.
Sense voltage during CC phase jumps between 38-55mV.
Will have to put a scope on to see why that is. Seems to settle down during the CV phase.
Not sure what the two steps in the Amps plot is before termination.

CHarge_run_s8.PNGCHarge_run_s8-excell.PNG
 

nz_lifer

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Aug 26, 2020
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Plot for float.
This TP5100 board terminated charge at 4.150v

1613979814067.png

Next steps
-Calibrate offsets for voltage and current measurements.
-Update code to use Current as trigger to switch from end of charge to float. And cycle termination.

Using the led output of the TP5100 modules was no good. Too much noise?
I could add a RC filter. Would have to be for each channel.
Will need to check it with a scope. Will leave for now as the current sense should be just as good.
Also one less thing to solder during assembly.
 
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