Author Topic: How I made a 12volt NiCad battery pack  (Read 4009 times)

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Norm

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How I made a 12volt NiCad battery pack
« on: July 26, 2009, 08:51:40 PM »
  First of all the basic package:





taking the yellow wrapper off, then cutting

everything loose you're left with these three

sticks and the spot welded tabs that the wires

were attached to.

   Each stick is 6 volts, the two sticks to your

right are in series makig 12 volts at the other

end. The one to your left is to be removed....

   The easiest way to do this is to stick it in

freezer for about an hour. It will seperate from

the others quite easily and taking a table knife

will strip the excess glue strips.

 



Leaving you with like in the orange hi-lighted,

after you have done another one like this,

you will have 2 double sticks and 2 single sticks,

Now if you work it right the tabs on a positve

terminal and the negative shell will be long

enough to overlap and be soldered making this

also a 12volt.

The bottom view of the soldered tabs will look

like the 2 yellow sticks in bottom view.

  Now you have 3 double sticks...arange them so

they look like bottom view (positive at bottom

negative at top) and glue them all together with

hot glue...not guaranteed that they will stay

together so we wrap strapping tape around...top

and bottom....the tape holds them together and

the glue keeps them from shifting.

  Flipping them so we have top view, they then

have soldered 14 guage wire soldered to the tabs

....paralleling the 3 12 volt sticks making a

12 volt 3.9 amp/hr unit.

Leaving a little wire sticking over like in

hi-lighted green view....then you stack a few of

these units with the positive wires on one side

and the negative wires on the other side, you

can then solder a buss-wire onto them to parallel

the units......maybe 12 guage will be heavy enough.

  Making a box with 1/2 inch plywood for ends and

bottom of the box and clipboard or 1/4 inch

plywood for the sides....I used clipboards cause

they were easier to get at Walmarts than plywood

at Lowes....

  ....a nice carrying strap glued and screwed to

the ends and I wound up with this....






(Oh Yes and notched ends at diagonal opposite

corners for the terminal bolts)

« Last Edit: July 26, 2009, 08:51:40 PM by (unknown) »

zeusmorg

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Re: How I made a 12volt NiCad battery pack
« Reply #1 on: July 26, 2009, 03:34:01 PM »
 Decent looking build, Norm.
« Last Edit: July 26, 2009, 03:34:01 PM by zeusmorg »

ghurd

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Re: How I made a 12volt NiCad battery pack
« Reply #2 on: July 26, 2009, 07:56:55 PM »
Wow Norm...

That is a serious battery for a... ???

What are you putting that on?

G-
« Last Edit: July 26, 2009, 07:56:55 PM by ghurd »
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Norm

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Re: How I made a 12volt NiCad battery pack
« Reply #3 on: July 26, 2009, 08:37:14 PM »
Ghurd:

 that's 1 of 4 to go on the trike a 3 wheeler

48 volt riding mower and runabout....I'm pretty

sure it will work ...at least to run around in the yard??
« Last Edit: July 26, 2009, 08:37:14 PM by Norm »

Bruce S

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Re: How I made a 12volt NiCad battery pack
« Reply #4 on: July 27, 2009, 08:16:29 AM »
Norm;

  Nice write up. I like the idea of keeping the terminal posts far apart from each other. 12Vdc w/19.5 Ahrs could bite someone quick!!


I'm looking forward to seeing the other boxes built up. I'm betting the 48V at 19Ahrs will move you around the yard more than just a little :-().


Do you plan on having a different 12V set for running lights and radio?


Oh!! Hows the repaint on the trike coming along?


Bruce S

« Last Edit: July 27, 2009, 08:16:29 AM by Bruce S »
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zap

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Re: How I made a 12volt NiCad battery pack
« Reply #5 on: July 27, 2009, 09:10:11 AM »
Nice work Norm... nice looking packs... and I love the straps!

« Last Edit: July 27, 2009, 09:10:11 AM by zap »

Norm

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Re: How I made a 12volt NiCad battery pack
« Reply #6 on: July 27, 2009, 06:37:16 PM »
  Been very busy today fixing the weedwacker to

run on powerpak tried 48 volts think it'll need

72 ( that's 4 18volt paks in series with thermistors

removed and tapped in at each 18volts for charging

...and it will need some small wheels....but then

again 36 volts and a sharp metal tip  blade would be

better than string??

besides generating 40 watts and running Grandson

over to some birthday party and mowing the

daughter's lawn that is almost getting away from me

with the rain we have been having Whew !

I just now had time to think

about painting the bike frame....as soon as I

finish the light sanding then ready to prime !

« Last Edit: July 27, 2009, 06:37:16 PM by Norm »

Norm

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Re: How I made a 12volt NiCad battery pack
« Reply #7 on: July 27, 2009, 06:45:00 PM »
Yes Zap....these are what I've been busy pedaling

to keep charged up and running down with the

weedwacker motor....research....Fun ! How's the

aching back coming along LOL !
« Last Edit: July 27, 2009, 06:45:00 PM by Norm »

richhagen

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Re: How I made a 12volt NiCad battery pack
« Reply #8 on: July 27, 2009, 07:51:20 PM »
Bruce was kind enough to send be a few of those 'Bruce Packs'.  I am planning to do something a bit similar, and a bit smaller, I will consider the freezing method for getting them apart.  Thanks for the writeup.  Rich
« Last Edit: July 27, 2009, 07:51:20 PM by richhagen »
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Norm

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Re: How I made a 12volt NiCad battery pack
« Reply #9 on: July 27, 2009, 09:00:59 PM »
Yes the freezing method is the best and easiest

way....You'll be amazed at how easily they come

apart...glad to be of help, Rich

Enjoyed a lot of your write ups also.

 
« Last Edit: July 27, 2009, 09:00:59 PM by Norm »

Bruce S

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Re: How I made a 12volt NiCad battery pack
« Reply #10 on: July 28, 2009, 08:35:13 AM »
Rich,

Once you decide let me know if I can help w/ more.

I'd like to see how long one of your famous lights would last on a pack.

I built the one you sent and lit it up in my office and was asked to disconnect after the cleaning crew said it was disturbing to see the light on all the time.

It stayed lit for days :-D


Cheers;

Bruce S

« Last Edit: July 28, 2009, 08:35:13 AM by Bruce S »
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Ungrounded Lightning Rod

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Re: How I made a 12volt NiCad battery pack
« Reply #11 on: July 28, 2009, 08:00:03 PM »
Did I miss where you told us where/how the batteries are obtained?
« Last Edit: July 28, 2009, 08:00:03 PM by Ungrounded Lightning Rod »

Norm

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Re: How I made a 12volt NiCad battery pack
« Reply #12 on: July 28, 2009, 09:27:44 PM »
Bruce S has offered these particular type of

batteries on the forum at various times they are

18 volt packages.
« Last Edit: July 28, 2009, 09:27:44 PM by Norm »

Bruce S

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Re: How I made a 12volt NiCad battery pack
« Reply #13 on: July 29, 2009, 07:20:11 AM »
And Norm has gotten so good at re-purpose(ing) them I think a rename of them is in order. Instead of Bruce packs (name given by NTL some 2 - 3 years ago) the rebuilt ones should now be called Norm sticks.


Norm, Speach Speach !!! :-D


Cheers

Bruce S

« Last Edit: July 29, 2009, 07:20:11 AM by Bruce S »
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Norm

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Re: How I made a 12volt NiCad battery pack
« Reply #14 on: July 29, 2009, 09:37:01 AM »
Norm sticks ...Huh?

Aw Shucks....twer'nt nothing.

Always looking for the best and easiest way to do

things with what's available.

Well back to the battery boxes....second one ready

to assemble after I have my second cup of coffee.
« Last Edit: July 29, 2009, 09:37:01 AM by Norm »

ghurd

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Re: How I made a 12volt NiCad battery pack
« Reply #15 on: July 29, 2009, 10:48:01 AM »
Send cup of coffee?  At Noon?

Never going to collect more coffee

cans at that rate.


Gosh Norm...

I am on my second 12-cup POT.


One more cup and I could hand sand

a motor rotor for neo installation!  ;)

G-

« Last Edit: July 29, 2009, 10:48:01 AM by ghurd »
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Norm

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Re: How I made a 12volt NiCad battery pack
« Reply #16 on: July 29, 2009, 11:39:11 AM »
At my last job most of us worked 10 minutes every half-hour.

20 minutes break every half-hour. That gave me enough

time for sipping one cup of coffee and 2 cigaettes and if I was in the mood to smoke,

light up another on the way to my group of cells.

.....so after 22 years of that I retired and

started thinking of quitting smoking.

  Coffee pot was always there at work....at home

my wife made the first pot...I would have to make

the 2nd or 3rd.

  When I did quit smoking....coffee didn't seem

to go as well without a cigarette....altho'

when I substituted pretzel sticks for the

cigarettes, I could dunk them in my coffee !

( try that with a cigarette !)

and you thought you had problems....LOL !  
« Last Edit: July 29, 2009, 11:39:11 AM by Norm »

Bruce S

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Re: How I made a 12volt NiCad battery pack
« Reply #17 on: July 30, 2009, 07:06:52 AM »
ME too!

2nd cup is with me on the drive to work. I don't measure amount of coffee by cups it's by pots.

Doc asked me about slowing down on coffee, I asked him what his learned opinion of my health was. He said looks good so I said why mess with a good thing?

He just laughed.


at 52 I can still work 16 hour days and make it in to work by 7:30.

I'll keep the coffee :-)cheaper than booze :-()


Cheers

Bruce S

« Last Edit: July 30, 2009, 07:06:52 AM by Bruce S »
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Airstream

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Re: How I made a 12volt NiCad battery pack
« Reply #18 on: July 30, 2009, 10:35:33 AM »
but if its 16 hours to do 8 hours work...


Nawsir, just kidding.  Good attitude BS, err... Bruce S.!

« Last Edit: July 30, 2009, 10:35:33 AM by Airstream »

Norm

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Re: How I made a 12volt NiCad battery pack
« Reply #19 on: July 30, 2009, 11:21:36 AM »
Well....when it's so strong you can chew it...

2 cups will last you all day...LOL !
« Last Edit: July 30, 2009, 11:21:36 AM by Norm »

Bruce S

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Re: How I made a 12volt NiCad battery pack
« Reply #20 on: July 30, 2009, 01:59:11 PM »
Ohhh too funny :-) was soooo funny had to get another cup :-().


Cheers;

Bruce S

« Last Edit: July 30, 2009, 01:59:11 PM by Bruce S »
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Bruce S

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Re: How I made a 12volt NiCad battery pack
« Reply #21 on: July 30, 2009, 02:08:33 PM »
Norm;

 Now that's real coffee. Go ole ARMY boiled stuff!! While "visiting" in S.Korea , that's how we made it by the gallons.

Come back stateside and the stuff was like water.


Back to the Post at hand>>>>

Norm, how's the 2nd one coming along?

I've been looking long and hard at the weed wacker part as well and believe that it may be one that must have a much higher voltage. I don't think the 48 or even 72 is going to make it run, it may be the type that needs to 110Vac input which would put trying to run it from pure DC up in the 140Vdc area. NOT a voltage range to be mucking about.


Let me dig into the one I have at home over the weekend and get some voltage readings from both sides of the little device and make sure it is a rectifier and if it is post some voltage readings for you.


I don't yet have the batt tester back from it's calibration appointment, but I do have some know batteries that I can remove from my other bag of goodies if you get close to running out.


Cheers

Bruce S

 

« Last Edit: July 30, 2009, 02:08:33 PM by Bruce S »
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Norm

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Re: How I made a 12volt NiCad battery pack
« Reply #22 on: August 01, 2009, 07:45:36 AM »
Bruce, Yes it would be a good idea to be really

sure that the device is what it looks like it is.


I finished the second box and have enough to fill

a third box and almost enough for the 4th box....

but no real emegency rush as I have 2 boxes of

the first ones that are a different configuration

and have slightly more capacity 32 sticks instead

of 30.....write more later going shopping right

now....so later......

« Last Edit: August 01, 2009, 07:45:36 AM by Norm »