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8 Jul 2020 16:23:53 UTC
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Black & Decker Battery Project, Part 2
As a second step in the Black & Decker battery project, I take a look at how the battery fits into the tool and what sort of room I'll have inside the pack for installing new batteries.

There seems to be just enough room for 3 - 18650 cells side by side and then 2 more laid on top. 18650 cells are 18mm dia. and 65.0mm long, thus the numeric designation. I was hoping I might be able to use a spring loaded battery holder but with the tight clearance (only 4mm to spare), I'll need to use solder-tab cells in order to tightly pack them. 5 cells in series gives 18V at 3.6V/cell or a bit over 20V when fully charged at 4.2V/cell.

I want to install both a 5S balance connector as well as some sort of battery monitor or battery management system (BMS). There seems to be two or three basic types.

- The first is just a volt meter that you use to check the state of charge with.

- The second type is similar but features an audible alarm when a low voltage set-point is reached.

- The third type is a full BMS or battery protection board that actually shuts off the battery pack before it is discharged too far.

I'll need to get some dimensions for the various options and see what can be made to fit. The Craftsman C3 lithium battery packs have a built-in BMS that shuts off power and also display a green/yellow/red state of charge reading. That works quite well and it would be nice to duplicate some or all those features.

The simple volt meter display would be rather inconvenient to turn the tool over to look at in the middle of using it. The beeper type might work if it is loud enough to hear over the noise of the tool. The full BMS is ideal, but those seem to have limitations on the amount of current they can handle.

Here are some links/videos I found that pertain to this project:

An interesting NiCad replacement for the B&D battery pack from Harbor Freight:
- http://www.instructables.com/id/Cheap-Black-Decker-18Volt-battery/

A 18V NiCad to 6S Li-Ion conversion:
https://www.youtube.com/watch?v=w1o1efFqaOY

Craftsman 14.4V to 4S Li-Po conversion:
https://www.youtube.com/watch?v=lVTH8wVR-xc

So, stay tuned to this channel for updates as I make progress on this battery conversion project. Thanks for watching!
...
https://www.youtube.com/watch?v=qRjjKjnDWQw
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