Replacing a ruptured battery + Some adjustments

Firmware/software/electronics/mechanics
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ion
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Posts: 13
Joined: Sun Nov 30, 2014 9:32 am

Replacing a ruptured battery + Some adjustments

Post by ion »

Well, after getting set up. I flew it for a day. Finally getting it to fly stable didn't take too long.

It landed upside down on many occasions and I didn't realize this would happen (Note, battery terminals cut after I seen this when I returned home):
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I've never had a battery rupture, and luckily was careful enough not to get any of the gel on my skin. Anyways, I dropped it in a (BIG) 10 gallon bucket of water to hopefully dilute the stuff and later throw it out. It's not safe to just throw in the garbage, right?

Anyways,
I had an old pair of bluetooth headphones that has a similar battery. It doesn't have any of the technical info on it, like voltage or mAh, but I figure if I can charge it with USB, they both have to be about the same, minus mAh capacity. Voltage readings while connected to the PC are about the same as well, I guess due to the integrated charge/power controller and regulator on board.

I ended up destroying the headset, and doing away with all the unnecessary stuff (speakers, board - saved for later).

Well, here's some pics so you don't have to keep reading ;)
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Again, I'm reusing the connector from the original battery, used some solder + heat shrink tube to get it secured, and tape to keep the wires down.

Worked perfect! New battery = 1.3x the weight of the original battery (They feel about the same??)

I ended up adjusting the min / max thrust on the client program to 80, then to 90, and finally 95%
min thrust is at 40%, which does almost nothing anyways.

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Size comparison:
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Sorry about the rotation, imgur did it.
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I ended up attaching some wires OVER the ends of the battery, to keep it from falling off if the nano were to land upside down (and I've done this a hundred times already...)

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There are some caveats though, with this.

Maybe I have a bad unit? But everything was tested ok with my multimeter.
Before the battery change, the nano shuts off if the battery gets around 30% or so. It'll just shut off, and I turn it back on, it stays on for 4 seconds and shuts off again.
Maybe it's a fail-safe. But with this new battery, the same thing occurs, maybe even more.


It will also shut off if I hold full thrust for 10~15 seconds even on a full charge. With both batteries.
I do not however charge it for more than 15 minutes at a time so I assume that's my fault.


However, allowing the new battery to charge for more than an hour (usually with the headphones) - gives me a full charge.
I guess the heavier battery puts more stress on the motors. It does fly, but if I release thrust it will just slowly drop down. Giving it full thrust will falling doesn't help, and may kill it.


Sorry I don't have a scale to measure the battery weights.

Maybe what I need is better tips on how to make this fly, with the new battery. Unless this thing is designed to only carry a certain weight. But what are people adding to it anyways? :)

Are there config tweaks I can change and get better performance? I haven't really looked into it because I don't want to change something and forget what it was later.
whoenig
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Posts: 395
Joined: Mon Oct 27, 2014 2:55 am

Re: Replacing a ruptured battery + Some adjustments

Post by whoenig »

It sounds (and looks) like it got too heavy actually. The Crazyflie is specified with 5g of payload, however the flight performance decreases significantly if you actually put 5g on it (5g is 25% of its mass!).

For the battery issue: The firmware is calibrated on the given battery for charging. Additionally, there is a safety power off feature: first the red led will be steady for a while, if the voltage drops even more the flie will just shut off. This prevents it to malfunction (if the voltage drops too much, the microcontroller might compute garbage results).
ion
Beginner
Posts: 13
Joined: Sun Nov 30, 2014 9:32 am

Re: Replacing a ruptured battery + Some adjustments

Post by ion »

Thanks for the info.

I've tried to take that into consideration, but as I said I have no scale or anything to measure the weight for this new battery.

I can get it to fly, only if I give it full throttle for the take-off. But I'll see about removing the battery's controller circuit and just hard-wire it.

I've read that might be causing the battery to shut off if too much power is being used. Not sure about the microcontroller, though.

I switched out the old propellers too, and I'm getting better hovering. I may have damaged the other ones to hell and back ;)
ion
Beginner
Posts: 13
Joined: Sun Nov 30, 2014 9:32 am

Re: Replacing a ruptured battery + Some adjustments

Post by ion »

Update: The new propellers are doing their justice and I can hover at about 90% thrust again! w00


On the downside, I still have not removed the battery protection pcb yet, and I'm still getting the kick-offs, but can't the voltage drop be compensated with a capacitor? *Very short term, just and idea



Also, where can I buy more propellers?

It seems there was 5 in one pack and 4 in the other.
whoenig
Expert
Posts: 395
Joined: Mon Oct 27, 2014 2:55 am

Re: Replacing a ruptured battery + Some adjustments

Post by whoenig »

Removing the battery protection pcb is actually dangerous: your battery can explode during charging. There is no specific protection chip on the flie itself.

You can usually buy a propeller pack wherever you bought the flie. It should be around 5$ for one pack (4 CW and 4 CCW I think).
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