Hi Alan,
Hi Phil,
I was perplexed to see the approach taken in that article. For one thing, the idea of accepting the inevitability of catastrophically destroying batteries on a semi-regular basis blows my mind. The writer is probably still abusing his batteries without solving the original problem. The idea of building a rig to catch the beginning of disaster, and terminate charge, is not entirely bad. I understand that Motorola build a pressure sensor into the LiIon cell phone packs for just the same reason. Secondly, I don't buy the statement that LiPos don't need an excuse to go awry. No Sir! Batteries vent with flame for one of several reasons ( which all boil down to imbalanced overcharging).
1) Mechanical damage: even the vast majority of cell phone flame-outs happens immediately or shortly after a good hard drop to a concrete-like surface. (about 75 exploding cell phones per year in the USA) On the other hand I have a buddy who has put 70+ additional flights on a 5S/5.3 A-H pack that jettisoned from a Pattern plane at 200' and landed in soft grass! Go figure ...
2) If one cell in the pack overcharges sufficiently it will be damaged, puff, and maybe vent. This often happens because the pack becomes imbalanced and while the entire 4S pack may have reached the correct 16.8 V charge termination voltage, some cells will be lower and others too high. It doesn't take much. A balancing charger like the FMA Balance-Pro, CellPro, or Thunder Power balancing series is the safeguard here. Even well treated batteries can become imbalanced, though it takes many many cycles for this to happen. The industry is catching up, here. By the way, balance is less important after discharge: it is vitally important at full charge.
3) Over discharge is often the cause of imbalance. LiPos should never be run without a properly set ESC low-voltage cutoff of 3.0 V per cell or maybe slightly higher. I'd bet money on this one as the most common cause of problems: running down till the power droops was acceptable with nickel-based cells but not lithium. For less weight critical missions, a battery monitor that looks at each individual cell and shuts down the motor if any one of them droops below 3.0V is the best solution. For our weight-critical mission, just don't drain them below 80% charge used ... ever, and use a balancing charger often if not all the time.
4) Over-currenting and overheating LiPos wounds them and reduces capacity. Of course, the individual cells will not all be identically abused (think of the ones in the middle of the pack) and the imbalance will later cause problems at charging time.
We already take this much care in filtering the fuel we use in our wet-powered Stunters. It's just a different skill set.
Sorry if I come on strong.
later Friends,
Dean P.