Some years ago, I wanted to make a LiPo ESR (Effective Series Resistance) tester for keeping track of the health of my LiPos. The tester would work by measuring cell voltage, with and without a load, to calculate the effective cell resistance. This is a measure of the battery quality, and also a way to monitor the health of the battery, by watching for cells going bad (resistance goes up when this happens).
At the time, 3S were the biggest batteries I was using, and so I designed my tester to work with up to 3-cell LiPos. The tester used an LCD display, and indicated ESR readings for all cells at once, along with overall pack ESR. By using cell ESR along with Pack ESR, the cable/connector resistance could be computed, which is useful as well.
My original prototype got a lot of use, but it was bulky, as it was wired on a breadboard, using through-hole components. But it served its purpose, and there was nothing on the market that did what it did (multi-cell measurements at once).
Here’s a picture of the guts my original prototype (what’s left of it):
More recently, I was exploring ways to make the design more compact, as well as to support up to 6-cell batteries. I designed a PCB this time. This allowed me to make the design a lot more compact, as well as to add the additional circuitry needed for 6-cell batteries.
“V2”, as I called it, was a success. It displayed cell ESR for up to 6-cell batteries, and displayed all 6 values at once. Here’s a picture of the
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