In this bachelor's degree thesis we have described a complete process of re-designing battery pack for powering DAQ devices that can operate in harsh invorement, for example increased temperature. The need for re-design came from market, because previously used batery charging controller went obsolete. Our job was, to make a controller, that will be able to charge two baterries with allready embeded balancing circuit, control logic for whole system, and overcurrent protection for each battery. One of requriment was also, that batteries are hot-swappable.
For final product we have designed all the schematics, PCBs, ordered them, tested and assembled first two prototypes. We have made functional, temperature, isolation and electrical-safety (burst, surge) tests in laboratory, and we have also driven battery pack for about 60 km on the back of motorcycle. We have also written firmware, which controls whole system. Due to change in shape of PCBs we had to adapt aluminium case for the product.
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