July 8, 2024

Custom portable multistation chargers for drone swarms.


10 station 80W/channel commercial drone charger prototype.

Multibay charger for lithium ion drones.

The requirement was for a field charger that could be transported easily, and charge 10 SLA (sealed lead acid ), flooded lead acid or VRLA batteries simultaneously. Each battery charging circuit is fully independent with its own smart controller, and status LEDs. The power supply has universal input 85 VAC to 235 VAC 50/60 cycle. We put it in a Pelican™ style case with an o-ring gasket to make it rugged and waterproof. The microprocessor controlled charger boards monitor fault conditions as well as monitor each 12V battery separately for state-of-charge and end-of-charge.

The front panel contains:

Custom charging voltages and currents available.
Battery temperature reporting
Configurations for 3S 11.1V, 4S 14.8V, 6S 22.2V and 12S 44.4V.
800 Watts total charge per case. Typical configurations
- 10 channels 5000mAH 14.8V 1C charge rate
- 30 channels 5000mAH 1.4.8V 0.3C 3-hour charge rate.
- For other configurations see table below.
End of charge LED indicators
If the power to the charger fails the batteries are kept safe

Options: This product type could be extended to any number of batteries, different battery chemistries, and different charge algorithms. It can also be rack mounted, or repackaged for indoor use. The microcontroller boards can also monitor battery temperature if required.

Detailed Specifications
	All specifications below depend on the customer's requirements and confituration.
Input	85-235 VAC 50/60 Hz
Number of Batteries	1 to 60 simultaneously
Nominal Battery Voltage	4.2 to 58.8 V
Battery Capacity	1 to 40+ Amp-Hours
Total Charging Power	800 Watts (1200 Watts also available.)
Weight	22 lbs, 10 kg
Connectors and cables	According to customer's requirements
Size	approximately 8 x 19 x 16 inches

The following chart shows some examples of configurations using the 800 Watt Pelican case:

Voltage	Battery Size	Estimated Hours to full charge	Maximum Channels
(charge voltage)
3.6V (4.2V)	3AH	1 hour	60 channels
7.2V (8.4V)	3AH	1 hour	30 channels
10.8V (12.6V)	3AH	1 hour	20 channels
14.4V (16.8V)	3AH	1 hours	16 channels
14.4V (16.8V)	12AH	4 hours	16 channels
22.2V (25.2V)	3AH	1 hours	10 channels
43.2V (50.4V)	3AH	1.5 hours	8 channels
43.2V (50.4V)	5AH	2.1 hours	8 channels
42.2V (50.4V)	10AH	4.2 hours	8 channels
42.2V (50.4V)	22AH	11 hours	8 channels

The follwing chart shows examples of configurations using the 1200 Watt Pelican case:

Voltage	Battery Size	Estimated Hours to full charge	Maximum Channels
(charge voltage)
3.6V (4.2V)	3AH	1 hour	90 channels
7.2V (8.4V)	3AH	1 hour	45 channels
10.8V (12.6V)	3AH	1 hour	30 channels
14.4V (16.8V)	3AH	1 hours	24 channels
14.4V (16.8V)	12AH	4 hours	24 channels
22.2V (25.2V)	3AH	1 hours	15 channels
43.2V (50.4V)	3AH	1 hours	8 channels
43.2V (50.4V)	5AH	2.1 hours	12 channels
42.2V (50.4V)	10AH	4.2 hours	12 channels
42.2V (50.4V)	22AH	7 hours	8 channels

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multichannel lithium ion battery charger for drone swarms

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