The simplest and most costly solution is to order a replacement battery pack. But have you considered just replacing the cells in the battery pack? This approach saves money and reduces waste. Furthermore, you can select replacement cells with a larger capacity than the originals. This isn’t just a repair; it’s an upgrade! It’s All Gone Quiet…
The simplest solution is to visit the equipment manufacturer’s website to see if a replacement battery pack is available. Sometimes there isn’t and, when there is, the prices can come as a shock. In my case, the equipment worked just fine and looked to have a good few more years of life in it — a new battery would suffice.
Building a battery pack from individual cells generally requires a degree of dexterity, electrical expertise, and a spot welder. As you can see from the old unwrapped battery pack in Figure 3, the five green cells are neatly connected at the positive and negative contacts via thin, spot-welded nickel strips.
Once all the cells have tested good and have been marked for polarity, you are left with a set of battery cells almost ready for assembly in the battery pack. When you disassemble the old battery pack, it is important to document how the cells are strung together and the pack is constructed by taking several photos.
But don’t pitch that tool! Many battery packs can be revived by replacing the individual battery cells. In this article, James gives step-by-step instructions for rebuilding a battery pack for an electric drill by spot welding metal ribbons to the battery terminals of the new cells.
By replacing the cells in your product's battery pack, you can save money and reduce waste. Here's a DIY solution.
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