DSO138 Rechargable Battery

thingiverse

This is a custom battery pack designed for my DSO138 Combo tool case. The battery uses actual spring tabs to maintain constant contact with the batteries at all times: https://www.ebay.com/itm/Wholesale-Silver-Tone-Metal-Spring-Battery-Contact-Plate-Set-For-AAAAA-Batteries/382246713722 The batteries are sourced from here: https://www.ebay.com/itm/80X-High-energy-1-2V-AA-Rechargeable-Ni-MH-Battery-Green-for-Lifhts-or-Toys/401434155033 First, print two of the bottom case and two of the separators. Next, assemble and solder the battery terminals as shown in the picture. The voltage take-off is located on the bottom plate on both sides and on the upper side at the turn-around point. The turn-around voltage is 6V, while the positive voltage is on the end at 12V. With the batteries I have, it forms a 12V 3.3AH battery, which is a substantial battery for my DSO. After attaching the springs to the bottom plates, use several 3-2 aluminum rivets to secure the plate to the separator. If you don't have rivets, 3mm bolts can be used as an alternative in most designs. However, this approach results in a significant waste of reusable hardware since this part will never need to be disassembled again. Inserting the batteries is quite challenging due to the spring tension. To make it easier, I recommend using a vice. Two long bolts or all-thread pieces hold the entire assembly together once the batteries are in place. After tightening the bolts, solder on your battery leads. Once I've confirmed that the design is complete and functional, I will post the DSO housing design for reference.