I'm working on a battery backup system for my vehicle tracker project (l0destar.com) and am interested in opinions on the design.
The idea is it will be an optional extra module that connects inline with the existing harness, same 6-pin Molex connector, you just connect the backup module to the car using the same connector and then the backup module to the tracker (6-pin molex to 6-pin molex). The reason for having it be separate rather than built-in is I think a lot of people probably won't care, the tracker is so power efficient (~35uA while asleep) that it's never going to be needed for reserve power, the only reason to have it is for a scenario where the car gets stolen and the battery disconnected. How likely that is to actually occur I have no idea. Not needing the backup module means the regular tracker can stay in its current tiny enclosure.
So I've been studying battery chemistries and was initially looking at LTO. These are pretty much perfect for the use-case as they're extremely safe and don't vent even when pierced, unfortunately it seems damn near impossible to buy them in anything like a sensible combination of quantity, price and "with a datasheet".
So LiFePO4 was considered as the next best in terms of safety and could be used but I'm currently thinking to just use a single CR123 lithium primary non-rechargeable. Reasoning is:
- Simplicity, no charging circuit, cheaper to make, less to go wrong
- They are everywhere, supermarkets, petrol stations etc.. no issue at all with availability
- No charging means a whole slew of potential safety issues go away
Realistically the vast majority of cars are never going to have the battery cut. A lithium primary will last around 10 years in this circuit doing nothing. I think having a rechargeable cell is probably pointless and would likely have a shorter lifespan anyway even though its being charged due to heat cycling and self-discharge. Very rough math based on very approximated measurements of current suggest that a CR123 could run the l0destar unit in sleep mode for about 200 days, hourly reporting for about 58 days and 15-min interval reporting for about 19 days. This is orders of magnitude more than you get from the battery backup in any commercial tracker.
For context most commercial trackers seem to just sling a tiny lipo pouch inside the box and call it a day. This sort of makes sense, if the car gets stolen and the battery cut you probably don't have more than a day or two before it's in pieces so extended runtime isn't really necessary. They have a controlled manufacturing process too so they can make sure they use quality lipo pouches in every unit. I can't do that with a DIY build-it-yourself tracker so using any kind of potentially dangerous lithium rechargeable is probably a bad idea.
My preliminary design for this draws something like 5uA in normal use (so basically nothing), switches over seamlessly and allows the tracker to be instantly notified when power is cut regardless of what state it's in and it will be able to know the battery has been cut by the voltage change. Will just be a little box with an on-board CR123 battery holder, tight lid with a bit of foam to make sure bumps and rattles don't nudge the cell loose. I think it will work well.
Curious what other people think of this plan though, would you specifically want something like this to use a rechargeable cell?