DeWalt Battery Balancing Connector

DeWalt Battery Balancing Connector

This is my own design for a DeWalt battery connector.

I have seen other DeWalt connectors, but they usually only have 2 connectors. I wanted access to all connectors (see below about balancing) so I designed this model.

The model was designed from scratch using FreeCad (files attached).

This has been my first major design using FreeCad - so apologies if the design was done in a strange way!

The MainAssembly file uses the "A2Plus" plugin, which allows a project to made up of several sub-parts.

I have included the .STL's so these can just be sliced and printed.

I used PLA, with 0.3mm layers on my Prusa MK3S

For the main body place the connectors on the baseplate - that way you can print with no support.

This connector allows you to rejuvenate your tool batteries. The standard DeWalt chargers, charge all cells in series.

The problem is over time, some cells get out of balance, reducing the capacity of each charge. To fix this, you can get balancing chargers. I'm using a charger for RC lipo batteries. This needs a connection to each cell within the battery - the DeWalt battery exposes these via the smaller connections on the battery.

I won't go into the wiring here - Google "dewalt battery pinout" for more information; its pretty straight forward.

Additional parts needed:

• A RC battery charger
• 2x M3 threaded inserts, to hold cover in place. Use a soldering iron to melt these in place
• 2x M3 x 30mm screws to hold cover in place
• Brass strips (1mm thick) cut to size for connectors - use a hacksaw and file to shape, then superglue into each slot.
• Wiring and connectors for your battery charger.