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On one hand, this circuit could have a glaring defect, but on the other hand the microcontroller could theoretically contain an independent simple shunt reference of about 0.6V below the lithium cell's maximum voltage.

I won't release this video until I can prove my thoughts, as it would be inappropriate to diss a product as being potentially dangerous when it just had an unusual design quirk.

https://www.youtube.com/watch?v=pvH54RVZ2sw

Files

Perplexing solar light

I made this video in two parts while travelling, but now wish I had the other parts or some suitable test equipment to test my theory that it might have a design defect that could overcharge the lithium cell if the light is left in sunshine while switched off. Fortunately in most situations the light will be left switched on continuously after purchase, and will therefore have the charge control circuitry active. The use of a processor controlled transistor for charge control is very similar to the circuitry of the skeleton shaver I reverse engineered a while ago. It makes me wonder if the chip is a microcontroller with a built in dedicated lithium charge system or if it is just relying on software and an analogue to Digital converter to measure the cell voltage. My pondering about whether the chip could somehow use a single pin to measure cell voltage as well as control the transistor is possibly viable if the cell voltage and transistor base voltage were added. Technically speaking the chip could contain a simple zener or fixed voltage reference so the transistor turned off as the cell voltage reached a charged state. Theoretically the base bias resistor is also going to have a hard time on a sunny day when the base is shunted, as the power dissipation would be just above its rating and the processor would also be shunting about 50mA on its control pin. They may be over-economising on these designs. If you enjoy these videos you can help support the channel with a dollar for coffee, cookies and random gadgets for disassembly at:- https://www.bigclive.com/coffee.htm This also keeps the channel independent of YouTube's algorithm quirks, allowing it to be a bit more dangerous and naughty. #ElectronicsCreators

Comments

Anonymous

What about measuring the resistance from 0v to the mystery IC connection when the switch is off. Does it get pulled to 0v? (Sorry if I missed you doing that.)

Nigel Walker

Consider me perplexed too, Clive! What if we call the connection to the top left NPN base charge, the one to the right of the on/off switch Vi, and the chip /not/ a microcontroller. I think it's more analogue than that. If the charge input has an NPN with the emitter to ground and collector to charge input, plus a resistor from charge to its base. If the switch is off, the charge input is kept low and the battery never charges or discharges. The solar cell can float high when lit and not source much current. Then if the Vi input has a PNP with a suitable base resistor and limit resistor it can pull the charge input high to allow the battery to charge, and add a 3V9 zener across the first NPN so it doesn't charge above 4.2V. Add a small state machine to control brightness using PWM, and another transistor & zener so if Vi drops too low there's something to turn the LED output off. Does any of that make sense? It wouldn't use much silicon area.