Power and battery management
THE topic par excellence that I am asked about time and time again. "How did you manage to go 40 days without a power socket?" is a common question. So what did I do?
I started experimenting many months before the expedition, with a few points in mind when it came to the power supply:
Solar power was the only practicable solution
it had to be as light as possible
I needed several days of autonomy, i.e. the ability to charge my devices even in persistently bad weather
My batteries had to comply with airline regulations
As I had started flying and building FPV drones a few years earlier, I was now very familiar with DIY solutions. I decided quite early on to simply build my own power bank.
In the following, I'll explain in simplified form what exactly I did, but I should also point out that I would probably go back to an existing, conventional solution for the next expedition. Reasons and solutions for this can be found in the tips at the end of the article.
My self-built battery case was basically a Pelicase with a total of 81 battery cells, which I soldered together to form 9 individual batteries (12 volts), each with 99 Wh and 6 cells. This meant I could be sure that I could take these batteries with me on the plane and connect them together with self-made adapter cables to form a large power bank before the expedition. A small workaround that worked very well.
The Pelicase also contained a solar power regulator and a temperature measuring device. Lithium-ion batteries work in the cold, but as soon as you charge them when they have a core temperature of below 5-6 °C, you destroy them relatively quickly. That's why I put two heating pads (red in the photo) in the case to warm up the batteries before charging.
This gave me a "main power bank" that I could connect directly to my two large 130-watt solar panels and which supplied all our technical devices with power: Cameras, sound equipment, cell phones, other team members' power banks, GPS devices, etc. Thanks to the high capacity of almost 1 kWh (equivalent to around 270,000 mAh if you want to compare it with normal power banks), this gave me a good 7-8 days of power in a row without having to connect the power bank to the solar panels. This was extremely helpful, especially at the start of our expedition, as the sun only really showed itself for the first time after a good week.
To get the power from this self-made battery case into all our technical devices, I needed a charger. In my case, I repurposed a charger from my FPV drone hobby and also soldered some of the necessary charging cables myself. For example, I was able to charge all seven sound recorders at the same time using just one connection.
If you've followed me this far, you can probably guess why I'd rather buy a ready-made power bank with built-in USB-C plugs next time. My setup worked perfectly for me and this expedition, but you need a very deep knowledge of electrical engineering to make sure the tent doesn't blow up - which can happen when experimenting with batteries.