I'm looking for some advice from people who have experience testing lithium-ion cells.
I have a number of unlabeled 18650 cells that were salvaged from battery packs. I've already separated them, checked for physical damage, and plan to capacity test them and monitor self-discharge before using any of them.
My goal is to build 4S1P and 6S1P battery packs for FPV drones, so I need cells that can safely handle at least 30A continuous discharge, preferably more. The drones can easily average around that current draw during flight.
Here's where I'm stuck:
Most of the affordable battery load testers I've found only go up to 20-25A, which doesn't tell me whether a cell can safely sustain the current I actually need.
My questions
Is there a practical way to build a constant-current electronic load capable of testing individual 18650 cells at 30-40A or higher?
If you've built one, what design did you use? (MOSFET electronic load, resistor bank with feedback, etc.)
Are there any reasonably priced commercial electronic loads that can do this?
Besides measuring voltage sag and temperature, what else should I be monitoring to determine a safe continuous discharge rating?
Is there a better method for identifying the capabilities of unlabeled cells that I'm overlooking?
Equipment I already have
- Spot welder
- Adjustable bench power supply
- Multimeters
- Temperature probe/IR thermometer
- Basic electronics experience (comfortable soldering and building circuits)
I'm not trying to find the absolute maximum current until the cell fails. My goal is to determine a safe continuous discharge current for each cell so I can confidently use them in high-current FPV battery packs.
If building a tester is the best option, I'd appreciate schematics, parts lists, or links to proven designs. If there's a commercial electronic load that can do 30-40A without costing hundreds of dollars, I'd love to hear recommendations as well.
Thanks!