Author Topic: Segway battery charging failure  (Read 842 times)

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Offline clr22182Topic starter

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Segway battery charging failure
« on: March 06, 2026, 07:33:47 pm »
Because of an old lower extremity injury and persistent disability the use of generation 1 Segways has been a Godsend, but they are getting long in the tooth such that the battery charging circuits are notoriously fragile and frequently fail.

The battery charging and DC motion powering circuits are located in a module in the base of the units consisting of two circuit boards which deliver two DC voltages to the base of the unit.  The battery charging circuit can be powered by either 120vac or 240vac for charging the batteries.  One circuit board ~40vdc @ 60 ma to maintain battery charging and the other circuit board delivers 100vdc @ 60ma to power the transmission and balancing/locomotion.

The problem is that the battery charging circuit, presumably a bridge rectifier, and voltage transformer is fragile and frequently fails.  It is presummed that the most common failure mode involves diode failure and/or capacitor failure.

Is anyone facile enough with circuit board diagnosis/repair to take on a project which I will fund to repair the battery charging circuit board and check the integrity of the 100 vdc 60 ma circuit board competence?

Please respond if you wish to discuss this issue.  I have several modules which need repair, including one unit which has one functional battery charging circuit and the other battery charging circuit that has failed.  This situation will allow determination of a good circuit vs a failed circuit for comparison purposes.

Thank you, and all the best,
C. L.. Rogers
clr22182@gmail.com
571 275-0998
« Last Edit: March 06, 2026, 09:59:48 pm by clr22182 »
 

Offline NiHaoMike

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Re: Segway battery charging failure
« Reply #1 on: March 07, 2026, 07:18:24 pm »
What kind of battery is it exactly? Might it be possible to use an off the shelf ebike charger?
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Offline clr22182Topic starter

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Re: Segway battery charging failure
« Reply #2 on: March 08, 2026, 02:16:41 pm »
Good morning,

The generation 1 segway batteries come in two models.  The original model from 2000 to about 2006 were dual packs of 36 vdc nickel metal hydride (NiMH) packs monted to the bottome of the Segway standing platform. And after 2006 a transition to 80vdc LiON batteries occurred.

I have purchased an 80vdc battery charger but having to remove the batteries physically after every use for charging is both labor and time intensive such that it is prohibitively inconvenient and only one battery of the dual pack can be charged at a time with a single charger.

By far, the best option is to try to find an electronic technician with the interest and skills to repair the circuit boards which power the internal battery charging circuits.

I will fund to a reasonable extent anyone who is interested in taking on this project, and there is a substantial need for such repair of existent generation 1 Segways which could become a reasonable business for anyone interested and capable.  I have access to a superb Segway battery rebuilder who could serve as a conduit to those who need help with maintaining their Segways' charging systems of which there are almost certainly thousands worldwide.

Thank you for your interest and suggestion.

All the best,
C. L. Rogers
clr22182@gmail.com
571 275-0998
 

Offline wraper

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Re: Segway battery charging failure
« Reply #3 on: March 08, 2026, 02:49:12 pm »
The problem is that the battery charging circuit, presumably a bridge rectifier, and voltage transformer is fragile and frequently fails.  It is presummed that the most common failure mode involves diode failure and/or capacitor failure.
Sounds like a bunch of nonsense. It almost certainly uses SMPS where transformer failure is very rare and bridge rectifier is used for mains input only, and it failing by itself is not that common either.
Quote
One circuit board ~40vdc @ 60 ma to maintain battery charging and the other circuit board delivers 100vdc @ 60ma to power the transmission and balancing/locomotion.
60mA current is absurd too.
 

Offline clr22182Topic starter

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Re: Segway battery charging failure
« Reply #4 on: March 09, 2026, 02:18:43 pm »
Sir,
All i can tell you is that the DC voltage and ma specifications are stamped on the module.
Arrogant and disrespectful comments are not constructive.

C. L. Rogers

 

Offline wraper

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Re: Segway battery charging failure
« Reply #5 on: March 09, 2026, 02:34:40 pm »
You did not provide any photos and it's hard to find anything about it as nearly all search results are about Ninebot scooters. I said 60mA is absurd because it will take forever to charge the battery with current this low. You did not even say which particular model it is, just a few weird claims.
 

Offline clr22182Topic starter

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Re: Segway battery charging failure
« Reply #6 on: March 11, 2026, 11:50:53 am »
Yes, you are correct, almost everything regarding Segway scooters are now Ninebot oriented.  After Dean Kamen sold the Segway Human Transporter business to an Engish businessman, he died while riding one of his Segways on his estate, fell off a cliff and met his demise.  He died intestate and the origninal Segway business was sold to a Chinese company about 2012.  The Chinese have proceeded to kill the original Segway design which is no longer manufactured including the original NiMH batteries and I think they also killed the LiON batteries which replaced the NiMH batteries about 2006.  Unfortunately the Ninebot models have not proved as reliably helpful for those of us who need an ambulatory aid and even at least one of the battery rebuilders has found the Ninebot systems so difficult to work with they refuse to try to help maintain Ninebot batteries.  So that leaves someone with my disability no choice but to try to maintain functionality of the original Segway system with the original technology of the i 167, i 170 and i 180 segway models.  I have tried to transition to the later generation 2 Segways with the lean steer method of control which is not nearly as stable as the original rigid upright handlebar generatiion models such that the generation 2 Segways are not helpful for rider stability with only one leg for good balance.

Pictures of the Segway batteries may be confusing if one is not familiar with the two battery padk models (NiMH and LiON)can be seen at:

 https://duckduckgo.com/?q=Segway+NiMH+i+167+generation+1+battery+pictures&iar=images&atb=v481-1&t=chromentp&iai=https%3A%2F%2Fcdn.shopify.com%2Fs%2Ffiles%2F1%2F1550%2F6951%2Fproducts%2FFile_000_1024x1024.jpg%3Fv%3D1479516717

The NiMH battery packs (of which two are mounted to the bottom of the standing platform ) consist of two 30 cell 1.2v subC  battery arrays in seried producint 36 vdc. for a total of 72vdc power for each battery pack.  These batteries were originally produced in France.

The LiON battery packs since 2006 have 18650 LiON cells arranged to produce about 80vdc each.  Unlike the NiMH batteries, because of the fire risk, travel with these batteries cannot be used with the airlines.  These LiON packs are listed as 10-12 ah capacity which increased the generation 2 Segways range to the 10-12 mile range but as mentioned the lean steer mechanism of the generation 2 units are substantially less stable for someone with a single leg balancing capability, such that they are not nearly as user friendly.  For myself using the gen 2 units is not possible.   For some of the original gen 1 Segways with software updates both NiMH and LiON batteries can be used.  Maintaining batteries howeve is the limiting factor over time as the batteries age out due to recycle depletion.  Careful battery maintanence with daily short term recharging is very helpful to maintain battery health but about every 5 years the batteries must be rebuilt with new cells due to natural degradation of battery capacity.  When, however, the battery charging circuit in a Segway fails it is obviously destructive for continued use of the unit.

All this data can be confusing to someone unfamiliar with the orginial invention of the Dean Kamen Segway device which originally began with a model designated as "p133" which is now ancient history in the world of Segway human transporters.

So, as you can see,  the issue of battery maintenance is of paramount importance, especially the battery charging circuits in the Segway units themselves. 

I also have an off board battery charger, but it is impractical for everyday use.
 

Offline clr22182Topic starter

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Re: Segway battery charging failure
« Reply #7 on: March 22, 2026, 12:16:34 pm »
Good morning,
Sorry for the delay in direct response to your thought about using an off the shelf charger. My Luddite tendencies sometimes intrude on communications.

Yes off board charging is possible, but only if one physically removes the battery packs from their mounted position under the standing platform.  This process is possible but given charging is necessary every time the Segway is used for any period, it is not very practical or user friendly.  Additionally, there are two battery packs BMS is so sophisticated that maintaining the battery health demands that intermittent charging for about 1 hr of every 24 hours to optimize battery longevity.  Both the older airline friendly NiMH batteries with approximately 3-5 yr lifespans and the second generation LiON batteries with 5-10 year lifespans can be re-celled at substantial cost varying between $800 and $1700 but for obvious reason it is only economically reasonable to be faithful to battery maintenance. 
Off board battery chargers were manufactured by Segway and I own a used offboard charger but using it regularly is time and labor intensive.  Finding a way to repair the integrated battery charging circuit board(s) would be by far the better option.

Thank you for your interest.  If anyone is interested in pursuing this circuit board diagnostic/repair problem I will fund their work to a reasonable degree.  I have several charging units both functional to "go to school on" and some dysfunctional that need repair.  Additionally, it is likely that with the large number of older Segways still in the market a small business could be created to keep them functional for others.

All the best,
C. L. Rogers
clr22182@gmail.com
571 275-0998
 


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