Author Topic: Battery-charging: DIY solutions  (Read 7145 times)

Danneaux

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Battery-charging: DIY solutions
« on: February 11, 2012, 09:02:12 pm »
Hi All,
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[An observation...
Our discussions of battery-charging systems are a bit scattered among topic headings. As discussions naturally do, they grow and diverge in wondrous ways and pretty soon take a course that makes it hard to find a particular sub-topic. Given the growing interest in dynamo battery-charging, it seems a good idea to clearly label fresh sub-topics with a prefix, like "Battery-charging" for easy future searching.]
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There are many commercial solutions for charging a battery or battery-operated device from a dynohub, but they can be expensive. If you're handy, it is possible to build your own device to power your appliances while on-tour.

Most DIY accounts are lacking in some way, but the idea of making one's own just took a huge leap forward, thanks to Trevor Luker at oddbikes ( http://http://oddbikes.com/ ), who has very generously released the schematics and PCB layouts of the OddPower charger for general use under a Creative Commons license ( http://creativecommons.org/licenses/by-sa/3.0/ ). Under this provision you are free to share, remix, or adapt the work under the conditions you attribute the work in the manner specified by the author or licensor and if you alter, transform, or build upon the work, you may distribute the result under the same or similar license to this one. The idea is to give back to the wider cycling community any improvements you make.

By any standard, this is a gift to the cycling community, and we all owe Mr. Luker a hearty "thanks and well done". A Technical Architect and Project Manager by profession, Trevor's avocation is cycling the world on a bike equipped similarly to a Thorn.

The charger connects to most modern hub-dynamos (SON recommended) to deliver a clean & steady 5V output at up to 1A in accordance with USB specifications. The other end connects to your USB device via a standard charging cable and can readily be used with external batteries including a buffer battery. The final product generally resembles a B&M e-Werk in appearance, but does not offer user-selectable output. Final appearance and weather-resistance is up to the DIY builder and will depend on packaging.

Everything you will need to know is contained in a .zip file available here:
http://oddbikes.com/downloads/OddPowerV1.zip
This file contains the complete schematics & PCB design of OddBikes' OddPower V1 charger.

Mr. Luker indicates release of v. 1.0 will allow him to concentrate on the complete schematics and board design design for the version 2 smart charger. I can hardly wait.

Best,

Dan.
« Last Edit: February 12, 2012, 06:00:28 am by Danneaux »

Danneaux

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Re: Battery-charging: DIY solutions
« Reply #1 on: February 12, 2012, 05:55:07 am »
German site Future-Bike has plans for Minimal-Loader and Low-drop Loader chargers for use with dynohubs.

Minimal Loader in the original German: http://fahrradzukunft.de/12/minimal-lader/
Google Translate English version: http://translate.google.com/translate?sl=de&tl=en&js=n&prev=_t&hl=en&ie=UTF-8&layout=2&eotf=1&u=http%3A%2F%2Ffahrradzukunft.de%2F13%2Fsteckdose-unterwegs-3%2F&act=url
The Minimal Loader is designed by Andreas Oehler, a mechanical engineer at Schmidt dynohubs.

Low-drop Loader in the original German: http://fahrradzukunft.de/12/low-drop-lader/
Google Translate English version: http://translate.google.com/translate?sl=de&tl=en&js=n&prev=_t&hl=en&ie=UTF-8&layout=2&eotf=1&u=http%3A%2F%2Ffahrradzukunft.de%2F13%2Fsteckdose-unterwegs-3%2F&act=url
The Low-drop Loader is designed by Paudler Michael, Master of IT technicians and crafts.

Best,

Dan.

benstevens

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Re: Battery-charging: DIY solutions
« Reply #2 on: May 30, 2012, 02:56:46 pm »
There is some solder it together yourself stuff here (in German):
http://www.forumslader.de/Neue-weiterentwickelte-12V-Version-von-JensD.183.0.html

Basically enables you to charge a pack of batteries that can then be used to power your lamp or provide a USB outlet.  I'm just contacting him now to see if the printed circuit boards are available.

Danneaux

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Re: Battery-charging: DIY solutions
« Reply #3 on: May 30, 2012, 04:40:24 pm »
Quote
...some solder it together yourself stuff here...
Very nicely found, Ben!

Google-Translated English version here:
http://translate.google.com/translate?sl=de&tl=en&js=n&prev=_t&hl=en&ie=UTF-8&layout=2&eotf=1&u=http%3A%2F%2Fwww.forumslader.de%2FNeue-weiterentwickelte-12V-Version-von-JensD.183.0.html&act=url

This employs a few of Oehler's low-loading circuit functions with the added "trick" of a switchable charging scheme, depending on speed, required charging capacity, and rider output. If I understand correctly, the author cautions it needs an isolated ground-return path to maximize the charge.  Neat stuff, and I'll dig a little deeper as I read more about it and ponder a bit. I love Li-po (lithium-polymer) batteries for this application.

Please, can you let us know of any replies you get from Jens During?

Always good to have another DIY entry here, and this looks really intriguing.

Best,

Dan.
« Last Edit: May 30, 2012, 06:49:42 pm by Danneaux »

benstevens

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Re: Battery-charging: DIY solutions
« Reply #4 on: June 06, 2012, 10:43:02 am »
I have had an email back from Jens and he is sending me a board in exchange for some translation work (I studied the third year of my electronics degree at the TU Dresden).  Will post some pictures of everything once it is built up - hopefully in time for our Scotland trip at the end of July.

Danneaux

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Re: Battery-charging: DIY solutions
« Reply #5 on: June 08, 2012, 04:33:49 am »
Quote
Jens... is sending me a board in exchange for some translation work.... Will post some pictures of everything once it is built up
Oh, that would be outstanding, Ben. Very much looking forward to the photos and report, and to hearing how it worked for you on your tour of Scotland.

Thanks for the update!

Early good wishes for a wonderful time on-tour, with good weather, smooth roads, and lots of fun.

Best,

Dan.