Name: Bicycle Cellphone Charger Circuit Assembly Manual Device: Nokia/Blackberry List of Components:

Transcription

1 Name: Bicycle Cellphone Charger Circuit Assembly Manual Device: Nokia/Blackberry List of Components: Serial numbername Quantity Component number 1 5 V Regulator 1 U MicroFarad Capacitor 1 C MicroFarad Capacitor 1 C2 4 Heat Sink 1 H1 5 Nut #4 1 N1 6 Bolt #4 1 B1 7 Aluminium Washers #4 2 M1 8 Plastic Washers 4 P1 9 USB A Female Connector 1 J Pin Power Jack 1 J1 11 Thermal Paste 1 T1 12 Cotton Swab 1 S AWG RED Wire 1 R AWG Black Wire 1 BL1 15 Lead Free Solder 1 SO1 16 Breaboard 1.5 inches x 1.5 inches 1 BB1 17 Crazy Glue!!Warning: Components being used to build this circuit may vary with the components you have. Consult with the supplier before proceeding.

2 Circuit Schematic Figure 1: Charger circuit Schematic Step 1: Figure 2 Figure 3

3 Apply a thin coat of thermal paste on the back side of the regulator by using cotton swab as shown in figure 2 and 3. Step 2: Figure 4 Place the regulator on to the heat sink such that the drill holes line up. Step 3: Figure 5 Figure 6 Place the Aluminum washer on the bolt and then attach 2 plastic washers such the plastic washers face the regulator s drill hole. Now attach the arraignment to the regulator as shown in the figure above.

4 Figure 7 Figure 8 After the bolt is placed through the drill hole, attach 2 plastic washers followed by Aluminum washers and then secure the arrangement with a nut.!! Warning: While tightening the nut, the regulator tends to slide. After the nut is secured, move the regulator back to its original position. Picture below is a reference of how it should look after attaching the bolt. Figure 9

5 Step 4: Figure 10 Figure 11 Clip the USB connector holder pins. Figure 12 Figure 13 Figure 14 Place the USB and power connectors as shown and solder the connections.

6 Step 5: Figure 15 Figure 16 Place the 10 microfarad capacitor (shown in blue) and then place the 22 microfarad capacitor such that the negative pin of bot the capacitors are in the same line as shown in the picture. Then solder the connections. Solder connections are shown in the figure below. The positive pins of the capacitors are also marked below. Figure 17 AS you can see from the above picture, all the pins in a straight line are interconnected. Hence a connection to a pin can be made on any of those pin holes.

7 Step 6: Figure 18 Figure 19 Cut about 0.9 inches of red wire and strip 0.25 inches on either side of the red wire. Figure 20 Use the wire to connect the positive pin of the 10 microfarad capacitor to the positive pin the power jack. Solder the wire to the board.

8 Step 7: Figure 21 Figure 22 Cut about 1.6 inches of black wire and strip 0.6 inches on either side of the black wire. Figure 23 Connect the negative pin of the power jack to the bread board ground line as shown. Solder the wire to the board.

9 Step 8: Figure 24 Figure 25 Cut about 1.5 inches of red wire and strip 0.25 inches of wire on either side. Figure 26 Connect the positive pin of the USB connector to the positive pin of the 22 microfarad capacitor. Solder the connections. Pin layout of a USB connector is given below. Pin Name Cable color Description 1 VCC Red +5 VDC 2 D- White Data - 3 D+ Green Data + 4 GND Black Ground Table 1 Figure 27 Note: In order to charge smartphones, Connect pin 2 to pin 3 to create a short.

10 Figure 28 Figure 29 Cut about 0.9 inches of black wire and strip 0.25 inches of wire on either side. Connect the ground pin of the USB connector to the ground pin of the ground line. Solder the connections. Step 9: Figure 30 Figure 31 Place the regulator with the heat sink as shown and also cut about 1.6 inches of black wire and strip about 0.6 inches of wire on either side.

11 Figure 32 Figure 33 Connect the black wire from the ground strip to the negative pins of the capacitors and also bend the regulator such that it is horizontal to the board. Solder all the connections. In order to make sure all connections are correct, use a multimeter to check the connections and also perform a point to point test. Step 10: Figure 34 Figure 35 Apply some crazy glue between the USB connector and the board.