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E-Bike mobile charger

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Ruplicator
(@ruplicator)
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Joined: 4 years ago
Posts: 127
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I know most of the posts here have to do with microcontrollers but this was a quick project that someone may be able get a take-way.

My wife and I enjoy biking but our knees started to give use a lot of problems. A couple of years ago we purchased a couple of e-bikes and have enjoyed them immensely. Since we tend to do more than one bike trail in a day, I built a charger to top off the batteries while we are driving between trails.

I'll include some CAD drawings and a picture of the final product of a project that incorporates several off-the-shelf components with 3D printing. 

The charger is made of 3 main purchased components, (DC-DC converter, fan and voltage and amp meter) and the 3D printed case. You will notice that the purchased components are included in the drawings. I have found it is much more reliable to replicate a component that must be fitted with the 3D print and delete the replicated items before printing. The charger was going to be as small as possible so it was even more important in this application. 

The cigarette outlet in the back of my car can only handle 10 amps so the output of the DC-DC up converter which puts out 42 volts is current limited to ensure no fuses are blown. The mobile charger won't charge the two bikes in parallel as fast as two wall chargers but its not meant to bring them up from full discharge.

The case was printed in 3 snap-together pieces out of PETG filament so it could withstand the temperatures of the charger and being left in a hot car. I've had several things melt in a car here in Georgia that were printed out of PLA.

I haven't totally completed this project as I'm waiting on a 20 amp cigarette plug ordered from china on ebay. But all the testing looks good and I'm happy with the charge times.

 

Bike Charger Photo

   
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