Many compromises were made in the name of convenience
Power ratings, wireless relays, complex logic between the switches, charging from the back EMF generation of the motor - These things are gone. Once you sit down in a lab with only the parts you have, the tools you have and limited time, you need to choose what you are actually going to use this box for.
- The number of boost converters has been reduced from 10 to 7.
- There is no wireless control.
- The switches now directly control the current (no high current relays)
- The boost holder has been physically cut in half to allow for more room.
To summarise what's left:
Power flows from the batteries (5-10 AAs) and into the boost/buck converter that then chargers the supercapacitors with a constant 0.6-0.8A. These banks of super caps are balanced by two parallel balance boards. The output of these caps then goes to 7 boost converters connected in parallel that then connects to the output. Of course, all of the switches and panel meters for displaying the status of everything important remain.
![](https://cdn.hackaday.io/images/2699331477802454192.jpg)
On top we can see the wrapped super capacitor bank, which is sitting on the 7 boost converters in the 3d printed holder. The boost/buck converter is floating freely wrapped in black tape:
Problems!
- I made a mistake with some grounding assumptions and the charging circuit is well and truly dead. However, it did its job successfully for quite a while. Another board is on the way!
- Due to my rushed solder job (don't judge) I overheated the contacts of 3/4 of the panel meters and internally de-soldered contacts. Luckily, when I paid my parents a visit, Dad suggested and carried out a fix that he was very familiar with (these panels are almost $20AUD each).
- I completely ran out of space due to the magnitude of the cables coming out of the 7 boost converters, which simply took too much room. As you can see, half of the box is filled with panel equipment and vacant space criss-crossed with wires. I believe I will have to make the battery mount external (glue it to the top lid). This is okay though as then I don't have to open the box again (there is leaded solder everywhere).
Discussions
Become a Hackaday.io Member
Create an account to leave a comment. Already have an account? Log In.