The charger circuitry and 2 AA batteries fit into an Altoids gum tin, and will run your iPod for hours: 2.5x more than you'd get from a 9V USB charger! You can use rechargable batteries too.
iPod video (tested, using alkaline batteries): 3hrs more video (1 full recharge)
iPod mini (tested w/rechargeables): 25 hours more (1.5 full recharges)
iPod shuffle (unverified): 60 hours more (5 full recharges)
Weight (with 2xAA): 3.5oz
This project is suitable for beginners, some soldering tools are necessary but even if you've never soldered before it should be pretty easy. You can etch a circuitboard and/or breadboard this up, or simply buy the kit from the adafruit webshop.
I've also documented the process of designing this kit, in case other people interested in designing and making kits are interested in learning how to start selling their own kits!
This project was developed under support from EYEBEAM, thanks!
- This instructions are outdated, some
- minor changes have been made to
- the kit to make it better. If you're building
- a purchased kit please read the docs at:
- THANKS!!!! - ladyada
Step 1: The Process (Meta documentation)
I also include the schematic/layout files in Eagle format. The prototype one is best for etching at home (its single sided)
Step 2: The Process: Come up with an idea
*Aaron Dunlaps 9V USB charger
*Another 9V + 7805 USB charger (Instructables)
*Jason Streigel's 9V+7805 USB 'battery' (hackaday)
*Ians Firewire switching charger (Instructables )
*Chris DiClerico's 9V+AA's firewire charger
OK, there's probably even some I'm missing. So what's the overarching theme here? Almost all use 9V batteries and a 7805 (an extremely common linear 5V regulator: makes a solid 5V from 7-18V input). This design works great because, well, 7805's are awesome and 9V's provide 7-9V depending upon how 'dead' they are.
However, there's one thing about 9V's that I've learned (from lots of bad experiences). One is that they don't have a lot of amp-hours: that is, how much current (amps) they can provide and for how long (hours). A duracell 9V provides -about- 500mAh over its lifetime. That's 500 mA (or .5A) for one hour or 100mA for 5 hours. That number is somewhat idealized but its a good starting point.
Another problem is that they don't like to supply a lot of current, because they have high internal resistance (~2ohms), but basically that just means that if you want a lot of current (say to resuscitate a drained device) the 9V wont provide all 500mAh, but maybe more like 400. (Say you're drawing 250mA, then .25A*2ohm = 0.5V lost to internal resistance. For more info on 9V, read the duracell datasheet )
Another problem with the 9V+7805 scheme is that a 7805 is a linear regulator. That means if you want 100mA at 5V (basically, USB power) then you're taking 100mA at 9V and then losing the 4V*100mA = 400mW (.4W) difference as heat.
As the battery wears down to 7V the heat loss goes down to (7-5V)*100mA=.2W but you're still getting bad efficiency. At best the efficiency is 72% (5V/7V) and at worst its 55% (5V/9V) That means you're losing about a third of the battery power to heat!
I'll also throw out that the 7805 itself has a quiescent current of about 5mA so you're always losing 5% (5mA/100mA) efficiency just for regulation! (& that's at least since if you're trickle charging the battery at 50mA then the 5mA quiescent is 10%)
OK so basically the 7805+9V solution works but the efficiency is startlingly low, say 60% or so, and provides only 300mAh at 5V.
We can engineer better!
Step 3: The Process: Engineering a better solution
The process of how a boost regulator works is somewhat beyond the scope of this document, suffice to say they work great but are a little more annoying than linear regulators because you have to pick out an inductor and wire up some extra parts. You can get a lot more info about Boost Converters at wikipedia which is also where I stole the boost topology image from.
Step 4: The Process: Enclosure selection
I know that the parts for the kit must be all through-hole (no surface mount) and easy to work with. I also want AA batteries, 2 is good although I know from experience that most boost converters will work with any number from 1 and 3 just fine. I have a predilection for Altoids tins and I also know that I can fit ~2 AA's into a gum tin so I pull out a tin and take some measurements.
OK 2 AA's fit well, so now I rummage through my collection of battery holders and find one (PCB-mount) which seems to be pretty good, it doesn't have a switch but I don't need one anyway (see quiescient calculations, later on)
So I take some measurements...Looks like I have about 1.25" x 0.7" semicircular PCB space at the top for the circuit board.
I also try out another battery holder I have, this gives me more space, 1.25"x0.85"...but the batteries go in sideways so one would have to remove the holder to change the batteries. I'd prefer that you can just take them out directly, so I don't go with this one (it also turns out I don't need that extra space)
(I now do a little hack to turn the PCB mount 2xAA battery holder into a wire-lead one. Basically I just solder on red and black 6" wires and clip off the PCB through-hole leads. This is actually a little difficult because the plastic melts and you have to sort of keep it in place while you solder. Its not suggested :) )
Now that's done I'm ready to think about what I can cram into that space.
Step 5: The Process: Boost chip selection
- 8-DIP package
- Internal FET switch
- 100mA output @ 5V
- 2V minimum input voltage
I then select 1 output, 8-DIP (to differentiate between 18-DIP) and select all the current-outputs >=100mA and apply the filter. There's till about 40 options. So then I select the all voltage input ranges that start with 2V or less. Also I select all the Adjustable, and 5V-inclusive output voltage options
Looking over this list, it looks like I have a lot of options so I'm going to go back and select only the chips that can be preset to 5V (as opposed to adjustable ones that use 2 resistors to set the voltage). 5V is very common so every reasonable DC/DC chip will be available with such an option.
Now there are about a dozen options.The LT1073, LT1111, LT1173 and LT130x as well as the MAX751 & MAX756. They're all pretty much the same, so I basically make my choice based on price at 100 pieces (since I'm planning to kit it up). I also know that Maxim is great about sending samples so I decide to go with the MAX756 (datasheet) which is $2.32/100. Note that I could have gone with any of them, so this a somewhat arbitrary choice.
According to the datasheet, I can supply up to 200mA @ 5V, run off input voltages as low as 0.7V and the efficiency is about 85% with 2 AA batteries. The chip also runs at 500KHz which is pretty fast and means that the inductor can be pretty small (~22uH) Anyway,I've used this chip before and its worked out well for me.
Step 6: The Process: Inductor selection
What we want is through-hole, which actually means its going to be hard to find an inductor; almost all inductors are surface mount. But I'll take a look at what digikey has to offer. I search for "fixed uH inductor ~smd ~smt" which means I don't want SMT/SMD (surface mount) and I want a non-adjustable inductor that is in the uH range (not mH or nH). I then filter out inductors with 1-3A current and 18-27uH inductance.
That filters it down to about a dozen choices. The SLF inductor is actually surface mount, and we're going to outright ignore the ones that cost more than $2.50. Inductors for small electronics like this should cost around $1-$2, as a guideline. That leaves us with the DN7418-ND "INDUCTOR 27UH POWER AXIAL" and the 6000-220K-RC "INDUCTOR HI CURRENT RADIAL 22UH." Both of these look good, with about ~1.5A saturation current and 0.07 ohm DC resistance.
I also check out Mouser. The online search for mouser isn't as nice as Digikey's so I end up looking at the paper catalog instead. I only found one inductor, really, the 18R223C (22uH radial power inductor) and/or the 18223C (axial version) that also has plenty of power capacity and a 0.03ohm DC resistance.
So, order 2 of each of these.
Step 7: The Process: Rapid Prototyping
The circuit itself is simple, I want one large electrolytic cap for low frequency smoothing on the battery, and an output cap pair (electrolytic and one ceramic cap for high freq. smoothing). I also need the chip, a reference voltage capacitor, the inductor and a schottky diode to finish off the boost regulator. I happen to have some 1N5818's, which are often used as schottky diodes in boost regulators. I also need a USB type A female jack, of course, and two holes to solder the battery pack into. You can compare the schematic to the topology diagram in step #3 keeping in mind that this chip has an internal transistor switch.
All these parts must fit into the space left over from the battery pack. I make EagleCAD library parts for the inductor and chip (the rest are already there) and lay out the board. I'm not going to detail making library parts in eagle or pcb layout, others have done so already. Use whichever software you want, I like Eagle because there's a free version available for download if you're just making small PCBs.
Since I am know this is just a prototype version, I make the PCB single sided -- for easy etching. I also make the traces really large. I print out a paper version of the PCB and punch the parts through to verify that they're the right shape/package.
I get my etching setup together, turn on the heater for the etching tank, and print out a bunch of tiled PCB layouts on toner transfer. I transfer the toner onto a single sided PCB and etch it in the tank
Then I clean off the toner transfer, drill the holes with a dremel drill-press with carbide drill bits, and cut out the shape.
Then I solder the parts in, and fit it into the case with the battery pack, using double-sided foam sticky tape to hold down both the battery holder and the PCB without shorting the PCB to the metal tin.
Step 8: The Process: Prototype testing
Its also time to verify the math for efficiency: how good is it, after all?
So, in theory, we should be able to calculate the efficiency of the boost converter from datasheet info. We're basically boosting 2.5-3VDC -> 5VDC at around 50mA-100mA. Looking at the MAX756 datasheet, note the efficiency graph.
So we should be getting around 85% efficiency, perhaps a little more. I think the only thing that can really change this number a bit is the inductor. (Below, I verify I'm getting 82% efficiency)
If we're getting 82% efficiency conversion from 2 x 3000mAh Duracells, that means we get (2 * 1.5V) * 3000mAh * .83 = 7.38 Watt hours. Compare that to a single 9V as we calculated before: (1 x 9V) * 500mAh * .65 = 2.93 Wh. So we're going to get about 2.5x more power out of these two AAs than a single 9V.
With rechargeable batteries, we get (2 * 1.25) * 2200mAh * 81% = 4.45 Wh (about 50% more than an alkaline 9V and 3x more than a rechargeable 9V)
Next, lets verify the efficiency using test equipment, and try out the different inductors to see if they make a difference. Instead of using batteries, I'll provide 3V from a bench supply that will also tell me how much current is being drawn. And instead of an iPod I'll fake the load with a resistor. Since the standard USB current draw is 100mA from 5V, that means I need a 5V/.1A = 50 ohm load. I can't just use a tiny resistor because 5V * .1A = 1/2W and most resistors are 1/4W. So instead I take two large 100ohm 'power' resistors, and twist them together. I also check the resistance to verify that together they are 50ohms. I also find a 20ohm power resistor. This will allow me to not only test a 100mA load but also a 250mA load.
I perform 4 tests with 2 inductors: 100mA load for both 2.5V in and 3V in (rechargeable and disposable batteries) and 250 load for both.
My results are summarized in a table attached as the second image
It looks like inductor #2 is little more efficient, probably due to the fact it has a lower DC resistance (30 milliohms instead of 70mohm of the other inductor). It's also a bit cheaper so I'll go with that inductor.
Regardless, it looks like the efficiency is around 82% which is about what I expected.
Another thing to note is that I don't put an on/off switch in like you'd need with a 9V+7805 regulator. That's because the quiescent current of the MAX756 is very low, on the order of 100uA (0.1mA). I measured this myself and got about 75uA.
That means that the self-discharge rate is ~2000mAh / 0.1mA = 20,000 hours, more than 2 years. Most batteries don't last that long! Therefore we don't need a switch, when nothing is plugged in, almost no power is being used.
(in the end, i found another radial inductor that was cheaper and as efficient, which is what I use in the kit)
Step 9: The Process: Kit budgeting
I tend to decide whether I want to sell something based on how popular/useful/easy it is. I think that this kit will be pretty popular and useful because lots of people have stuff that charges/powers over USB. Also, it seems like other people are selling similar things (like the 9V + 7805 type charger, or Griffin's 9V charger, or Belkin's 4xAA charger) It's easy to make because all the parts are through-hole and there's not a lot of them.
I'm going to basically assume I'll sell 200 or so within a few months, and I'll order parts in batches of 100, so I should budget that way. (I often buy more than 100 PCBs at a time because of the scale economies involved in PCB manufacture, as I show later.) It turns out so far that I can sell a couple hundred units of a kit in a few months, particularly if it gets picked up by a blog or web site. This may or may not be true for you, however if you cant afford to make 25 kits at once you're going to find that its hard to make any money in the process.
To figure out how much to charge, I make up a table with different quantity prices
To calculate the PCB costs, I used Advanced Circuit's insta-quote service.
These prices are for 2 PCBs, which I'll cut in two, because its cheaper (probably because they don't like dealing with very small circuit boards). I usually go with 2 week turn prices. Note that the PCB quote doesn't include the $150 one-time tooling NRE fee, which adds $3 to the /50 price and $1.50 to the /100 price. Advanced Circuits is a little expensive, but they're very good on quality and they're good at catching mistakes. Anyways, you can try going with a cheaper shop but I can only vouch for these guys.
There's also shipping prices included, maybe $1/per. In general, I double the parts cost to come up with the 'retail' cost. In this case, I'll charge $19.50. Anything less than $10 or $20 is great because $20 are considered to be stuff/food coupons, really.
Step 10: The Process: Finishing up!
I actually do another etch test, to verify eveything one last time. Then I tile two boards together (cheaper) and generate gerbers.
I use gerbv (free software) for viewing and verifying the gerbers. On windows, I use GC-prevue
I always check the boards with www.freedfm.com before I ship them off to be made. I used 4pcb.com so it's the same company but even if you don't go with 4pcb.com as your PCB manufacturer, it's a neat service.
A week later (depending on your turn time) A box shows up with the circuit boards!
Then I sit in front of a computer and do a lot of website stuff. I also take a lot of photos. A good photo setup will make documentation easy. I have a simple 150W ECT bulb + diffuser setup at EYEBEAM. A tripod is key!
Step 11: Make: Tools
First get your tools together. There are a few tools that are required for assembly. None of these tools are included. If you don't have them, now would be a good time to borrow or purchase them. They are very very handy whenever assembling/fixing/modifying electronic devices! I provide links to buy them, but of course, you should get them whereever is most convenient/inexpensive. Many of these parts are available in a place like Radio Shack or other (higher quality) DIY electronics stores.
Step 13: Make: Place diode and electrolytics
When you put the parts in, bend the wire leads out a little so the parts stay up against the board when you turn it upside down to solder.
Step 14: Make: Solder
Make sure the iron is 650deg. Touch the tip at a 45deg angle so that its heating both the hole/ring and the wire lead, then touch/poke the solder in with your other hand.
Step 15: Make: Clip
Step 16: Make: Place ceramic capacitors, inductor & jack
Solder these parts in too. When soldering in the USB jack, make sure to put plenty of solder in the two large side holes: they are the mechanical connection for the jack. If you don't make a good solder joint (filling in the hole completely with solder) then the jack will eventually break! So do a good job.
Step 17: Make: Clip 2
Step 18: Make: Final soldering
Solder the pins of the socket, and the two wires. You might have to hold them against the board from underneath, if they seem to be slipping out.
Step 19: Make: Done!
Step 20: Test: Make sure it works
Step 21: Case: Mintification
You'll need the MintyBoost kit, an empty gum tin, a pair of tinsnips and two pieces of doublesided foam sticky tape (the tape is included in the kit).
Step 22: Case: Cut
Step 23: Case: Bend
Step 24: Case: Test fit
Don't put the batteries in for this test! The circuit board could short against the tin and destroy the circuit!
Step 25: Case: Final fit
The tape keeps the circuit board in place as well as keeps the pins from shorting against the tin
You might have to push down on the battery holder once its in, to "pop-out" the bottom a little...the case will not quite close otherwise.