How to Charge Any USB Device by Riding Your Bike

Step 9 Future Plans

In order to make the device more economically viable as a consumer product, several improvements must be made in the areas of weather-proofing, circuit streamlining, and cost reduction. Weather-proofing is critical to the long term operation of the unit. One technique considered for the motor was to encase it in a Nalgene container. These containers are known for being waterproof and nearly indestructible. (Yes, we ran over one with a car to no ill effect.) Additional protection was sought against the forces of nature. Expansion foam would seal the unit, however the material has limitations. Not only is it difficult to position properly, but it would also prevent ventilation essential to the overall operation of the device.
As to the streamlining of the circuit, possibilities include a multitasking voltage regulator chip and a custom printed circuit board (PCB). The chip could replace multiple voltage regulators, this would decrease both the product's size and heat output. Using a PCB will provide a more stable base because the connections will be directly on the board and not floating beneath it. To a limited extent it will act as a heat sink because of the copper tracing in the board. This change would decrease the need for excessive ventilation and increase component life.
Cost reduction is by far the most important, and difficult, change that must be made to the design. The circuit itself is extremely inexpensive, however the motor costs $275. A search is underway for a more cost efficient motor that will still meet our power needs.

Comments

[Rainbowjeremy]

An easy solution to the streamlining and weather proofing of the design would be to replace the generator that the team built with a dynohub, a genarator that puts out 6v and is built into the hub of the front wheel.
http://harriscyclery.net/itemdetails.cfm?ID=2974