This is "How to Install a USB Charging and 5 volts DC power circuit in your Motorcycle."
I wanted more power in my charger, and I wanted the flexibility to do more with it like hook up a Raspberry Pi... so, here is this instructable on how to get it started and installed.
Some highlights of my install:
- Custom cabling was made with CAT5 (white) and used the TIA-568B standard
- Allows charging at the triple clamp and in the trunk
[NOTE: 12/5/15 I've finally continued to document my work and share it on Instructables. My charging circuit is not home grown anymore. I currently run 3 of these http://www.batterytender.com/Chargers/USB-Charger-... on a BMW S1000RR. These chargers are plenty for a Raspberry Pi, a screen, an iPhone, etc... my work is focused on getting new technology to work on mobile, not creating something that I can find off the shelf for a reasonable price. I decided to save time and install these instead. I wired them up to the battery, put two in the trunk and one by the triple tree. I had to install an extension by soldering it and using heat shrink to protect the solder points.]
Step 1: Why Would You Want a USB Charger on Your Motorcycle?
2. To charge your GoPro, but I would personally rather use a Raspberry Pi ;-)
3. To power your Raspberry Pi!
4. To power your Radar or GPS
In my setup we do not use an inverter or those small USB chargers that plug into a cigarette lighter socket. Instead, we use a DC-DC converter (DC to DC converter) that provides 5VDC + at up to 3A.
This allows us to more than enough power and allows us to efficiently, and reliably have a 5VDC charging circuit on our motorcycles.
In my experience the little adapters you buy at retail tend to fail after a while. This setup has proved more reliable and efficient.
Step 2: Tools Needed to Install USB Charging and 5vdc Power in Your Motorcycle Using the TIA-568B Standard With CAT5 Cabling and Connectors
- CAT5 Crimper
- CAT5 Stripper (Orange)
- Shears (Scissor)
- Wire Strippers
- Small Screwdriver set
- Needle Nose Pliers, curved are advantageous but not necessary.
- Soldering iron
Step 3: Parts List for Mobile Charger...
(1) Perf board
(2) CAT5 Female RJ45 Jacks
(1) Approx. 15ft CAT5 cable, white or whatever is your preference or within your budget...
(1) about 5 inches of solder
(2) Female USB Jacks (from Jameco)
(1) Mini Fuse Holder (from Jameco) make sure to get fuses at 3A or higher
NOTE: I tried the Meanwell SCW12A-05 (from Jameco as well) but it did not give me a solid 5 volts out so I upgraded my setup to the more reliable SKE15A-05.
Step 4: Prepare Your Circuit/idea/materials... for the Build of an Awesome Mobile Charger
Start with laying your materials out in an organized fashion, this is important to get a nice circuit with minimal frustration.
I layed out everything on a table first:
- DC-DC Converter
- Perf Board
- USB Connectors
- CAT5 RJ45 Female Jacks
This allows me to get a visual of what my circuit will look like in the end. It also allows me to temporarily test the circuit (with tape if need be) or with jumper wires.
As I am going along prototyping I constantly take measurements to ensure I have a good fit, especially since we are doing this on a motorcycle with limited space.
I do this many times before I am done, even though it takes longer but it will be worth it said the grasshopper.
Step 5: Start Soldering, Stripping & Crimping... Solder Your 5v DC Circuit So You Can Have Some Fun on Your Motorcycle ;-)
Proper crimping is essential, and this requires proper stripping of the cable as well. I use two pair of CAT5 wires for each conductor (positive and negative.)
For the connectors I use standard automotive type crimp connectors to go to the battery. For the back of my circuit I solder everything by putting my DC-DC converter on a perf board and then attaching wires to the back.
For the USB connector I bought dual connectors from Jameco and only soldered the negative and positive leads (pins 1 and 4.) If you are charging an iPad or iPhone you may need to add some voltage at pins 2 & 3 (more on that later, iPhones require a voltage on the data pins to charge.)
Step 6: Install the Charger in the Trunk and Connect to Battery
In my circuit I wired the connectors straight thru with the TIA-568B standard for CAT5 cabling. This worked out nicely and I can easily cross connect power in my circuit with a normal store bought CAT5 cable (but I make my own so I can make custom lengths that are just right for the motorcycle.)
Step 7: Completed Custom Charger for Motorcycle or Mobile
From here you can integrate the USB ports into any custom molding or enclosure. I simply heat shrank the USB connectors after I soldered the power leads from the CAT5 cable. The heat shrink for this had to be at least 5mm in diameter.
For the trunk I ended up cutting out a box on the laser cutter that would hold the DC to DC converter, and a fuse. I cut this out of clear acrylic and added the Suzuki GSX-R logo. It sits under the seat so you don't really get to see it, but that's just the way I like it.
P.S. I will promise to improve this instructable with more detail, comments are encouraged as I hope some people are able to make these on your own. Good luck and remember, if you got tape on it it ain't done yet, or uhh maybe it's a prototype...
Step 8: Advanced Topics
Here are some ways to use CAT5
- for servos
- for Micro USB cable
- for Lightning Cable
- for LEDs