Simple iPod USB charger

In this instructable, I will show you how to build a simple iPod charger! It's easy to make and modify, and is built to charge as fast as an official Apple USB charger.

Before we start, here's a little note:
###############################################################################
DISCLAIMER: I'm not responsible for any damage of any kind to humans, materials, etc. by the use
and construction of this device. By using this device, you must agree to this condition. Otherwise, you
musn't use this device.
###############################################################################

Sorry for some bad pictures, but they seem to went through a pixelation filter while uploading. You can see the original pictures by clicking the "i" in the top left corner of the picture.
Also, sorry for my bad English.

Feel free to comment or to pose questions!

Are you ready? Let's get started!

EDIT: added pcb in Eagle format.

Step 1 The things you will need

To make this charger, you need this (common available) components:
-a 7805 voltage regulator
-a 1000µF, 35V electrolytic capacitor
-a 4.7µF, 15V electrolytic capacitor
 -2* 100nF capacitors
 -2* 5k (multiturn) trimmers
 -a USB connector, type A, female; or you can demolish an old USB cable
-a power supply that can provide at least 7.5V, and 1200mA
-a DC jack
-wires
-sticky, rubber feet
-a prototyping board
-solder: use 60/40, raisin core solder
-a 5K/W or better heatsink with M3 mounting bolts
-silicon cooling paste

And this tools:
-a soldering iron
-a sponge (to clean your soldering iron)
-diagonal cutters
-tweezers may be handy
-a iron saw
-a basic range of screwdrivers
-a screw or a drill
-a solder sucker or desoldering braid
-a basic multimeter that can measure resistance, and DC-voltage

You will also need this skills:
-you must know how to solder, if not check this video: http://www.youtube.com/watch?v=I_NU2ruzyc4
-basic electronic skills
-you must know how to use your multimeter

Comments

[iApple guy]

A couple Queshtons:

1. Will this work with iDevices that need power through the data pins
2. Is there enough current to charge an iPad. If not how can I make it able to charge a iPad... Schematic?

[heatseeker96]

1: They don't need power through the data pins, devices like the iPhone, iPad, iPod touch,... need a certain voltage on the data pins to tell how much current they may draw from the adapter (the 2 trimmers do that work).

2: I don't know, but one of my friends has an iPad 2, so I will do some testing tomorrow and let you know if it works. Else, I will look at the official iPad charger to see how I need to improve the design.

[iApple guy]

Should I post a picture of the side of the charger that has all the info on it amp, volt, current, etc.?

[heatseeker96]

I've done some testing and the result is: it works with the iPad 2! (propably with the other iPads too).
But, I think it charges a bit slower than the official charger, if you want to test/change this: cut an old usb cable in half and put it in the official charger, measure the voltage on the data pins (please tell me your results, I don't have any spare cables), adjust the 2 5k trimmers to the same voltages, use an adapter that can supply at +/- 2.5 Amps and replace the 7805 with a 78S05 or a 78T05 (you also need better cooling and I highly reccomend using thicker cables).

[heatseeker96]

No, thanks. I need to configure an iPad for one of my friends and he has given me the charger, cable,... to do that. I will post the results in a few hours.

[akimirza]

hi
what cooling paste?
It should be silicone paste...

[heatseeker96]

Isn't that the same? I don't have many experience with it, but on my tube it sais: "silicone grease" when I asked for cooling paste (it works fine).

[silencekilla]

Will this work with the iPod Touch 4G?

[heatseeker96]

It should work with the iPod Touch 4G. I've used the original discovery of Ladyada when she disassembled an official  Apple charger. ( http://www.ladyada.net/make/mintyboost/icharge.html ) I wanted to make a MintyBoost! from their site, and found that page, so I created this charger (until I've the money for the MintyBoost! kit).

[silencekilla]

thank-you that was one of the most informative reply's i've ever gotten on here and 5*'s for the instructable.

[heatseeker96]

You're welcome! (Thank-you for rating!)

[silencekilla]

Do you have any availiable PCB files for this project? If so where can i find them. I am also subscribing to you here on instructables and hope to see more fantastic electronics projects like this one.

P.S. ONE FINAL QUESTION (.........for now ) Where did you find such a big heatsink i've been looking for ones like thoughs for a while now and havent found a single one anywhere. Please let me know. Thank You

[heatseeker96]

I can create a pcb (eagle) if you want that.

I'm using a Velleman heatsink, type ML97/1.5 dimentions: 42x38x25mm, thermal resistance: 5K/W It's a bit overkill with my new adapter, but it's designed to operate at 12V, 1A, roomtemp: 35°c or below, and still keep the 7805 below 115°c (it can handle 125°c).
I couldn't find a company that sells them to USA, but if you are European, you can order them from Conrad. You can also try Ebay.

[inhaos]

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