Teachers all face storage problems. We have been looking for a way to store and charge batteries for our robots in the classroom. Organization of batteries is a problem many engineering and robotics teachers encounter when storing items and taking them to competitions. Our project will eliminate the problem of space and create a functional way to carry batteries on the go.

NOTE: We used recycled and re-purposed materials from our Career and Technical Center due to time & budget constraints. Many steps and materials can be replaced in this project, so this does not need to be specifically built like ours. However, this guide will show you the steps to creating this miracle on wheels.

Supplies

(4) 2x4x3
(7)Wood Panels 29 1/2 X 22 3/4
(4) 3D printed caster wheel adapters
(4) Caster wheels
(1) Nylon shoe rack
(7) Surge Protectors
(2) 3D printed handles
Assorted Screws
Spray Paint
Drill
Driver
Nail gun
Saw

Step 1: Step 1: Build Base

Take one wood sheet, 4 screws, and three 2x4x3. Place two 2x4x3 on each end of the wood panel 29 3/4" apart. Cut one 2x4 to 22 1/4" and place between the two boards. Drill two pilot holes in each board 21 1/4 inches apart. Screw the boards into place.

Step 2: Step 2: Attach 2x4s to Sides

Use two 2x4x3 on each side where the support beams are on the bottom. Drill pilot holes through the base of the boards into the bottom support beams. Screw the boards into the bottom support beams.

Step 3: Step 3: Attach Middle Section

Cut a rectangular space at the bottom of two sheets of wood panels. Measurements are 6 1/4 x 3 inches. Screw into both sides of supports.

Step 4: Attach Side Panels

Attach two wood sheets to the side support beams by drilling them on. Cut one sheet twice, with the measurement of 8 1/4". Attach above the side panels. Drill pilot holes 20 7/8" inches apart from each other on both.

Step 5: Fill the Excess Space

Because we used re-purposed materials, we had a space where we needed more wood. So, we cut one wood sheet in half and attached it above the board in the middle. This step can completely be omitted if you use plywood where you have the option to cut to size.

Step 6: Complete the Base for Storage

Cut two sheets of wood panels with measurements of 29 1/2" x 9". Attach them to the front and back of the side panels to create a storage space. Drill 2 pilot holes on each board 27 inches apart and screw into base.

Step 7: Finishing Touches

Spray paint
Cut a nylon shoe rack in half, then hang each half to both sides.
Add surge protectors
Attach 3-D printed handles to side boards.
Drill hole for surge protector to go through.
Screw the caster wheel adapters into the bottom support beams. Then, super glue the caster wheels into the adapters.

Step 8: If We Were to Make This Again.....

As stated earlier, we used completely recycled parts and 3D printed parts from our CTE center. When we revisit this project and make improvements we will make the following changes/adjustments:

We will use plywood instead of the thin wood panels
We will buy caster wheels and adapters instead of using recycled ones (3D printed adapter is not ideal for supporting the load - we used ABS filament)
We will measure school bus doors to ensure we can load charging station onto the bus. If this size does not fit, we will scale down the charging station or make other modifications.

Introduction: Mobile Charge Cart