This is my 8th instructable. In this project I have reused my old laptop battery, I recycled an old mobile charger. The laptop battery wasn't charging the problem was with two of li-ion cells connected in series to the battery. There were six of them I removed the damaged one and reused 4 undamaged li-ion cells. This Powerbank is green because it gets charged by solar as well as mechanical energy(e.g. moving wheel of a cycle ).
I got this idea 2 months ago. Me and my family were going on a road trip. we were in hurry. My Father's phone was discharged so he took the powerbank. When we crossed half of the journey our car's tire got punctured. My Father had the number of mechanic so he connected his phone to the Powerbank. But..... the Powerbank was also discharged. We waited there for too long for someone to help. As its rightly said necessity is the mother of invention. That time I got this idea, a Powerbank that gets charged by solar energy and rotatory or mechanical energy.
It has a emergency flashlight, Music reactive LEDs and Speaker. Its compact easy to handle and above all its Green i.e. runs on renewable source of energy.
Remember when you will charge it you will charge its li-ion cell, so it has a main switch, that changes the Powerbank from charge to discharge mode. Another pushbutton switch switches the L293D IC and starts the speaker and LEDs.
Please appreciate my hard work, vote for me in the contest and kill that follow button.
If you want to make one for yourself than all the parts are available on digikey store. Its a good site.
Here's the link to video
Here is the solar charging.
Step 1: Parts
For makers in U.S. you can search these parts on digikey. Add filters and buy what you like.
• 1 * Hardboard
• 1 *Old laptop battery(or li-ion cells)
• 3 * 5V voltage regulator(here7805)
• 2 * DC Adapter jack
• 2 * White LEDs
• 4 * Blue LEDs
• 1 * Audio jack
• 4 * Switches
• 1 * LM386 IC module
• 1 * 8 ohm speaker
• 2 * TP4056 Balance Charging Module
• 1 * TIP 35 or 31
• 3 * Voltage reg. Heat sink
• 1 * Motor
• 1 * 5V solar panel
• 1 * DC 10V adapter
1. Hot glue
2. Soldering iron
3. Solder wire
6. Rainbow Wire
7. Wire cutter / stripper
8. Poster Colors and Brushes
Step 2: Battery Breakdown
Break open the laptop battery stealthily with a screwdriver and cut the cells apart and check the voltage of each of them through the cells which show reading below 1V and keep the rest ( they CAN be used).
Be careful while doing this select the right multimeter slot and prevent short circuit.
Note: Lithium -ion cells are not meant for beginners because they have high power density.
Step 3: Assembling the Battery
We want an output of around 5V each cell is around 3.8V. Therefore we will connect 2 batteries in series and 2 in parallel. Solder the batteries with wire and take 2 extension wire out of it. DO NOT CONNECT + AND - OF SAME BATTERY.
Step 4: TP4056
Be careful while soldering TP4056 with battery because accidentally when I was connecting the - terminals together I connected + of a cell to its -
The battery is divided in 2 sets each consisting 2 cells connected in parallel and these 2 sets will be connected in series so to give a thresh hold of 7.01 V.
Connect + of Set 1 to Bat+ pin of TP4056 and - of it to Bat- .
Use another TP4056 for Set 2 and follow the same.
For easy handling tape each Set .
Step 5: Mains
In this step we will make a main switch for the Powerbank that will
join the 2 sets in series when to be used to charge mobile and will connect t the same to sets in parallel on charging of Powerbank.
Connect IN- of both the TP4056 to the 2 terminals of switch.
Connect positive of Set 2 and negative of Set 1 to opposite ends of switches(so that at the same time when these two are in contact inside the switch the - terminals are disconnected)
Now when positive of Set 2 and negative of Set 1 are in contact than positive of Set 1 and negative of Set 2 has a potential difference of 7.01V.
I colored this switch red because its not meant for playing.
I will try my best to explain you the circuit in next step.
Step 6: Speaker and LEDs
Solder all LEDs in parallel and then take 2 terminals out of it .
Solder the GND of audio jack to the third pin of TIP. and any one of the other to the first pin of TIP.
Solder the + terminal of LEDs to + of battery and negative of LEDs to TIP middle pin (follow the circuit).
Solder the speaker to the module. There is no +/- in speaker solder directly. Take 2 terminals out of battery and solder to +/- of LM386 module.
Solder audio jack positive and negative to LM386 signal pins.
Note: Details on making an audio amplifier is not given here. You should must look at some audio amplifier instructables . Or search the web for Great Scott, he is a great guy.
Step 7: DC 10V Adapter and 7805
This adapter is used to charge the batteries via electricity.
Solder a DC adapter jack to PCB take the Positive terminal from it to 7805 reg. 1st pin and the Negative terminal to 7805 middle pin. Do the same for one more 7805(on the same jack). Take the third pin(7805) to IN+ of TP4056 module do the same for another module too.
Top Tip: Connect appropriate heat sink to 7805 voltage reg. because they become very hot when in use.
Step 8: Solar Charge/ Mechanical Charge
Its time for Soldering! Load you weapons and come to the battle field. Solder a 5V voltage regulator to PCB.
Now solder positive terminal of DC adapter jack to the first pin of 7805 and the negative to the middle pin. Solder a switch to the third pin of 7805 and join the other terminal to TP4056 IN+, join IN- to the middle pin of 7805.
Now the Powerbank is ready to be charged by solar energy just insert the adapter of Solar Panel to jack and switch the button , it will charge.
Step 9: Connection Final
This step involves the connections of the Powerbank. I tried my best to explain than also if something is missed out, please comment.
TP4056: Connect positive terminal of Set 1 to Bat+,Connect positive terminal of Set 2 to Bat+(of other module).
7805 regulator: There are 3 7805 voltage regulator used here 2 for DC adapter, 1 for Solar charge. 1st pin of it is input voltage, 2nd is ground, 3rd is output. For efficiency you can also add capacitor to it.I didn't add a capacitor.
That's it for this step.
I have drawn the circuit on an art sheet sorry for my poor hand writing.
Step 10: Flashlight
Take 2 LEDs solder them in series and with a switch attach them to + and - of any Set
Step 11: Taping
Tape all the open wires to minimize the risk of short circuit. Tape the batteries together. Proceed to next step.
Step 12: Old Charger Breakdown
Carefully break the charger with help of a screwdriver. Do not apply to much of force because it may damage the inner parts(e.g. resistors capacitors etc.)
Take out the circuit board, find a capacitor rated above 220 V solder 2 wires to it attach these wires to the + of Set 1 and - of Set 2 .
Be careful with polarity, capacitor + to Battery +.
We will use the charger pin to charge mobile phone.
Step 13: Enclosure Built
Enclosure is your choice I chose an isosceles trapezium. Mark the hardboard, cut it, drill it and its done proceed.
Drill holes for LEDs and a large hole for speaker.
For cutting use paper cutter.
Step 14: Hot Glue Time
Now its gun time, place everything and hot glue them. Place the batteries one over other glue them. Glue the hardboard and proceed.
Step 15: Painting
I chose poster colors which was a bad idea. Choose acrylic ones. I colored it white first thereafter I made a green coating over it. Color and design depend on your creativity.
Step 16: Test It
I connected my phone to it and it was charging perfectly(because its a powerbank). Speakers are good, LEDs and Flash is working fine. Its getting charged very well by solar panel and DC Voltage. The only problem I faced was that the indicator LEDs of TP4056 were hidden. They should have been visible.
Step 17: The End
Thanks for reading 17 step "not so interesting but useful instructable" Please appreciate the efforts and follow me plus vote for me in the contest. Thank You!