|
|
|
Thread OP
|
High Power Portable Charge Station w/ Revolectrix Bump Controller and Android Tablet
Hey everyone,
I'm one of the Beta testers of the new Revolectrix Bump Controller and have posted some pics of my new charge station in the Bump Controller sneak peek thread (see resources below). Between the BC sneak peek thread and my local club, there seems to be quite a bit of interest in my new portable charge station so I created this thread to share the details for those interested in building their own or something similar. Parts List (my setup) Carrying Case - Home Depot Ridgid 22" Pro Organizer http://www.homedepot.com/p/RIDGID-22...2571/205440492 Plastic Deck - ABS Textured Plastic Sheet 1/8 Thick x 12 x 24 http://www.amazon.com/gp/product/B00U7X8RT6 Android Device - Any Android Smartphone or tablet that has Bluetooth 4.0 with Low Energy (aka Bluetooth Smart or Bluetooth LE) I am using a Samsung Galaxy Tab Pro 10.1" tablet because I wanted a BIG screen. One Beta team member uses a $50 Digiland 7" tablet (DL701Q) http://www.bestbuy.com/site/digiland...=1219354106671 (on sale for $39.95 at the time of this posting) Control Unit - One Revolectrix Bump Controller http://www.usastore.revolectrix.com/...-Controller_64 Chargers - Two Revolectrix PowerLab 6 http://www.usastore.revolectrix.com/...PowerLab-6_134 Power Supplies - Two HP HSTNS-PL11 75 amp converted for 12/24 volt 1800 watts of power https://www.rcgroups.com/forums/show....php?t=2538703 Parallel Charge Boards - Use your favorite charge boards or charge cables. Cooling - See list below Two 92mm x 25mm Fan 12V DC: http://www.ebay.com/itm/171167931291 Two 92mm Black fan Grill: http://www.ebay.com/itm/261264106277 Mounting Screws for Fans/Grills: http://www.ebay.com/itm/260628733511 Case Thermometer - 12 Volt DC Digital Thermometer http://www.ebay.com/itm/141731838162 AC Power Cables/Connectors - See list below C20 Power Inlet: http://www.amazon.com/gp/product/B00917YWMK C19 Power Cord: http://www.amazon.com/gp/product/B00GMPVAJM Dual C13 Y-Splitter Cable: http://www.amazon.com/gp/product/B00KWTT046 Resources Bump Controller Sneak Peek and Beta team Thread https://www.rcgroups.com/forums/show....php?t=2518304 Notes: Case Temp Monitoring - The addition of the mini LCD 12 volt Digital thermometer shows me what the under deck air temperature is. Charger & Bump Controller Monitoring - The Bump Controller displays the temperature of the chargers and the Bump Controller. The Bum Controller also provides power supply voltage and current for each charger and in total. Charger Operation Monitoring - Bump Controller and Android phone/tablet give me all the of the information I need for what setup and charging operations. Cooling Holes - I used a 1" diameter hole saw to drill the deck and carrying case. Do NOT try to use a spade type drill bit in plastic - it will not work out well. Ask me how I know! Mounting Power Supplies and Chargers - I used 1"x4" Extreme Grip Velcro to mount the two power supplies to the bottom center of the carrying case. Supplies are side-by-side. I used standard 3/4" wide Velcro to mount the Chargers to the bottom of the carrying case. The front of each PL6 charger sits on top of the 92mm fans attached with standard Velcro. I added a 1/2 wide wood flat surface to the fans edge so the Velcro had a good surface to stick to. The wood flat was glued to the 92mm fan using contact cement. Carrying Case Prep - Remove the six orange bins and two slide in dividers from the bottom of the case. Then pop the top plate out of the carrying case lid so that you have the full depth and width of the lid area available to mount your tablet and/or store power & charge cords. It's a bear to get out but once you get one edge started, you will be able to pop it out. Next, drill baby drill... Drill the 1" holes in the bottom of the carrying case. Drill lots of them. These will serve as the cooling intake as I have my fans blowing out of the case (bottom when case is open and resting on a table ready to charge). Deck Prep - Cut deck to size. If you are mounting a Bump Controller under the deck as I did, you will need to cut a rectangular hole in the deck and drill four 6-32 size screw holes. I made 1/8" plate about 7-1/4' x 3" to hold the BC up under the deck. (note - the Bump Zone sticker should be available from Revolectrix after/around the release of the BC in Jan 2016). Drill three 1" holes in the deck. two in front for the charge cables and one in the rear center for task lighting or other cables can come thru near the hinge line if needed. Put a rubber grommet in each 1" hole to dress up the hole and protect cables from chaffing. Cut a rectangular hole in front case in handle area for the digital thermometer. Cut rectangular hole in rear of case and drill two screw holes for mounting of the C20 power socket. Install your gear! Note - you will need to cut off the single end of the Y-splitter power cable and solder the leads to the correct terminals of the power inlet. The dual Y outlets plug into your power supplies. Get stuck and need help - ask your questions here. Best, Chris |
|
|
Last edited by JC Spohr; Nov 08, 2015 at 10:57 PM.
|
|
|
|
|
|
|
Thread OP
|
Please note that my setup is not 100% complete yet. I still have to mount the tablet and power & charge cord holders in the lid area.
One other note on the deck. I cut it so that it sits down on the front and back edges of the carrying case where the top of the removable dividers were. I added a 3/4' wide strip of the scrap extra from cutting the deck to each side of the case using contact cement. This provides side support of the deck. My deck is friction fit and is not screwed or velcro'ed down. To pop it open and get at the under deck components, I just stick my finger in one of the front 1" cable holes. Best, Chris |
|
|
|
|
|
||
|
Quote:
Glen |
|
|
|
||
|
|
||
|
Thread OP
|
Quote:
The fans do raise the noise level and are probably overkill but I wanted to ensure that on a hot Summer day that there would be no overheating issues. I think I met that design goal and then some.  Chris |
|
|
|
||
|
|
|
|
|
My Case
Hi Chris,
Per your request I am posting my charge box. (I'm the guy who asked for the dimensions of the bump controller in that thread). I had obvious inspiration from the RC Squared boxes. I have a CNC Router and a Laser cutter so using all my tools is a real treat. There are red LED's below that light up the JR DMSS window, also, those are the text writing fans for extra bling. I ordered the tablet you gave in the first post. The bump controller will double stick tape down right in front of that hole. its power and ext. lead from the charger are taped and waiting. Powered by 24vdc, 47A. There are safety banana jacks and a 9-pin Amphenol connector on the case side for the charger to parallel board hook-up. 12vdc bananas on the deck if needed and Last, has a couple USB ports for a phone charger if needed and a 5v supply under the deck for the tablet. |
|
|
Last edited by imacav8r; Nov 23, 2015 at 10:25 PM.
|
|
|
|
|
Thread OP
|
^^^^^---------- Very Nice!
Thanks for posting and sharing it . I think there are going to be some Verrrrrrry nice customized cases coming out due to the BC's existence. Kelly, the BC's lead designer/architect, also has a CNC setup and he shared some pics of it with the Beta team. I crowned him the King of Cases because of it. Maybe he will drop some pics of it here. It truly is awesome. Best, Chris |
|
|
|
|
|
|
|
Thread OP
|
I simply tapped 12 volts off of the first power supply using a pigtail that I made up consisting of four JST connections.
One JST powers the digital thermometer the second and third power the two 92mmm fans and the fourth is for the task lighting that I will add later since I also fly electrics at night. You can see a close up in photo # 10 counting from top to bottom and left to right in my original post. The JST pigtail comes across the top of the first power supply. Best, Chris |
|
|
|
|
|
|
|
|
Some quick pictures of my past case build.
Before the Bump Controller my case had the open space in the front which housed the charger, MPA balance boards and spare power supply. During the beta testing of the bump controller the consistency and ease of use prompted me to find a permanent mounting spot in the case for the Bump Controller and charger. Still have space left for my MPA boards cables and adapters. Ed |
|
|
Last edited by eddiscus; Nov 25, 2015 at 02:12 PM.
|
|
|
||
|
|
Quote:
|
|
|
|
||
|
|
|
|
Thread OP
|
Couple things to note for you guys who are building portable charge stations like or similar to mine...
1. I am working on a wiring diagram and will post it to this thread 2. I have a friend whose son is offering CNC cut decks to complete charge stations Best, Chris |
|
|
|
|
|
||
|
|
Quote:
|
|
|
|
||
|
|
||
|
Thread OP
|
Quote:
They are launching a website with complete details of their products/services and it is expected to be online in the next few days. I'll post in this thread as soon as i get the info and can update the 1st post of this thread. Best, Chris |
|
|
|
||
