Go Green! Charge your phone with FIRE!

This Thermal Electric USB charger allows you to plug in, charge and use your device! It contains 4 - Thermal Electric modules that charge up 4 NI-MH backup batteries for the purpose of charging your phone.

Step 1: MATERIALS

Go Green! Charge your phone with FIRE!

Tools

Wire Strippers
Soldering Iron
Drill
Flush Cutters
Heat Gun
Pliers
Etchent
Computer
NI UltiBoard
Nails/Braid Nailer
Wood Saw
Hack Saw
Grinder
Sand Paper
Metal File
Electrical Tape
Super Glue

The Charging Station

• PCB

• Maxim DS2715 IC and surrounding circuitry - DS2715 Data Sheet

• 4 - Duracell NIMH batteries (Duracell 2400mAh - Rechargeable backup)

• On/Off - Single Pole Toggle Switch

• Three position switch - T.E.G/OFF/BATT

• Momentary Push Button - Current Measurement

• LED (Charging/Fault indicator)

• 2 - Molex connectors: 4-pin female & 2-pin female

• OKW Plastic Enclosure - Link is here: Free Sample Link

The Monitoring Station

• 20x4 - SainSmart LCD - Link is here: Amazon Link

• 4 - AAs battery backup

• Three position switch - T.E.G/OFF/BATT

• Arduino Uno Microprocessor - Arduino Site

• Resistor Dividers (Limits the current and Voltage for Safe Measurements)

• AD623 - Instrumentation Amplifier and surrounding Circuitry - AD623 Data sheet

• 2 - USB Charging Ports (from car charger)

• Wood (luan)

• 2 - Metal Hinges

The Oven

• 4 - Vktech TEC1-12706 Thermoelectric Coolers/Generators - Link is here: Amazon Link

• Arctic Silver 5 Thermal Compound 3.5 Grams - Link is here: Amazon Link

• Cooking Pot

• Heat shrink and radiant heat tape - Link is here: Amazon Link - Heat Tape

• Scrap metal for oven fabrication

• 3/8" Threaded rod and hardware

• 1/4" Bolts and hardware

• 5/16" Tech Screws (Self-Tapping Screws)

• Steel Leader (fishing leader)

Step 2: The Generating Pot

Go Green! Charge your phone with FIRE!
Go Green! Charge your phone with FIRE!
Go Green! Charge your phone with FIRE!
Go Green! Charge your phone with FIRE!
Go Green! Charge your phone with FIRE!
Go Green! Charge your phone with FIRE!
Go Green! Charge your phone with FIRE!
Go Green! Charge your phone with FIRE!
Go Green! Charge your phone with FIRE!
Go Green! Charge your phone with FIRE!
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The Cooking Pot contains the 4 - T.E.G modules sandwiched between the heat sink. Thermal Compound is added to both sides, this allows heat to transfer easily, preventing the modules from overheating. The modules are then shrink warped together and soldered in series. To attach the heat sink to the pot, steel fishing leader is wrapped around the pot in between the fins of the heat sink. One both sides it is then screwed into the metal pot using metal screws. Once secure, use a metal file or grinder to trim excess screw and seal it with super glue. The Thermistor is added into the heat sink to act as a thermometer and will give me an accurate reading of the temperature. The Thermistor is in set up in a voltage divider configuration that is fed into the Arduino.

Step 3: The Charging Station

Go Green! Charge your phone with FIRE!
Go Green! Charge your phone with FIRE!
Go Green! Charge your phone with FIRE!
Go Green! Charge your phone with FIRE!
Go Green! Charge your phone with FIRE!
Go Green! Charge your phone with FIRE!

The Charging Station Consists of 4 NI-MH batteries, charge controller circuit, all in a OKW plastic enclosure. The Charge Controller Circuit consists of a DS2715 Maxim IC and its surrounding components. The datasheet is provided in this link Maxim DS2715 Data Sheet, I used the typical Linear application circuit by Maxim and added/tweaked the circuit to accommodate my needs. I used Voltage Dividers to allow me to make measurements on the circuit to lower the voltage and current going into the Arduino.

The NI Ultiboard PCB Layout
↓↓↓↓↓↓↓↓↓↓↓↓↓↓↓↓↓↓↓↓↓↓↓

Go Green! Charge your phone with FIRE!
NIMH Charging Circuit_Old_Version.ewprj147 KB

Step 4: The Monitoring Station

Go Green! Charge your phone with FIRE!
Go Green! Charge your phone with FIRE!
Go Green! Charge your phone with FIRE!

This Station Can measure the Voltage, Current, Power and Temperature of the Generator. It does this by using the Analog inputs of the Arduino. Resistor Divider circuits are needed to prevent damage to the Arduino.

Step 5: The Oven

Go Green! Charge your phone with FIRE!
Go Green! Charge your phone with FIRE!
Go Green! Charge your phone with FIRE!
Go Green! Charge your phone with FIRE!
Go Green! Charge your phone with FIRE!
Go Green! Charge your phone with FIRE!

This Shows the Assembly of the Oven in Steps, but unfortunately I didn't take photos of the actual construction.

Step 6: The Code

This is the code for the Arduino UNO it can be editied or downloaded from the Arduino IDE.

The link is here: Arduino IDE

Go Green! Charge your phone with FIRE!
RJD_Senior_Project.ino4 KB

Step 7: The PowerPoint

This is the PowerPoint that I used to present my Senior Project at my college.

Go Green! Charge your phone with FIRE!
Thermal Electric USB Charger.pptx180 MB

Step 8: The Video

 
 

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