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Charging module

Modified 2019-09-24 by hosnerm

For the construction of a charging module, you have many degrees of freedom. This includes the choice of material of the wooden structure (may be metal as well), the type of connection between the structure elements (screws, glue, nails), the length of the cables and many more.

However, the following requirements need to be satisfied:

In the following, you find the description on how we did it in Zurich.

Material for one charging module Section 4.1 - Material for one charging module

Extra tools for assembling Section 4.2 - Extra tools

A charging module for charging Duckiebots Figure 4.1.

Assemble a Autobot that is capable of autocharging Unit B-1 - Autobot specifications and assembly

A resulting charging module during operation.

Material for one charging module

Modified 2018-09-01 by ThomasAckermann

In this list, X will denote the number of charging rail tiles in a charging module. Reminder: One charging rail tile can fit 3 Duckiebots ( 1.5 per lane).

  • 8 \times brass rod Ø4mm , length ( 10cm + X \times 59cm )
  • (X + 1) \times wooden structure top piece ( 2 \times 2 \times 90cm )
  • (2 \times (X + 1)) \times wooden structure side piece ( 2 \times 2 \times 20cm )
  • (2 \times (X + 1)) \times wooden structure floor piece ( 10 \times 10 \times 1cm )
  • (4 \times (X + 1)) \times woodscrew for high voltage pole, i.e. screw Ø3.2 \times 40mm
  • (8 \times (X + 1)) \times screw M3 \times 30mm and M3 nuts
  • (2 \times (X + 1)) \times insulator - self-print here or order here
  • Drill Ø4mm and Ø6mm
  • 2 \times power supply which enables you to drive 5V and 30Amps
  • \frac{1}{per power supply} \times power cable
  • \frac{3}{per power supply} \times cable-end-sleeve
  • 18 \times cable shoes M4 Ø4-6mm²
  • 4 \times M4 screw 10mm and M4 Nut
  • Ø4mm \times 6m red cable
  • Ø4mm \times 6m black cable
  • 8 \times laboratory plug CAT I Ø4mm

Extra tools

Modified 2018-09-01 by ThomasAckermann

In order to put things together you may need the following extra tools:

  • crimping tool
  • wire stripper
  • hot glue gun
  • solder iron and solder
  • drill
  • screw driver

Building a charging module

Modified 2018-08-22 by Julien Kindle

Assemble the wooden structure

Modified 2018-08-23 by Julien Kindle

Assemble the wooden structure as in Figure 4.2. This part may differ from our reference part. The important and neccessary specifications are: (i) the structure must be larger than one tile such that a road (with margins on both sides) may fit underneath and (ii) the space between the tile and the bottom part of the crossbar must be exactly 21cm (see Figure 4.4).

An assembled wodden structure.

Prepare for mounting the insulators

Modified 2018-08-23 by Julien Kindle

Make sure you have the parts ready seen in Figure 4.3.

Parts needed to prepare and assemble a high voltage pole.

Drill the holes

Modified 2018-08-23 by Julien Kindle

Drill 3mm holes such that the insulators will be centered after mounting, seen in Figure 4.4

2D sketch of a high voltage pole.

The 6mm holes (depth roughly 5mm) are optional and act as a hideout for the screw heads. The resulting holes should look like Figure 4.5.

Drilled holes.

Mount the insulator

Modified 2018-08-23 by Julien Kindle

Mount the insulator 3D prints as seen in Figure 4.6 and Figure 4.7.

The assembled insulator.
How the screw head is hidden.

Fix the high voltage poles to tiles

Modified 2018-08-31 by ThomasAckermann

Use double-sided tape to mount the high voltage poles to the tiles (Figure 4.8). Make sure that the high voltage poles are aligned throughout the whole charging module.

Optional: you could also use hot glue instead of double-sided tape.

Bend brass rails and mount them

Modified 2018-08-24 by Julien Kindle

Bend the charging rails 5cm on both sides (in the same direction) to ensure that Duckiebots do not get stuck when arriving at the charging rail tiles (Figure 4.8).

Then, clip the brass rails into the insulators.

Glued high voltage poles with clipped in charging rails.

Solder laboratory plugs

Modified 2018-08-25 by ThomasAckermann

Strip the insulation of the four red and four black cables on both sides with a wire stripper off. Then solder four red and four black cables each to a laboratory plug as seen in Figure 4.9. These cables should be approximately 20-25cm long.

Soldered laboratory plugs to the cables.

Attach cable shoes

Modified 2018-08-31 by ThomasAckermann

In order to crimp a cable shoe onto a cable, you need the following things which you can see in Figure 4.10.

Crimping tool with a cable and a cable shoe M4 Ø4-6mm² .

First put the cable shoe onto the uninsulated cable such that it looks as in Figure 4.11. Then take the crimping tool, put the cable inside the yellow hole and press the cable shoe on it.

Crimped cable with a cable shoe.

Connect the cable to the power supply

Modified 2018-08-31 by ThomasAckermann

Mount a cable shoe Ø4-6mm² with a crimping tool on the other side of these cables you have soldered. Then connect two red and two black cables respectively together with another cable shoe with a M4 screw and a M4 nut as seen in Figure 4.12. Then connect to the third cable shoe the corresponding red/black cable which will go towards the power supply. This third cable should be long enough to reach the power supply. Also attach to the end of the third cable a cable shoe.

Connection of the cables to the rails.

Plug the soldered laboratory plug cable to the brass rail

Modified 2018-08-25 by ThomasAckermann

Connect the laboratory plugs to the bended ends of the charging rails as seen in Figure 4.13. The cables of the brass rods must be polarized as seen in Figure 4.14. Make sure that you connect the four rods on the left to one power supply and another four rods on the right to the other power supply.

Connection between cables of power supply and charging rails.
The polarities of the brass rods.

Prepare the power cable for the power supply

Modified 2018-08-31 by ThomasAckermann

Take the power cable Figure 4.15 and strip the isolation off. Then attach a cable-end-sleeve with the crimping tool as seen in Figure 4.16. Then connect the prepared cable to the power supply exactly as it is shown in Figure 4.17.

Note: It is important that ground, phase and neutral phase is connected the right way, so the colors need to match.

A power cable.

One end of the power cable before and after.
Attached power cable to the power supply.

Attach to power source

Modified 2018-08-31 by ThomasAckermann

Connect the power supply to the rails. Red cable to V+ and black cable to V- as shown in Figure 4.18. Make also a connection between the two power supplies ground, in order to have a common ground.

The connected power supply.

Adjust the output voltage of the power source

Modified 2018-08-31 by ThomasAckermann

Turn on the power supply by plugging in the power cable. There is a voltage regulator - the plastic screw - (see Figure 4.18) next to the V+ connection - there you can adjust the voltage. Take a screw driver and a multimeter and measure the Voltage across V+ and V-. The Voltage should be adjusted to 5.5V.

Test your setup

Modified 2018-08-31 by ThomasAckermann

Place an assemblied Duckiebot Figure 1.17 which is capable of charging underneath the charging rails, turn on the power supplies and see if the battery is going to charge.