High Tech Fuse Block

Discussion in 'Vendors' started by craftycoder, Sep 19, 2012.

  1. craftycoder

    craftycoder Motobrain PDU

    Joined:
    Oct 13, 2009
    Oddometer:
    2,337
    Location:
    Atlanta
    It draws 1.2 nano amps when the "relay" pin is low and 6.5mA when the "relay" pin is high.

    1.2 nano amps is roughly 3 million years of battery life for a standard 35AH battery. This was an important feature and it required that I design a tool specifically to test this.

    This is the nano amp current sensor I design for this purpose.
    [​IMG]
  2. oldandgray

    oldandgray Adventurer

    Joined:
    May 3, 2009
    Oddometer:
    23
    Location:
    Nebraska
    This would be an item that I would be very interested in having on my bikes.
    :clap
  3. craftycoder

    craftycoder Motobrain PDU

    Joined:
    Oct 13, 2009
    Oddometer:
    2,337
    Location:
    Atlanta
    I've been busy all weekend working on an updated version of the 8 channel Bluetooth PDU. After testing the current version you've seen in the videos, I've made some performance updates. I've also added 2 channels of true hardware constant current. Those two channels will be selectable as a constant current source or traditional fused circuit. You cannot do both, so if you short circuit a constant current source it will just source however many amps you tell it to. This may be a fire hazard but it does have utility. I would not use constant current without specific need, but when you need it, you really need it.

    I have more testing to do with with a version of the hardware I just received in the mail on Thursday. When that testing is complete, I'll be making any changes necessary to this version and I think we will be very close to a final prototype. This version is a little bit bigger. It is 3" wide instead of 2.93" wide. The performance improvements were worth the modest size increase. I did have to make the board 4 layers which is more expensive but the board is WAY to crowded to be 2 layer any longer.

    [​IMG]
  4. craftycoder

    craftycoder Motobrain PDU

    Joined:
    Oct 13, 2009
    Oddometer:
    2,337
    Location:
    Atlanta
    I just tested the single channel board at 13A. No problems. The load, was a giant 1Ω resistor and a cooling fan for it. I ran the test for about 15 minutes. The cooling fan could not keep up and I ended the test when the resistor hit 220C (about 430F). That is just too hot for things on my bench. The circuit ended the test almost 6 degrees warmer than the table it was sitting on (so not even warm to the touch). That means that it ate 13A for breakfast! This seems like a winner! I've got a couple parts coming in the mail for the prototype that we are going to build up in the epoxy goop. Assuming that one will function well without air to vent off excess heat, we will build up 50 prototypes and get them into peoples hands to play with.

    I apologize if it is hard to keep track of all the stuff I've been talking about here. I have two different products I am currently working on in this motorcycle power space. The "dumb" single channel board (that this message is about) and the "smart" bluetooth 8 channel board. Sorry if you are getting confused from time to time.
  5. craftycoder

    craftycoder Motobrain PDU

    Joined:
    Oct 13, 2009
    Oddometer:
    2,337
    Location:
    Atlanta
    Testing of the single channel continues. I pushed it to 19A of current sourcing. No problems at all, I am impressed!
  6. spoon

    spoon Rubber's gone!

    Joined:
    May 15, 2007
    Oddometer:
    219
    Location:
    Snow in New Mexico
    I am in for one of the smart versions. How do I sign up.

    spoon
  7. craftycoder

    craftycoder Motobrain PDU

    Joined:
    Oct 13, 2009
    Oddometer:
    2,337
    Location:
    Atlanta
    When the are ready to sell, I promise it won't be a secret.
  8. tdcarter

    tdcarter Adventurer

    Joined:
    Aug 27, 2012
    Oddometer:
    79

    I need it.
    . I need it!!! :clap

    Happy to test a final prototype
    :wink:

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mso-para-margin-left:0in; line-height:115%; mso-pagination:widow-orphan; font-size:11.0pt; font-family:"Calibri","sans-serif"; mso-ascii-font-family:Calibri; mso-ascii-theme-font:minor-latin; mso-fareast-font-family:"Times New Roman"; mso-fareast-theme-font:minor-fareast; mso-hansi-font-family:Calibri; mso-hansi-theme-font:minor-latin; mso-bidi-font-family:"Times New Roman"; mso-bidi-theme-font:minor-bidi;} </style> <![endif]--> [FONT=&quot]16ยบ for the hour commute this morning made me reconsider why I only have 2 channels of heated gear on the bike. Might be time to break out the socks and finish some heated pants.
    [/FONT]
    T
  9. Davis53

    Davis53 Been here awhile

    Joined:
    Apr 29, 2005
    Oddometer:
    581
    Location:
    Northern California
    I am in.
  10. craftycoder

    craftycoder Motobrain PDU

    Joined:
    Oct 13, 2009
    Oddometer:
    2,337
    Location:
    Atlanta
    Hey y'all, I've got some updates on the development progress. The redesigned 8 channel board has been ordered and should arrive late this week I believe. Assuming it works, I will write up the firmware to do circuit breaking and constant current as well as voltage measurement as all that. The next step is creating a iPhone app that covers the basic functions and allows for programming the unit. Then, more bench testing followed by on road testing.

    The single channel is moving right along as well. The "final" version of the boards are currently on the bench being tested. They are working perfectly. No issues at all. I've wired them up every conceivable WRONG way and they have not yet broken or caused a fire (YMMY). Running it at 19A, which is 4A above the nominal current load (of 15A), is well within its capability which is nice but again not advised. With a "normal" load of 2 headlight bulbs the device runs warms 2 degrees above room temp (which is how we measure it's strain). This is a very low number and very inspiring.

    Now for the bad news, its the Chinese new year and our off shore supplier is closing for February (I wish I got a month off for new year). We did not get an order in for new single channel boards in time, so lonestrom and I are going to have to build the next batch of prototypes ourselves. We only have enough parts to build 16 more instead of the 50 though. We will build them up, epoxy them, and then get them in the mail to distributors ASAP (in hopes of inspiring orders for product). We expect to have the single channels available for purchase by April (assuming no surprises).

    The ETA for the 8 channel bluetooth PDUs is still up in the air. If the hardware I receive on Friday is good, April is possible but seems unlikely to me. Too many questions still unanswered, not the least of which is how do I fund the building of the first round of devices? Stay tuned...

    Some images of the single channel being built. The grey stuff in the top photo is solder paste and bottom photo is what they look like after the parts are placed and they are cooked in the reflow oven.
    [​IMG]
    [​IMG]
  11. Craneguy

    Craneguy British Hooligan

    Joined:
    Apr 29, 2011
    Oddometer:
    1,030
    Location:
    Riyadh, KSA, Cuernavaca, Mx, Houston, Tx
    It's looking great.

    Will you have an Android app too?
  12. tdcarter

    tdcarter Adventurer

    Joined:
    Aug 27, 2012
    Oddometer:
    79
    My response exactly.
    Looks wonderful and sign me up for pre-round funding, but can I use it with my Droid?
  13. craftycoder

    craftycoder Motobrain PDU

    Joined:
    Oct 13, 2009
    Oddometer:
    2,337
    Location:
    Atlanta
    Great question. I expect to. There is no DIRECT support for bluetooth 4 in Android currently. I happen to have a Motorola RAZR with BT4 and I have done some basic tests which make me believe it will work on my phone. I need to use libraries that are written for the specific phone though, which is pretty annoying and not very Android like. There are also hardware libraries available for the bluetooth Broadcom chipset in the Nexus 7 and other similar devices. This means that whatever Android software I write will have to be specific to the hardware in the device which makes it a rather unattractive thing for me, the developer. I use a RAZR, so obviously I want to use this on my phone so you can expect support of that device. I certainly expect Google to support BT 4 in the future though, so it just a bit of a waiting game to see how this bleeding edge tech get supported, and when.

  14. Craneguy

    Craneguy British Hooligan

    Joined:
    Apr 29, 2011
    Oddometer:
    1,030
    Location:
    Riyadh, KSA, Cuernavaca, Mx, Houston, Tx
    That's astonishing considering the nature of Android.

    Us droiders await developments with interest.

    Galaxy S3 here.. Hint hint :D
  15. tdcarter

    tdcarter Adventurer

    Joined:
    Aug 27, 2012
    Oddometer:
    79
    Again, same....
  16. pro-bassoonist

    pro-bassoonist Been here awhile

    Joined:
    Jan 21, 2007
    Oddometer:
    145
    Location:
    Gurnee, IL
    Hi, have you thought about Kickstarter?
  17. craftycoder

    craftycoder Motobrain PDU

    Joined:
    Oct 13, 2009
    Oddometer:
    2,337
    Location:
    Atlanta
    Yes, of course. Many options available.
  18. tdcarter

    tdcarter Adventurer

    Joined:
    Aug 27, 2012
    Oddometer:
    79
    The Banshee horn (another motorcycle toy) got it's start through there. Think he more then doubled his needed funds for starting.
  19. craftycoder

    craftycoder Motobrain PDU

    Joined:
    Oct 13, 2009
    Oddometer:
    2,337
    Location:
    Atlanta
    Lonestrom and I spent the weekend building up single channel boards. We have 11 of them built and tested. All are working as expected. The potting boxes and epoxy did not arrive in time for potting this weekend but we will pot them later in the week or next weekend. Loctite was gracious enough to furnish us with potting chemistry and I would like to offer many thanks for their generosity. I had some off brand chemistry and a little sewing kit box that I used in lieu of a potting box and potted up one board. Photo below. I attached it to my bike and it worked as expected, no drama (15A for an hour and it was 3 degrees warmer than ambient temp). We will be shipping these pre-production samples to vendors as soon as we have potted them so that can test them out and provide enough orders to get this product kicked off.

    The new 8 channel printed circuit boards are in Chicago on their way to me and will arrive in the next day or two. These may very well be ready to go. If so, I have a bunch of firmware and software to write and then much testing to do on and off the bike.

    [​IMG]
  20. justlookin

    justlookin Been here awhile

    Joined:
    Dec 16, 2007
    Oddometer:
    277
    Location:
    Ohio
    Started to read this entire thread and think my eyes qlazed over at about page 4 - am not tech savy - have no blue tooth anything and probaly never will. Positive I will never have some fancy phone and wondering if you will have a dumb manual version for guys like me. I like the idea of power management as I have a power limited bike (XC-W) and would like to run some heated gear and control LED headlights and LED dash lights. I intended to order a Rowe Electronics unit this week when I saw this thread - I really would prefer to help an inmate :wink: