Battery Box for Bicycle to support PNA (Navi), Mobile, ... (devices that can get power via USB) by TuxMan

Last crawled date: 3 years, 1 month ago

I have a Falk iBEX30 cross PNA (Navigation System) on my bicycle with a battery that lasts about 4 hours. Too less for longer tours, but it can be powered external via mini USB for example by a power bank or by the generator for the bikes headlights. The only problem with it is, that it goes into USB device mode if a common USB cable is used and shows just the USB symbol on the display. That doesn't help me much if I want to know my route.
One solution could be to modify the USB cable so that it only has the wires for ground and 5 Volts, not the lines for the signals. That is, what I did but I went one step ahead putting a LiPO battery into a little box with some electronics and mounting it to my bike. This battery is loaded by the generator and provides external power for my PNA for several more hours. A usual USB power supply could also be used for loading the battery before you start.
The box and the clamp are separate parts screwed together. So it is a bit modular and only the clamp has to be modified to mount it somewhere else.
The inner diameter of the clam is 45 mm
The distance between the two holes for mounting the box is 18 mm
The published version is my final V 1 and had already some iterations. It does what I expected, but there could be some enhancements:
The opening for the switch could be in the design. I made it by filing. I had to add the switch because there is a LED on the second circuit that consumes some power.
Provisions in the box to mount the electronic parts, I did it with hot glue.
Enhancements to see the status LEDs on the small PCBs from outside the box
An additional USB connector A-type female to connect different USB cables.
I'm not sure, if I will do this modifications. But if I do this entry will be updated.
Please see also "Misc Notes" later on this entry