Ryobi ONE+ 18v battery USB charger
Description
So many times we've wanted to go to the pool or beach, or even just a long trip in the car and realised that one of our devices is running low on charge. I realised I had a number of expensive Ryobi batteries doing nothing in between mowing the lawn which would be perfect as a portable, high-capacity power bank. I had a quick look at what already existed but there seemed to be numerous problems with the contacts and wiring and accessing them, or they were just ugly. My design consists of a solid base matching the profile of the battery, with an open top for easy access to the components. An easily removable lid is then fitted to close it all off. (You can tap it from the inside through the battery shaft with the handle of a screwdriver to knock it off) The red base in the photos is my initial prototype where I didn't allow for the wires and lid. The version here has been corrected. After designing the charging unit I realised it would be even better if you didn't need to drag around cables with it, so I designed an optional storage tray which can clip on top in place of the lid. To maximise storage space without increasing the size too much I designed a new, thin lid for the storage compartment. The battery this was designed for is shown in the images but it may fit other models with a similar "top". Only two parts are required to be purchased, both from AliExpress. 1. Leaf spring battery contacts (https://www.aliexpress.com/item/1005001813339484.html) 2. Car USB quick charging unit (https://www.aliexpress.com/item/1005005136620619.html) (1) The battery contacts are 6.4mm wide to easily connect with the battery terminals and they have two spikes on the back which clip in place in the base unit so they don't come loose. The only way to remove them is to pry them off with a screwdriver. (2) There are many types of these USB chargers available including three ports, four ports, USBC, with or without displays and power buttons. There is approximately 69mm of space in between the wall of the battery shaft and the inside of the front hole. I have two 1m USB cables in the storage tray but I have bought three 25cm cables like those shown here (https://www.aliexpress.com/item/1005006604073822.html). For my prototype I just snipped the lugs off the end of each wire that came with the charger and soldered it directly to the contacts. Ideally, you would cut them to length and pass them through the holes after soldering to the tab on the contacts. PRINTING All parts were printed with 10% infill with tree supports in Cura. Main body: You will need to turn this upside down before printing to reduce the supports needed. If desired, you can put a support block on the indent on the inside of the shaft. You can probably also do the same for the top of the ovals beside the shaft as it won't matter if these are a bit rough. Lid (main body): No supports required but you may need a brim to prevent warping. Tray: As with the main body, you will need to flip this upside down to reduce the supports required. Be careful when removing the supports that you don't snap the two "spikes" off, though it won't matter if you do. Lid (tray): I needed to use "normal" supports instead of trees for this part as the trees weren't supporting the overhang on the latches in my version of Cura. Again, you may need to use a brim to prevent warping. Tray: Flip this upside down also. Lots of trees are required for this part but they come off easily enough.
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