Power your USB devices like Phones, Raspberry Pi, Arduinos from a multitude of power sources like solar arays, cars, boats, batteries. Just plug in and use without any hassle.
We provide 2 versions of the USB adapter that look the same have the same parts except one that has a different series.
The Basic Unit outputs 5 volts at 500 mA while having a huge range of voltage input from 7 to 28 volts.
The Extended Version Unit outputs 5 volts at 1000 mA while the input range is from 8 to 42 volts.
Since the unit works with both DC and AC, it has natural input protection for reversing polarity. Just plug it in any way and it works.The case is very rugged and waterproof.
The output USB plug needs an USB cable to be connected and used to power your device.There is no need for any software to install. Just works.
The story behind the project
We did a lot of work with Raspberry Pi boards. Having to move the board around a lot, it became apparent that powering the board has become a pain. When we played with Raspberry Pi in the front of the TV, we had to power it from a DVD player that was right next to the TV which was OK because it had an USB port. When we were in the lab, we had to power the board from a power supply. When we mounted the board on a robot, it had to be powered from a 24 volts battery. This is how we come up with the idea of an adapter that would use a big range of voltages and provide the 5 volts which is compatible with the USB ports. We subsequently realized that a lot of devices are using the USB connectors to get the power like phones, Arduino boards, etc.
The main idea of the product was to have a nice design and the least amount of cables. We first designed the case to give a feel how it looked. It was empty but the shell will be filled with resin for the prototype.
The case was milled on the CNC machine from plastic.
The case was filled with resin after the board was inserted. The final product will be made entirely from resin .
The first PCB board was etched in-house but it was functioning well. The final product boards will be ordered from an outside company.
The part is built in the United States. All the plastic parts are built and molded in-house. The only part that is bought from outside the country is the bare-bone PCB board that is populated in house.
At this stage the product is already designed and the prototype is made and there are no modifications in the design. All the PCB design files are waiting to be sent to the board house.
Those are the steps that we follow in our production
1. Electronic Part Purchasing
The first step is the purchasing of electronic parts.
Usually we buy the parts from Digikey or other electronic parts provider.
The resin is being purchased from an American producer.
2. Sending the order to the PCB manufacturer
We send the design files to the manufacturer that makes the bare electronic boards. Usually we receive the bare boards in one week.
3. Populating PCB boards
This is the part where we solder the parts on the PCB boards.
4. PCB Board testing
With the PCB boards fully populated, we test the boards by inputting a voltage and reading the voltage on the output. Any failed boards are discarded or fixed.
In this step the PCB boards are encased in plastic. A liquid resin is pored into the mold that contains the PCB board. After the resin is hardened, it will be removed from the mold and cleaned.
6. Inspection and Testing
The units will be tested again to make sure that they work .
7. Packaging and shipping
The units will be packaged and the customer's information will be added to the shipping boxes and will be taken to the postal office.
Risks and challenges
In case of a reasonable demand, all units will be built by us; if the demand is higher the parts of the unit will be outsourced locally which means a longer lead time. We have experience with building and shipping products, and also we have most of the equipment in house. With all this, we try very hard to minimize the risk.
Also if there is a higher demand there might be some parts shortages which might delay the production. Fortunately the parts could be procured from multiple places.
- (40 days)