A prototype is a preliminary model of something. Projects that offer physical products need to show backers documentation of a working prototype. This gallery features photos, videos, and other visual documentation that will give backers a sense of what’s been accomplished so far and what’s left to do. Though the development process can vary for each project, these are the stages we typically see:
Proof of Concept
Explorations that test ideas and functionality.
Demonstrates the functionality of the final product, but looks different.
Looks like the final product, but is not functional.
Appearance and function match the final product, but is made with different manufacturing methods.
Appearance, function, and manufacturing methods match the final product.
AU $1 = US $0.77 = EURO €0.73
What is a bike dynamo
A bike dynamo is an electric generator that convert mechanical power into electricity, in this case your leg power is converted into electricity. The electricity is then regulated through a charging controller to provide the same output as a normal smartphone charger. You only lose about 12W of leg power to provide the same power output as a 2000mA 5V smartphone charger.
What is EP stands for
Reason For This Project
As a road cyclist, I do lots of night time riding. A set of head and tail light is must have during night time riding. Built in battery power light are great. However they have a common problem - drain battery too quick. Especially the head light.
The built in battery of the head light degrade in performance after 3 months of usage.
The battery life indicator
light goes to red very quickly. What use to last an hour on of usage now only
does half an hour.
The built in battery is hard to
replace. I can only buy another set of light.
I want to keep my phone,
headlight, and taillight charged while cycling.
To be able to keep my phone and
both light charge while under operation require 10W of power.
Most commercial dynamo system
cannot produce that sort of power.
The look of most dynamo system
is bulky, heavy and hard to install.
Therefore the EP Charger
project was born.
What is EP Charger
EP charger is a high efficiency
twin small electric generator USB charging system design for road bike.
It is 100% green power, it converts your leg power into electricity to charge all your electronic gadgets on your bike.
The EP charger is designed and
built in Perth Australia.
98% of the parts are CNC machined
out of 6061 aluminium alloy.
It is environmental friendly.
Save electricity and battery life of your electronic gadget: smart phone, GPS,
camera, built in battery power light.
The whole EP charger system
only weights 170g, but it can delivery whopping 10W(5V @2000mA ) of power when
cycling at a speed of 24kmph(15mph).
It is dual USB port meaning you
can connect more than one device at a time.
It is powerful, light weight,
compact, stylish, water resistant.
Easy to install, can be install
in 15 minute.
Upside down road bike view of the twin dynamo mounting position
EP Charger Specification
Max twin dynamo power output:
Twin dynamo weight: 130g
Max USB charger output: 5V
1000mA each USB port, total 5V 2000mA
USB charger DC input voltage: 10-55V DC
USB charger weight: 40g
Start charging output:
8kmph (5mph) –
100mA at 5V (0.5W)
12kmph (7.5mph) – 500mA at
16kmph(10mph) – 1000mA at 5V(5W)
20kmph(12.5mph) – 1500mA at 5V(7.5W)
24kmph(15mph) – 2000mA at 5V(10W)
No high speed power cut out
Photos of power output vs speed
Photos of water resistant test
Video of water resistant test
Video For No Load Wheel Test Spin
5 set of early birds prototypes
Video for twin dynamo position adjustment
Video for detail of the 5 sets of prototype
Some more parts left over
9 sets of hand made new stainless steel spring for twin dynamo
Dynamo contacting position adjustment on a tyre
New 8 charging controller board, dynamo bridge board and the rest of the parts
8 dynamo bridge board in the re-flow oven
CNC Machine Parts In The Factory
Road Test 1
Road Test 2
Road Test 3
New 20 Dynamos
New CNC machine parts
Big Frame Installed On A Big Fork
New 8 Charging Controller Units
Photos of big frame installation on a non road bike
New charging controller mounting bracket design for 22mm-32mm handle bar
Mounting bracket without charging controller
Mounting bracket with adapter for 22mm handle bar
Mounting bracket parts in the factory
Mounting bracket parts have arrived
Mounting bracket install on a 32mm handle bar
Mounting bracket(with adapter) install on 22mm handle bar
Time Line for the next few months
Risks and challenges
There is always risk in any project. The final production is happening in Perth Australia, meaning better quality control and delivery product in time.