Solar Powered Stereo v2
by OpenSourceClassroom, published
This is continuing the design of the previous stereo with some major design changes. The differences between this model and the last are that this one has a larger (3.4W) solar panel that is on a hinge to better capture the sunlight. Due to size constraints, I decided to take out the phone charger for this model. Using the 6600mA lithium ion battery, you will maximize your music playing times. This stereo LOVES to jam out in the sun but is also happy just chillin on your desk. Enjoy!!!
Print all parts. Solder stereo amplifier circuit and charge controller circuits. Start assembly with Stereo amp circuit housing and connect speaker and power wires to stereo amp circuit. Mount stereo amp circuit into housing. Place speaker wires through single hole on side of stereo amp circuit housing and leave enough to attach speakers later. Attach stereo amp circuit to the bottom of the housing using (4) 4mmx10mm socket head screws. Run Power wires up through hole on divider plate and place phone controller battery housing together and screw in 4mmx20mm socket head screws to hold together.
Hook up circuit ---> Solder solar panel to DC input on charge controller (Make sure you put the wire through the two square holes on back of phone charger battery housing first). Also place the USB charging cable through the square holes. Notice that it is a tight fit. This hole was designed to have the USB charger go through it. You will have to work it through there, but a tight fit is better than being loose and sloppy.
Hook up battery and USB charging cable to the charge controller. (battery will sit in back cavity so make sure to place battery back there and run wires through the one square hole to center cavity). You can add foam tape to the inside of the cavities to keep components from slipping around. Do not place components inside unit just yet. WAIT and test all electronics before you put them in the housing (I learned this the hard way).
Attach your speaker boxes by lining up the screw holes on the sides of the speaker boxes with the holes on the stereo amp/phone housing. You will run the speaker wires through the singled out hole. Attach the speakers to the phone housing using (4) 4mmx16mm socket screws on the upper holes and (4) 4mmx20mm socket head screws on the lower holes.
Now for the power to the stereo amp. You must wire up the Voltage Step-up regulator before sending power to the stereo amp circuit to get proper voltage to the amp circuit. Follow instructions on how to do that with the package. Then finish wiring the power into the stereo amp.
DO NOT PLACE COMPONENTS INSIDE HOUSING YET!!! After all wiring is complete turn on your stereo using the power switch located in the front of the unit. Notice the unit will not turn on You will need to take a micro screw driver and a Volt meter and adjust the voltage step-up regulator until you are supplying the amp circuit with around 12V. Then the blue light should come on and your stereo will be working properly. Wire up the speakers and screw them into the place using the same screws for speakers and speaker grill.
Attach the hinge cap to the top of the unit and attach the solar panel to the hinges. You can choose to add various types of screws to the hinge to enable easy adjustability of the panel to your liking.
You can add 8 rubber feet to the bottom to give it a nice cushion support to sit on.