Bike Windcharger (easy to print)

by Marco222, published

Bike Windcharger (easy to print) by Marco222 Jul 30, 2015

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This is a practical charger for smartphones or any other device that you can echarge by a USB cable.
It is ideal to use when you travel by bike and you need to recharge a little your phone .

The helix is driven by the flow of air through a series of gears that increase of 4 times the number of revolutions actuates a motor that converts the kinetic energy into electrical.

It is important to use a voltage converter, otherwise the devices in charge can burn if it is left for a long time !

The engine produces a voltage of approximately 11volts , so I used the electronic board charger for the machine that converts 12v to 5v.
To use the electronic card you have just to take it apart and connect the motor wires to the respective pole.


This is not the final version .
I think that in the next update will make the assembly of the wind charger even simpler , reducing the number of major pieces from 4 to 2 in I hear that is more intuitive and easy to assemble .

UPDATE (read)

With this update I made ​​caricabaterie wind easier to assemble and especially to print, now it consists of only two parties to which must be added the three gears and the elic.

You will need to print only the parts with the suffix ( easy to print ) plus the three gears and propeller

This is the motor (mine is a bit different because I already had one like that, but this is very similar , and certainly will be fine):


This is the USB Charger:


This can be use if you want to charge more devices at once:


these are the links of videos charger in action :




I have printed the first version of the windcharger, because I had already started printing the pieces before the upgrade .
Anyway the exterior design that the updated version has, is cleaner


The two files (part. 1 and part. 2 easy print) were printed in PLA at 15% infill, with two shells at 0.26mm layer height and both files need support material.

The three gears were printed in PLA at 50% infill, with two shells at 0.26mm layer height without support material ( you have to turn the ingraggi of -90 degrees on the x axis then print ) .

The two helixs were printed in PLA at 70% infill, with two shells at 0.26mm layer height with support material.

you just have to print the following files:

Helix 2 (2)
Helix 2 (1)
motor gear 1
gear 2 (middle)
helix gear
part. 2 (easy print)
part. 1 (easy print)

The other files are not needed because they belong to the old version .
The two helixs are not both necessary, you choose which print.

the assembly of the charger is not complicated, what you need it is:

1) molded parts
2) lighter
3) 12v engine
4) 5 screws 2.5 x 7 mm (approx)
5) 3 screws 3 x 15 mm
6) 2 elastics
7) 2 cylindrical sticks (one for connecting the propeller with the respective gear, to be fixed to the propeller and to the gear, of dimensions 2.5 x 33 mm and the other that should be placed in the hole between the engine and the propeller where the gear 2 must be free to rotate, size: about 25 x 2mm)
6) drill bits (to enlarge some hole if necessary)

First you need to remove the lighter PCB and solder two wires where before there were the metal contacts.
After you have to place the motor and the electronic board of a cigarette lighter in their respective housings after welding together the wires.

Now insert the sticks ciidrici in their respective positions, fixed gear propeller to his stick, making sure not to touch the plastic and after placing the gear 2 sliding it onto the stick of the old with the wide end up and leaving Free to turn (if necessary enlarges the hole of the gear).
Finally put in position the engine gear and the two rubber bands .

The first elastic has to go into the grooves in the wake of the propeller and gear lower than 2nd gear.
The second band must pass between the gap wider and higher 2nd gear and in the wake of the engine.

At this point places the assembled parts on your bike handlebars by passing into the larger hole in the seat of the electronic board.

Place on the assembled positioned on the bike the other side of the charger, fixing it with the 5 screws 2.5 x 7mm in the lower part and the remaining 3 screws 3 x 15 mm in the upper part.
At this point you just have to fix the propeller that you have chosen to print to his stick, connect the USB cable to the circuit board to charge your smartphone or any other device you prefer.

Some advices :

If you want the charger to operate easily without friction problems you should set the helix stick with two ball bearings to reduce friction significantly .
Elastics must not be too tight , just enough to transmit the movement of the propeller to the engine .

If your charger doesn't work after placing the three gears and rubber bands you should remove the second gear (gear middle 2 ) and directly connect the gear motor to the helix .
This will definitely work , and do not forget to put grease on the gears .

Be certain that the energy used to ride will not be wasted !!

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Where would I look to find the dimensions and the diagrams of all the peices

Lavoro ben fatto complimenti!

What are those litttle metal pieces on the gears? Where can i find something like that.

They are simple metal cylinders that I cut from a longer bar. I bought it at a local bricolage store.

Why not use the generator on the bike instead? it is loads more efficient, especially if it's a hub type generator.

Because it is for the catch the wind challange? maybe?

Comments deleted.

"current" of 11v? That's an interesting measurement of current...

I meant that the output voltage produced by the motor is 11 volts

Ok, Glad to know you know the difference.