Bosch PowerTube 80 percent cutoff

This is a project to cut off the Bosch charger for PowerTube batteries at around 80%. It uses a ShellyPlus 1 Wlan relay, ESP32 and a photo resistor. I know that there are many ways to detect and cut off the power, but this is just a different method.

The 3D printed part holds the photo resistor and could be attached to the Bosch PowerTube 500/625/750 and also newer 600 and 800. The photo resistor detects the 5. LED at around 80% and will switch the ShellyPlus 1 off by WLAN thru the ESP32.

PowerTube_625.stl will work with PowerTube 500/625/750.

PowerTube_600_800.stl will work with the newer PowerTube 600 and 800Wh.

Printsettings, 15% infill and no supports needed. PLA and PETG working.

This is the wiring of the photo resistor to the ESP32 Devkit

For the housing of the ESP32 you can use this Case combined with PowerTube_600_800.stl :

https://www.printables.com/model/50035-esp32-devkit-v1-chunky-case

If you use the PowerTube_625.stl you can use my modified version of this stunning case from @bkgoodman. This contains a additional bottom plate.

https://www.printables.com/model/1280602-esp32-case-625

The sketch for the ESP32 is also provided in the downloads.

I used a simple 3-way socket and connected the ShellyPlus 1 between the socket and the plug (prototype without housing).

If you like to print your own junction box i recommend to use this model that's made for the Shelly Plus:

https://www.printables.com/model/405206-shelly-plus-1pm-junction-box

Instruction how to connect the Shelly Plus 1 with the ESP32:

https://diytechadventures.de/esp32-schaltet-shelly/

Parts needed (example, no affiliate):

ESP32

https://www.amazon.de/AZDelivery-unverlötet-Development-Nachfolgermodell-inklusive/dp/B08BTWJGFX/ref=sr_1_3_sspa?crid=XKYYIA875WX9&dib=eyJ2IjoiMSJ9.2-ottk631jCQ5MK4rDMpWOe41AHMgaFUOGRpMaTkSJ6nLl-Igy5XdEqTNWduybad0SgAyIkOrDu91_eo1ZJrytH5Xwmmst6KjeVmYqSsqmFuPjmZI_oTyRyMO49fxqlcvceVczxBDO_0SDYI4wFqStzSROul88A_Kni8Ab4h4MTEvUEyyHYArhV_dlVuGb_GsNpG7NiCI-_0NZiiKKhGX4Sx6wbpwOcQYbZg335UlfQ.UT2N-HjLoNGgnFtjEbjVB1XfkQO_2e3s4NnPgrc9YSg&dib_tag=se&keywords=esp32&qid=1744983953&sprefix=esp32%2Caps%2C136&sr=8-3-spons&sp_csd=d2lkZ2V0TmFtZT1zcF9hdGY&th=1

ShellyPlus 1

https://www.amazon.de/Shelly-Plus-1-WLAN-Schalter/dp/B09K3XGC14/ref=sr_1_6?adgrpid=71532258699&dib=eyJ2IjoiMSJ9.RPNSnaxYKnkUu2HeGO_6Z7aAxinA3_A0YJFj2at9syHl08tzXajOAKqLmDG77GkpY66f1GpGuFcpv24QNeLNKb2xOzB0PxLZXRykbenTBmHIGnWmYcrK2AVdpxCC-L8OXQvsRkFwwaYmnB_WJWFquCYKBXA22rN6vAVNheRuRdzX_sfAgor88Rx8mxv7pZbI8_QW89Nlt5_02x6EQbTyeKIXAXQPMldI3fZy_j29kfsgqmtz2G9_UP1pAYuJw5s0bqiQWgkLdy_VhSgcfWN47aqdM4Cbm57qo6f9Z8H7SHs.OjRbNzFQBe738TAYPDioVDeEONWTaEK6ysISkDtIKdA&dib_tag=se&hvadid=676585916816&hvdev=c&hvlocphy=9043789&hvnetw=g&hvqmt=e&hvrand=13343170910255191256&hvtargid=kwd-1431417252203&hydadcr=26457_2797074&keywords=shelly+plus+1&mcid=8134b05db03435aabffe38e428360c3a&qid=1744984104&sr=8-6

3-way socket

https://www.amazon.de/3-fach-Tischsteckdose-Steckdose-Steckdosenleiste-Kindersicherung/dp/B00506XU2Y/ref=sr_1_8?crid=3D63SD11RAUF4&dib=eyJ2IjoiMSJ9.y3Rf5vi-BRxqRP95R3pOzyi8iyEuCdTZYhxdo3N9Yq0cPN4QxZqX-Y2vyG7e4NSHRq0Rx2uWvCVfEZmtHtinMj6rnLnyWPxkfcNsAJqXIK9GgTXHgCafIYq60D7cG-N-Z8t0EuOEoigjENjrTmJ7HaAxD0PB0HhnQST3DIikRBiPRH2OJFAweTFNDqUaFaxPitnIZge9hEA4GVBvHBAn27WAWV9ImevvqfoL-eQJo0HY1gE7aj4oSI3daHGjopLuEDkOf_DkUmNJrYfn8k3ETdisMKUrgvD_5GfnRgWwt2U.0hVvu_XlXaglqLB471E-J3rUM_fWGS81rF-UQEqylhk&dib_tag=se&keywords=3+fach+steckdose&qid=1744984187&sprefix=3+fach%2Caps%2C151&sr=8-8

Photo resistor

https://www.amazon.de/AZDelivery-10Stück-Fotowiderstand-Resistor-kompatibel/dp/B089YNCYG4/ref=sr_1_7?crid=3NET04H74T5X1&dib=eyJ2IjoiMSJ9.X4W2PlF2Qay6FT0ZOP2z00rUSa-Ir43M5xEQHhfwdYF6uhdGXaf0paSHcddWWtAAU2_zI9nTVW8pFHCfENVYkiNL83w_w_29USgKnyYDQj-ibBpHWNxY5KIfB_otAtOmfwr8LIaB-FJr8bp2DxbSzus0OAU1X7fLoBFCcKrrBhKRJHG2mlJzebNbgsyY1Zfj3AwkTdyX_leQQIvDdIkVHqsyU6hVSimwsttz9CIxR-4ea1wK_gcMpqDzBEF4N_G_V2ghFA69IzKkd6_5Vu60mWDa8DQ2Q6gZ3TPUF-SrOoI.xf5D5e99DKfh1dihLIsuneATCszIjnAoU98xb9t0Q5k&dib_tag=se&keywords=fotodiode&qid=1744984222&sprefix=Fotodio%2Caps%2C115&sr=8-7&th=1

10K Ohm resistor

https://www.amazon.de/SCOOYUCK-Widerständ-Toleranz-Metall-Widerstande/dp/B0DLV4MT9G/ref=sr_1_7?crid=1BI2I3PX0ACHU&dib=eyJ2IjoiMSJ9.cs813Y0PlM4QjO8tKHQivvSBxcKHwYovrp6H4Cy_xei2M0MUA6FIaaKV6i7UgxuicVtIFFt1BdV7juHI8-GzhV8kiORiLNNzDnkYFwVxS5bJJqNhhegEZMpMQ_PJzTsVRUPsyi88OiX-XMHXzlzJ0mT49huuy1PJjErHjLZfoF4Vo0Q778I_9Bx896LsBGpGHyuMCFbxlsTktfGpLqq3_zXAbzCtcKutlXrcvBN5f156jEp4KRLvLeiHlKSe5zwuyAYKlDLsp_p3xnvPeOrkZ075HEAtWjCCB517__uClAw.i_EmE8B2p77GyTeB1rAtCLWEH8Nwy8NlZaVwB5fgSpw&dib_tag=se&keywords=10k%2Bohm%2Bwiderstand&qid=1744984258&sprefix=10k%2Caps%2C106&sr=8-7&th=1