USB powerbank adapter for Bosch 18V battery packs

This is a USB power bank adapter for the Bosch 18V battery packs (Series Power4All).
4h 51m
1× print file
0.20 mm
0.40 mm
51.00 g
19
64
0
1480
updated August 12, 2022

Description

PDF

Use your Bosch 18V Power4All batter pack as USB power bank adapter for charging up to three devices on the go.

IMPORTANT NODES: 

  1. The 18V lipo battery packs are usually unprotected (with no charging or discharging circuit on  board).
    Take care during soldering/wiring. 
    DON'T SHORTEN THE BATTERY WIRES!
  2. Usually on the lift side “+” and on the right side “-” - check the markings on your battery pack.
  3. Configure the XH-M609 module to a voltage cutoff of at least 14.5 volt - the default setting of 12V can damage your battery pack permanently.
    → Just press two times “+” and use “+” and “-” for increasing and decreasing the value.
  4. And please don't call me if everything is on fire!

 

Wiring (see picture)

…to connect the battery pack:

  • 2x 16AWG wire red á 15cm (or just 1 if you don't want the switch)
  • 1x 16AWG wire black á 15cm

…to connect the 3 USB boards:

  • 3x 24AWG wire red á 15cm
  • 3x 24AWG wire black á 15cm

 

Printing parts (in assembly order):

(I used Prusament Galaxy Black PLA with the default settings for "0.2 mm speed". No Brim or support needed.)

  • 1x “BatteryAdpater”
    • add one USB board (just snaps in) - can be a little bit tight
    • add two Crimp Terminal Connectors with cables (use some hot glue)
  • 1x “MainBody”
    • add four M3 screws to connect the “BatteryAdapter”
    • add one HCW-M635 module (holds in place without any screws)
    • connect all wires to the correct 2 screw terminals (see picture)
  • 1x “TopExtension”
    • add the two USB boards (just snaps in)
    • slide in the “TopExtension” completely into the “MainBody” (maybe add some hot glue)
  • 1x "TopCover"
    • add two M3 screws to hold everything in place

 

Additional parts needed:

  • 1x XH-M609 “DC 12V-36V Charger Module Voltage OverDischarge Battery Protection Precise Undervoltage Protection Module Board”
  • 3x USB board e.g. “QC3.0 QC2.0 USB DC-DC Buck Converter Charging Step Down Module 6-32V 9V 12V 24V to Fast Quick Charger Circuit Board 5V”
  • 2x 6.3mm “Male Crimp Terminal Connectors”
  • 6x M3 screws (6mm) - or just those somewhere laying around in your lab

    Optional:
  • 1x Switch e.g. “PB05A High-Quality Self-Locking SPST Normally Open Mini Push Switch Opening 7MM Small Button With Gold-plated ON-OFF 1A 250V AC”
    (Don't buy accidentally NON-Self-Locking ones!)
     

Kudos

  • to “3D print Dude(GreaseMonkey88)” for the base design of the socket adapter!
  • and @greatscott, @spiessa and @witnessmenow for the inspiration to this project!

Happy printing!

Tobias (@tstoegi)

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