Battery / Charging system monitor

[Guest]

While poking around on radioshack thinking about tearing apart a set of earphones for a helmet speaker system (earbuds are illegal in PA ) I was thinking of making something like this:

http://www.motorcycle-superstore.com/1/4/70/8115/ITEM/Kuryakyn-LED-Battery-Gauge.aspx

It seems a bit overpriced for some (probably) simple circutry, except for the fact I am not an electronics expert. I make my dad do those things, since hes been working on them since the 1950's.

So here's the question: Do ya'll have any sort of ideas how one of these doodads can be made for under 40 bucks, perferably with good old radioshack parts and various doodlehangers we probably have in the garage? Or should i just drop the ~$50 for this fancy contraption?

[posplayr]

While poking around on radioshack thinking about tearing apart a set of earphones for a helmet speaker system (earbuds are illegal in PA ) I was thinking of making something like this:

http://www.motorcycle-superstore.com/1/4/70/8115/ITEM/Kuryakyn-LED-Battery-Gauge.aspx

It seems a bit overpriced for some (probably) simple circutry, except for the fact I am not an electronics expert. I make my dad do those things, since hes been working on them since the 1950's.

So here's the question: Do ya'll have any sort of ideas how one of these doodads can be made for under 40 bucks, perferably with good old radioshack parts and various doodlehangers we probably have in the garage? Or should i just drop the ~$50 for this fancy contraption?

There are various types of electrical monitors they generally would fall into three categories:

1. Analog dial (like a VDO guage)
2. Discrete LED (such as the one being pointed out)
3. LCD alphanumeric display (there are a few around)

Having had all three types, as well as being as being an engineer, for me the the best is #3 because of the resolution to what is typically 0.1 volts. As far as accuracy #1 and #2 are probably going to be about the same.

http://www.ebay.com/itm/12V-24V-Motorcycle-LCD-Battery-Voltage-Meter-Monitor-New-/400276963094?hash=item5d325dbf16&item=400276963094&pt=Motorcycles_Parts_Accessories&vxp=mtr

If you are worried about the difference in spending $30 v.s. $40 I can't give you much advice, but there is a device on ebay which is similar to this but is a single multi colored LED and it is cheaper.

http://www.ebay.com/itm/6v-12v-24v-LED-Battery-level-voltage-monitor-meter-J-/200627678428

As an alternative the Show Chrome is also about $35 but has several other features (volts, temp, clock, ice detect).

https://signin.ebay.com/ws/eBayISAPI...1&pageType=573

For the number of alternatives and types of packaging available for under $25 I can't see building anything unless it is something you really want to do.

The biggest trick is finding something you will like in it's final appearance on your bike.

[cableguy]

Seems like each LED would connected to a thingy so as the voltage changes so would the lights? Sorry if my technical jargon is to hard to understand

[posplayr]

Seems like each LED would connected to a thingy so as the voltage changes so would the lights? Sorry if my technical jargon is to hard to understand

There have been at least two attempts at doing DIY versions that have been posted here at GSR. From what I recall one of the last contributers finally gave up because of the complexity of waterproof packaging for doing a simple one off design.

[Steve]

I have two of the meters that Posplayr mentioned in his third link. I like them.

The accuracy of the voltmeter is rather close. One of them was less than .1 volt off, the other was .3 volt.

Also nice to see time and temperature while riding.

The display is also dual-color, blue and orange. The orange matches the GS lighting exactly.

It's not waterproof, so keep that in mind when mounting it.

.

[Chrkut]

I would think a waterproof design would be the simple part
Just get a plastic box, throw a plexi or plastic window in it with some silicon to keep the water out, and do some sort of gasket/silicon around where the wires would go in. Not exactly the prettiest thing in the world, but I do like saying, "hey, you bought that online? My dad and I made mine out of things we had in our garage."

[bakalorz]

While poking around on radioshack thinking about tearing apart a set of earphones for a helmet speaker system (earbuds are illegal in PA ) I was thinking of making something like this:

http://www.motorcycle-superstore.com/1/4/70/8115/ITEM/Kuryakyn-LED-Battery-Gauge.aspx

It seems a bit overpriced for some (probably) simple circutry, except for the fact I am not an electronics expert. I make my dad do those things, since hes been working on them since the 1950's.

So here's the question: Do ya'll have any sort of ideas how one of these doodads can be made for under 40 bucks, perferably with good old radioshack parts and various doodlehangers we probably have in the garage? Or should i just drop the ~$50 for this fancy contraption?

I did one using 2 LM 3914s and 2 10-segment LED bargraphs for a 20 LED display. It was probably about $10 ... MAYBE 20

I have plans somewhere still ... if anyone wants them, send a PM with an e-mail where you can receive attachments ...

I waterproofed it with liquid electrical tape. then put it in a cardboard housing ... and rubberbanded it on top of the guages ... just a temporary thing to see if I liked it ... It stayed like that for a couple of years ...

It uses a generic radioshack board so you don't have to etch one.

I liked it better than numerical displays, because you can read it at a glance.

[robertbarr]

I think there are two basic problems with any type of charging system warning. First, if it's some sort of L.E.D., it's likely to be either too dim (in sunlight) or too bright (for night riding). Problem two, of course, is waterproofing.

Someone here had mentioned using an A-D to blink an L.E.D. if the voltage dropped below some threshold. No indication for O.K., just a notification of a problem if/when it develops. This sounded pretty well thought out to me. Still, I'm nosing around for a water-resistant housing for a 2" analog gauge. Nothing like seeing the system's continuous reaction to load & r.p.m. changes.

[Steve]

Still, I'm nosing around for a water-resistant housing for a 2" analog gauge. Nothing like seeing the system's continuous reaction to load & r.p.m. changes.

I have a 2" VDO gauge on my Wing. It's pretty much out in the open, but it is shelterd by that monster thing called a "windshield".



That glare shield over the speedo and tach is far enough forward, it does nothing to shelter the voltmeter and thermomter.

.

[pete]

I initially used Martin's circuit to make a 20 LED gauge up, but I had to go all fancy and ended up making it too unwieldy and unsuitable for mounting on a bike

So, in the end I went with this:

http://www.ebay.co.uk/itm/LED-MOTORCYCLE-BIKE-Battery-level-and-Charge-monitor-/200609174686?pt=UK_Motorcycle_Parts&hash=item2eb53d149e#ht_3605wt_952

It's big and bright enough to see in the daylight and I tested it with a variable voltage source and it appears to be just about spot on accurate according to my multimeter.

It also doubles as a battery level indicator and I added a push button switch under my custom dash so I could flick it to battery level monitor mode when I want to. It's not 100% waterproof and they tell you to add some sealant if it will be exposed, but I have a 2.5mm sheet of acrylic perspex over my whole dash that protects it and my fly screen seems to keep most of the water off too.

Here's how it is installed:

[bakalorz]

I think there are two basic problems with any type of charging system warning. First, if it's some sort of L.E.D., it's likely to be either too dim (in sunlight) or too bright (for night riding). Problem two, of course, is waterproofing.

I was worried about visibility when I made mine ..
I recessed it about an inch in the cardboard housing ...

that kept the sun off it unless it was DIRECTLY over your shoulder behind your head ... 99% of the time it was easy to see, even on bright sunny days.
even the 1% that was bad, as soon as you turned even a little bit, you could see it again.

It was also good at night, not too bright, integrated well with the rest of the guages.