Sunday, December 4, 2022

MagSafe Enabled Wireless Power Bank

By Ashwini Kumar Sinha

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efy testMagSafe, a magnetic technology embedded into the internal engineering of iPhone 12 model, was originally created as a safety feature for MacBook charging cords. It creates a new ecosystem of accessories for easy attachment and faster wireless charging. The cost of a wireless power bank with MagSafe ranges from ₹5000 to ₹7000. Apart from being expensive, it is difficult to procure from the market.

Bill Of Material
Component name Quantity Description
Inductor coil 1 For wireless power
5V stepup charging BMS 3 5V stepup charging module
Wireless power TX module 1 Power transmitter
3.3V rechargeable battery 2 2000mAh or 1000mAh
3D printed case 1 Powerbank case

This DIY project is of a wireless power bank with MagSafe, which can not only charge iPhones but also other compatible devices (including IoT devices). It offers the benefit of having a wireless powering system, MagSafe technology, and a USB charging system that is compatible with many devices.

Fig. 1: MagSafe enabled wireless power bank
Fig. 1: MagSafe enabled wireless power bank
Fig. 2: Components used
Fig. 2: Components used

Designing

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The size of the battery is important for designing a proper case. Both the battery and the charging module have to fit inside the case, which has to be cut to make provision for input power charging (USB) and output power. A cavity is also made on one wall of the case for the coil and MagSafe magnet to be placed, as shown in Fig. 3.

Fig. 3: Case design
Fig. 3: Case design
Fig. 4: 3D printed power bank case
Fig. 4: 3D printed power bank case

For the circuit, we can either use a 5V step-up battery management IC or a module. A TP4056 one-ampere battery charging module was used in the author’s prototype. The module’s output is connected to a wireless transmitter, as shown in Fig. 5.

Fig. 5: Wireless power bank circuit
Fig. 5: Wireless power bank circuit

Connections

The battery terminals are soldered either with the wires directly or a battery pack connector strip. In case of multiple batteries being used, make sure to connect the batteries in parallel (see Fig. 6). Next, connect the battery step-up charging module as shown in the circuit diagram. The wireless charging coil should now be soldered with the input of the wireless power transmitter module and its output with the charging module output pins (see Fig. 7 through Fig. 10).

Fig. 6: Connecting the batteries in parallel
Fig. 6: Connecting the batteries in parallel
Fig. 7: The module and battery cells
Fig. 7: The module and battery cells
Fig. 8: Battery terminal soldered
Fig. 8: Battery terminal soldered
Fig. 9: Wireless transmitter charging module connected to the charger module
Fig. 9: Wireless transmitter charging module connected to the charger module
Fig. 10: The circuit diagram
Fig. 10: The circuit diagram
Fig. 11: Fixing the coil and magnet
Fig. 11: Fixing the coil and magnet
Fig. 12: Fixing the coil and circuit along with battery
Fig. 12: Fixing the coil and circuit along with battery

The coil may now be fixed in the cavity with a magnet for MagSafe. Above this fix the battery along with the BMS module in USB cavity of the 3D-printed case. Finally, fix the top cover (see Fig. 11 through Fig. 14). For MagSafe, fix the circular magnet in cavity with glue.

Fig. 13: An inside view
Fig. 13: An inside view
Fig. 14: Author’s prototype without the top cpver
Fig. 14: Author’s prototype without the top cpver
Fig. 15: The author’s prototype
Fig. 15: The author’s prototype
Fig. 16: Testing power bank and charging AirPods
Fig. 16: Testing power bank and charging AirPods
Fig. 17: Testing power bank’s wireless charging system by powering LED wirelessly
Fig. 17: Testing power bank’s wireless charging system by powering LED wirelessly
Fig. 18: A phone being charged
Fig. 18: A phone being charged
Fig. 19: LED glowing to indicate power transfer
Fig. 19: LED glowing to indicate power transfer

Testing

To test the circuit, plug in any device to the USB and notice it charging. (In the pictures an Airpod case is shown plugged in.) Next, bring any wireless device (a wireless LED is shown in the pictures) and see the LED glowing, as shown in Fig. 19, as the power bank emits power in the form of electromagnetic waves. A phone can be charged by placing it on the device, as shown in Fig. 20.

Fig. 20: Phone charging
Fig. 20: Phone charging

Ashwini Kumar Sinha is a technology enthusiast at EFY

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