@win7

Had to tear the unit down, do plastic welding since the screw mounting slots broke.
Probably I would rate this as a 0/10 in the reparability scale by myself -_-.
Also, bypassed the 10 V regulator on the charger boost converter module and now it can work from 9V.
Planned to add another separate boost converter for the inverter to prevent inverter’s low voltage protection from kicking in.
Bypassed the regulator here as well. I feel kinda lazy and tired, probably will log more time from tomorrow,,

Had to harvest a boost converter from my old bench power supply, fix it (it was dead shorted due to an internally shorted capacitor)

Planning on adding a pre-boost converter for the inverter and the charger functions. They refuse to work below 10.2 V, disregarding 20~30% of battery capacity.

Recorded the voltage, current, milliamp hours, power drawn along with time stamps. Gosh, my hands are numb now -_-.

Welp, killed another boost converter. This one failed by having its output voltage always equal to the input voltage no matter what, unlike previously where the boost converter failed as a direct short.

Other than this, I spent a lot of time troubleshooting the charging MPPT function, which seemed to not have proper limit and tripped whatever charger I had connected it to. Had to change the values quite a bit but nothing helped.
In the end I noticed that the initial_in_voltage variable was set to the absolute minimum trigger point whenever the charger was connected, therefore the condition where the (initial_in_voltage - in_voltage variable <= 0.2) inequation is always held true and therefore the Arduino ramped up the PWM no matter what, it took a ton of time to figure out -_-
In addition to this, I had also spent a around 2h in testing the power station regarding its thermals and max. power capability..

Successfully completed the soft started board in order to prevent the inrush current drawn by the XL4016 module from tripping certain chargers. It felt endless, I had to use 2 NPN transistors in an inverter configuration in order to not use a PNP transistor since I did not have one lol.

Also 3D printed and replaced the old battery case for a newer one which has ventilation holes, helping in keeping the battery temperatures low..

In the process of making the soft starter circuit for the XL4016 module, since the inrush current trips some chargers, I’m set on using a 555 timer chip in order to turn on a relay 2s after powering on the relay.

Anyways, tested the bare-bones version of the power station at around 100 W and/or 10A of current and it worked beautifully, though I was scared to my core when doing so, not wanting this setup to blow up like last time which killed the boost converter and both the charger modules.

Printed the left side panel, tried to print the bottom panel but failed, also the BOM list final is ready!!

Well, seems like the assembly process is going to be hard due to a ton of wires and obstacles :(

Had to trim the direct source connector panel twice for it to fit in the right side panel
Boost converter module is held under really high amount of tension probably due to 10mm bolt and nuts.
Made orientation and placement mistakes while installing the chargers panel -_-

Looked through the designs and measurements, edited them when necessary, tested the charging circuit, not sure why but it trips my MacBook’s PD 30 W charger but not my Samsung PD power bank, probably due to inrush currents.
After a long conflict, finally printed the right side panel, need to proceed with the left, top, bottom and back panel as well.
I don’t know, I’m scared to waste ~100g of filament and ~10h of time over a failed print just because of a dimensional mistake or inaccuracy, I’m just looking through the final model in Fusion 360 countless times,!

Birthday devlog today🎉!

Did a ton more of CAD work, including modification of slots and sketches, and boy was it painful!. I had to re-draw each sketch on top and repeat this once again since I need one for negative extrusion and one for filling the already existing slots. All caused by my poor judgement of the dimensions of the other parts

But here I am! Also, had tweaked the code a little, did some power wire replacements and stuff

Working on the mainboard mount.
The mainboard is planned to be mounted on top of the battery pack. Not sure how I’m gonna figure out how to make mounting holes on the bottom panel. Its 12:20 AM rn, need to go to bed,,,

Probably a really messy workbench right now.

Anyways, once again, did quite a bit of working, especially in CAD and 3D printing.
Finally, I’ve hit 100% of the program storage space in my Arduino Nano when uploading my code. Need to optimize the code.
Had to snap off the screw mounts and the bottom section of the button mount cover for it to fit, fixed it in the later version though.
Also, spent 5 full minutes troubleshooting, opening the mainboard out of its case only to find out that nothing was connected (power button, navigation buttons, etc.). Probably, late night fatigue kicking in,,

Printed out the front panel, got a ton of work to do on the other panels.
Thinking of whether or not to add a fuse in series to the direct source connector..
I feel like fitting all of these components into their designated space might be a very tedious task.
Its just a pain to measure and ensure everything is in its own designated region and every part seats in properly, and also, found a mini bug, which is to be fixed in the code,,

Printed and assembled the chargers part

And also, I’m in the middle of designing the right side panel, gonna take up a ton of time as I’m using hit and trial method

Completed the modelling part of the inverter case, charger panel and probably also the front panel.
Did some minor bug tweaks in the code
Also finished cutting the copper sheet for the inverter module

TERRIBLE NEWS: I lost 3D models of the main front panel, the inverter case AND the chargers panel to a power outage. I know I should’ve saved it but I either complete it and save it or just have them lying in my RAM overnight till it finishes and that power outages are rare for me, but here I am!

Completed the bench power supply part, printed the front side in orange and screwed it on the gray bench power supply mount since I’m planning to use orange on gray as opposed to gray on orange.

Also added an extra master XT60 connector for direct battery access connections.

Officially over the 100h mark! 🎉

Designed the front plate of the chargers, designed a stencil to drill through the copper sheet that acts as a small ‘heatsoak’, soldered some cables and much more

Did quite a bit of various work today, but the one that made me glad is the successfull printing of the bench power supply part after 5 devastating failed attempts.
Designed the case in Fusion 360
Worked on the header connections
Worked on the bench power supply part

Completed the case for the inverter part, switched to digital operation of the fan instead of analog due to never ending problems.

Completed the addition fan and LED interface to the mainboard. I had to add a separate boost converter to the setup.
Still the addition of fan causes fluctuation in time to empty readings, need to fix them in code,,

Finally completed the haptics part, there are still some areas that do not work like intended, but I cannot really do much about it.
Designed as well as printed cases for the main board and batteries for enhanced safety.
My streak has not extended for today despite 3h of work today.,

Worked on the haptics for quite a while, still need to add haptic feedback/notification for other messages displayed on the screen, though it is SOO BUGGY! I had to work on it for 3 full days, yet I still feel like the haptic patterns were inconsistent, gotta do more fixing tomorrow, or probably I might focus into something else for a while.