PowerBlock

 

Theory

The PowerBlock contains a rechargeable Lithium Ion (Li-ion) battery. The battery provides about 3.7 volts. This is not enough for the BrainBlock. The PowerBank has a circuit that boosts the voltage up to 5V.

The circuit also protects the battery while it is charging and being used.

Below is a picture of an 18650 Li-ion battery next to a smaller AA battery. AA Batteries are only 1.5V compared to 3.7V of Li-ion batteries.

 

Assembly - Part I (Battery)

1. Materials Required

   
   
   1 - Powerbank
   1 - Battery (18650)

2. WARNING - Placing the battery in backwards
   will immediately DAMAGE your PowerBlock
   

3. 
   Place the circuit board into the plastic case.
   It should slide straight down into place.
4. 
   Place the battery BESIDE the case with the
   
   Negative (-) end at the spring end
   Positive (+) end at the USB end
   
   
5. 
   Check with Mr. Dash before continuing
6. 
   Place the negative (-) end against the spring
7. 
   
   Press the battery down into place
8. 
   Check that your PowerBlock works before placing the cover on
   See the Connection Diagram below for more details
9. 
   
   Snap the cover on
   It will only go on one way
   (the little rectangluar part that sticks out goes at the USB end)
   

 

 

Assembly - Part II (Top Lego)

1. Materials Required

   
   
   1 - Powerbank (with cover)
   1 - Brick 2x12
   1 - Brick 2x3
   
   
2. 
   Drill a hole in the 2nd spot from the end of a 2x12 brick
   (This is so you can see the battery charging LED)
3. Build a jig that looks like this
4. 
   Place your "black" 2x12 brick into the jig
   If you don't have a 2x12 you can use a 2x10 + 2x2
5. 
   Place the PowerBlock in the jig
6. 
   Pull the jig in half
   If you don't have a 2x12 you can use a 2x10 + 2x2
7. Remove the "black" brick that will be glued and place wax paper under it
   If you don't have a 2x12 you can use a 2x10 + 2x2
8. 
   Sand and Acetone the top of the PowerBlock
   Sand and Acetone bottom of the "black" 2x12 brick
9. 
   Ensure the end with the hole you drilled is at the end of the PowerBank with the USB connectors
10. 
    Check with Mr. Dash before continuing
11. 
    
    Superglue the edges and circles of the 2x12 brick
    Superglue only goes on edges (do not fill the holes)
12. 
    Carefully bring the PowerBank down onto the "black" brick.
    Press firmly (but not too hard) together for 1 minute.
    Do not wiggle, move, slide any part of the assembly while gluing.
13. 
    Wait at least 5 minutes before removing the jig
    You don't need to hold it during this time

 

Assembly - Part III (Front Lego)

1. 
   Sand the end of the PowerBank
   Acetone the end of the PowerBank
   Ensure it is the end that does NOT have the USB connectors
   
2. 
   Build this small jig on the end
   Make sure it is the end without the USB connectors
3. 
   Protect the new end-jig using 2 pieces of wax paper
4. 
   Sand the bottom of the 2x3 "black" brick
   Acetone the bottom of the 2x3 "black" brick
5. 
   Build another jig to hold your 2x3 "black" brick
   Protect the jig using wax paper
6. 
   Check with Mr. Dash before continuing
7. 
   Superglue the edges and circles of the "black" 2x3 brick
   Superglue only goes on edges (do not fill the holes)
8. 
   Carefully bring the jig with the "black" 2x3 brick onto the end of the PowerBlock
   Press firmly (but not too hard) together for 1 minute.
   Do not wiggle, move, slide any part of the assembly while gluing.
9. 
   Wait at least 5 minutes before removing the jig
   You don't need to hold it during this time
10. 
    You're Done! This is what it should look like when you are finished.

 

Connection Diagram

1. Charging Mode

   
   To charge your PowerBlock plug it into a USB port on your computer:
   Big USB end into the computer
   Small USB end into the PowerBlock
   
   You should see the charging LED flashing red on the PowerBlock (through the hole you drilled)
   
   

   100% Charged Full

   
   When the PowerBlock is fully charged the LED will stop flashing and stay on.

2. In Use Mode

   To use your PowerBlock plug your BrainBlock into it:
   Big USB end into the PowerBlock
   Small USB end into the BrainBlock
   
   
   Some PowerBlocks will show a Blue LED when in use
   (Don't worry if yours does not)