Heated Grip PWM Temp Controller

Well finally got around to finishing up a couple of home made temp controllers for the grip heater elements. It uses a 555 timer and power mosfet to control the heat using pulse width modulation. Temperature is controlled using a dial pot. It is based on a design I found on the net. Seems to work ok so far. Time will tell how it will hold up.

Using PWM doesn't waste any power on low settings. I plan on wrapping the heating elements around the outside of the grips, closest to my gloves. That way I can maximize heat to my hands while keeping the controller on a very low setting. Thus consuming the least amount of power. Which will free up power for lights, battery, etc.

Overall cost under $30 plus time. The electronic components are relatively cheap. The most expensive parts are the case, connectors, pot, etc.

For those who may be interested in a project, here are some pics, schematics, and wiring diagram.

NICE JOB!
How about a parts list of what you used with any part numbers and where you purchased them. I would like to add that to my Skorpion.

I ordered everything from Newark
http://www.newark.com/

If you are only building one or two you don't need to order the large circuit board (#1)(4.5"x8"). You should be able to find a smaller similar one.

The Mini Universal Mate-N-Lok connectors (#6-13) are optional. Cheaper to go with bullet terminals.

If you substitute the power mosfet (#14) go with one with low on resitance and hi current capacity. That way you won't need to heat sink it.

The original designer used the circuit to run heated vest. He put the electronis in a magnetic automotive key case, covering the magnet in rubber, and slapped it to his steel gas tank (keeping it somewhat portable).

You may want to opt for a slighter larger enclosure as everything just fits in there and there is a real sequence to assembling. Here is the list. Good luck.

PARTS LIST (image)


Text version (hard to read but handy if you want to copy part #s)

# ID# Description Newark# Manf Type# "CatalogPage" "Unit Cost(Catalog)" "Quantity" "Cost"

1 B1 Circbord printed circuit prototyping board, 3-hole pads THSP 4.5x8.08" 87F660 Vector 3677-6 370 $25.740 0 $0.000

2 C1to4 0.1mF Capacitor Tantalum 42V 49C5881 Vishay 199D104X9035A1V1 423 $0.508 2 $1.016

4 D1to4 1N914 Diode DO-35 package 58K9617 NTE 1N914 324 $0.029 2 $0.058

5 E1 Enclosure 1.97x.1.38x0.67" plastic 83F8732 Hammond 1551GBK 2275 $2.030 1 $2.030

6 J01 Mini Universal Mate-N-Lok 2 pin connector plug 69h8555 AMP/Tyco 172336-1 796 $0.378 3 $1.134

7 J02 Mini Universal Mate-N-Lok 2 pin connector cap 99F3365 AMP/Tyco 172343-1 796 $0.331 3 $0.993

8 J03 Mini Universal Mate-N-Lok connector Pin 52F2283 AMP/Tyco 171638-1 $0.138 6 $0.828

9 J04 Mini Universal Mate-N-Lok connector Socket 66F1674 AMP/Tyco 171639-1 $0.114 6 $0.684

10 J05 Mini Universal Mate-N-Lok 3 pin connector plug 66F1669 AMP/Tyco 172166-1 796 $0.546 $0.000

11 J06 Mini Universal Mate-N-Lok 3 pin connector cap 08J4507 AMP/Tyco 172329-1 796 $0.360 $0.000

12 J07 Mini Universal Mate-N-Lok 4 pin connector plug 95F2736 AMP/Tyco 172167-1 $0.569 $0.000

13 J08 Mini Universal Mate-N-Lok 4 pin connector cap 25C3122 AMP/Tyco 172159-1 $0.837 $0.000

14 U2 Power Mosfet ST Microelectronics 120A 0.0043ohms TO-220 89K1607 STMicroelectronics STP100NF04 $1.740 1 $1.740

16 P1 Pot 100K 1/4"x3/4" shaft BOURNS 04F3044 BOURNS 91A1A-B24-B20 529 $4.650 1 $4.650

17 K1 Knob 0.63"x0.47" black with white line 57F2343 Tyco PKE-60B-1/4 $3.880 1 $3.880

18 L1 LED Panel mount red 3x8mm w Lumex 09J9252 Lumex SSI-LXR3612ID 1309 $1.980 1 $1.980

19 R1&2 Resistor 500ohm 94C5141 Vishay 5043ED499R0F12AF5 546 $0.129 2 $0.258

20 U1 555 Timer Chip 06F7573 Intersil ICM7555IPA $0.534 1 $0.534

21 S1 Switch sealed Toggle 50F5502 Tyco AE101MD1AV2B 1676 $4.940 1 $4.940
Sub-Total $24.73
Tax $3.46
Ship 2.00
Total $30.19

Nice work Steve. :rock: