Battery Charging Dock Clips for TGA Zest Plus Mobility Scooter

thingiverse

Battery dock clips that allow TGA "Zest Plus" and possibly other two-battery Mobility scooters to be charged while removed from the scooter. The official dock costs up to £200 UKP. Designed so that polarity can't be accidentally reversed, but someone probably could if they tried hard enough. Both batteries must be connected to charge. The left and right clips look very similar and can be clipped on in the reverse position, but they won't stay on or fit properly even though the polarity will be correctly maintained. They can be wired with the plug to the left or right, and it may be better to cut the positive wire rather than the negative wire when wiring to the right. Marking the positive terminal with a colored dot helps, but isn't essential. Supports are needed for printing. The prototype was printed with supports designed into the STL file and Mickey Mouse ears in ABS. The back panels can be reversed, and 5 spots of CA glue permanently secures them. Four 1.6mm copper-clad circuit boards (single or double-sided) cut to 23mm x 19mm are required, as well as one 3-pin female XLR cable-mounted socket (a professional microphone type), three Zip ties, and one meter of sheathed two- or three-core flex cable (approximately 1.0 mm square). The earth wire is not used. Assembly notes include rounding the edges of the PCB to help insertion into battery terminals. If the PCB doesn't fit tightly, glue may be needed. One-sided PCBs can be installed either way round. Zip ties with a drop of CA glue secure cable strain relief. Check battery and charger polarity with a multimeter. Batteries must connect in series, not parallel, with a link between the positive terminal of one to the negative terminal of the other. The prototype charger has a positive connection to XLR pin 1 and a negative connection to XLR pins 2 and 3 (joined).