Small but Mighty Portable PSU (DIN Compatible)

The PSU I have been using was taking up significant area so I wanted to replace it for a while. Instead of buying a smaller one, I decided to go all out and design my own custom one.

There are plenty of PSUs made out of the SK150C out there but as far as I am concerned this is the first one combining the following features:

1. Compact size
2. DIN Mount
3. Externally accessible Fuse for easy oopsie repairs on the go (10A fastblow 20mm Fuse)
4. LED Driver/Battery powered
5. Wall mounted to portable PSU in second. Just pull out of the mount and approach the connector halves together
6. Foolproof connector design. Housing fits one way and magnets repel eachother when trying to plug it the wrong way. The female side is meant to connect to the power side cause it has a divider in the middle of the body to prevent accidental shorts.
7. Accepts banana terminal and XT60 Connectors
8. On Off push button switch
9. Ventilation channels designed in the case for when you are pushing serious amperage though it

The parts print in 16h.

If you find this project interesting you should consider subscribing to my Youtube Channel FR2W. There are plenty projects to come 😉.


BOM:

Wall Mount:
10x2 neodymium magnets -4pcs

Magnetic Connector:
6x3 neodymium magnets - 4pcs
M3x5mm wormscrews - 4pcs

PSU:
SK150C - 1pcs
Ferules - 6pcs
4mm Ring terminals - 2pcs
Banana Jack - 2pcs
XT60 panel mount connector - 1pcs
M2.5 bolts - 2pcs
M3x5mm heat inserts -4pcs
M3x10mm bolts - 4pcs
20mm Fuse Holder panel mount - 1pcs
10A Fastblow 20mm glass fuse - 1pcs
Latching push button switch - 1pcs
Silicone Wire
Super Glue
Heatshrink tubing

Tools:
Wire stripper
Soldering Iron
Ferule crimper

Wiring is pretty straight forward (see uploaded wiring diagram image)

Magnetic Connectors:

Each half of the magnetic connector has 2 magnets that need to be placed in opposite polarity to eachoter. This is to achieve the hands free connection and to not allow reverse polarity connection by magnetic repulsion. The pointy side of the connector indicates +. Any project you see using this connector I designed will feature this polarity.

The worm bolts are supposed to carve their own threads and they are what ensures contact between the ferule and magnet side. The bolts also make sure that the wire won't come loose by pinching it tight. Do not over tighten them just snug them down. You should be able to tug them without them sliding out of place. 

You might need to glue the magnets in place to prevent them from getting out of their pockets. Make sure you don't get glue on the sides cause then the ferule wont make contact with the magnet and power will not flow through them.

Make sure you keep the magnets away from metal debris as it will interfere with connection reliability. If the magnetic contacts get contaminated use compressed air, a toothbrush or some low adhesion power sticky substance to remove them.

Print Settings:

Walls: 2
Infill(%): 10
Infill Pattern: Triangles
Top/Bottom Layers: 3
Supports: Normal(auto)
Variable Layer Height: 1.00 (Speeds up print)

 
Notes: I would have loved to make this USB type C powered too but EU has decided to add a tax on overseas purchases (3€ per seller I think) so I wasn't able to get a hold of the type C power module.