PowerBox for Sailing Boats
Wall-mounted 12-volt power supply with replaceable 18-volt batteries.
A compact, wall-mounted PowerBox was developed to provide a reliable 12-volt power supply on a sailing boat. Instead of using a conventional 12-volt lead-acid battery, the system is powered by replaceable batteries from the Bosch 18V tool battery platform.
The PowerBox supplies the navigation instruments, mast-mounted displays, masthead light, and dimmable LED lighting inside the boat. An additional 12-volt connection is available for future devices or temporary equipment.
All switches, fuses, electrical connections, and electronic components are integrated into a custom-designed, 3D-printed enclosure. Waterproof connectors allow the individual devices to be connected securely and disconnected when required.
Initial Situation
Many small and medium-sized sports boats do not require a large or complex electrical system. Nevertheless, a limited number of essential devices still need power, including navigation instruments, mast displays, navigation lights, and interior lighting.
The previously used 12-volt battery was heavy, inconvenient to transport, and difficult to charge. It required a separate charger and could not be replaced quickly while on board. There was also no central unit combining the power supply, switches, fuses, and connections.
The objective was therefore to develop a solution that:
- replaces the existing 12-volt battery
- uses lightweight and easily replaceable batteries
- centralizes switching and protection
- provides clear and structured wiring
- uses waterproof external connections
- can be permanently mounted to the wall of the boat
- can be extended with additional 12-volt devices
Defined Solution
A permanently installed PowerBox was developed around a replaceable Bosch 18V tool battery. The battery can be removed within seconds, charged outside the boat with a standard charger, and replaced with a fully charged spare battery when necessary.
Because the connected devices operate at 12 volts, a DC-DC converter was integrated into the enclosure. It safely reduces the battery voltage from 18 volts to a regulated 12-volt output for the boat’s electrical equipment.
The connected systems include navigation instruments, mast-mounted displays, the masthead light, dimmable LED interior lighting and one spare 12-volt connection. Each circuit is protected by an individual fuse, and all external devices use waterproof plugs.
Result & Added Value
The PowerBox replaces the previously distributed and improvised electrical setup with a central, permanently installed power unit. Switches, fuses, voltage conversion, and external connections are now combined in a single compact enclosure.
The main advantage is the replaceable battery system. The battery can be removed easily, charged using an existing Bosch charger, and replaced with the spare battery when required. There is no longer a need to carry a heavy and inconvenient 12-volt battery between the boat and a charging location.
The centralized design makes the wiring easier to understand and maintain. Each device has a dedicated switch, fuse, and connector. The dimmable LED lighting improves comfort below deck, while the additional 12-volt connection keeps the system extensible.
Technical Design
The PowerBox enclosure was individually designed and produced using 3D printing. Its dimensions and internal structure were adapted to the available mounting space, switches, connectors, battery interface, and electrical components.
The enclosure contains:
- the battery connection and power input
- a DC-DC converter from 18 volts to 12 volts
- separate fuses for the individual circuits
- wiring for switches and outputs
- connections for waterproof plugs
- the control system for dimmable LED lighting
The modular design allows future modifications. The currently unused 12-volt output can be assigned to another device, while switches, fuses, and connectors can be replaced individually when required.
Technologies
- 3D Printing
- CAD
- Bosch 18V
- DC–DC Conversion
- 12V Electronics
- Prototyping
Tags
- NiceToHave
- 3D-Print
- Sailing