Bionx

Bionx Console Adapter

This contains Kicad designs for a flex PCB that can be slotted under the G2 console for easy interfacing with the bike's CAN bus.

The PCB breaks out all of the pins from the console (including throttle).

Manufacture

The file gerbers.zip contains all of the necessary fab files and it can be uploaded directly to JLCPCB and other board houses, with no further changes necessary.

JLCPCB currently has a deal where you can get 5 x flex PCBs for $2, and if you use their lowest cost shipping option, you can get these delivered for a total of around $5-6.

Five easy steps to order:

1. Go to JLCPCB
2. Click on the Get Instant Quote button (no need to change the options next to it).
3. Click Add gerber file and upload the gerbers.zip file from here.
4. Select Flex as the base material. You will see a yellow render of the PCB.
5. Change no other options, just click Save to cart and finalise the order.

If you select Global Standard Direct Line shipping, this will cost a little over $3, rather than $20+ for DHL/Fedex, though will take a couple of weeks.

The $2 deal is for 0.11mm PCB - thicker options are much more expensive, but this one works (you may want to manually add a stiffening film).

Usage

The PCB simply slips into the console holder, ensuring the PCB pads line up with the metal pads, then slide the console on, taking care not to let the PCB slip.

On mine, I added a little extra rigidity by using some 0.2mm mylar sheet that I cut and added holes for the PCB pads, using contact cement to bond them together. You don't have to do this, but you need to be a little careful at preventing the PCB from slipping.

You can then solder wires to the GND, CAN_L and CAN_H pads, which you then connect to your CANBus adapter. I used soft silicone wire and hot glue - more rigid wire and/or no hot glue risks tearing the pads off.

The other pins are also broken out for those who want to experiment more.