Fast window mod - motor relays on a PCB! (8 Viewers)

[jonnyd42]

tl;dr - make your door switches last forever, make your windows move faster without replacing the tracks, and do it without a rats nest of wiring

Inspired by this thread and the wiring mess I found in my truck today, I decided to design a small (37mm x 33mm, and 20mm high) PCB. Here are some eCAD screenshots - going to get some boards fabbed and tested in my FJ62. This mod will reduce the current passing through your switch contacts from ~7A to ~40mA (0.04A), which means contacts won't arc / pit.

Boards include:

1. flyback diodes to protect against back emf from the coil discharge on switching.
2. a side mounted molex connector on there so that you don't have to solder anything - just need to pin in a connector.
3. automotive grade relays - the relays I chose are capable of sustaining 20A each, so they should last a long time.
4. 3x 140mm mounting points so you can zip tie or mount to something. In the shipping version I'll probably reduce the hole size and 3D print a little enclosure box...for prototyping I want zip tie access

Going to modify the design tomorrow to support a different relay that has both a 12V & 24V coil version, so that I can solder in whatever people need and send them out. If everything tests well I'll implement these in my truck and sell them if anyone is interested.

 

[jclark]

I’d buy 2 sets.

@CruiserTrash

 

[kevin in okinawa]

you are about to be everyone's hero! well, except for the crank window guys.

 

[IronNam]

How fast can I throw money at you?
How fast can you throw these parts at me?

I want it now

 

[CruiserTrash]

@jonnyd42 As somebody else on here who designs PCBs: nice work. Admittedly I don’t know much about the 62 window circuit, but taking the high current off the switch contacts is a good move. Flyback diode is a nice touch. You could also look at opposing zeners for flyback/spike protection too. Fat traces (may as well use the real estate), and a big ground plane too. Excellent.

FYI Omron makes some nice, robust, and very small PC-mounted relays. I’m not sure what the exact criteria are for this application but some of their continuous 20A units are half the size. Just something to check out as you finalize your BOM and design.

 

[thatcabledude]

If you make that for 80series you could probably retire as wealthy man in a few years. Lol

I have wanted to something like this for my 80 using wire and relays for a long time. Would not small and tidy like your creation. Bravo!

 

[dbbowen]

Im unfamiliar with the fj62 window circuit, but where in the diagram would these sit? Would it replace the factory window relay control box? Will door lock relay functionality for the solenoids be built into them?

The reason i ask is i want to eventually convert my 60 to power windows and locks. Ive done it before on a firstgen 4runner but just used the OEM relay control box and all the parts and just redid the wiring like oem. This seems like a great solution for those wanting to install power windows in their crank window 60 series.

 

[jonnyd42]

Wow love the excitement here! Few updates for folks on next steps / timing:

1. when can I buy? / ETA - expect about a month. This is just a design right now, I will order the boards and parts tonight. Then I'll need to assemble and test them. I'll provide updates along the way!
2. how will you test the design? - I have a bench top setup I use for other electronics projects with several programmable power supplies and an electronic load. I'll run a set of the boards through 1000s of cycles to validate that there's nothing wrong with the parts batch. For boards that ship out, I'll run the boards through a functionality test (just a few cycles) but won't do the 1000s, since that will wear out the relays.
3. what will it cost? - I'm still thinking about that. I want it to be reasonable - stay tuned.
4. how do I pay? - my current thought is that I'll have folks just donate directly to my late fiancee's 501c3 foundation as "payment" and then I'll ship out the stuff. Kelly passed away in a tragic bike accident this past October and she had a lot of causes she was passionate about (helping veterans get jobs, homelessness, educational opportunities especially for women etc). We have her foundation up and running and have already begun giving out scholarships to students who meet the right criteria, and helping local schools where they need. She was my best friend of 11 yrs. Anyway, with this method your purchase of the relay kit would be fully tax deductible.

 

[jonnyd42]

If you make that for 80series you could probably retire as wealthy man in a few years. Lol

I have wanted to something like this for my 80 using wire and relays for a long time. Would not small and tidy like your creation. Bravo!

Does the 80 use the same wiring method as the 60? Where the actual switch passes the current through to the motor?
If so the same board will work in an 80.

 

[jonnyd42]

Im unfamiliar with the fj62 window circuit, but where in the diagram would these sit? Would it replace the factory window relay control box? Will door lock relay functionality for the solenoids be built into them?

The reason i ask is i want to eventually convert my 60 to power windows and locks. Ive done it before on a firstgen 4runner but just used the OEM relay control box and all the parts and just redid the wiring like oem. This seems like a great solution for those wanting to install power windows in their crank window 60 series.

Building on the great work by @slcfj62 and borrowing his diagram, the board effectively does everything written in pencil in the pic below.

I can design a factory replacement window relay control box if that's of interest to people.
What I posted does not have door lock relay functionality built into them, though I can also design that if it's of interest down the line.

Let's start with this project, get it working, and then happy to explore other ideas!

 

[dbbowen]

Building on the great work by @slcfj62 and borrowing his diagram, the board effectively does everything written in pencil in the pic below.

I can design a factory replacement window relay control box if that's of interest to people.
What I posted does not have door lock relay functionality built into them, though I can also design that if it's of interest down the line.

Let's start with this project, get it working, and then happy to explore other ideas!

View attachment 3926192

Id 100000000% be interested in something like that and would be willing to help test or supply sweat equity. A module for folks wanting to ADD power windows and locks would be huge for 60 series owners imo. Before i learned of this pcb option, my plan was to use many individual relays instead of the oem control relay box

 

[HemiAlex]

I need a set. Count me in.

 

[jonnyd42]

Alright I redesigned it with a new relay family (the gray blocks are spatial placeholders since the new part doesn't have a nice 3D model). Same physical footprint and pinout, so if people want 12V or 24V all I have to do is solder in the right parts. Same PCB, two configs. Will double check my work later and order the first batch for testing.

I'll also CAD up and 3D print some small enclosures so that I can ship it out with an enclosure rather than just a raw board. That way you won't have to worry about pins on the bottom side shorting to the door metal / chassis GND.

Should have updates in about 2-3 weeks!

 

[Roonie]

I am in for my 62

 

[MWM1]

Please add me to the list! I would like to have the power door lock function to match my existing FJ62 with brown interior. Thank you so much, and look forward to contributing to the charity!

 

[AndersBror]

Count me in for my 62!

 

[redeyeracing]

Take my $!!!! I'm in!

 

[CBfj62]

Count me in as well!

 

[costahh]

As everyone else in this thread count me in as well!

 

[jonnyd42]

Boards & parts have been ordered! Stay tuned!