Controls Enclosure

Description

The controls enclosure does something? TODO

Contents

TODO: layout picture

Controls Leader Board

Github Link: https://github.com/lhr-solar/Controls-LeaderPCB

• Connectors appear to all be vertical.
• The Motor CAN connector needs to be located towards a side of the enclosure so that it can be plugged in.
  • Motor CAN Plug: Mouser, TE Connectivity
  • In addition, the motor CAN plug requires threading to secure it in place (as the connector on the PCB is missing it for some reason). An extra "nut holder" has been added.
  • As the plug is rather large, to protect it and prevent it from being bumped, a 3D printer cover is added for it.

Controls Lighting Board

Github Link: https://github.com/lhr-solar/Controls-LightingPCB

• Make sure you have the right version of the lighting board! The current version appears to be in branch "MCPV2". (Double check!)
• All connectors except J3 (which goes to the Controls Leader Board) are vertical.
  • J3 is horizontal with crappy old wires that don't bend well. Would be best to give it ~50mm of clearance from the edge of the board.

Wiring

For wiring information, please see Controls Enclosure Wiring. 

Additional Design Notes

Due to this enclosure's relatively small size, we decided to utilize 3D printing for the body of this enclosure for simplicity (with a laser-cut acrylic cover).

As this enclosure is 3D printed, its size is constrained by the print volume of the printers we have access to.

• Bambu Lab
• Ender 3

Boards are recommended to be at least 6mm apart from one another. Currently, value is about 10mm.

Mounting

The controls enclosure is mounted to the right of the driver on the pipes using cushioned loop clamps. There are 3d printed tabs between the clamps and the enclosure to provide spacing so that the enclosure does not intersect with the diagonal frame tube which sticks out considerably. Currently, stickoutyness is also constrained by the area of the nut for the loop clamp. It would be optimal if this can be reduced. 

Moving the mounting forward and to left side should also be considered, as the diagonal does not protrude as much and the wiring between the enclosure and the driver display would be shorter. 

Fabrication

BOM

1

Main Body

3D Print (Controls_Enclosure.SLDPRT)

1

Cover

Laser Cut (Controls_Cover.SLDPRT)

1

Latch Cover

3D Print (TODO)

1

Latch Bolt

3D Print (TODO)

1

Nut Holder

3D Print (TODO)

20

Heat-Set Inserts

Ordered Part (Location TODO)

2

Spring (0.3x4x15 mm)

Ordered Part (Location TODO)

Wire diameter x outer diameter x Free length

TODO

Screw (M3, Xmm)

Ordered Part (Location TODO)

Procedure

1. Perform test prints/cuts to ensure tolerances are fine. Use the cut tool in Bambu Slicer to focus on just the portions you need. You may need to adjust depending on what printer/laser you use.
   1. Latching Mechanism: Ensure that the bolt slides smoothly and that the cover fits onto the screw point on the enclosure main body. 
   2. Motor CAN Nut: Ensure that the connector threads fit. 
   3. Motor CAN Connector Protector: Ensure that the bayonet connector slides on and off smoothly. 
   4. Cover Slot: 3mm acrylic from TIW should be able to slide within it smoothly. 
2. Make the parts.
   1. Recommended Print Settings: TODO (slicing settings, recommended orientation, etc.)
      1. Fabrication Files: TODO - Actually maybe better to just keep these in Bild
   2. Recommended Laser Settings: TODO
      1. Fabrication Files: TODO
   3. Controls Enclosure Body: should only be printed with tree supports, otherwise the Motor CAN protector connection point may get gunked up. 
   4. Latch Bolt, Latch Cover: both should optimally be printed with a draft shield (or in an enclosed printer) with high bed temperatures (90 deg. C with TIW PETG), as warping could make the parts unusable. 
3. Assembly
   1. Remove support material from 3D print.
   2. Install heat-set inserts using a soldering iron. (Refer to guide TODO.)
      1. 16 in main body 
         1. 8 for securing PCBs. 
         2. 2 for securing latch. 
         3. 6 for mounting. 
      2. 4 for nut holder.
   3. Install latch.
      1. Insert springs into holes at the bottom of Latch Bolt.
      2. Slide Latch Bolt into rails on Latch Cover.
      3. Insert latch assembly into the outlined region for it in the main body. You may need to hold the body upside-down so that the springs in the assembly do not fall out. Screw in place using M3 TODO screws.
   4. Install nut holder.
      1. Insert nut into nut holder.
      2. Secure nut holder in place using M3 TODO screws.