E-Box Progress Tracker (2020-2021)
This page explores the progress to date for the 2021 E-Box design. The progress changelog starts from March 5, 2021 as the e-box frame went over a drastic redesign, and progress on the old frame design was made obsolete.
OUTSTANDING ITEMS
- Task: Buy 1/4" and 1/8" acrylic sheets for lid and second level laser cutting (to be completed once campus lockdown is over)
Assigned To: Jasmine Milan (or anyone else on campus)
Estimated Completion Date: (when campus lockdown ends) - Task: Get the lid laser cut. DWG in fab folder in GrabCAD (MR21-EB-013-AHu)
Assigned To: Austin Tailon Huang (or anyone else on campus)
Estimated Completion Date: (when campus lockdown ends) - Task: Print the remaining power pole mounting powers (6x MR21-EB-008-JAM)
Assigned To: Austin Tailon Huang
Estimated Completion Date:
- Task: Determine if there are issues with the 3D printed hinges, address issues if they arise and get them printed (2x MR21-EB-003-MAG, 2x MR21-EB-004-MAG)
Assigned To: Austin Tailon Huang
Estimated Completion Date: - Task: 3D print the small lid strain reliefs (2x MR21-EB-004-JAM)
Assigned To: Austin Tailon Huang
Estimated Completion Date: - Task: 3D print the large lid strain relief (1x MR21-EB-003-JAM)
Assigned To: amillsem@uwaterloo.ca
Estimated Completion Date: - Task: 3D print the fan finger guards (4x MR21-EB-018-AHu)
Assigned To: Austin Tailon Huang
Estimated Completion Date: - Task: 3D print the custom second level mounting standoffs (2x MR21-EB-017-AHu)
Assigned To: Austin Tailon Huang
Estimated Completion Date: - Task: 3D print the large insulating standoffs for the e-box frame (2x MR21-EB-015-AHu)
Assigned To: amillsem@uwaterloo.ca
Estimated Completion Date: - Task: 3D print spacer for handle latch (1x MR21-EB-014-AHu)
Assigned To: Austin Tailon Huang
Estimated Completion Date: - Task: Update the connector place holders (USB and Ethernet) to reflect actual real life models
Assigned To: Jasmine Milan
Estimated Completion Date: - Task: Update lid and fasteners to use low profiles rather than countersunk flat heads in CAD
Assigned To: Austin Tailon Huang
Estimated Completion Date: - Task: Get vicor model from Andrew and put it in the CAD
Assigned To: Austin Tailon Huang
Estimated Completion Date: - Task: Update the connector place holders (USB and Ethernet) to reflect actual real life models
Assigned To: Jasmine Milan
Estimated Completion Date: - Task: Finalize second level layout and laser cut second layer piece (this needs to be done with electrical in person
Assigned To: TBD
Estimated Completion Date: TBD
PROGRESS CHANGELOG
| Date | Entry By | Category | Description | Photos |
|---|---|---|---|---|
| Austin Huang | Design work | -Changed from panel + bracket design to sheet metal folded welment for box cage as per DEMTOOL recommendation | -- |
| Austin Huang | Design work | -Changed to 0.06" aluminum stock size from 0.125" to allow lightest weight possible for box with integrated PEM fasteners. 0.06" thickness also recommended by DEMTOOL fabricators | -- |
| Austin Huang | Design work | -Added floating PEM nuts where possible | -- |
| Austin Huang | Design work | -Changed cutout arrangement on front panel to be collinear and make dimensioning/drafting easier | |
| Austin Huang | Testing | -Printed out PP75 and PP15 connector mounts and verified design compatibility | https://drive.google.com/file/d/1mOEV_tIviqRacl9V4E0k38bJpZEeyZdM/view?usp=sharing |
| Austin Huang | Design work | -Added 3d printed spacing plate to ensure handle mates with latch properly (MR21-EB-014-AHu) | https://drive.google.com/file/d/1koiq2B3c5_KjrVf1s7W5OjIfySod6zhl/view?usp=sharing |
| Austin Huang | Design work | -Designed 3d printed standoffs to mate with chassis frame, to insulate box from frame as metal fasteners provide an electrical contact point (MR21-EB-015-AHu) | https://drive.google.com/file/d/1H6pcw0b5p6n93d0g3QvuGgrAW6v9efqm/view?usp=sharing |
| Austin Huang | Design work | -Sorted out powder coating details, and will powder coat box with gray coat to fully insulate. Gray gloss is reflective and low absorption for Utah radiant heat | -- |
| Austin Huang | Design work | -Added laser engraved logo to acrylic lid | https://drive.google.com/file/d/1gdgDdSWNKEybTDUQ_NevmjVaY4UF97cu/view?usp=sharing |
| Austin Huang | Fabrication | -Made first draft of fabrication drawing | -- |
| Austin Huang | Design work | -Changed from stainless steel floating nut to standard CLA (aluminum) nut. Avoids possible corrosion cell between nut and box by matching material | -- |
| Austin Huang | Design work | -Spec'd out IP54 rated 120mm fan filter to provide airflow within the ebox while protecting box from dust intake | -- |
| Austin Huang | Design work | -120mm fans too big for ebox walls, so changing to 80mm fans. Spec'd out low noise fans 80mm fan with 40ppm filter guard. Not IP rated, but full IP rating isnt available for this fan size and is likely overkill for our box. | https://drive.google.com/file/d/1ZdVsyUPntdI0wBcyHV8lU0SQcgTiWv4X/view?usp=sharing |
| Austin Huang | Design work | -Added second level to EBOX for better routing. Still need to rearrange layout inside the box, but will get to that soon | -- |
| Austin Huang | Design work | -Inserted weights for OTS components in ebox | -- |
| Austin Huang | Design work | -Updated drafting drawing for fab | -- |
| Austin Huang | Design work | -Discovered miscommunication with molex connectors, and that cables will not actually be mounted to face of box. Redesigned cutout to use adaptable cable tie rack mount for any cable (MR21-EB-019-AHu) | https://drive.google.com/file/d/10Hrvq9TkgUa7zFNBdpsDQnjzZY3ORyyK/view?usp=sharing |
| Austin Huang | Design work | -Discussed fan CFM with melvin, and decided to select higher noise, larger high CFM fans. Concern was raised that previous fans did not provide sufficient air recycle rate to prevent the jetson from throttling in Utah. -Also decided to use finer filter on intake fan and courser filter on exhaust fan to promote better dust expulsion within the ebox | -- |
| Austin Huang | Design work | -Designed 3D printable fan finger guards for inside of E-Box (MR21-EB-018-AHu) | https://drive.google.com/file/d/1JmE2j44RajsC8M1XCkSJRHhF4WvF6s-m/view?usp=sharing |
| Austin Huang | Fabrication | -Finalized drawings and ordered E-box, E-Box Order History (2020-2021) (ORDER COMPLETED) | -- |
| Austin Huang | Fabrication | -Printed cable tie mounts (MR21-EB-019-AHu) -Also updated FAB drawing to reflect some redlining done by Demtool. As per their recommendation, did not use CLA nuts and used zinc plated SS nuts as CLA nuts strip very easily. | https://drive.google.com/file/d/1iBqVJdt_y5l070qSjyEnL3Exb7rA5myU/view?usp=sharing |
| Austin Huang | Design Work | -Designed 3D printed standoffs for custom second level placement (MR21-EB-017-AHu). They include a drafted nut pocket for the board screw, and small ducts on the bottom face for adhesive (hot glue) to flow into. Also slightly oversized, as hopefully acrylic will deflect and the standoff fit will be tight -Added COCAR to assembly and arranged second floor in theorized arrangement in CAD. | https://drive.google.com/file/d/1HXlWfhuFuPSmSQQxuoYn3RVs0LPLTe9_/view?usp=sharing |
| Austin Huang | Fabrication | -Ordered all outstanding McMaster/Digikey components | -- |
| Austin Huang | Testing | -3D printed detachable hinges (MR21-EB-003-MAG, MR21-EB-004-MAG), found clearance issues when mating them together although it is likely due to bed warping. Need to reprint and investigate after fixing warping | https://drive.google.com/file/d/1reFW9jQ_qV09xu4P3N8ZXoCBGWGdpPLq/view?usp=sharing |
| Austin Huang | Design Work | -Made DXF for second level, updated box standoffs to be single printed unit rather than two pieces (MR21-EB-015-AHu) | https://drive.google.com/file/d/1BDvW3LWn9pc1eq7-TRSj2f_XOsmQRRVQ/view?usp=sharing |
| Austin Huang | Design work | -Added vicor to CAD | -- |
| Austin Huang | Fabrication | -Printed the handle space and strain reliefs for lid, and extra PP75 mount | https://drive.google.com/file/d/11otGdqX3lipCnho2339H4GzRWFocqAQU/view?usp=sharing |
| Austin Huang | Fabrication | -Printed remaining PP15 mounts | https://drive.google.com/file/d/1NIEffY5LOy7YhIi7Jd61q5W7Y7U2t4f7/view?usp=sharing |
| Austin Huang | Fabrication | -Updated lid fasteners in assembly -Started to print out fan finger guards (1 complete) | -- |
| Austin Huang | Fabrication | -Finished printing all the finger guards for the fan | -- |
| -- | -- | -Ebox has been delivered! | https://drive.google.com/file/d/1RjxUxCY5uxUT-xpRd0s8caOgYYKbpI7l/view?usp=sharing |
| Austin Huang | Fabrication | -Printed standoffs | https://drive.google.com/file/d/1hqqIOG3UVyOs27ItFCdVq2dXB9LVPfUc/view?usp=sharing |
| Austin Huang | Fabrication | -Printed hinges. Hinge design was fine, I just had to upgrade/optimize some stuff with my prints to get them to mate correctly | https://drive.google.com/file/d/1fPnJFiqf__AQJg4Ca8Iio0UTfXvS_0up/view?usp=sharing |