Design Iteration 1:
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This design iteration uses the bldc motor and servo motor from the previous model of the gimbal for the pitch and pan axis.
A front and back casing was created to encapsulate the camera for protection.
The front casing includes slots to allow the cooling vents on the camera to remain open.
A bracket is fastened to the back of the case which is used as the pitch axis mount while allowing for an extension in the camera’s field of view when the pitch axis is angled downwards.
The servo is currently mounted on the outside of the body.
Design Iteration 2:
Adjustments have been made to the outer frame with an additional part added - the servo mount to place the servo on the inside of the gimbal, allowing for it to be a more compact structure.
The pitch axis mount bracket and the back casing have been combined into one part allowing for an overall stronger structure not requiring the use of any additional fasteners.
Concerns exist with the front casing as it would allow dust to enter into the vents, so currently a solution is being researched to ensure that protection from dust and active cooling is achieved.
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Design Iteration 3 (In Progress):
The front casing was redesigned and the vents were removed to prevent dust from entering the vents. The re-design took the following thermal recommendations from Intel RealSense into account:
The bottom cut for the vents has been removed and the top has been kept open with an additional part added to mount two 20mm x 20mm fans
Dust mesh filters were designed to be placed above and below the case.
Rubber sealing has been added between the front and back casing as well as the front casing and camera lense allowing for additional protection against dust.
The link to the rubber sealing added (diameter of 2 mm): Link
Passive Cooling Recommendations:
Mounting Bracket Material – Utilize mounting screws (2X M3 screws) and
material that is the same or similar in nature (equal or lower thermal
resistance or high conductivity) as the peripheral housing that the D400
Series depth cameras are made from. Material – Aluminum 6000 series.
Increased Mating Surface – Mounting bracket mating surface with D400
series depth camera can be increased by a factor of 2X. The larger the
mounting bracket mating surface area to the depth camera the better.
o Reduction of mating surface imperfections, defects, roughness and
gaps is recommended. Any increase in defects in the material can
increase the thermal contact resistance, reducing effectiveness of
heat dissipation of the thermal solution. Attachment options
should be comprised of epoxy compounds or thermal tape/paste.
Heat Sink – The addition of a heat sink can also improve heat dissipation
from the D400 series depth camera. Use of a material such as Aluminum
6000 series or similar with equal or lower thermal resistance to the mating
surface is recommended.
Active Cooling Recommendations:
While heat pipes and liquid cooling solutions offer advantages, they also
increase the complexity of system integration substantially. The use of a
fan with direct air flow to the depth camera (back mounting surface 2X M3
screws) is preferable.
