CaseFrontplate (2006-03-16 04:43:08)

Alubos front-plate with window for econoseal connectors

News: having supply-chain problems, we're trying things. It seems the new party will work. [ http://www.american.hu/GenBoardv31/GenBoardv31/TransparentBox/ unresized big pictures about box with transparent frontplate ]. They use a precise, but expensive technology. We will manufacture transparent (for demo purposes) and Al frontplates, but the Al endplate is being moved to another, cheaper technology (with the option of DB connectors).


Assembly warning

It is very important to solder the EconoSealIII connectors with the frontplate applied and verified to the GenBoard/VerThree/CaseAndMounting : otherwise it might be impossible to apply frontplate later (without unsoldering connectors) depending on how the connectors were soldered.


Offsetted frontplates

Thanx to a lousy CNC-er a bunch of frontplates were manufactured with imperfect sizing. The small pegs from the EC36 connector bottom must be removed (or halved, but removing is easier) with a knife and the connector legs bent a bit (0.5 mm not visible as the legs are 20+ mm long). The price is therefore discounted to 2 Euro. They are mixed with a set of good plates, that needs nothing special to make a good match.

The transparent frontplates are not affected at all - those are perfect match and (partly because of the lack of pegs) very easy to work with.


Manufacturing notes

The EC18 (smaller window than the EC36) window is on the left side when looking onto the side without gasket-notches, and the overlap being at the bottom holes. (this is important to verify before manufacturing, because the early revision files had it mirrored!)

looking onto the side without gasket-notches:

front.jpg

looking onto the side with gasket-notches:

inside.jpg

twoparts.jpg

The assembled box:

box.jpg

the part press fit together you need to smash them together with a vice or tap them together.

to verify sizes (this picture uses the broken inch unit :-):

end.jpg


Simple endplate and OLD, OBSOLETE frontplate :

endplate1.JPG


TODO:


Simplify design


No need for these with the 2D machining:


Surface finish - optional

options:


What format is needed to manufacture? - alternatively they can just redesign, given the pictures, files, Alubos and connectors.

What tool do they use to make the toolpath?

I can export but it take some work on the import it seems that inporting/exporting from one CAD to the next seems to always need some work.

The HU countryside (unreliable partner) shop could use

BUT THIS IS NOT GOOD FOR NOW

Required format: we need this for now:

The 2 part frontplate must be in 2 different files (especially if it is EPS). One better be mirrored so the same sheet-laying and tool-mounting logic applies. The height must be specified as extra input: simple in this case: the mid-height is 1.48 mm (total is 3.00 mm, but 2*1.5 mm will be somewhat > 3.00 when put one onto the other).

Don't worry too much: we will adjust the edges, especially at the overlapping section after the test-run. I think the edge of the overlap section when going from half to full height will be angled so a faster tool can be chosen: so the boundary will have to be offsetted a bit unless the edge refers to the mid-height (which it should, IMHO, so probably no worries).


Measurements in mm

Plexi version's division1 (all referenced from ECxx top edge):

-16, 21 (EC.. window), 36 mm

(just 1 mm lower than on [this pic], which is -15, 21, 37mm. The truth should be somewhere midway: -15.5, 21, 36.5 mm although if it's higher, the EC can be raised without much problem.)

division2 (all referenced from left drill):

13.0 (EC18 window), 45.9 , 76.0, (EC36 window) 138.9 , 153 (right drill)

the side is not straight but a parabola: climbs 4 mm on +-24mm:

4 = y = 1 / 144 * x * x = 1 / 144 * 24 * 24

Radius at EC36 and EC18 top: 2mm

Radius at corners: 5..7 mm

The above data is enough to make it's size match. The rest is free to size. Please verify.


Latest frontplate design - 2004.Nov

[Picture]

[Picture without dimension lines]

[Autocad file]

[Autocad file without dimension lines]