Custom enclosure

[rg]

Just added this so as not to distract another thread....

Thank you for your reply.  I have no experience in this area at all. If I have a prototype can it be scanned into a CAD program for printing? This would make it easy to reproduce.

I'm getting out of my depth now

No problem - if you post up some pictures of the completed prototype case - sounds like you're building it by hand - I'll ask you for dimensions of specific features and see if I can recreate it in OpenSCAD.  There are 3D scanners which can digitise existing objects, but a) I don't think they work well with objects that have significant internal voids and b) I don't have one.

Probably scope for a thread on enclosures as I think we've hijacked the Regulator and ARF topic enough now!

Its possible to generate 3D meshes from photos....

http://www.123dapp.com/catch

https://memento.autodesk.com/about

[Richard]

OK, as promised here is photos of an alternative enclosure for PilotAware. There is a little bit of work to do to make everything fit together but there is no soldering involved.

With this enclosure 3 of the 4 mounting lugs are removed along with the 3 of the smaller mounting lugs on each side of the box. Leaving just one.

The Raspberry PI B+ Has to have the four mounting holes very carefully drilled out to 3.3mm to accept the 3mm plastic screws. The screws are bonded to the bottom of the case with 90 second epoxy (Local DIY Store) using the PI B+ as the template, ensuring it is as far back as possible and the SD Card can still be removed.

After the glue has set slide the Raspberry PI B+ from the 3mm screws, first marking the position for the USB Power slot. Once happy with the power slot carefully plot the end plate and file the plate so it will slide over the SD card when it is in the Raspberry PI B+ This will allow it to be removed for updates.

Now the fiddly bit. Plot the location of the two antenna outputs on each end of the case in the end plates. and drill with a 6mm drill. I found it easier to first drill with a 3.3mm drill first to check the correct location. The end launch is the tricky one. Some trial and error is needed here. To make a good fit the hole had to be open up to countersink the nut for the SMA Launch, so a plastic washer is added to the rear and bonded in place.

Small extension are used on the ADS-B receiver end to convert to a SMA connector. This will allow for the development of better antennas. The Small antenna in the picture is on the ADS-B receiver and works OK and will provide limited coverage of the ADS-B to your tablet device.

The GPS and the ADS-B receiver have had there cases removed and the ADS-B receiver runs a lot cooler without it.

Make sure when you screw the top onto the case you just use the one remaining fixing hole and don't put the screws through the wrong hole or you will damage the PI B+ Electricians tape can be used to seal the edges after the box is closed.

Please follow all CAA and LAA protocols for safety for you and your aircraft. Do Not get distracted, and for testing let your passenger do the testing.  (FLY THE AIRCRAFT FIRST)

The Case used is:
http://www.rapidonline.com/Mechanical-Fastenings-Fixings/Hammond-1593XBK-Instrument-Case-GPABS-140-x-66-x-28-Black-30-2116

You will need the following too.

http://www.ebay.co.uk/itm/SMA-Male-to-MCX-Male-Jack-Straight-Coaxial-RF-Connector-Adapter-/191638005793?hash=item2c9e83e821


http://www.ebay.co.uk/itm/121774778279?_trksid=p2057872.m2749.l2649&ssPageName=STRK%3AMEBIDX%3AIT


http://www.ebay.co.uk/itm/250882040614?_trksid=p2057872.m2749.l2649&ssPageName=STRK%3AMEBIDX%3AIT

http://www.ebay.co.uk/itm/361362426353?_trksid=p2057872.m2749.l2649&ssPageName=STRK%3AMEBIDX%3AIT

http://www.ebay.co.uk/itm/201349905111?_trksid=p2057872.m2749.l2649&ssPageName=STRK%3AMEBIDX%3AIT

http://www.ebay.co.uk/itm/251145983389?_trksid=p2060353.m2749.l2649&ssPageName=STRK%3AMEBIDX%3AIT

http://www.charge4.co.uk/pilotaware.html

I hope this helps in tidying up the PilotAwre box

[bnmont]

I like it

[DavidC]

This does look so much nicer and robust. Couple of questions

1) Will the GPS dongle also fit into the same enclosure. My ublox dongle is longer than the ADS-B receiver.

2) Is black the best colour. Sitting on top of the coaming means it does get quite hot. I've used a white box which should help. Currently, the only indication that it might have overheated will be when GPS signal is lost.

[Richard]

This does look so much nicer and robust. Couple of questions

1) Will the GPS dongle also fit into the same enclosure. My ublox dongle is longer than the ADS-B receiver.

2) Is black the best colour. Sitting on top of the coaming means it does get quite hot. I've used a white box which should help. Currently, the only indication that it might have overheated will be when GPS signal is lost.

1) The picture are a little small, but yes the U-Blox7 is in the box it just has no outer shell it needs to be removed and is mounted in the top center USB slot

2) There is a Gray box and a transparent blue box from the same suppler. I agree, in summer the light gray could help keep the sun's heat at bay. This is the first box built like this and further test will reveal the outcome. May be a Fan could be added, this will need power from somewhere.

[rg]

Very nice.   I just took my device for its first flight.   I knocked my ads antenna putting it in a/c (not hard). And the dingle exploded. ..gggrrrrr

So will try and copy your setup but maybe with thinner nylon screws so I don't risk screwing up my pi board

[rg]

I'm going to work up a couple of designs for 30 printable enclosures.  I'll post something in the next week or so.

[Richard]

I'm going to work up a couple of designs for 30 printable enclosures.  I'll post something in the next week or so.

rg,
    That would be fantastic.... Just one thing, It may need to be a few mm shorter or where the ARF end Launch is mounted needs to be recessed. Also as with the design above, an improved way of screwing the two halves of the case together.

 I will be very interested in the end result.

[rg]

This is the kind of thing I'm thinking...all snap fit with dongles safely inside.  i'll wait and see whats going to happen with the ARF first

[Richard]

Your Design looks great.... It seems we are thinking along the same lines.  Yes I would wait to see the outcome of the ARF first to see if a replacment will fit into your design., it may need tweaking

Well Done.

[roweda]

Thinking about this mounting box and the new transceiver equipped daughter board, is it possible to obtain a measurement from the end of the USB socket to the inside edge of the casing where the transceiver SMA connect needs to butt up?

This will enable a Pi to be fitted into the Hammond casing now ahead of the new boards in February time.

Many thanks

Dave

[ianfallon]

I like the idea of the USB bits not able to jiggle out ( esp during aerobatics! ) but would imagine you get a lot of heat build up inside such a case ( ? )
Makes me start to think about the idea of adding a small fan to the design ( ? )

[Richard]

I like the idea of the USB bits not able to jiggle out ( esp during aerobatics! ) but would imagine you get a lot of heat build up inside such a case ( ? )
Makes me start to think about the idea of adding a small fan to the design ( ? )

Hi Ian.
    The heat build up is not too bad at normal operating and has no effect on the system at all. I intend to do an extreme heat test later with the new transmitter. (Reproduce a hot sunny day in the desert. (Fan heater))

A small cooling fan would be a good thing but it needs power from some where!!! I have removed all the outer casing on the ADS-B and GPS receivers and they do operate a lot cooler. I have also added a SMA connection to the bottom of the supplied ADS-B antenna. Also replasing the end of the case with a copper plate this is now the ground for the antenna, this is acting like a heat sink too, it seams to work very well and looks neat too.

Picture below.

[roweda]

I like the idea of the USB bits not able to jiggle out ( esp during aerobatics! ) but would imagine you get a lot of heat build up inside such a case ( ? )
Makes me start to think about the idea of adding a small fan to the design ( ? )

I think some drilled or Dremmelled slots in the upper and lower sides of the casing would assist venting, possibly in the end plates as well, similar to the black standard Pi cases.

[ianfallon]

Definitely looks good