Controls Enclosure

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 to contain a M12-1 3mm nut.

  • As the plug is rather large, to protect it and prevent it from being bumped, a 3D printer cover is added for it with a bayonet-style connector.

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 front-left relative to the driver using cushioned loop clamps. 

Fabrication

BOM

Printed Parts

1 - Main Body

• Source: Bild (.../22-ENC/22-ENC-01 Controls Enclosure/Controls_Enclosure.SLDPRT)

• PETG, at least 3 walls, 20% infill

1 - Latch Cover

• Source: Bild (.../22-ENC/22-ENC-01 Controls Enclosure/Controls_Enclosure_Latch_Bolt_Cover.SLDPRT)

• PETG, completely filled

1 - Latch Bolt

• Source: Bild (.../22-ENC/22-ENC-01 Controls Enclosure/Controls_Enclosure_Latch_Bolt.SLDPRT)

• PETG, completely filled

1 - Nut Holder

• Source: Bild (.../22-ENC/22-ENC-01 Controls Enclosure/Controls_Enclosure_Nut_Holder.SLDPRT)

• PETG, completely filled

1 - MotorCAN Protector

• Source: Bild (.../22-ENC/22-ENC-01 Controls Enclosure/Controls_MotorCAN_Connector_Protector.SLDPRT)

• PETG, completely filled

Laser Cut Parts

1 - Latch Cover

• Source: Bild (.../22-ENC/22-ENC-01 Controls Enclosure/Controls_Enclosure_Cover.SLDPRT)

• 3mm acrylic

Common Parts

20 - M3 Heat Set Inserts

20 - M3 Screws

• Max length: TBD

Unique Parts

2 - Spring (0.3 x 4 x 15mm)

• Wire diameter x outer diameter x free length

• Used for latch.

• Ordered from: Amazon

1 - M12x1 3mm Nut

• Used for MotorCAN connector.

• Ordered from: Amazon

Issues from 2023-2024

• Everything

• Sliding lid design requires too much clearance, limiting where the enclosure could be placed within the vehicle. It also becomes difficult to install with a ton of wires in the enclosure. This also impacts waterproofing.

  • Change to latches or ideally, screws.

• Large wire holes with too many wires (although this is more of an electrical design issue). This also impacts waterproofing.

  • Should use automotive connectors in the future.

• Having two boards directly next to each other increases the size of the enclosure unnecessarily by requiring additional connectors.

  • ONE BOARD!

• MotorCAN connector is not nice. (sticks out excessively, heavy, has no locking so required addition of nut to thread in place, kind of ugly).