Clear Acrylic Case for Motor Controllers

[bennelson]

*NOTE: Some photos are missing from this thread. The evil photo-hosting service just decided they weren't hosting any more and just plain stopped. With SOME of my photos, I had already started switching over to only posting through my own domain. I'll try to update old, broken photo links as I can.*


Hi everyone,

While I think the Open ReVolt project has been fantastic, I've always wanted a case for it that was just a little bit cooler-looking.

I just saw a recent blog entry by somebody who is a member of the same workshop co-op as I that I thought would work perfect for this!

Here's his blog entry - BoxMaker | Milwaukee Makerspace

http://milwaukeemakerspace.org/wp-co...12/01/box3.jpg

In this case, he was just making a box, but if I applied the same idea to make a box that was just missing the bottom, and cut square holes in the ends for the bus-bars, it would make a great case for a controller! (It would be fun to show off the guts, and much easier to see the trouble-shooting LEDs!)

This box was made with the tabs accidentally too big. Since I have access to a laser cutter (I still don't know how to use it!) I could perhaps do the work to design a case and THEN MAKE SURE I SAVE MY WORK! I could make extras to sell as a low-cost kit and/or share the file so that other people could download that and make it themselves on their local laser.

I was also thinking that it would be VERY cool to have the Open ReVolt logo laser etched on the top of the case!

[Camaro]

Something like this?

[bennelson]

Yep, very similar!

[bennelson]

I recently got to use the laser cutter at the Milwaukee Makerspace! Man, is that thing cool!

After just a few minutes of training, I imported the vector art of the Open ReVolt logo and started etching on some scrap plexiglass!

I also figured out how to CUT with the laser cutter. It's not all that powerful, so cutting takes a few passes, but comes out so perfectly clean, with a nice smooth edge!

I made two different versions of Open ReVolt tokens. Just the logo cut out in a round shape. Could be used as a keychain or something I suppose! (I even added a little hole at the top for that!)




The clear plexiglass was "top-etched" - the side you are looking at is the front. I figured that when I actually do the lid of the motor controller case, I want the logo cut from behind, so the top is smooth, and doesn't get dirt and gunk in the engraved logo. For the orange token, I mirrored the logo art, so that you look THROUGH the smooth side and the logo is cut on the back.



I ended up having to go back to the Makerspace this morning (I left my laptop there last night!) I had my travel coffee mug with me, and started wondering if I could laser etch my name on it.

Sure enough, I can. I just had to make sure it wouldn't roll while the laser etched it.



I also grabbed the lightning bolt from the Open ReVolt logo and used it on the back side of the coffee cup.



A friend of mine there has been doing some work carving plexiglass and edge lighting it with LEDs. It's very similar to what I would like to do with the controller case.



I still have to figure out the boxmaker software, choose the material, learn how to power a string of green LEDs, but THEN I can make a really awesome controller case! (Don't worry, I'll be sure to post all the files when I'm done!)

[dave koller]

Love this ben!!! Neat.......

[JayC]

Originally Posted by bennelson

I still have to figure out the boxmaker software, choose the material, learn how to power a string of green LEDs, but THEN I can make a really awesome controller case! (Don't worry, I'll be sure to post all the files when I'm done!)

LED series parallel array wizard easy as pie. Just need a DC voltage to start with.

Oh, and I design my circuits to be 10mA current or less. Most LEDs are rated for 20mA and underdriving them is a good way to prolong them. When I use superbrights, I use 6mA or less.

-Jay

[bennelson]

Thanks for the tips Jay!

[MPaulHolmes]

For the AC boards I'm just about to send in, It's going to darn near require a clear case. It's got crap sticking out the top, and 2 of the sides. haha.

[bennelson]

Might not be as much progress in the near future on this project as I would like.

I broke my ankle this weekend, so I might have to switch over to building a cyborg leg for a while. When I'm done with that, I'll finish up the clear case.

[esoneson]

Originally Posted by bennelson

Might not be as much progress in the near future on this project as I would like.

I broke my ankle this weekend, so I might have to switch over to building a cyborg leg for a while. When I'm done with that, I'll finish up the clear case.

Ben, now there must be more of a story here.
How did this happen?

Eric