Clear Acrylic Case for Motor Controllers
 

*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!

Something like this?

Yep, very similar!

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!)

http://gallery.me.com/benhdvideoguy/...13320105540001
http://gallery.me.com/benhdvideoguy/...13320105490001

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.

http://gallery.me.com/benhdvideoguy/...13320105660001

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.

http://gallery.me.com/benhdvideoguy/...13320105550001

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

http://gallery.me.com/benhdvideoguy/...13320105630001

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.

http://gallery.me.com/benhdvideoguy/...13320105470001

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!)

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

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

Thanks for the tips Jay!

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.

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.

:eek: :eek: :eek: :eek:

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

Eric