tag:blogger.com,1999:blog-5762680408292884492024-03-26T23:37:06.088-07:00William's EV Bimmer 325iWilliamhttp://www.blogger.com/profile/13072555311952861298noreply@blogger.comBlogger132125tag:blogger.com,1999:blog-576268040829288449.post-51057548394927422432024-03-26T08:49:00.000-07:002024-03-26T08:49:23.905-07:00Hyoper9 Motor Terminals<p> <span style="font-size: x-large;"> </span><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiU2pX_1nncAGegmi9rzGqE3vAXjfo64slfAcnx-M-zAAKU_dJ3jfWMlP50yEU2bgv-au6OLVRPcd3J4tihkA_TtSnCFzAO6il2yw6Imjn0pNzspNrazhzeluOp6iqZroTOwRdrUFdr1BE_FFzqszIKA4WoAFqrmkTMVcgbuviolXvqyVgc-tTdAaeyohie/s1920/DSC02232.JPG" style="margin-left: 1em; margin-right: 1em; text-align: center;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiU2pX_1nncAGegmi9rzGqE3vAXjfo64slfAcnx-M-zAAKU_dJ3jfWMlP50yEU2bgv-au6OLVRPcd3J4tihkA_TtSnCFzAO6il2yw6Imjn0pNzspNrazhzeluOp6iqZroTOwRdrUFdr1BE_FFzqszIKA4WoAFqrmkTMVcgbuviolXvqyVgc-tTdAaeyohie/s320/DSC02232.JPG" width="320" /></a></p><div class="separator" style="clear: both; text-align: center;"><span style="text-align: left;"><br /></span></div><div class="separator" style="clear: both; text-align: center;"><span style="text-align: left;">DSC02232 Showing the threaded terminals of a working Hyper9. The terminal block is attached at each corner with four M-6 x 15 cap head bolts. </span></div><p></p><p><br /></p><p> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiLkKB-g9-rZ78ExWSGJ-N_n8RerlFDZmDj1pbhAMdWH0x9DMUhLiUMKwYi6AT44DpKqR_NLB8XCY92ej5_izlJ3EfCTEz9q65Q-hXqyo2mPN4ztzIrmmu1nQhei9eksJWwVpJUIkJeF4ILMQ7S3WuHoPVe4so7VGPMHPOLXs3WmQhQCEjUM_RlemYg7fwv/s1920/DSC02017.JPG" style="margin-left: 1em; margin-right: 1em; text-align: center;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiLkKB-g9-rZ78ExWSGJ-N_n8RerlFDZmDj1pbhAMdWH0x9DMUhLiUMKwYi6AT44DpKqR_NLB8XCY92ej5_izlJ3EfCTEz9q65Q-hXqyo2mPN4ztzIrmmu1nQhei9eksJWwVpJUIkJeF4ILMQ7S3WuHoPVe4so7VGPMHPOLXs3WmQhQCEjUM_RlemYg7fwv/s320/DSC02017.JPG" width="320" /></a></p><p>DSC02019 Showing the threaded connectors at the end of each Hyper9 winding after the removal of the motor end cap and the plastic terminal block from a burned out motor. The windings are crimped (picture DSC02021 below). The fitting has M18 threads and the body of the fitting is tapered 18.50 mm (top) to 19.30 mm (bottom) so that tightening of the brass nut pulls the windings into the plastic housing.</p><p><br /></p><p> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhNnXqh9WDoRAaqgw30PmhMdnNt8WQA0fpxXW6Gdd99kS4J8HR3FolzcqewT1niOKSpcg7Q8UrJpChVTUIgyA6-OuvRTIrlmpENOkFVpiBSM5J0RDoWlWPTXivUTKylMwIVjGL2CiDtb1YuAzN3O6gtU-W6n2h4RAYkUj5AHlCIuAoBwJSmjMX6mwBXgZK7/s1920/DSC02018.JPG" style="margin-left: 1em; margin-right: 1em; text-align: center;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhNnXqh9WDoRAaqgw30PmhMdnNt8WQA0fpxXW6Gdd99kS4J8HR3FolzcqewT1niOKSpcg7Q8UrJpChVTUIgyA6-OuvRTIrlmpENOkFVpiBSM5J0RDoWlWPTXivUTKylMwIVjGL2CiDtb1YuAzN3O6gtU-W6n2h4RAYkUj5AHlCIuAoBwJSmjMX6mwBXgZK7/s320/DSC02018.JPG" width="320" /></a></p><p>DSC02018 exploded view of the terminal block. The brass hex panel nuts are M18 x 4mm thick. The brass inserts in the plastic block are also tapered 18.50 mm (top) to 19.30 mm (bottom). </p><p><br /></p><p> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgspFXJfDVkr_Hdl7k5AlYfudrrEyKyjdKXEW5nn2uAt88r_e5LEm6l1YN7D1o1KHJDLCJklFlL6eEmPpAKcv4nqUAZKqrDrsI9QZLwjLO6UYCfCYMupK_cgAsqw0wQcV8Jw6kjQY7PMUJibgSKpj1AsdGt3p068L_kUOaU4KkYbITd0FIeHvgiZBp4oIXu/s1920/DSC02021.JPG" style="margin-left: 1em; margin-right: 1em; text-align: center;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgspFXJfDVkr_Hdl7k5AlYfudrrEyKyjdKXEW5nn2uAt88r_e5LEm6l1YN7D1o1KHJDLCJklFlL6eEmPpAKcv4nqUAZKqrDrsI9QZLwjLO6UYCfCYMupK_cgAsqw0wQcV8Jw6kjQY7PMUJibgSKpj1AsdGt3p068L_kUOaU4KkYbITd0FIeHvgiZBp4oIXu/s320/DSC02021.JPG" width="320" /></a></p><p>DSC02021 Close up view of crimp used to secure motor windings.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjR5lwS8D4RGcqDc8gOj7bgenq80X6nYInm6aEqmjraJjAX8Fvp2yzO25gQ5_94ibRdgzeWCzoz8vIy-5KRUYMT3d8REh4h1cvLsamWAHwZ1zPg5dxcCDGTVcaVE-YYuMAzIlJkfUhTcvHF8ozNEsLc7RWCOIoW-6jQFUB1pdRsFEKALNP7HgG-wy7WscSm/s1920/DSC02023.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjR5lwS8D4RGcqDc8gOj7bgenq80X6nYInm6aEqmjraJjAX8Fvp2yzO25gQ5_94ibRdgzeWCzoz8vIy-5KRUYMT3d8REh4h1cvLsamWAHwZ1zPg5dxcCDGTVcaVE-YYuMAzIlJkfUhTcvHF8ozNEsLc7RWCOIoW-6jQFUB1pdRsFEKALNP7HgG-wy7WscSm/s320/DSC02023.JPG" width="320" /></a></div><p>DSC02023 Dimensions of the plastic terminal block located on the top of the Hyper9. Center to center dimensions for the 4 mounting corner bolts is 70 mm (L to R) and 40 mm (T to B).</p><p><br /></p>Williamhttp://www.blogger.com/profile/13072555311952861298noreply@blogger.com0tag:blogger.com,1999:blog-576268040829288449.post-71780179949964489912023-12-19T16:04:00.000-08:002024-01-03T11:23:42.515-08:00Redesigned Bus Bars<div class="separator" style="clear: both; text-align: center;"><span style="font-size: large;">Original bus bar design</span></div><div class="separator" style="clear: both; text-align: center;"><br /></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh_WfpfsbxZiGddrhxa3hyphenhyphenj6LitDOe15b_IOI2GmSRkLCwCNiEa8v8rIsmddg96DpWiL2GOh41edzVjnsOrYaWllObLPT31vHb9ivCdhC1XYUkymHcU7gKzRX9EubpvfJPpSVSBCw_rpbtMess-nOoEX62zlfBYgBtumPLpRAbGfruNI-VEpt0LS9KtNf7R/s1920/93-DSC01811.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1920" data-original-width="1080" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh_WfpfsbxZiGddrhxa3hyphenhyphenj6LitDOe15b_IOI2GmSRkLCwCNiEa8v8rIsmddg96DpWiL2GOh41edzVjnsOrYaWllObLPT31vHb9ivCdhC1XYUkymHcU7gKzRX9EubpvfJPpSVSBCw_rpbtMess-nOoEX62zlfBYgBtumPLpRAbGfruNI-VEpt0LS9KtNf7R/s320/93-DSC01811.JPG" width="180" /></a></div><br /><div class="separator" style="clear: both; text-align: center;">DSC01811 showing original bus bar configuration. The bars are long and they pass over the full top of the controller. After the main battery connections are made, then the B+ pre-charge terminal (top just left of center) is obstructed. One defect to this design is the closeness of all of the terminal bars.</div><div class="separator" style="clear: both; text-align: center;"><br /></div><div class="separator" style="clear: both; text-align: center;"><br /></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgPrXz78kMoGL54aXPQx3Gt6Y8Td6BOITa_X3NjcL7xl7oPdOlUKqbcRm9z1iha7cCjGBZRg-OgkNiVAcV_ufkgvDyK99FEc54eKikH9vfV0K7_V6OkQCJpOBNatAh1AIG98Q1gEP68D787cqd-2BochxIHw6-9NsJcGoohT2stKqxp5-7LHrnzquKyfNYB/s1920/DSC02196.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgPrXz78kMoGL54aXPQx3Gt6Y8Td6BOITa_X3NjcL7xl7oPdOlUKqbcRm9z1iha7cCjGBZRg-OgkNiVAcV_ufkgvDyK99FEc54eKikH9vfV0K7_V6OkQCJpOBNatAh1AIG98Q1gEP68D787cqd-2BochxIHw6-9NsJcGoohT2stKqxp5-7LHrnzquKyfNYB/s320/DSC02196.JPG" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;">DSC02196 After all power connections have been made, this picture shows that the B+ pre-charge terminal is hidden under the bus bar that connects the fuse (white top center) to the B+</div><div class="separator" style="clear: both; text-align: center;"> controller terminal (center left). </div><div class="separator" style="clear: both; text-align: center;"><br /></div><div class="separator" style="clear: both; text-align: center;"><br /></div><div class="separator" style="clear: both; text-align: center;"><span style="font-size: x-large;">Second version with shorter bus bars</span></div><div class="separator" style="clear: both; text-align: center;"><br /></div><div class="separator" style="clear: both; text-align: center;"><br /></div><div class="separator" style="clear: both; text-align: center;">The redesign requires significantly less copper plate to make the bus bars and the top of the controller is much less congested, but the design requires that the polarity of the controller motor terminals be reassigned. Controller terminal U1 must be changed to W1, and controller terminal W1 must be changed to U1. The V1 center controller terminal remains unchanged. A future post will step by step explain how the controller is reprogrammed. </div><div class="separator" style="clear: both; text-align: center;"><div class="separator" style="clear: both; text-align: center;"><br /></div></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi1EYbXpQoFVxBLYyz9YNpDEDXMIlVCZ3JD4p3BmouWFP2eyLSZGYppw5EZzIHPS808_Ip2k2j7fmDGzeJ7U-CK7O7DP_uiK-9uaI_Ej2BVoFELxNVHIJmzYrsnjjv88_p2sLYQvTkKGQ40YHCm_p1jToINwF7m7bVhQhZNGNj4ZjpKqnqMRBfySlKtllkP/s1920/DSC02191.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1920" data-original-width="1080" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi1EYbXpQoFVxBLYyz9YNpDEDXMIlVCZ3JD4p3BmouWFP2eyLSZGYppw5EZzIHPS808_Ip2k2j7fmDGzeJ7U-CK7O7DP_uiK-9uaI_Ej2BVoFELxNVHIJmzYrsnjjv88_p2sLYQvTkKGQ40YHCm_p1jToINwF7m7bVhQhZNGNj4ZjpKqnqMRBfySlKtllkP/s320/DSC02191.JPG" width="180" /></a></div><div class="separator" style="clear: both; text-align: center;"><br /></div><div class="separator" style="clear: both; text-align: center;"><span style="text-align: left;">DSC02192 End on view of the new bus bars. These prototypes were hand made and different vertical heights were tried. The final design will be CNC cut and the U1 and W1 bars will be mirror images. These bus bars use much less copper when compared to the originals. The bus bars appear to be close together, but actually they are very separated as is shown in picture DSC02190 and DSC02189 below. This is a dual shaft motor.</span></div><p><br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhaSlTcLWCcVBVTjWxwDRT-TWs5_383Bu_inNLv7bmowCB_mCM4tGgnePg17w3GHnMmzu500ieuVaRHrecyYTus4DH_Fn0B4EcLG1hadFje36IWVtTj_43m8xR2PjWriakc6GqS3Yw8FxXBLDJ4VdLcBgGOl4Nxs57fVSGduCB63YP013f75ka4-KOLBz7v/s1920/DSC02190.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhaSlTcLWCcVBVTjWxwDRT-TWs5_383Bu_inNLv7bmowCB_mCM4tGgnePg17w3GHnMmzu500ieuVaRHrecyYTus4DH_Fn0B4EcLG1hadFje36IWVtTj_43m8xR2PjWriakc6GqS3Yw8FxXBLDJ4VdLcBgGOl4Nxs57fVSGduCB63YP013f75ka4-KOLBz7v/s320/DSC02190.JPG" width="320" /></a></div><p>DSC02190 Close up top view showing how the U1 and W1 bus bars are offset (front to back) from the V1 bus bar. The distance between the controller housing and the U1 and W1 bus bars is about half the distance between the controller housing and the V1 bus bar.</p><p><br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhCM6gTYr3y09zlGkUIi9S3FQ7Ywnerfc0pVxbgj_F9wMYOWgLoD-SWE4KyJvnzqaKtSUuaTE5qdGmrMOc0dslLhChMjZp-c4NumShgwDbNR_9fY04AxVO1kNKwPB2DvpjSN5cXJrpoxzJCRPktZhGmiQQ7TW8mEdFbomV8nDhHesh97n_6athyvB2m9aAH/s1920/DSC02189.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1920" data-original-width="1080" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhCM6gTYr3y09zlGkUIi9S3FQ7Ywnerfc0pVxbgj_F9wMYOWgLoD-SWE4KyJvnzqaKtSUuaTE5qdGmrMOc0dslLhChMjZp-c4NumShgwDbNR_9fY04AxVO1kNKwPB2DvpjSN5cXJrpoxzJCRPktZhGmiQQ7TW8mEdFbomV8nDhHesh97n_6athyvB2m9aAH/s320/DSC02189.JPG" width="180" /></a></div><p>DSC02189 showing that the U1 and W1 bus bars are recessed and in a different plane when compared to the V1 bus bar.</p><p><br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgtoDGQrESYCDJj1nJ0ToeOs1XKbOs_vEMj6F3QYhCR53QekyGGqK1actm4IJqXjSs4fQv0tKp_Hmx22Pamcxhm791IrBy12-gVSBUBCloamUq2ZaeRG5KTE_iUvnRvUpDI9sukEt9GWzOddU3r_I03c7uiJnI9_ShM61uUdZ4z_cUycE0fxzcDyZwzZ6nQ/s1920/DSC02195.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgtoDGQrESYCDJj1nJ0ToeOs1XKbOs_vEMj6F3QYhCR53QekyGGqK1actm4IJqXjSs4fQv0tKp_Hmx22Pamcxhm791IrBy12-gVSBUBCloamUq2ZaeRG5KTE_iUvnRvUpDI9sukEt9GWzOddU3r_I03c7uiJnI9_ShM61uUdZ4z_cUycE0fxzcDyZwzZ6nQ/s320/DSC02195.JPG" width="320" /></a></div><p>DSC02195 New bus bars after placement of the controller outer box. Note that the B+ pre-charge terminal (on bottom right of controller between the V1 and W1 controller terminals.) is no longer obstructed. </p><p><span style="font-size: xx-small;">Edited 12/20/2023</span></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgVf2TBzWbN9Et8SDVScStMVk4rfL2dFP_QqRMbL9_-kBHGkh348bW_4NGj1KW8f0R71H3KsyRRk_CMUEt_1uNXt0fNlVKu1gj4ZMSJmwsRx6OJX8MdKsnr81y-MumgZX8rrcwqxiceZK3_wk10TMhix58UQRgliclTbXJnPSr0jbf27GsAiBxZxGxMZUAU/s1920/DSC02204.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgVf2TBzWbN9Et8SDVScStMVk4rfL2dFP_QqRMbL9_-kBHGkh348bW_4NGj1KW8f0R71H3KsyRRk_CMUEt_1uNXt0fNlVKu1gj4ZMSJmwsRx6OJX8MdKsnr81y-MumgZX8rrcwqxiceZK3_wk10TMhix58UQRgliclTbXJnPSr0jbf27GsAiBxZxGxMZUAU/s320/DSC02204.JPG" width="320" /></a></div><p>DSC02204 DSC02199 End view showing that both the motor terminals and the bus bars are fully enclosed within the controller box by including a "drop down" leg in the design. </p><p><br /></p><p><br /></p><p><br /></p>Williamhttp://www.blogger.com/profile/13072555311952861298noreply@blogger.com0tag:blogger.com,1999:blog-576268040829288449.post-81624224628114126082023-09-01T17:06:00.006-07:002023-09-11T15:52:30.604-07:00Adapter Plate Revisit - Part 2<p> </p><p>The 245 k bytes two dimensional DXF file that was created and previously described in the 6/30/2023, blog post was used within a CNC program to create the 2D outline of the housing. That information was loaded and massaged in a program called Master Cam ( https://www.mastercam.com/ ) to yield a file that was then only 3706 k bytes. The third dimension included at this point to define the depth of the internal and external cuts and the overall thickness of the plate. Finally the Master Cam data was loaded into a G and M Code that the CNC directly understands. </p><p>https://en.wikipedia.org/wiki/G-code </p><p><span style="font-size: x-small;">edited 9/5/2023</span></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgdd50DUdome9SISJocAijWOmdS5-jRV-gcqbqPel6rbARHuXToP6MQpUJvXc6-GeF1A9G2aEvyN6_F1CoS1M-iZ9GQqvT7WYXdNuJIvkjDydOUeBnNn9hvTXFbbdV4dS0yxw5IF2G1XDHChD7lSDlXd5NMy_cKgHaqTwrbw1x7ruS9u52DrXwVTKdAupOg/s1920/DSC01928.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgdd50DUdome9SISJocAijWOmdS5-jRV-gcqbqPel6rbARHuXToP6MQpUJvXc6-GeF1A9G2aEvyN6_F1CoS1M-iZ9GQqvT7WYXdNuJIvkjDydOUeBnNn9hvTXFbbdV4dS0yxw5IF2G1XDHChD7lSDlXd5NMy_cKgHaqTwrbw1x7ruS9u52DrXwVTKdAupOg/s320/DSC01928.JPG" width="320" /></a></div><p>DSC01928 showing one of the previous adapter plates (from a casting) overlaid on the 15.875"x13.625"x2" billet of 7075 Aluminum. </p><p><br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjdVD3g_UOcYc-vc1QFuE1elD8i1y5gN97P01zDpWQuEoxXBU4SeOIqiauZZoTcq3XbrSpeKP-y71U36hSp1AndOEuMeOeT2SEdTMulCzEQzk6k8sM7lrRS3FLQQvv7PwoHd4F6b6GYxkZ6KA8H4jSvkFFb7pNVDtbjBgIXaAvLt8QuQ6N0q2Xu8q02VtSy/s1920/DSC02038.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjdVD3g_UOcYc-vc1QFuE1elD8i1y5gN97P01zDpWQuEoxXBU4SeOIqiauZZoTcq3XbrSpeKP-y71U36hSp1AndOEuMeOeT2SEdTMulCzEQzk6k8sM7lrRS3FLQQvv7PwoHd4F6b6GYxkZ6KA8H4jSvkFFb7pNVDtbjBgIXaAvLt8QuQ6N0q2Xu8q02VtSy/s320/DSC02038.JPG" width="320" /></a></div><p>DSC02038 showing the trial "plate" produced from a piece of scrap 0.067" thick 6061 Aluminum using the DXF file after it was modified as described above to be compatible with the CNC machine. The transmission is shown standing on its drive shaft and the view is into the transmission housing. This trial plate confirmed that the outline and hole locations were all correct prior to cutting the expensive 2" thick billet.</p><p><br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi_Yaaib7Tk7tuKOFfkxxq7qKc0PgO_-C5fVUJ4sJQmSdoUD-PGlQfCWg2fm8Z0XL0oTzSn6xKFjnQkRuenT4pEbQKkAgPWJxUE5TnBgcUTMk1Vy_F2bTAgUfM7E2xu4F8El9oTExkCpI82rP0VQ_sxD2rZGP7hkVRqFdLA3WyQzNdrK-CvLh1ZiW8K2hBr/s1920/DSC02039.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi_Yaaib7Tk7tuKOFfkxxq7qKc0PgO_-C5fVUJ4sJQmSdoUD-PGlQfCWg2fm8Z0XL0oTzSn6xKFjnQkRuenT4pEbQKkAgPWJxUE5TnBgcUTMk1Vy_F2bTAgUfM7E2xu4F8El9oTExkCpI82rP0VQ_sxD2rZGP7hkVRqFdLA3WyQzNdrK-CvLh1ZiW8K2hBr/s320/DSC02039.JPG" width="320" /></a></div><p>DSC02039 showing a detail of how precisely the DFX file conforms to the actual outline of the transmission housing.</p><p><br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjUu5OoqZ1Xi_td3auzf-ZzAIyVSH78-4SQX1FDBXokoVtcNgUBHIreOJhtzDqjULDocfyPgK_uyjPtRyL0stdBwpTQsmgHETjRt_VXfeEOGWJhkbSwBXHHC_wigj7DzDs92kUWbWNScFTbRrQeDwwRTmCC4nE36rRR_nRMkeicpLBNJwD7bPjgYI6szXdv/s1920/DSC02041.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjUu5OoqZ1Xi_td3auzf-ZzAIyVSH78-4SQX1FDBXokoVtcNgUBHIreOJhtzDqjULDocfyPgK_uyjPtRyL0stdBwpTQsmgHETjRt_VXfeEOGWJhkbSwBXHHC_wigj7DzDs92kUWbWNScFTbRrQeDwwRTmCC4nE36rRR_nRMkeicpLBNJwD7bPjgYI6szXdv/s320/DSC02041.JPG" width="320" /></a></div><p>DSC02041 of the Leadwell V-40 CNC machine that was used to manufacture the billet plate.</p><p>These machines are available on eBay and other resale platforms for $27.5 - 40K. Some tooling is included. https://www.leadwellcnc.com/ </p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi2u28zWOW5fvkZ1m3GUBZrF5-An-DXTYuB8PJN_fa4e8MOPIOuy1fvhfgM4NCD_CRoK7EK6uayiQcXiJfJkNrU2OtG7sN0cnFV7KETzEz2vakrjOMvgNb09HtMDURbI6y50hAfTJvrO90Kuw1MOeG38d3edU4D4RfR4nr2TedQjvxt2szwIc2MmCvcns24/s4032/IMG_9613.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi2u28zWOW5fvkZ1m3GUBZrF5-An-DXTYuB8PJN_fa4e8MOPIOuy1fvhfgM4NCD_CRoK7EK6uayiQcXiJfJkNrU2OtG7sN0cnFV7KETzEz2vakrjOMvgNb09HtMDURbI6y50hAfTJvrO90Kuw1MOeG38d3edU4D4RfR4nr2TedQjvxt2szwIc2MmCvcns24/s320/IMG_9613.jpg" width="320" /></a></div><p>IMG_9613 showing the billet loaded into the Leadwell CNC prior to machining. <span style="font-size: xx-small;">Edited 9/5/2023</span></p><p><br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEinmaV5ayhFivvDo_e6nPCzLNXBBbWf1plxEcOYklTpdM0Ot6NGtlqbvdYCmLPTVsdk3Sz1ANWqapNC2OwLGseBX6LnRRu4xjywMy5aQLVmCMutwyvC4X2WKl78RqxLfhzOeJNnBKNkmDhLoE5EHH3XViC6SrmYKVe-IpwyrVOcnXYvMcMxOu7pmZXhCUai/s1920/DSC02043.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEinmaV5ayhFivvDo_e6nPCzLNXBBbWf1plxEcOYklTpdM0Ot6NGtlqbvdYCmLPTVsdk3Sz1ANWqapNC2OwLGseBX6LnRRu4xjywMy5aQLVmCMutwyvC4X2WKl78RqxLfhzOeJNnBKNkmDhLoE5EHH3XViC6SrmYKVe-IpwyrVOcnXYvMcMxOu7pmZXhCUai/s320/DSC02043.JPG" width="320" /></a></div><p>DSC02043 showing the initial cuts being made on what will be the transmission side of the future adapter plate.</p><p><br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhDwU_a0SubkEsDUzxd6m1uPCBMTtqdKMW2LKkbfr7rFfgLK1DIL4yLWPOEEYdlywRaaEeV4StyBmAikzpLJZHOquyBcjoJN2pdETuiLX0mtVL_kp5MEw2KhCt_sfqq2wiOIwemob4fzmVurI2DbudJrTmyQP_T-EmMZmN8GKI4l13jlab47X8uF9R5efjE/s1920/DSC02073.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhDwU_a0SubkEsDUzxd6m1uPCBMTtqdKMW2LKkbfr7rFfgLK1DIL4yLWPOEEYdlywRaaEeV4StyBmAikzpLJZHOquyBcjoJN2pdETuiLX0mtVL_kp5MEw2KhCt_sfqq2wiOIwemob4fzmVurI2DbudJrTmyQP_T-EmMZmN8GKI4l13jlab47X8uF9R5efjE/s320/DSC02073.JPG" width="320" /></a></div><p>DSC02073 Hyper9 (drive) side of the final billet adapter plate. The hole at the 12:00 is the center top and the hole at 6:00 is the center bottom of the transmission.</p><p><br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiCzpGZMHo63N8F1IpECaTckxUF7affcHh6fJirUFFhBW_lGkvo83R5yhYhkjDwll4vpNNWGb5d4pT1qBKkhUE4l9OdwGFhgzPJONJ7WWT1-L3LBg-pD2Ls9-LK6PQbJe4vTqp6NQOpeZDhjcFewsTzeDIdNIiWtum0JF7sbdkntt9nAeFlJbrfF1gKqp3u/s1920/DSC02075.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiCzpGZMHo63N8F1IpECaTckxUF7affcHh6fJirUFFhBW_lGkvo83R5yhYhkjDwll4vpNNWGb5d4pT1qBKkhUE4l9OdwGFhgzPJONJ7WWT1-L3LBg-pD2Ls9-LK6PQbJe4vTqp6NQOpeZDhjcFewsTzeDIdNIiWtum0JF7sbdkntt9nAeFlJbrfF1gKqp3u/s320/DSC02075.JPG" width="320" /></a></div><p>DSC02075 oblique view of the Hyper9 (drive) side of the final billet adapter plate.</p><p><br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEivYGR8KZw5FQSQ-ZFsASX7rz8E_FDWFaUu7isD9h5y3Vdt_tfjD-OeXEk9RlTilan8TLHUvHt3nxTvwu1GlPKH6iBkBLypq3Lwrorcn7B2I6RMFyrLRhJ6HJFeD99mywTS5u8I9piYqIeVyk6VvN-IssY_oWFZqaB6ILWroFBW8t_lNWzO0v6Ir6vADXC0/s1920/DSC02072.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEivYGR8KZw5FQSQ-ZFsASX7rz8E_FDWFaUu7isD9h5y3Vdt_tfjD-OeXEk9RlTilan8TLHUvHt3nxTvwu1GlPKH6iBkBLypq3Lwrorcn7B2I6RMFyrLRhJ6HJFeD99mywTS5u8I9piYqIeVyk6VvN-IssY_oWFZqaB6ILWroFBW8t_lNWzO0v6Ir6vADXC0/s320/DSC02072.JPG" width="320" /></a></div><p>DSC02072 Getrag transmission side of the final billet adapter plate.</p><p><br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjejGNgzD08BaiivhPI08sda1bNF3DFSidNxbYp0zvWUhO8xak9NF1kTSkgS84LeHjegsuMJ6Lg-A_JNH_RYICiz4ZYS6YOYF7nni8Dzf9vE8Vz0VagkG3DnVTnV_pEHP_0gSZYqaLgCHVjd50eLGWv3AWFADVQUbmyyklGQFUizeHUrxSjNy6hHB5U7c37/s1920/DSC02076.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjejGNgzD08BaiivhPI08sda1bNF3DFSidNxbYp0zvWUhO8xak9NF1kTSkgS84LeHjegsuMJ6Lg-A_JNH_RYICiz4ZYS6YOYF7nni8Dzf9vE8Vz0VagkG3DnVTnV_pEHP_0gSZYqaLgCHVjd50eLGWv3AWFADVQUbmyyklGQFUizeHUrxSjNy6hHB5U7c37/s320/DSC02076.JPG" width="320" /></a></div><p>DSC02076 oblique view of the Getrag transmission side of the final billet adapter plate.</p><p><br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiYMSgJgsdboEqFLaJsUppViZ4m_aPzsrRLHuqbq2Xtp2NcGINUrSTbAxEAOnLO9LI-ZCapMTDXOPiOWiORIl_D_2rtqko3ADjqQn_VS8A3QrrW5XioYJmQASt9Le6avSjmITMg79RGM4kgNYbIBQB2DkBVqYnqKYp31IKAaLXlz9GtGrs09uSXuDxe8XBp/s1920/DSC02080.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiYMSgJgsdboEqFLaJsUppViZ4m_aPzsrRLHuqbq2Xtp2NcGINUrSTbAxEAOnLO9LI-ZCapMTDXOPiOWiORIl_D_2rtqko3ADjqQn_VS8A3QrrW5XioYJmQASt9Le6avSjmITMg79RGM4kgNYbIBQB2DkBVqYnqKYp31IKAaLXlz9GtGrs09uSXuDxe8XBp/s320/DSC02080.JPG" width="320" /></a></div><p>DSC02080 compares the transmission side of the original adapter that was made as a casting (left) to the billet adapter (right). The casting weighs 4.92 kg and the billet weighs 5.66 kg. The original casting is several years old and it has air oxidized and discolored in the shop environment.</p><p> </p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjefkb5ufgyznAwiVXy46DYmyejGiUaXHVzVEF-YfZyjCT71kxLMGUYQhnNJ1yNzszsfhCXBok_g-9-S1QaxF1_yiAxFBy3PIL8ndbQoc-FAfJlRZQNBTFUvlnYM9tNBNxDHOQ6Xli0k20y6pf6uvpuOIWFqoUKfJKvJ1kP_Ap10wTtAEfPrBtoeaFiYr73/s1920/DSC02078.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjefkb5ufgyznAwiVXy46DYmyejGiUaXHVzVEF-YfZyjCT71kxLMGUYQhnNJ1yNzszsfhCXBok_g-9-S1QaxF1_yiAxFBy3PIL8ndbQoc-FAfJlRZQNBTFUvlnYM9tNBNxDHOQ6Xli0k20y6pf6uvpuOIWFqoUKfJKvJ1kP_Ap10wTtAEfPrBtoeaFiYr73/s320/DSC02078.JPG" width="320" /></a></div><p>DSC02078 compares the Hyper9 (drive) side of the casting adapter (left) to the billet adapter (right). The casting adapter has more mounting holes to also accommodate either the Warp 9 or Warp 11 DC motors. The casting hole pattern did not position the top center position of the transmission and the top center position of the Hyper9, so the 8 hole pattern closest to the 4" center opening was rotated slightly to the left. The new billet hole pattern allows for the attachment of the Hyper9 mounting platform (DSC01563 of 2/23/2023 post) and the Hyper9 controller enclosure (DSC01830 of 5/20/2023 post) such that each are now level and parallel to the floor. The holes in the billet at 1:00 and 7:00 are the top center and bottom center of the transmission respectively.</p><p><span style="font-size: xx-small;">updated 9/2/2023</span></p>Williamhttp://www.blogger.com/profile/13072555311952861298noreply@blogger.com0tag:blogger.com,1999:blog-576268040829288449.post-12289573268559866972023-08-06T17:57:00.003-07:002023-09-13T09:10:59.986-07:00Determining the Vertical Orientation of Getrag Transmission Relative to the Adapter Plate<p> When making the previous adapter plate for use with a Warp11 series NetGain motor, the rotational orientation of the adapter relative to the motor was not critical as the power cables exited on the side of the motor. By contrast, with the Hyper9, it is desired to locate the three terminals at the top of the motor, and all in a plane parallel to the floor. If so located, then it will be possible to attach a controller or controller housing box directly on top of the Hyper9. </p><p><br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhnKmlNByR5d1bo1ySEOBTbNBGEPoEe6JjEDTWDznRcGOnXXZ0C8TiVK82zplbI-SinQaMi6wmt7vt1GrNYVMk30uyxwb4abUihTyDhfMdDLxTHQxwJX3xnbEKSk06Pmpx471YLbVe91mz0HlWSr1vrkvIClWk8f_uriVMPMsLjik07I4oFVw1b6uCCN9xG/s1920/DSC01947.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="225" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhnKmlNByR5d1bo1ySEOBTbNBGEPoEe6JjEDTWDznRcGOnXXZ0C8TiVK82zplbI-SinQaMi6wmt7vt1GrNYVMk30uyxwb4abUihTyDhfMdDLxTHQxwJX3xnbEKSk06Pmpx471YLbVe91mz0HlWSr1vrkvIClWk8f_uriVMPMsLjik07I4oFVw1b6uCCN9xG/w400-h225/DSC01947.JPG" width="400" /></a></div><br /><p>DSC01947 Picture of a the Getrag 5 speed transmission installed in the E36. Note that the seam in the transmission casting seam is exactly at the bottom and center when installed. The center part of the cross piece is parallel to the floor, and thus perpendicular to the transmission seam. Note that the mounting points on the right are higher then on the left.</p><p>To mimic the installation of the transmission, a spare gear box suspension cross piece (BMW OEM 23701136498, $58.93 on eBay) along with a pair of rubber bearings (BMW OEM 22316799331, $21.52 on eBay), were then attached to the transmission tail. Two pairs of fully threaded bolts allow the transmission to sit squarely on the floor.</p><p><br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjkewVqwdO_QA4xiWnlPxK1Op60sRDqwHRHN09iR6n1EEcE0AiFeANbNBAzrD_HjTs_F0COWTJYysMCE6IqiBORmEtbxFMFbCKIWtCPnV2ylY7lGVG10g63o69Xc0pRFTB4-3lh-mtMFeWbqPVe0OhkuCvVaQEtOCLsfPQEfLxor21SbId3lK1Dv0GYCnAr/s1920/DSC01970.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjkewVqwdO_QA4xiWnlPxK1Op60sRDqwHRHN09iR6n1EEcE0AiFeANbNBAzrD_HjTs_F0COWTJYysMCE6IqiBORmEtbxFMFbCKIWtCPnV2ylY7lGVG10g63o69Xc0pRFTB4-3lh-mtMFeWbqPVe0OhkuCvVaQEtOCLsfPQEfLxor21SbId3lK1Dv0GYCnAr/s320/DSC01970.JPG" width="320" /></a></div><div class="separator" style="clear: both; text-align: center;"><br /></div><div class="separator" style="clear: both; text-align: center;">DSC01970 Top view of the rear transmission <span style="text-align: left;"> </span><span style="text-align: left;">suspension cross piece. Top of picture is toward the front of the car. </span></div><div class="separator" style="clear: both; text-align: center;"><span style="text-align: left;"><br /></span></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiHPtA2KAn5PwJRYw2XYYEBUtdIAXqQbBSOwjk34uBlFy_RWMhZ2MV7VNg3Nh7XePV_VN6EDX2LwOHBz4Y__FWoUEOJrTlkwc2Tpx42gLRRrpbsIaun2F9KrbMFo24iCAJqfOLR_P502_fscpe1S4cQ-JSvqR953Rbv4YNoQp6l0a3TVxqX9IhpiTf4JbhO/s1920/DSC01971.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiHPtA2KAn5PwJRYw2XYYEBUtdIAXqQbBSOwjk34uBlFy_RWMhZ2MV7VNg3Nh7XePV_VN6EDX2LwOHBz4Y__FWoUEOJrTlkwc2Tpx42gLRRrpbsIaun2F9KrbMFo24iCAJqfOLR_P502_fscpe1S4cQ-JSvqR953Rbv4YNoQp6l0a3TVxqX9IhpiTf4JbhO/s320/DSC01971.JPG" width="320" /></a></div><p>DSC01971 The fully threaded M12-1.75 ( L= 40 mm left and 90 mm right) bolts allow the transmission suspension cross piece to be leveled when resting on the floor.</p><p><br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjC8Hkr9hBVu0pTqZFdpGvVixRhJzsHIAGlrSv-i5QE7HEl8fbeiIIxqNTiutK7Kb6JnKB-u6nrHUyuYm0SgeROphLlldwV--6P3BXV1ZnE4QXthQ4mboATx5W_7ksUAFYLt0Mg6aPZjx1LQR3_KAE7TVeH0-vJbj5ngKWG8dow2GyKO4oONDmVwAV44fQo/s1920/DSC01978.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="225" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjC8Hkr9hBVu0pTqZFdpGvVixRhJzsHIAGlrSv-i5QE7HEl8fbeiIIxqNTiutK7Kb6JnKB-u6nrHUyuYm0SgeROphLlldwV--6P3BXV1ZnE4QXthQ4mboATx5W_7ksUAFYLt0Mg6aPZjx1LQR3_KAE7TVeH0-vJbj5ngKWG8dow2GyKO4oONDmVwAV44fQo/w400-h225/DSC01978.JPG" width="400" /></a></div><p>DSC01978 Showing the adapter plate attached to the transmission on the left and the tail of the transmission mounted on the suspension cross piece on the right. </p><p><br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh_-CFKF-Y2rLiygoLA5ZO1Qy2ygGlsaJwcesiHrCn6WuqoGFTWOlXPslOkvZjExThIiahhFjqegrETqzmpawUDZcvM7jwrJliE0-p02ZqaF3YxG4X-QWgtdSI56wPScB9dWSof5zzjzFBQ0DcY6dNV6Xk_3HYfloudspLgP7eZzMGXlD5O7pyB9jDMXSBT/s1920/DSC01980.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh_-CFKF-Y2rLiygoLA5ZO1Qy2ygGlsaJwcesiHrCn6WuqoGFTWOlXPslOkvZjExThIiahhFjqegrETqzmpawUDZcvM7jwrJliE0-p02ZqaF3YxG4X-QWgtdSI56wPScB9dWSof5zzjzFBQ0DcY6dNV6Xk_3HYfloudspLgP7eZzMGXlD5O7pyB9jDMXSBT/s320/DSC01980.JPG" width="320" /></a></div><p>DSC01980 Close up of the mounting. The 4 bolts of the suspension cross piece permit leveling of the transmission from each direction. </p><p><br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgz-NflQuQrWS1bGXZUVE03zlmtbnLAMVant6FvQHB2FMqEqQbfHKARNJ6vQxoUq8kNhGc2klSMn6QLnhOHVKAVTfqQhcSNYX6TKv6bRP_TTHsuyFzPZweIgKQXrY8EyjyZCbGLS2cZ_FARbwv5OahFdzZD3VADyqQ0SOCjw_YUatXptndFKMb5DEzRLnto/s1920/DSC01988.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="225" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgz-NflQuQrWS1bGXZUVE03zlmtbnLAMVant6FvQHB2FMqEqQbfHKARNJ6vQxoUq8kNhGc2klSMn6QLnhOHVKAVTfqQhcSNYX6TKv6bRP_TTHsuyFzPZweIgKQXrY8EyjyZCbGLS2cZ_FARbwv5OahFdzZD3VADyqQ0SOCjw_YUatXptndFKMb5DEzRLnto/w400-h225/DSC01988.JPG" width="400" /></a></div><p>DSC01988 Showing the location on the current adapter plate where the top of the Hyper9 will be located. When the Hyper9 is attached the center terminal will be in this plane. </p><p>The Hyper9 has four mounting holes that relative to center and vertical are located at 45, 135, 225, and 315 degrees.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi90xLdFXXI1CPqOuwji-KvM621alcdJfWernPVcvJ4dtME4QZ2hDZVw3Cq6hTJbUgV4QTX4UyYeXsEAotSFsPKfJ7l0V_Tkd1cG9JHlc9LmunzbcZt3cTpHQyHchd1ICqy61j1-qO70QI3R-JS1RUfedJ_KoJVszbe2Qa7FBwmGLRJuAQ1oAqyWYutBGQt/s1920/DSC01967.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi90xLdFXXI1CPqOuwji-KvM621alcdJfWernPVcvJ4dtME4QZ2hDZVw3Cq6hTJbUgV4QTX4UyYeXsEAotSFsPKfJ7l0V_Tkd1cG9JHlc9LmunzbcZt3cTpHQyHchd1ICqy61j1-qO70QI3R-JS1RUfedJ_KoJVszbe2Qa7FBwmGLRJuAQ1oAqyWYutBGQt/s320/DSC01967.JPG" width="320" /></a></div><p>DSC01967 of the serial number for the transmission for the transmission being used.</p><p>This transmission 4USCC7328SLA01518 (2 121 643) has a slightly smaller outer contour when compared to the existing adapter plate. This was also the case with the other Getrag transmission that was used. </p><p><br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgG6ronbx2Bi1ZlmtOuI6ahBXnKQrkvfvaVXak_hYbwryZwx653j9hr7VFIbwErPwrMZ5dPCkGQLqxKsQ9J9D0m8bymLIVpBi8bOEXLaL6EcQmVzAQ0woYZgmSfgiuuF4jAjzwF5YVdcAuimf-nAT9IgL0oWr7z8R9b-Ik_PoYcriUrSpYj_Isg5ChBGEIf/s1920/DSC01968.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgG6ronbx2Bi1ZlmtOuI6ahBXnKQrkvfvaVXak_hYbwryZwx653j9hr7VFIbwErPwrMZ5dPCkGQLqxKsQ9J9D0m8bymLIVpBi8bOEXLaL6EcQmVzAQ0woYZgmSfgiuuF4jAjzwF5YVdcAuimf-nAT9IgL0oWr7z8R9b-Ik_PoYcriUrSpYj_Isg5ChBGEIf/s320/DSC01968.JPG" width="320" /></a></div><div><br /></div><div>DSC01968 The bolt pattern is identical but the transmission contour is smaller then the adapter plate.. </div><div><br /></div><div><br /></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjaCBQNnVQrvKrk97e3ZPZwViJFPAGQT02lKg_mrJrctu_qg1pYEOYbx5v4s0nh8yPlS1VFJBVHrtpV2efPs8tO9CXs8urjpV8BjwPuUmnTeOo9OWIJT0GHWtsr_DHfSbTGAT4StVsp6bGYzS0wvQsECKRhdjiDSrNOx4CeKGmR2T-ZUitz2XW7WtGngDnS/s1920/DSC01969.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjaCBQNnVQrvKrk97e3ZPZwViJFPAGQT02lKg_mrJrctu_qg1pYEOYbx5v4s0nh8yPlS1VFJBVHrtpV2efPs8tO9CXs8urjpV8BjwPuUmnTeOo9OWIJT0GHWtsr_DHfSbTGAT4StVsp6bGYzS0wvQsECKRhdjiDSrNOx4CeKGmR2T-ZUitz2XW7WtGngDnS/s320/DSC01969.JPG" width="320" /></a></div><p>DSC01969 Showing the slightly smaller outer contour for the entire periphery. Bolts used for the pair of dowel pins is M12-1.75 x 90mm.</p>Williamhttp://www.blogger.com/profile/13072555311952861298noreply@blogger.com0tag:blogger.com,1999:blog-576268040829288449.post-21275734293381774142023-06-30T14:04:00.006-07:002023-08-31T15:26:15.804-07:00Adapter Plate Revisit 2023 - Part 1<p> </p><h1 class="title is-size-1 is-size-3-mobile" style="box-sizing: inherit; color: #46484e; font-family: myriad-pro, "Helvetica Neue", Helvetica, Arial, sans-serif; line-height: 1.125; margin: 0px 0px 1.5rem; padding: 0px; word-break: break-word;">Hexagon Absolute Arm 8525 7-Axis 2.5 Meter with AS1 Scanner</h1><p>After talking with Dana Green at Exact Metrology (office 262-533-0797), traveled up to Brookfield, Wisconsin with the Getrag 5 speed transmission and watched as it was scanned. The laboratory time was a little more then an hour, and the DXF file was returned to me the following day after the computer work had been completed. Total charges for a simple 2D scan was $500. </p><p class="MsoNormal" style="font-family: Calibri, sans-serif; font-size: 11pt; margin: 0in;">Exact Metrology</p><p class="MsoNormal" style="font-family: Calibri, sans-serif; font-size: 11pt; margin: 0in;">20515 Industry Ave</p><p class="MsoNormal" style="font-family: Calibri, sans-serif; font-size: 11pt; margin: 0in;">Brookfield, WI 53045</p><p class="MsoNormal" style="font-family: Calibri, sans-serif; font-size: 11pt; margin: 0in;"><br /></p><p class="MsoNormal" style="font-family: Calibri, sans-serif; font-size: 11pt; margin: 0in;">New location as of 9/1/2023 is:</p><p class="MsoNormal" style="font-family: Calibri, sans-serif; font-size: 11pt; margin: 0in;"><br /></p><p class="MsoNormal" style="font-family: Calibri, sans-serif; font-size: 11pt; margin: 0in;">3811 N Holton St</p><p class="MsoNormal" style="font-family: Calibri, sans-serif; font-size: 11pt; margin: 0in;">Milwaukee, WI 53212</p><p class="MsoNormal" style="font-family: Calibri, sans-serif; font-size: 11pt; margin: 0in;"><br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgXZJABfqz-z_uRovoD_DBfeJ_XQ8ST_D2knGsYMdGSI_rmCvFMO1H5Db0U7DTQtJcYG9uEkOI7jDn-BVcGaYYz6qZ5JCdFl4Nx2jJqlDqc0VVsaBgkaeQygJ6GqMnLY0XI0DRziQVeNXGjKDH3BdrjqbjPJuLegnbiSi22PMajyBEXb7MhranI5U-jfryE/s1920/DSC01918.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1920" data-original-width="1080" height="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgXZJABfqz-z_uRovoD_DBfeJ_XQ8ST_D2knGsYMdGSI_rmCvFMO1H5Db0U7DTQtJcYG9uEkOI7jDn-BVcGaYYz6qZ5JCdFl4Nx2jJqlDqc0VVsaBgkaeQygJ6GqMnLY0XI0DRziQVeNXGjKDH3BdrjqbjPJuLegnbiSi22PMajyBEXb7MhranI5U-jfryE/w360-h640/DSC01918.JPG" width="360" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><br /></div><div class="separator" style="clear: both; text-align: center;">DSC01918 Picture of the Hexagon Absolute Arm 8525 7-axis 2.5 meter with AS1 scanner. The arm was secured to a large 7800 pound steel table. These tools with software have a list price new of $90-95,000 for a turnkey system. This picture shows the beginning of the scan of the Getrag 5 speed transmission housing face. The number (946273) in the top left corner of the monitor is the number of data points collected so far. </div><div class="separator" style="clear: both; text-align: center;"><br /></div><div class="separator" style="clear: both; text-align: center;"><br /></div><div class="separator" style="clear: both; text-align: center;"><br /></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiIdwgEr4XtMhHb6tSCu364J6UlFpAytsz0X-HM3_xsgR2Ib_Q5vC6CFRua7-XmJkJusO7DLJB6ganPb4lpUqEl5ytF9wbSNdAxJbkrMmCLHabfdOHtEJFEmOMxvI4PhJIAPx-Lpt-Rx2UNVr-aBcs4d5oXEpC53k7P_jpOHDjBfo3B-LN-uywD2dsk9vb7/s1920/DSC01922.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="225" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiIdwgEr4XtMhHb6tSCu364J6UlFpAytsz0X-HM3_xsgR2Ib_Q5vC6CFRua7-XmJkJusO7DLJB6ganPb4lpUqEl5ytF9wbSNdAxJbkrMmCLHabfdOHtEJFEmOMxvI4PhJIAPx-Lpt-Rx2UNVr-aBcs4d5oXEpC53k7P_jpOHDjBfo3B-LN-uywD2dsk9vb7/w400-h225/DSC01922.JPG" width="400" /></a></div><div class="separator" style="clear: both; text-align: center;"><br /></div><div class="separator" style="clear: both; text-align: center;"><span style="text-align: left;">DSC01922 of the hand held AS1 Scanner.</span></div><div class="separator" style="clear: both; text-align: center;"><br /></div><div class="separator" style="clear: both; text-align: center;"><br /></div><div class="separator" style="clear: both; text-align: center;"><br /></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiMok8Q4eIHDOrWcud3sa_wDpD7pIxmIVR966-lCIMy6gMlbKAGx00KL1klB6dP0DCAKm9MBxz8qNzHtDa0uJY_V3UoNgs318uKaLNqu-5IokOApfwXJaDsVQCC5iB_sFanJpUI7HmHebpy2i-CRojEXKcx5doPR1MyidqWIXl0NsOAEeJzkt0_adRbpepw/s1920/DSC01919.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="225" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiMok8Q4eIHDOrWcud3sa_wDpD7pIxmIVR966-lCIMy6gMlbKAGx00KL1klB6dP0DCAKm9MBxz8qNzHtDa0uJY_V3UoNgs318uKaLNqu-5IokOApfwXJaDsVQCC5iB_sFanJpUI7HmHebpy2i-CRojEXKcx5doPR1MyidqWIXl0NsOAEeJzkt0_adRbpepw/w400-h225/DSC01919.JPG" width="400" /></a></div><div><br /></div><div>DSC01919 The blue line is the actual data point collection area, and the red line outlines the window within which the blue line must reside for data acquisition. The scan is a series of smaller "paint strokes" that the computer merges to create the 2D or 3D data set. The final scan accuracy is expected to be +/- 1.5/1000" ( which is +/- 0.0381 mm).</div><br /><div class="separator" style="clear: both; text-align: center;"><br /></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj-O2Fm8r5dv25RLatxZYF05GBCHHl_i4OS3Wr-uSotQtmipxClh-qJkSM-XTkNKgNPEmr8NchbCsTo7BRtu-BxUcfXViOZz0mhZsZiy24d1jKVftk0K-dBlNpvdF6wn6Q-UuwIHLI5oVwnDu_le9BWh7Hky4rCRbr8ZlsdbgTtXxuFeG_HpbZuONsr5cvl/s1920/DSC01921.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="225" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj-O2Fm8r5dv25RLatxZYF05GBCHHl_i4OS3Wr-uSotQtmipxClh-qJkSM-XTkNKgNPEmr8NchbCsTo7BRtu-BxUcfXViOZz0mhZsZiy24d1jKVftk0K-dBlNpvdF6wn6Q-UuwIHLI5oVwnDu_le9BWh7Hky4rCRbr8ZlsdbgTtXxuFeG_HpbZuONsr5cvl/w400-h225/DSC01921.JPG" width="400" /></a></div><div><br /></div>DSC01921 Showing the green area of the fresh data points just collected, the grey-black area is of those points already logged, and the blue area shows the back side surface points for the collected data. <div><br /></div><div>The DXF file will next be given to the CNC shop and the adapter thickness and Hyper9 motor orientation added to create a 3D file. Two adapter plates will be machined from a pair of 7075 Aluminum billets that are 2" x 13.5" x 18.75". (ALRO Outlet in Elk Grove Village, Illinois at $185 each, or $3.49/ pound).</div><div><br /></div><div>Note: To see the previous posts regarding the efforts to make previous versions of the Adapter Plates, enter "Adapter Plate" into the "Search This Blog" window at the right of the page that includes the most recent blog entry. </div>Williamhttp://www.blogger.com/profile/13072555311952861298noreply@blogger.com1tag:blogger.com,1999:blog-576268040829288449.post-35737844150901794482023-05-29T15:36:00.000-07:002023-05-29T15:36:33.684-07:00Internal Shelf Within the Hyper9 Control Cabinet<p> A piece of 5052 Aluminum 0.061" x 26" x 27" was purchased at ALRO Metals Outlet ($14.00), A 10.5" x 6.25" section was cut (DSC01847), and then formed into a platform with a top area of 10.5" x 3.25" and a height of about 1.625" (DSC01853 below). The Gigavac contactor and the Shawmut fuse will be secured to the platform, and both will be significantly above the chiller plumbing.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh32j7iYCym3hCdEE4DfBVt9vvy-Z2NcA9mrUXsbltG6M_Cm-DkkAHuwgHNmhYieyPJw3hI53USN6OosXAzV-WaNYcp3W6tNKGWGmXmFEBSA9zvvSduiyzDMWtxjAoM2esnIafPi07YAF-ud0WkzUhxV_kv44f_zT2DFIMnb8DAF4OIZyXS5dpRt_aO5g/s1920/DSC01847.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh32j7iYCym3hCdEE4DfBVt9vvy-Z2NcA9mrUXsbltG6M_Cm-DkkAHuwgHNmhYieyPJw3hI53USN6OosXAzV-WaNYcp3W6tNKGWGmXmFEBSA9zvvSduiyzDMWtxjAoM2esnIafPi07YAF-ud0WkzUhxV_kv44f_zT2DFIMnb8DAF4OIZyXS5dpRt_aO5g/s320/DSC01847.JPG" width="320" /></a></div><p>DSC01847 showing the dimensions of the 5052 Aluminum plate prior to cutting with a bandsaw.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgUhS5kubl4y02i2vMT0uBRe3w9HS764tjN_gMbS2WQ2KQn7cfQihfgrwTx7mxUFnRNCiZgPvhb-q3MN6jJhG9FyC-uaNRzuh5z_71duQvnmvXVrWJx9RELjiPeARXwFRtQ7fAT0ODDYLpiR5OIB2LItRGF2Yayp9bJ5Akb7SxRF-nmJ0LltL8m2QAX6g/s1920/DSC01853.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgUhS5kubl4y02i2vMT0uBRe3w9HS764tjN_gMbS2WQ2KQn7cfQihfgrwTx7mxUFnRNCiZgPvhb-q3MN6jJhG9FyC-uaNRzuh5z_71duQvnmvXVrWJx9RELjiPeARXwFRtQ7fAT0ODDYLpiR5OIB2LItRGF2Yayp9bJ5Akb7SxRF-nmJ0LltL8m2QAX6g/s320/DSC01853.JPG" width="320" /></a></div><p>DSC01853 showing the end view of the formed platform. The height to the top of the platform is 1.625".</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgJceuKlDRrapT3BrDjXPjYY4auF9aoQTPoTVzo8qTJHKNL8_X_fMaTQXMX2Zo-SC12ovnn6CXY5JZYepnxAS_z_z67rf0fUGZmnSOZQhSjjzWMQbEvmP2Co3RdvMMaON_lYKjF5jt-LwHE_kyXHZ33-QSKJ4Q04tIFu0Y5UJPYJuBiqklqHDQpIDtX4Q/s1920/DSC01855.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgJceuKlDRrapT3BrDjXPjYY4auF9aoQTPoTVzo8qTJHKNL8_X_fMaTQXMX2Zo-SC12ovnn6CXY5JZYepnxAS_z_z67rf0fUGZmnSOZQhSjjzWMQbEvmP2Co3RdvMMaON_lYKjF5jt-LwHE_kyXHZ33-QSKJ4Q04tIFu0Y5UJPYJuBiqklqHDQpIDtX4Q/s320/DSC01855.JPG" width="320" /></a></div><p>DSC01855 showing the pair of slots that were cut in the platform to allow for the chiller coolant pipes. The platform is upside down in this picture.</p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhiJOnoNQYsLd1NwkjlYpor8Np8OUD0RxwJQulj5V1pSP2zCG2_NFel2tVV-NPRTtCozD7EXFZLJZU3CdbtzfTMIsA51dUcbxwOxPymu-ZxneBdOaGpzqqtWYUEhRxqnKFEedVx9a5B_m_pmT7Ha_i6aUd8B72qqVvtBPIPMmdVY-0__vhmJnhmIZGW2Q/s1920/DSC01849.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhiJOnoNQYsLd1NwkjlYpor8Np8OUD0RxwJQulj5V1pSP2zCG2_NFel2tVV-NPRTtCozD7EXFZLJZU3CdbtzfTMIsA51dUcbxwOxPymu-ZxneBdOaGpzqqtWYUEhRxqnKFEedVx9a5B_m_pmT7Ha_i6aUd8B72qqVvtBPIPMmdVY-0__vhmJnhmIZGW2Q/s320/DSC01849.JPG" width="320" /></a></div><p></p><p>DSC01859 after placement of the Aluminum platform.</p><p>This platform fit easily between the cabinet wall and the controller (DSC01859). The height of platform was the maximum possible that would allow a simple Copper 90 degree angle to be fabricated and used to connect the contactor and the bottom terminal of the main shutoff switch. </p>Williamhttp://www.blogger.com/profile/13072555311952861298noreply@blogger.com0tag:blogger.com,1999:blog-576268040829288449.post-47069172443210763632023-05-29T15:15:00.006-07:002023-05-31T09:57:57.263-07:00Copper Bus Bars Internal Connections<p>A bandsaw, 12 ton press, and an Eastwood brake, were used extensively to produce the bus bars required to interconnect the "Power Input to the Master Shut off to the Gigavac Contactor to the Ferraz-Shawmut 500 amp Main Fuse to the Controller B+ Terminal". All bus bars were of 0.125" x 1.0" wide Copper plate. The contactor and main fuse were mounted to an Aluminum platform that will be described in the next post. The height of the platform placed the contactor, fuse, and controller terminals all in the same plane.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgPk9-toVQcHH3bQaF3_aL62fvD0wXt9fcSQzR8FphEFfPBMc6jSfBPX08ELBd_wN6DCIRVfZh7NJyxi3ylhMKHji6czp4U_C0c4FLEEQV1xM8GEPav_7KvCZ13QdhaLlavmovlc0vsi3_OTNktGVYXVBB4FLFl1vdtejbqmP80itR6eHE2DccynIT0Dg/s1920/DSC01869.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgPk9-toVQcHH3bQaF3_aL62fvD0wXt9fcSQzR8FphEFfPBMc6jSfBPX08ELBd_wN6DCIRVfZh7NJyxi3ylhMKHji6czp4U_C0c4FLEEQV1xM8GEPav_7KvCZ13QdhaLlavmovlc0vsi3_OTNktGVYXVBB4FLFl1vdtejbqmP80itR6eHE2DccynIT0Dg/s320/DSC01869.JPG" width="320" /></a></div><p>DSC01869 of the power input B+ (top right) bar connecting to the top half of the main shutoff switch (top left). This bus bar was previously described in the May 18, 2023 post. </p><p><br /></p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgsT41P2ip_ul8S1gbiQ09xdFdOYsRN9QzmKdBqgpzh3764mXn8USFP3VA-3demfCh6y32DaXfux0PZ_IzXXK9Uxu3nT2jrlKApLC6kMbOPTicF7Y8yR7myIcTJ1MkVkhsTZspF3PCVFyEDt-nkVhUiosV5pUlvcrHzTAf74bp93AbcqbiiiwaC9RPn1A/s1920/DSC01857.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgsT41P2ip_ul8S1gbiQ09xdFdOYsRN9QzmKdBqgpzh3764mXn8USFP3VA-3demfCh6y32DaXfux0PZ_IzXXK9Uxu3nT2jrlKApLC6kMbOPTicF7Y8yR7myIcTJ1MkVkhsTZspF3PCVFyEDt-nkVhUiosV5pUlvcrHzTAf74bp93AbcqbiiiwaC9RPn1A/s320/DSC01857.JPG" width="320" /></a></div><p>DSC01867 Bus bar to connect the master shut off switch B+ to the contactor prior to placement. The piece was made from a piece of 0.125" x 3" long x 2" wide Copper plate that was bent into a 90 degree angle with the press brake. </p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhyo9ia9ZzSsJgiFTRHAv3dpjScjzvHBMzGxV-3sMLOg1Sg-MNm9Jkjan39mIugmvBjG--0HAUTYe_coICJv-hJMnHyIM2QfzOZnHmvM5oriG3YqpqIkd9WErcKekpBuq8i1jTiK4OwUX1XCOixWjnOl-6-vDjz_K37SSwzQUCn9R14jH4YJnd9gXgetg/s1920/DSC01868.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhyo9ia9ZzSsJgiFTRHAv3dpjScjzvHBMzGxV-3sMLOg1Sg-MNm9Jkjan39mIugmvBjG--0HAUTYe_coICJv-hJMnHyIM2QfzOZnHmvM5oriG3YqpqIkd9WErcKekpBuq8i1jTiK4OwUX1XCOixWjnOl-6-vDjz_K37SSwzQUCn9R14jH4YJnd9gXgetg/s320/DSC01868.JPG" width="320" /></a></div><p>DSC01868 Bus bar connecting the master shut off switch B+ to the contactor (middle back of picture) after installation. Removal of the Copper bar adjacent to the nuts (lower right) allowed for the use of a 17 mm socket wrench for tightening. </p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEghzEa-KeKciwWQB8G5MJ8KDmdnJN9r4yGzNAwAVrR6Ymj2KoSZupjBVFhKR5N93YEoNgFcSc8yLwdJzVvlbZseinaWsXAibC429kdlFIkZ9wrGyia9RZ79WikTLMP3gVtDFJW63MGPBg7voO4wmtZDl1a2KblEiAxUoB_yjI4fo4g6px0iGZkxiIYW-A/s1920/DSC01860.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEghzEa-KeKciwWQB8G5MJ8KDmdnJN9r4yGzNAwAVrR6Ymj2KoSZupjBVFhKR5N93YEoNgFcSc8yLwdJzVvlbZseinaWsXAibC429kdlFIkZ9wrGyia9RZ79WikTLMP3gVtDFJW63MGPBg7voO4wmtZDl1a2KblEiAxUoB_yjI4fo4g6px0iGZkxiIYW-A/s320/DSC01860.JPG" width="320" /></a></div><p>DSC01860 Bus bar for connecting the contactor to the main fuse prior to placement.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhqRpBrDiW8u7IdNYBmfmXlqFbtCD6qlJzLzLxX-kqQyt0yMiudF5jxjpyQmx666GzTvmUJobiaadI3hHpUCSk-YJRAxMWNInGL0NetAB2BHwxSYUxLDGzJuaZNXUy6Y5HZhzHAU23C4sVHN9RwtN7Vk_OOzCtmK3rEbaqu26VuezztWtylCXWFvZD2QQ/s1920/DSC01861.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhqRpBrDiW8u7IdNYBmfmXlqFbtCD6qlJzLzLxX-kqQyt0yMiudF5jxjpyQmx666GzTvmUJobiaadI3hHpUCSk-YJRAxMWNInGL0NetAB2BHwxSYUxLDGzJuaZNXUy6Y5HZhzHAU23C4sVHN9RwtN7Vk_OOzCtmK3rEbaqu26VuezztWtylCXWFvZD2QQ/s320/DSC01861.JPG" width="320" /></a></div><p>DSC01861 Bus bar connecting the contactor to the main fuse after installation.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiBMFHojtOOzpFFoLQFQYRx1AlWP0F6HhW0kt_cIHtLaplIvyOuRbUkFMykJiXCvwZjgr6GFEMQM_Ct1X7TuM8OlejQrf2K9NCaXZGn6FuxKtvLpUZFCLgp7B60GioKEOC94ChqPTC6Rf-ArJuHYh5hxFlKiHNTI0H6LIfQHGnCfpMKbkYjZRwTEI5O_A/s1920/DSC01862.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiBMFHojtOOzpFFoLQFQYRx1AlWP0F6HhW0kt_cIHtLaplIvyOuRbUkFMykJiXCvwZjgr6GFEMQM_Ct1X7TuM8OlejQrf2K9NCaXZGn6FuxKtvLpUZFCLgp7B60GioKEOC94ChqPTC6Rf-ArJuHYh5hxFlKiHNTI0H6LIfQHGnCfpMKbkYjZRwTEI5O_A/s320/DSC01862.JPG" width="320" /></a></div><p>DSC01862 Side view of bus bar connecting the contactor to the main fuse after installation. By taking advantage of the same height for the surfaces, no bends were required in the bar.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj5x-HSPVjrP-sSEb9r8sttyNaYqAgCdjli1xtd7cOncVQAByY34n-cmWS33WCtkmBhdYCF9wdzVgEtKXEySODMrh9TOVuV-fUsj4dJpRcDif72ipbMNgMQZAdNjsf3lp6T4zDAw-ubA1K91uHRBU1RyGotCoNrXdq3-BXzgxIUMCPwtdqktR4nDWLbAg/s1920/DSC01873.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj5x-HSPVjrP-sSEb9r8sttyNaYqAgCdjli1xtd7cOncVQAByY34n-cmWS33WCtkmBhdYCF9wdzVgEtKXEySODMrh9TOVuV-fUsj4dJpRcDif72ipbMNgMQZAdNjsf3lp6T4zDAw-ubA1K91uHRBU1RyGotCoNrXdq3-BXzgxIUMCPwtdqktR4nDWLbAg/s320/DSC01873.JPG" width="320" /></a></div><p>DSC01873 Side view of the bus bar Ver. 1 connecting the main fuse output to the controller B+ terminal prior to placement.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjSrpFaiZuFeefmRTNd7jIcZiXeIlybFwS9yf4SvVT3dbjP29U0AyvhvdfLaSvUEo_8kxsiW4ojUneHyTXSqBmA8fM8CoC6sOO_on6U8tObCJZqiObS4nmOOAf48G4lFbj-cugLJn9-j6WyilTLC2GQxYCubmDG2If0QonL7qiIHrX1C4wIv5xYTo-tOw/s1920/DSC01875.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjSrpFaiZuFeefmRTNd7jIcZiXeIlybFwS9yf4SvVT3dbjP29U0AyvhvdfLaSvUEo_8kxsiW4ojUneHyTXSqBmA8fM8CoC6sOO_on6U8tObCJZqiObS4nmOOAf48G4lFbj-cugLJn9-j6WyilTLC2GQxYCubmDG2If0QonL7qiIHrX1C4wIv5xYTo-tOw/s320/DSC01875.JPG" width="320" /></a></div><p>DSC01875 Oblique view of the bus bar Ver. 1 connecting the fuse output to the controller B+ terminal prior to placement.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgfOYTPsS26nlyymg9oKEROQVXHTPNaXd76GBadwi4PfKrnyzhX67jKGKXh0aSHpDrKwfaX3i7Uj115b77X53Y6Eg8n6ZqiFWTMY8airVSbctU7FRpe5LcBf-2DQzHd8KsY4WbNUt156GLsMzV4uzz2BtUsMhrmaihA4ePB7-FRX-_ZCjNSSiNEZuPZLA/s1920/DSC01871.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgfOYTPsS26nlyymg9oKEROQVXHTPNaXd76GBadwi4PfKrnyzhX67jKGKXh0aSHpDrKwfaX3i7Uj115b77X53Y6Eg8n6ZqiFWTMY8airVSbctU7FRpe5LcBf-2DQzHd8KsY4WbNUt156GLsMzV4uzz2BtUsMhrmaihA4ePB7-FRX-_ZCjNSSiNEZuPZLA/s320/DSC01871.JPG" width="320" /></a></div><p>DSC01871 Bus bar Ver. 1 connecting the fuse output to the controller B+ terminal after installation. The overall height above the mounting points is 1.25". Note that there is easy access to the B+ pre-charge terminal underneath this bar. </p><p><span style="font-size: xx-small;">edited 5/31/2023</span></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjFJFU1cwJSPifg_rcXlevRAfWXIuROe3Wnz1Ud1lNi_H52VLhIkPgj6SEpZ0aNgCiJrtXI53Rtmxf8g0qqraapUBnf6Nv-pW0dUE220x9pua2Fdey8coi3kQDzGp7EpKQPB7c_I1WjpjWx6UMhtHnDJIEfoLn99wylOAkhq7fcPSd8icuMYlOA8AThkA/s1920/DSC01888.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjFJFU1cwJSPifg_rcXlevRAfWXIuROe3Wnz1Ud1lNi_H52VLhIkPgj6SEpZ0aNgCiJrtXI53Rtmxf8g0qqraapUBnf6Nv-pW0dUE220x9pua2Fdey8coi3kQDzGp7EpKQPB7c_I1WjpjWx6UMhtHnDJIEfoLn99wylOAkhq7fcPSd8icuMYlOA8AThkA/s320/DSC01888.JPG" width="320" /></a></div><p>DSC01888 Bus bar Ver. 2 connecting the fuse output to the controller B+ terminal after installation. Making the vertical height and the tab length at 1.25: fit the press brake well, but a 1.0" height and 1" tab length was difficult. The use of a vise and mallet was required to finish the job.</p><p><br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgAleR_nnNDpl7ioiU-uiSXpaC_7fo3M0uaDe5-Yclx-3drXs3gaFUT0J1TZmeoU1u4YUbN0BIwl4Lc5VEAjBRCpAv8uJrSoOlHG9tiKta-1gVWLTEV96IkFr-2MFAusVfmXbAJiaxr5pqdeHpZLtL5flyCWEDuOi0fca0v1IhyimHxf1hO0lQYQKmR_w/s1920/DSC01889.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgAleR_nnNDpl7ioiU-uiSXpaC_7fo3M0uaDe5-Yclx-3drXs3gaFUT0J1TZmeoU1u4YUbN0BIwl4Lc5VEAjBRCpAv8uJrSoOlHG9tiKta-1gVWLTEV96IkFr-2MFAusVfmXbAJiaxr5pqdeHpZLtL5flyCWEDuOi0fca0v1IhyimHxf1hO0lQYQKmR_w/s320/DSC01889.JPG" width="320" /></a></div><p>DSC01889 Bus bar Ver. 2 connecting the fuse output to the controller B+ terminal after installation. No loss of access to the B+ pre-charge in this smaller lighter version. The overall height is now 1.0".</p><div class="separator" style="clear: both; text-align: center;"><br /></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiC9aQ7-67r7cEgagfp5YByepJCWDkDWaamkz_oZ--QZy9zZmtovay9idBoAo2viBqNbHi8lEbZz0Yxp0EicVnn0Wur51D7y1GPhCqMj83VgeZJbavdnOE8SCDG9AHKOK9JU0O3rcGn4XoV9qU5hDUm7aBXYESFNjANpS81jCKkZ8lGwi6cJ0U4nvUEIw/s1920/DSC01876.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="360" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiC9aQ7-67r7cEgagfp5YByepJCWDkDWaamkz_oZ--QZy9zZmtovay9idBoAo2viBqNbHi8lEbZz0Yxp0EicVnn0Wur51D7y1GPhCqMj83VgeZJbavdnOE8SCDG9AHKOK9JU0O3rcGn4XoV9qU5hDUm7aBXYESFNjANpS81jCKkZ8lGwi6cJ0U4nvUEIw/w640-h360/DSC01876.JPG" width="640" /></a></div><br /><p>DSC01876 Showing the close proximity of the controller's K3 RS-232 serial port to the Power B- terminal on the cabinet (bottom right side). </p><p><span style="font-size: xx-small;">Edited 5/30/2023</span></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiMDmOXzhbv9Gmf361hHvAK5CG52lOG_XXMu-NGNAYTEDEVCr7nuPWF3T7UrIlYOBbxg0v2n8Nk651fg-L7PjM1qrH1nqOaocEX6mu5P_0JFTvFW000ImQgu1lyuqvljOeb-hHtcKK0wd_JUzsf6Lw9bPYjMB73UBkPHoeWo3XhXj6QJHZzMjY0rkVfrA/s1920/DSC01878.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="225" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiMDmOXzhbv9Gmf361hHvAK5CG52lOG_XXMu-NGNAYTEDEVCr7nuPWF3T7UrIlYOBbxg0v2n8Nk651fg-L7PjM1qrH1nqOaocEX6mu5P_0JFTvFW000ImQgu1lyuqvljOeb-hHtcKK0wd_JUzsf6Lw9bPYjMB73UBkPHoeWo3XhXj6QJHZzMjY0rkVfrA/w400-h225/DSC01878.JPG" width="400" /></a></div><p>DSC01878 Showing the manila folder cardboard test model that was used during the design process (the wooden rod for additional rigidity).</p><p><br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEihM7LWymXqMgkcR-y5VIHnlIxs3HTso6hLiTGOFgI-ytxvtYW2WLi39EKxAWF7Kikf5tt6EKQT_sYXm7v4oCnnDwDs-2JbDni5O6vRs7OU_wv_Z36otXpKg5cLj6ldPUoL2stWPvvZF7aZPqiwjrSAYuqL6hc871h7Ra6Aoo4H4_QOL0Yv0mBwm_sgsg/s1920/DSC01884.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="360" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEihM7LWymXqMgkcR-y5VIHnlIxs3HTso6hLiTGOFgI-ytxvtYW2WLi39EKxAWF7Kikf5tt6EKQT_sYXm7v4oCnnDwDs-2JbDni5O6vRs7OU_wv_Z36otXpKg5cLj6ldPUoL2stWPvvZF7aZPqiwjrSAYuqL6hc871h7Ra6Aoo4H4_QOL0Yv0mBwm_sgsg/w640-h360/DSC01884.JPG" width="640" /></a></div><p>DSC01884 Showing the preliminary Aluminum test model fashioned after the cardboard test piece. Note that there is significant clearance around the RS-232 serial port </p><p><br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiuvLDObys4uAwvjHTlXRjJhmQyZBnQdD_79jZ13hgZ2RDzEiKcuB8JHcmEsR8VLLyge0fEgWuPPqilWUzJcBB2nR-uNExmSMuB6ZerFqylTB4jHT5iY5SEJ-dYrlP--i6kD-zyMJrkFe4dMrN_s3CiWEd5RPWwq8lzCNP6bzq1DwJ-i8NNTXknchvL7A/s1920/DSC01883.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="225" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiuvLDObys4uAwvjHTlXRjJhmQyZBnQdD_79jZ13hgZ2RDzEiKcuB8JHcmEsR8VLLyge0fEgWuPPqilWUzJcBB2nR-uNExmSMuB6ZerFqylTB4jHT5iY5SEJ-dYrlP--i6kD-zyMJrkFe4dMrN_s3CiWEd5RPWwq8lzCNP6bzq1DwJ-i8NNTXknchvL7A/w400-h225/DSC01883.JPG" width="400" /></a></div><p>DSC01883 Detail of the connection at the power B- input terminal on the side of the cabinet.</p><p><br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgbeRHN9AC3JCbmciHfxynEyfgIyookD1WAt0AAxEh_d5ECdx8QQa_mK5IRZ_ky54g3nDrJyAtq4tVPxNpi8te_lkhHl8ciafB4_Hq2Qx7J7QllNSK31yx9aV61_LVPnouSwiX1T9WGuNKbLEeFzO-ps-A3Qfm6LBC9VuCZzWxAfK7wt8XuvyWQPLp9nA/s1920/DSC01887.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="360" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgbeRHN9AC3JCbmciHfxynEyfgIyookD1WAt0AAxEh_d5ECdx8QQa_mK5IRZ_ky54g3nDrJyAtq4tVPxNpi8te_lkhHl8ciafB4_Hq2Qx7J7QllNSK31yx9aV61_LVPnouSwiX1T9WGuNKbLEeFzO-ps-A3Qfm6LBC9VuCZzWxAfK7wt8XuvyWQPLp9nA/w640-h360/DSC01887.JPG" width="640" /></a></div><p>DSC01887 Showing the vertical height of the Aluminum test bus bar above the U1,V1, and W1 controller terminals. The final bus bar will next be fabricated in Copper.</p><p><br /></p><p><br /></p><p><br /></p>Williamhttp://www.blogger.com/profile/13072555311952861298noreply@blogger.com0tag:blogger.com,1999:blog-576268040829288449.post-41960432778548899112023-05-20T06:30:00.004-07:002023-05-30T20:33:43.399-07:00Chiller Plate Plumbing Incorporated into the Controller Enclosure<p>Using Aluminum pipe, the hose barbs connections to the chill plate (which may leak over time) were located external to the enclosure. A coolant leak within the controller box would likely go unnoticed until damage has already been done. Teflon tape will be used on all threads and the enclosure penetration will employ grommets to reduce dirt and water entry. </p><p>All fittings are 1/8" NPT Aluminum and were sourced from McMaster-Carr:</p><p>2 x 90 degree elbow, part 44705K266, at $5.87 each;</p><p>1/8" pipe x 1.5"L nipple, part 44665K161, at $1.97;</p><p>1/8" pipe x 2.5"L nipple, part 44665H121 at $2.59:</p><p>1/8" pipe x 6" nipple, part 44665k119, at $4.75;</p><p>1/8" pipe x 8"L pipe nipple, part 44665K411, at $6.03:</p><p>qty 2 x 1/8" pipe to 1/4" hose barb, part 5357K51, at $7.44 each.</p><p>2 x Buna-N Rubber grommets, A=11/16", B=1/16", C=7/16", D=15/16", E=5/16". Part 9307K25 at 50 for $10.91.</p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEi4tNchFff1xBBpFskefhBakdjb1R1OqW7LzPeiHswKIZye69LKcB3TVnMyMPzxToMOUt4F-TGEnyoLSkx1fl5s5EonY27IQ1chRaZVC-zEoyOWvLGDeqyVGT2GaZ1BuF-3VIkN4tv3mqqucN2ktxDO4xKXAwn6PWKC0UXj1VrZYBMCq3beslAa2ve8NA" style="margin-left: 1em; margin-right: 1em;"><img alt="" data-original-height="157" data-original-width="190" height="240" src="https://blogger.googleusercontent.com/img/a/AVvXsEi4tNchFff1xBBpFskefhBakdjb1R1OqW7LzPeiHswKIZye69LKcB3TVnMyMPzxToMOUt4F-TGEnyoLSkx1fl5s5EonY27IQ1chRaZVC-zEoyOWvLGDeqyVGT2GaZ1BuF-3VIkN4tv3mqqucN2ktxDO4xKXAwn6PWKC0UXj1VrZYBMCq3beslAa2ve8NA" width="290" /></a></div><br />.<p></p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgSRTruBdRdGORTiojlQ-da4_FErCGZcynLpUT_FCPdL2f0GfLkvEqKS6jUBWT2NaENFpvZDii26irw4XVZnfxXlCS-euxu9lbE_wQdMiDoejfAPEltcauPQLk2yvm-iIjRNkqMDaBucM2fN0DMvCZ5JlAvwMx0ONmzB9EbCbtTx8H84AnPKqDwbbRNhg/s1920/DSC01761.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgSRTruBdRdGORTiojlQ-da4_FErCGZcynLpUT_FCPdL2f0GfLkvEqKS6jUBWT2NaENFpvZDii26irw4XVZnfxXlCS-euxu9lbE_wQdMiDoejfAPEltcauPQLk2yvm-iIjRNkqMDaBucM2fN0DMvCZ5JlAvwMx0ONmzB9EbCbtTx8H84AnPKqDwbbRNhg/s320/DSC01761.JPG" width="320" /></a></div><br /> DSC01761 of the above Aluminum fittings finger tightened to the controller (this shows an exit to the high voltage side).<div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi1HM93x_Hapo0PkEHtHcbeuHmzF4YX_t8H_SkK9JPylE2XtQaeFCug5UiYIajC7vSyE_5ysHMR7NqCKB6VDv952cIYSrPcyM7vQaP5V0v5SaL6dVhgl1gEMQW6YtbAsND_mMffQ5FDgLo7flbFSJq32Uj9_iiQLIPo1567QZewhHZjStaKumQmCiLMMg/s1920/DSC01760.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi1HM93x_Hapo0PkEHtHcbeuHmzF4YX_t8H_SkK9JPylE2XtQaeFCug5UiYIajC7vSyE_5ysHMR7NqCKB6VDv952cIYSrPcyM7vQaP5V0v5SaL6dVhgl1gEMQW6YtbAsND_mMffQ5FDgLo7flbFSJq32Uj9_iiQLIPo1567QZewhHZjStaKumQmCiLMMg/s320/DSC01760.JPG" width="320" /></a></div><p>DSC01760 after placement of the controller enclosure as a trial fitting showing that after tightening there will be room for the tubing. Two holes with grommets will be prepared through the left wall of the enclosure for exit of the tubing (this shows an exit to the high voltage side).</p><div class="separator" style="clear: both; text-align: center;"><br /></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjgGmxgGfBRCjfuEKJ-2BIEj7OwkTuuvA6Vll9VvKXLmLen-gv2gkY1uQBoaU6C58uWE4NCvEAf1vDltlxq6jfMkQwEIaJWAAI4s71pI9LF_WPOsHojk73DYpGXOvKfuMypyM74V1Utd579ZlCdL36DXfSEvZspbo39eFWFjG664AyMS0ngSQiLUqk84g/s1920/DSC01830.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="225" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjgGmxgGfBRCjfuEKJ-2BIEj7OwkTuuvA6Vll9VvKXLmLen-gv2gkY1uQBoaU6C58uWE4NCvEAf1vDltlxq6jfMkQwEIaJWAAI4s71pI9LF_WPOsHojk73DYpGXOvKfuMypyM74V1Utd579ZlCdL36DXfSEvZspbo39eFWFjG664AyMS0ngSQiLUqk84g/w400-h225/DSC01830.JPG" width="400" /></a></div><p>DSC01830 after final installation with tubing exit to the low voltage side.</p><p><br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgJlsbxhQeDEQquOYMZznzdhPNDC7_tQB9lw9GssjPVFkZYXX2SiTKixmbaUkQGJznAcgnSUyX3Lv6SAB-SO0yoQjclkQwOeVdQMHAwiEwzHm3MYERHRzlgusty041LkuZOPuWJpNFjzCF1vc-y7ABuZ7Jogfiz0thRUTtwnYbMCI5-IyFx_AA3NXqjxA/s1920/DSC01829.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1920" data-original-width="1080" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgJlsbxhQeDEQquOYMZznzdhPNDC7_tQB9lw9GssjPVFkZYXX2SiTKixmbaUkQGJznAcgnSUyX3Lv6SAB-SO0yoQjclkQwOeVdQMHAwiEwzHm3MYERHRzlgusty041LkuZOPuWJpNFjzCF1vc-y7ABuZ7Jogfiz0thRUTtwnYbMCI5-IyFx_AA3NXqjxA/w225-h400/DSC01829.JPG" width="225" /></a></div><p>DSC01829 close up showing the exit of the cooling lines on the low voltage side. The USB port for motor programming is at the top. Did not have an 11/16" drill and instead used a step drill and measured the opening with calipers until sized correctly. </p><p><br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhNbeGsW_M5wGt7XnBlZNb2f7z0hSgWWRwKsVG5v93rChE3q1E_mPZN9jxh7IlxXqqUDjrw0fAx-U7SvZ7zLv1DjQ_hS6XHe6_Xkgyju7CtxG6nkArrLnMoPPIr7ZIXJEtt2kDYkX25ABpY-ghWJLnK_RmgOhgvEOn4WtYiiC9ppCCu0Gg6FTjDcMkm-w/s1920/DSC01831.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="225" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhNbeGsW_M5wGt7XnBlZNb2f7z0hSgWWRwKsVG5v93rChE3q1E_mPZN9jxh7IlxXqqUDjrw0fAx-U7SvZ7zLv1DjQ_hS6XHe6_Xkgyju7CtxG6nkArrLnMoPPIr7ZIXJEtt2kDYkX25ABpY-ghWJLnK_RmgOhgvEOn4WtYiiC9ppCCu0Gg6FTjDcMkm-w/w400-h225/DSC01831.JPG" width="400" /></a></div><p>DSC01831 showing an Aluminum plate located internally for mounting of additional components.</p><p><br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhKyzYkrQ41SlZK3UxTHY1KUokNczm9jGAJQXz0dRG1G_4t3qaWWzCn7kCfRtxfo_nEXCjcmp0Um581RwLyQi7R1mnaVaTtpMmAcAeOkoc_7_s8sdc_CYt6PRiXGw_goUdJJ559prc6NA_EN8gRIPI-UbY8o8XB_rHKrNJrgHjP5nHI6yfXa9iIEIHiNg/s1920/DSC01832.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="225" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhKyzYkrQ41SlZK3UxTHY1KUokNczm9jGAJQXz0dRG1G_4t3qaWWzCn7kCfRtxfo_nEXCjcmp0Um581RwLyQi7R1mnaVaTtpMmAcAeOkoc_7_s8sdc_CYt6PRiXGw_goUdJJ559prc6NA_EN8gRIPI-UbY8o8XB_rHKrNJrgHjP5nHI6yfXa9iIEIHiNg/w400-h225/DSC01832.JPG" width="400" /></a></div><p>DSC01832 showing possible placement of components. Power feed at upper left, master shutoff switch (red handle) lower left, controller top center, 500 amp fuse lower row (second from left), contactor (third from left), and optional amperage current sensor bottom right.</p></div>Williamhttp://www.blogger.com/profile/13072555311952861298noreply@blogger.com0tag:blogger.com,1999:blog-576268040829288449.post-49973846079531088542023-05-18T14:28:00.002-07:002023-05-30T20:35:21.419-07:00Rincon Power High Voltage Battery Disconnect HVBD4AXR<p><span face="Arial, Helvetica, sans-serif" style="background-color: white; font-size: 1.7em;">HVBD4AXR - 400 A Continuous High Voltage Battery Disconnect</span></p><p>A Rincon high voltage battery disconnect was selected for mounting on the controller enclosure as a maintenance switch. This switch is available in 300A, 400A, and 600A versions. The 400 amp (continuous) version was selected and it can handle up to 2000 amps for one minute. (EV West sells for $159).</p><p>The disconnect switch data sheet can be found here:</p><p>https://uploads-ssl.webflow.com/605a2a14a7fc9726a217b0b2/6261cad9b014d13f844e4d93_HVBD%20SERIES%20DATASHEET_REV_D.pdf </p><p><br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhHtpf4JI9LbQ7fcC7e7gjDL9JIg8IVxSMZhE7BVvft2JmPro7JHG0vqNLqi67oADzG3-G9I7py8_EHlkRyLMsE6LOaDIyC-3BT7raqQf3ng5T5oQB0Jn1t0fvFl8jUN09Php4hbQOAXVKxadl1IR47NQTHjopKHGVHFMV4ijke4wrNYju7GffYwcCBvQ/s1920/DSC01741.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhHtpf4JI9LbQ7fcC7e7gjDL9JIg8IVxSMZhE7BVvft2JmPro7JHG0vqNLqi67oADzG3-G9I7py8_EHlkRyLMsE6LOaDIyC-3BT7raqQf3ng5T5oQB0Jn1t0fvFl8jUN09Php4hbQOAXVKxadl1IR47NQTHjopKHGVHFMV4ijke4wrNYju7GffYwcCBvQ/s320/DSC01741.JPG" width="320" /></a></div><br /><p>DSC01741"external view" of the Rincon power switch in the "on" position. The M8 mounting holes are 100mm center to center. The bolts are torqued to 110-120 IN-LB. The handle is equipped with a lockout-tag out feature that accommodates a lock whose shank is less than 8.2 mm (0.32"). In this picture the switch is in the ON position.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiJ1uI3y4_kBGERSyH2wC-V-y1uUDOLBA5sApg0MVi_R0SOaW6yB0BlHbgJX1edjoAwgcSuIhU6t7qa0ygffLPNnjEI4rMkOGj6N92emvhffeM46MfqtxxIJl-nR-X0iqLNr3ttxxSRgTvpjIDh2RfNCnC7xIR444AXYGoL06Jd_SZOX8-w0cyH3ChdRQ/s1920/DSC01744.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiJ1uI3y4_kBGERSyH2wC-V-y1uUDOLBA5sApg0MVi_R0SOaW6yB0BlHbgJX1edjoAwgcSuIhU6t7qa0ygffLPNnjEI4rMkOGj6N92emvhffeM46MfqtxxIJl-nR-X0iqLNr3ttxxSRgTvpjIDh2RfNCnC7xIR444AXYGoL06Jd_SZOX8-w0cyH3ChdRQ/s320/DSC01744.JPG" width="320" /></a></div><p>DSC01744 of the "internal view" of the Rincon power switch. </p><p><br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiOhK0DdhcOss0Z5p_L98H0AQtRa0l_ynXK2myn6fLya4x4r1wDH0VaZ1ezTr7s-DVVJACuGE6U7gfe2roeRlU41rI-2IOQ5xt9YnpXlAMAHGhUBgFptHCI75q6BJ-7WJhdfsyEAMYOHNu6RMhJxa7-JBFlx8lA_92I_7dqP1BnK6eMlhdakOxo7Amydg/s1920/DSC01745.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiOhK0DdhcOss0Z5p_L98H0AQtRa0l_ynXK2myn6fLya4x4r1wDH0VaZ1ezTr7s-DVVJACuGE6U7gfe2roeRlU41rI-2IOQ5xt9YnpXlAMAHGhUBgFptHCI75q6BJ-7WJhdfsyEAMYOHNu6RMhJxa7-JBFlx8lA_92I_7dqP1BnK6eMlhdakOxo7Amydg/s320/DSC01745.JPG" width="320" /></a></div><br /><p>DSC01745 side view showing the M10 (316 SS) electrical studs are torqued to 90-100 IN-LBS. The diameter of the switch body is 68.65 mm (2.70 ").</p><p><br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgkfwsCiqxPoHgwlF4Fk8eIYppSyeHm8OdXOy3cin1LIw1p5e2Ctpqw-JEBkxVK-fgw_n-q6kaFJRd9y96xGohv53vPAtyO4gJR7s3H1-aBSPOr58KV3PNXPKSEBpYyJklz1tERkllMzFkbzlVAbULcOZv6fISpFSumEVfLGLzY90ZnqPlhZJB1N9UDWQ/s1920/DSC01762.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="225" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgkfwsCiqxPoHgwlF4Fk8eIYppSyeHm8OdXOy3cin1LIw1p5e2Ctpqw-JEBkxVK-fgw_n-q6kaFJRd9y96xGohv53vPAtyO4gJR7s3H1-aBSPOr58KV3PNXPKSEBpYyJklz1tERkllMzFkbzlVAbULcOZv6fISpFSumEVfLGLzY90ZnqPlhZJB1N9UDWQ/w400-h225/DSC01762.JPG" width="400" /></a></div><p>DSC01762 after attaching Avery 5165 shipping label stock to the side of the controller enclosure and outlining the required cuts needed to mount both the Rincon HVBD4AXR switch (right) and the Rebling 7009-3 power receptacle (left).</p><p>The Avery adhesive on the back of the label is very strong. If was found that using a propane torch to heat the reverse side of the Aluminum resulted in softening of the adhesive. It was possible to use a plastic putty knife to scrape off nearly all of the label. Acetone on a cloth was then used to remove any residual film.</p><p> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj1h8VntHRfP3Xo97zidHZM4fKM3LwXtRs0oXBSgYlsgVwjdxjKArJERBzSD3F5_fqsyksA0GS7_pUDmxyjvwE0u2g14dnWzEvdAX1kedB24bqsry_gebCG6ofzY9y96D131SO7-3Nx9EBuCwbAD9D8i7qR8yX03KRzL_Va1lc_eO4VZO_6DJ46SOtL6Q/s1920/DSC01808.JPG" style="margin-left: 1em; margin-right: 1em; text-align: center;"><img border="0" data-original-height="1080" data-original-width="1920" height="225" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj1h8VntHRfP3Xo97zidHZM4fKM3LwXtRs0oXBSgYlsgVwjdxjKArJERBzSD3F5_fqsyksA0GS7_pUDmxyjvwE0u2g14dnWzEvdAX1kedB24bqsry_gebCG6ofzY9y96D131SO7-3Nx9EBuCwbAD9D8i7qR8yX03KRzL_Va1lc_eO4VZO_6DJ46SOtL6Q/w400-h225/DSC01808.JPG" width="400" /></a></p><p>DSC01808 of the Rincon disconnect switch mounted on the side of the controller enclosure. The switch is in the off position with a lock in place.</p><p><span style="font-size: large;"><br /></span></p><p><span style="font-size: large;">Connecting the Master Switch to the Power Receptacle</span></p><p><span style="font-size: xx-small;"> updated 5/23/2023</span></p><p>A bus bar was prepared using a 0.125" x 1" x 5.625" copper plate. </p><p> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhoqdjgcc4LuzYozGhr6JJrZ-jStODVYk_fRIGgmW9zlHdbYpJ643BN-PYXuGBT_rBAna-1PF59OwFRFmShnmhZtNPLbSfQY3fwOhkem_iF8LQ3wkCrx5xlUnk-xrMBYpeiOw6w-FGKj95fzbiIUdryLcB6-Mmt5F_yBZ7REVLwqai8oA2Mp8mckeoaeg/s1920/DSC01836.JPG" style="margin-left: 1em; margin-right: 1em; text-align: center;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhoqdjgcc4LuzYozGhr6JJrZ-jStODVYk_fRIGgmW9zlHdbYpJ643BN-PYXuGBT_rBAna-1PF59OwFRFmShnmhZtNPLbSfQY3fwOhkem_iF8LQ3wkCrx5xlUnk-xrMBYpeiOw6w-FGKj95fzbiIUdryLcB6-Mmt5F_yBZ7REVLwqai8oA2Mp8mckeoaeg/s320/DSC01836.JPG" width="320" /></a></p><p>DSC01836 showing the length dimensions. </p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjP5HXF-sz9z7BpB0n_YRNBuOa-lvfMIJ0ZK0BJhvvTgBPTahXNBaYXgQ6bFn0o4coiMRAvuh4h-y4pnxqSGns_EsG1Imd14FplD_ulACOE0ZIsuRRk8IKHqbR-6HuRVb2mMj7F6J8TjYC-JQVBOd-CdtR2GjCs2bpZPVSYYotCRpcEFL4CAZrmchJW1g/s1920/DSC01837.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjP5HXF-sz9z7BpB0n_YRNBuOa-lvfMIJ0ZK0BJhvvTgBPTahXNBaYXgQ6bFn0o4coiMRAvuh4h-y4pnxqSGns_EsG1Imd14FplD_ulACOE0ZIsuRRk8IKHqbR-6HuRVb2mMj7F6J8TjYC-JQVBOd-CdtR2GjCs2bpZPVSYYotCRpcEFL4CAZrmchJW1g/s320/DSC01837.JPG" width="320" /></a></div><div class="separator" style="clear: both; text-align: center;"><br /></div><div class="separator" style="clear: both; text-align: center;">DSC01837 showing bend height. </div><p></p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg043Q4dLGZ2sDPOtm9A-sDbSX5dLH_-lJYVLjMcrEfO6BeJqgQHDCwb1LAb0MFqY58aQOLZxmRlQ7aoLcPuar4uX0pggbA-HsnbqyFpnt9tBzkvE7-5M1UMa3EEpyysdu8R3Ro3VBUOfijDs6Cj3bcuY-J7OUNb-Crn-QmAnWFd-4Y_WbkHrBmR0knyA/s1920/DSC01833.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg043Q4dLGZ2sDPOtm9A-sDbSX5dLH_-lJYVLjMcrEfO6BeJqgQHDCwb1LAb0MFqY58aQOLZxmRlQ7aoLcPuar4uX0pggbA-HsnbqyFpnt9tBzkvE7-5M1UMa3EEpyysdu8R3Ro3VBUOfijDs6Cj3bcuY-J7OUNb-Crn-QmAnWFd-4Y_WbkHrBmR0knyA/s320/DSC01833.JPG" width="320" /></a></div><p>DSC01833 after installation of the bus bar. The height of the bend was slightly smaller then needed and a 0.125" copper washer was used on the power receptacle (upper right) to compensate.</p><p><br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhu-ZENjELfHEqW2xDEyPyoJbF5xiUZQCNMP6Rd5XXWBUJMtaEm8WFootfsLeV9r3_4_6J-XILfdhxE08lkgil7Fdi75e08XMGc-nQIbXgSXYf2ZUgtXPG8L_wuk_N3yMSECbBTwTgekpsPi1MFoEDeWnocBWRGiK7n0uFw_kd9lSng8t1GA0EdV6HMQw/s1920/DSC01834.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhu-ZENjELfHEqW2xDEyPyoJbF5xiUZQCNMP6Rd5XXWBUJMtaEm8WFootfsLeV9r3_4_6J-XILfdhxE08lkgil7Fdi75e08XMGc-nQIbXgSXYf2ZUgtXPG8L_wuk_N3yMSECbBTwTgekpsPi1MFoEDeWnocBWRGiK7n0uFw_kd9lSng8t1GA0EdV6HMQw/s320/DSC01834.JPG" width="320" /></a></div><p>DSC01834 side view of installed bus bar that connects the master shut off switch (Rincon) and the Rebling 7009-3 power receptacle. In the foreground is the controller U1 bus bar.</p><span style="text-align: center;"><br /></span><p></p>Williamhttp://www.blogger.com/profile/13072555311952861298noreply@blogger.com0tag:blogger.com,1999:blog-576268040829288449.post-48062208679670078962023-05-18T14:14:00.002-07:002023-05-22T10:39:36.094-07:00Main Battery Pack Connector and Control Box<p>Purchased from EV Motor Verks Store (573-388-4580, sales@evtv.me) a Rebling 7009-3 Battery Receptacle ($88) and a Rebling 7016 Battery Disconnect Plug Cable Mount ($290). The 7009 is equivalent to the Rebling 7002 connector and the connector set is rated at up to 750 volts DC, 750 amps continuous, and up to 1500 amps peak. These connectors are rated for aircraft use and they are positive locking and very robustly manufactured.</p><p>Data sheets can be found here:</p><p>https://rebling.com/pdf/Rebling___Datasheet-Product___7016%20Avionics%20Cable-Mounted%20Plug%20ver%2020220602.pdf</p><p>https://rebling.com/products/two-wire-avionics-plug </p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh65YpjPqk6epI0ErxTRqBtM7SxNdWLpsby7_YWZsReGAx1FTrr_So9KOGBSSGooD5DP2AQWLUnfEx6e_lJ0D7ImlWeuJldADiCbmbsPlgZBraCfbqieLicr1zSqOcqfH1XwUlnRpwPCb1jDyE6vnaeDCVTSYn_GXHSjO9h60Z-6o8ffeVULNBdeZRbZw/s1920/DSC01728.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh65YpjPqk6epI0ErxTRqBtM7SxNdWLpsby7_YWZsReGAx1FTrr_So9KOGBSSGooD5DP2AQWLUnfEx6e_lJ0D7ImlWeuJldADiCbmbsPlgZBraCfbqieLicr1zSqOcqfH1XwUlnRpwPCb1jDyE6vnaeDCVTSYn_GXHSjO9h60Z-6o8ffeVULNBdeZRbZw/s320/DSC01728.JPG" width="320" /></a></div><p>DSC01728 picture of assembled female Rebling Plastics 7016 (right side) and male Rebling Plastics 7009 (left side, equivalent to Rebling 7002). </p><p><br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEihaaPfTWpnKf08xSa9G-oA119-UHTN3VTue98ME2EvDKDyvrJaDU8ZINbM-4P2aZHc-xZFuhNa5darJ0YbEmjJPWaPTt4D0TOCUIbRbDORZANjKQPIKSyV_cy3NStoK7f6LFfjRtw0FU7hRHet6yxBV6ipLSVhMwx2Xmr-aeMMBjW0caKxBAXWVCU2Xw/s1920/DSC01705.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEihaaPfTWpnKf08xSa9G-oA119-UHTN3VTue98ME2EvDKDyvrJaDU8ZINbM-4P2aZHc-xZFuhNa5darJ0YbEmjJPWaPTt4D0TOCUIbRbDORZANjKQPIKSyV_cy3NStoK7f6LFfjRtw0FU7hRHet6yxBV6ipLSVhMwx2Xmr-aeMMBjW0caKxBAXWVCU2Xw/s320/DSC01705.JPG" width="320" /></a></div><p>DSC01705 view of openings that allow for 2/0 electrical cables.</p><p><br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhFJqC9P-AkQGJYJYHzl22UE3nfeauqf8c9B_u_MwbqG7jvMYCi2h5206NG8oa5nJ4SeZhNhIUKl3ySqTRSLs2dQ_89rdJg0Z-dDXMauoDPEZr05ZTMLkYJ6ZczdlMC5nw6gflGO6f5pEvAkWmBd7cHPcHaEdixU0hgapABdjaPzJDervcfvIMUcKgPmw/s1920/DSC01726.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhFJqC9P-AkQGJYJYHzl22UE3nfeauqf8c9B_u_MwbqG7jvMYCi2h5206NG8oa5nJ4SeZhNhIUKl3ySqTRSLs2dQ_89rdJg0Z-dDXMauoDPEZr05ZTMLkYJ6ZczdlMC5nw6gflGO6f5pEvAkWmBd7cHPcHaEdixU0hgapABdjaPzJDervcfvIMUcKgPmw/s320/DSC01726.JPG" width="320" /></a></div><p>DSC01726 showing the 7009-3 (Top) and the locking plunger (center) that is rotated into the receptacle using the <span face="-apple-system, BlinkMacSystemFont, "Segoe UI", Roboto, Ubuntu, "Helvetica Neue", sans-serif, "Apple Color Emoji", "Segoe UI Emoji", "Segoe UI Symbol"" style="background-color: white; color: #2f2b2b; font-size: 15px;">half-turn handle. </span></p><p><br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEivOv3v2M5EVf4_bsCnnjcabg6rILW4DHp3NmRmoVxHCX1jhzf9fUxqdBS2G8_SzwOZWRuJvneYGb10Pkls-Kqmn7WZ2yw_hExv-IO4M1a8iQ5PgE86GCbYiNyKihkOGFX6CmBF_D1f1yrpIZSqnGxiOG55jZtyK22Hy8PqzAdELIcKRmU1f8R_x2ky6w/s1920/DSC01703.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEivOv3v2M5EVf4_bsCnnjcabg6rILW4DHp3NmRmoVxHCX1jhzf9fUxqdBS2G8_SzwOZWRuJvneYGb10Pkls-Kqmn7WZ2yw_hExv-IO4M1a8iQ5PgE86GCbYiNyKihkOGFX6CmBF_D1f1yrpIZSqnGxiOG55jZtyK22Hy8PqzAdELIcKRmU1f8R_x2ky6w/s320/DSC01703.JPG" width="320" /></a></div><p>DSC01703 left side is Rebling 7009-3 (male) and on the right side is the Rebling 7016 (female).</p><p><br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgeGPRvddWGzvNI9E6soZTKiuPg4JnB3V3Tt3BIWkJNKSr3Bi2bcHkRohGgIOqM5yhQLdIDC28gIa0_hz282Vyh5W-st-R4DHuex9m1O9mFt18LKf5Pis5f5IF3zfEcZHBPC0i62HJt8dZelzpiUKZXphC8epaA9EukbwdSJrRy44S488pnP91lzyhJEA/s1920/DSC01731.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgeGPRvddWGzvNI9E6soZTKiuPg4JnB3V3Tt3BIWkJNKSr3Bi2bcHkRohGgIOqM5yhQLdIDC28gIa0_hz282Vyh5W-st-R4DHuex9m1O9mFt18LKf5Pis5f5IF3zfEcZHBPC0i62HJt8dZelzpiUKZXphC8epaA9EukbwdSJrRy44S488pnP91lzyhJEA/s320/DSC01731.JPG" width="320" /></a></div><p>DSC01731 showing the Rebling 7009-3 (terminal studs, 5/16-18, far left as would be viewed from within the control box), middle (male, as would be seen from outside the control box) and the Rebling 7016 (female) far right top view. </p><p><br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgdWTSmF0PN3ikuW7WZcvTvFe3_66S9m8Ra3JHIAL2aLQg0qVqR-Hl9iTABc5vOperIHY-Rg6Ilh1vChLR4K2KsOICVSaaIzNUN-uLWsDLmDv7AZpYXIlgBzR_VF77FPgGBxxfD0SRf6DkC8GNWxS0VocfI5vCrbSMKyjLZ0KRABQY7Ialhnp0PR86wFQ/s1920/DSC01723.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgdWTSmF0PN3ikuW7WZcvTvFe3_66S9m8Ra3JHIAL2aLQg0qVqR-Hl9iTABc5vOperIHY-Rg6Ilh1vChLR4K2KsOICVSaaIzNUN-uLWsDLmDv7AZpYXIlgBzR_VF77FPgGBxxfD0SRf6DkC8GNWxS0VocfI5vCrbSMKyjLZ0KRABQY7Ialhnp0PR86wFQ/s320/DSC01723.JPG" width="320" /></a></div><p>DSC01723 exploded view of the Rebling 7016 connector. 5/16-18 studs (center) are shown securing a pair of 2/0 terminal lugs. The far left and far right plastic housings are bolted together with a pair of 10/32 x 1.625" bolts.</p><p><br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi2dZ-a0HfsN9UO58tMrNGiwb066lyPV9J0iDy5-WTfp0tefkOIaqCd5Csl3Ef9O7PnCSAvCs8ylwXD2FF5dIkBXoSSIDF2D89995qSFc890Za8N1EMmj2AhcCdBO6WEH_PatWqCXP7Juc2YE5_wAcs9_qrGpX0U1Ble2edP6AbqjhGz8tETlG8e4tLjw/s1920/DSC01725.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi2dZ-a0HfsN9UO58tMrNGiwb066lyPV9J0iDy5-WTfp0tefkOIaqCd5Csl3Ef9O7PnCSAvCs8ylwXD2FF5dIkBXoSSIDF2D89995qSFc890Za8N1EMmj2AhcCdBO6WEH_PatWqCXP7Juc2YE5_wAcs9_qrGpX0U1Ble2edP6AbqjhGz8tETlG8e4tLjw/s320/DSC01725.JPG" width="320" /></a></div><p>DSC01725 showing 7016 after installation of (+) and (-) 2/0 power cables.</p><p><br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhI9I5vS3GqY2TgMPm8ptXV42D9tVJj5_UsJu4trrch7yZlRdrO1PJK74IiNqUczbXifr3qg-8Xle_lFEErTiuzJB_aOwX6DZB-JZkig54kwDUsvnetIkoPd0zS1TTvEmfNWXYbUfWLMv58vGclhi22LLN2PzquKqhkcUWsPOKaEYYNw2g7iwg2sZARZw/s1920/DSC01796.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhI9I5vS3GqY2TgMPm8ptXV42D9tVJj5_UsJu4trrch7yZlRdrO1PJK74IiNqUczbXifr3qg-8Xle_lFEErTiuzJB_aOwX6DZB-JZkig54kwDUsvnetIkoPd0zS1TTvEmfNWXYbUfWLMv58vGclhi22LLN2PzquKqhkcUWsPOKaEYYNw2g7iwg2sZARZw/s320/DSC01796.JPG" width="320" /></a></div><div class="separator" style="clear: both; text-align: center;"><span style="text-align: left;"><br /></span></div><div class="separator" style="clear: both; text-align: center;"><span style="text-align: left;">DSC01801 showing the installed Rebling connector (left side) on the side of a controller enclosure. The 7009-3 fits within a 1.50" x 2.90" opening in the controller box. </span></div><p>The rounded part of the 7009-3 are 1.375" diameter with a center to center distance of 1.54".</p><p>A cardboard template of the 7009 was prepared and used to mark the Aluminum of the box before cutting.</p><p>The four mounting bolts are 10-32 x 0.5" and Stainless Steel was selected.</p>Williamhttp://www.blogger.com/profile/13072555311952861298noreply@blogger.com0tag:blogger.com,1999:blog-576268040829288449.post-86516552593206194712023-03-03T10:06:00.002-08:002023-03-03T10:06:34.435-08:00Cooling Fan Mounted to Hyper9 Cradle Support <p>Initially it was desired to mount a simple 12V fan to the side of the Hyper9 motor. .Acrylic was chosen for transparency.</p><p> <span> </span><span> </span><span> </span><span> </span><span> </span><span> </span><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgkTVilOQsu8WxJmRjLpi2-rzJBCa2FRkBF_rqaENmO8__pTDvIzcDV_rHVFbZtNNGYncIGDv8DXC5QsIycRp5B8ju2592qS-XyzCGycMqTDRSUtRiRnXbvssskLj3Hs2XFzhSMkEfLM3x3FwarVakpBgtJJUbiwS5XW6xzoLQWTlmijMwRU-fV1zS1kw/s1920/DSC01508.JPG" style="margin-left: 1em; margin-right: 1em; text-align: center;"><img border="0" data-original-height="1080" data-original-width="1920" height="225" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgkTVilOQsu8WxJmRjLpi2-rzJBCa2FRkBF_rqaENmO8__pTDvIzcDV_rHVFbZtNNGYncIGDv8DXC5QsIycRp5B8ju2592qS-XyzCGycMqTDRSUtRiRnXbvssskLj3Hs2XFzhSMkEfLM3x3FwarVakpBgtJJUbiwS5XW6xzoLQWTlmijMwRU-fV1zS1kw/w400-h225/DSC01508.JPG" width="400" /></a></p><p>DSC01508 of the preliminary template made from a vanilla file folder for trial fitting.</p><p><br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgBYSQkTFuqsYik5DiOtfZVi0vJOdJFT4Sm4ZDqTok5jSj4hC4Qd0BiLxMMG6T0Qzy89lN2z30YCHpv6qFt8_dfMGRNycnCO5vac4YZogCKeFWj0zWHwpDPvBbohSN-8luMi5vbGetMW8ZBkB9Ie6C40C4I-9oFYzn1UA6s2UjXQSxNXCy57y42eY04IA/s1920/DSC01509.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="225" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgBYSQkTFuqsYik5DiOtfZVi0vJOdJFT4Sm4ZDqTok5jSj4hC4Qd0BiLxMMG6T0Qzy89lN2z30YCHpv6qFt8_dfMGRNycnCO5vac4YZogCKeFWj0zWHwpDPvBbohSN-8luMi5vbGetMW8ZBkB9Ie6C40C4I-9oFYzn1UA6s2UjXQSxNXCy57y42eY04IA/w400-h225/DSC01509.JPG" width="400" /></a></div><div><br /></div>DSC01509 After attaching Avery 5165 (8.5 x 11") shipping label to the a 12" x 6" X 3/16" Acrylic sheet (McMaster-Carr part 4615T26 at $7.28), the dimensions were drawn. Note: Later removal of the Avery was difficult. The Avery should have been applied to the acrylic side with the factory provided plastic scratch preventing film as it then could then have been peeled off without difficulty. To remove the Avery the piece was soaked in water overnight, the top paper layer scrapped off with a plastic putty knife, and finally an Isopropyl alcohol (rubbing alcohol) wetted rag was used to remove the label adhesive.<div><br /></div><div>Cooling fan outer dimensions are 4.75" x4.75" x 1.5". (Sunon EEC 0381 B2-000U-A99, DC 12V, 5.1 Watt, Digi Key part # 259-1498-ND delivered price including China tariff at about $21.50 each.<br /><div><br /></div><div><div><br /></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgarqionMLGCob8Rc-OqkT54R9cQwp97_E36rZUZcXxeA9Duy7yye0YS0e67UYhDKQOgvnzffQ9iSjoaNxVt26ljMrdnWvNOVbfHj6O8Q7blWeC0FrMlz-nqLDGo36vV83P3gUFc-kajI4Bs5fGsz1HfVyrFc7lUU6raeR2ExXZkIbMYINbY1pEFgMzMQ/s1920/DSC01625.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgarqionMLGCob8Rc-OqkT54R9cQwp97_E36rZUZcXxeA9Duy7yye0YS0e67UYhDKQOgvnzffQ9iSjoaNxVt26ljMrdnWvNOVbfHj6O8Q7blWeC0FrMlz-nqLDGo36vV83P3gUFc-kajI4Bs5fGsz1HfVyrFc7lUU6raeR2ExXZkIbMYINbY1pEFgMzMQ/s320/DSC01625.JPG" width="320" /></a></div><br /><div><div>DSC01625 showing the acrylic fan positioned on the side of the motor. When mounting the acrylic to the top half of the cradle, the cut outs at the bottom (left and right) allow the fan to be positioned within a 1.75" range. </div></div></div></div>Williamhttp://www.blogger.com/profile/13072555311952861298noreply@blogger.com0tag:blogger.com,1999:blog-576268040829288449.post-23062019201876494242023-02-23T09:37:00.008-08:002023-05-30T20:42:49.877-07:00Cooling Fans Mounted to Hyper9 Controller Support - 1.0<p> To build the controller support, a sheet of 0.063-0.067" 5052-H32 Aluminum measuring 27" x 10.5" was prepared. </p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjaPJKAII5dQgXgQdQdo407onX8IxxJC_BeU4-nkeIzyjvYWc4iRbd07071fbCgtpkfaPSwB_8wIU9pdwlLhE8_p2xkh0I4rieCap377yiAd-I0wlmlPulCh5Z-ymJfeCbiu6DXDOfyRDQ0L4a8DvVCC4KsFPn2OvS5shWrrs_DXrmQqbl19a2DsxMvjg/s1920/DSC01560.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjaPJKAII5dQgXgQdQdo407onX8IxxJC_BeU4-nkeIzyjvYWc4iRbd07071fbCgtpkfaPSwB_8wIU9pdwlLhE8_p2xkh0I4rieCap377yiAd-I0wlmlPulCh5Z-ymJfeCbiu6DXDOfyRDQ0L4a8DvVCC4KsFPn2OvS5shWrrs_DXrmQqbl19a2DsxMvjg/s320/DSC01560.JPG" width="320" /></a></div><div><br /></div><div>DSC01560 after boring out the fan vents (4.5" diameter) and drilling the 5/32" holes for the mounting bolts, the sheet was bent to shape. The original motor cradles offered by NetGain have a 15 degree flare, so the bottom mounting surfaces of the support plate were bent 15 degrees (relative to the base) to conform. Top bends are 90 degrees. The Top surface is 10.5" x 11.75" with the sides 6.25" x 10.5".</div><div><br /></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhh6rbkNUDWGV23bQ9U7VzSg0JgEJ_GpSBRmoi0xn8b2Uc_Aq5uOiTmk0F_4N83nSuahR9kgW79RGX_B7mkssGxwrbaFe_lwp9S4W4tcdzQv64Qd00gnBaUSQd3otGD6gVAFuNoMSZvAuWNSznZF9RGgF6-peFhRr_DwnmmmZ14TU5UFpp0Ypqx9G7hNg/s1920/DSC01562.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhh6rbkNUDWGV23bQ9U7VzSg0JgEJ_GpSBRmoi0xn8b2Uc_Aq5uOiTmk0F_4N83nSuahR9kgW79RGX_B7mkssGxwrbaFe_lwp9S4W4tcdzQv64Qd00gnBaUSQd3otGD6gVAFuNoMSZvAuWNSznZF9RGgF6-peFhRr_DwnmmmZ14TU5UFpp0Ypqx9G7hNg/s320/DSC01562.JPG" width="320" /></a></div><div><br /></div><div>DSC01562 side view showing the pair of 4.5" vents for the box fans and the 5/32" holes for mounting.</div><div><br /></div><div><br /></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgfnQiLaw9om4fj0UZULq5zRqmH-JqceWp5SLA1B6y1JIl-k9ox0FXGynQl3M22GC5ygGmrYGc8FCLvOHvzSnE8o0Bi1xglUItDL05vuuIMdGys8jWMPpkaYZfj9NdryTBJrY4FUnONmH5DWcuX598I3su8yDbPVKBfLwNxYJ22PemrsmAp2KW7N0LeUQ/s1920/DSC01563.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgfnQiLaw9om4fj0UZULq5zRqmH-JqceWp5SLA1B6y1JIl-k9ox0FXGynQl3M22GC5ygGmrYGc8FCLvOHvzSnE8o0Bi1xglUItDL05vuuIMdGys8jWMPpkaYZfj9NdryTBJrY4FUnONmH5DWcuX598I3su8yDbPVKBfLwNxYJ22PemrsmAp2KW7N0LeUQ/s320/DSC01563.JPG" width="320" /></a></div><div><br /></div><div>DSC01563 test fitting of the platform with the Hyper9.</div><div><br /></div><div><br /></div><div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg5uANThYRLFnEVtANBWLHjgVQv6LWfAW_dtlsG4vw_vsx69LEa2ecHRTJz_na8-p4H8BhiKs8h4wk3_9WbPudFR2oV1KcGXMfh2BJBfaGK2OjOg59IzZXE-_2aneGJoBVHOyjMEpVJh_rMfe0SFdouUF0c64409PNT_suztMfUdjlcj1RDDTyePc7cIA/s1920/DSC01647.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg5uANThYRLFnEVtANBWLHjgVQv6LWfAW_dtlsG4vw_vsx69LEa2ecHRTJz_na8-p4H8BhiKs8h4wk3_9WbPudFR2oV1KcGXMfh2BJBfaGK2OjOg59IzZXE-_2aneGJoBVHOyjMEpVJh_rMfe0SFdouUF0c64409PNT_suztMfUdjlcj1RDDTyePc7cIA/s320/DSC01647.JPG" width="320" /></a></div><br /></div><div><br /></div><div>DSC01647 showing original controller support version 1.0 o n the left and the newer version 2.0 on the right. The left side is compatible with a mounting surface that is 15 degrees from the platform, while the right side is parallel to the mounting surface. <span style="font-size: xx-small;"> Edited 3/23/23</span></div><div><br /></div>DSC01645 showing the end on view of the support platform attached to the cradle.<div><br /></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiflfTxUgOPk6LePtfK5acXm5sNWzr7jM7-S8pB8GSJSyWWlsK0wZDdvXBquE0PK0IIklNf7IEQy_b6nFrvCm7tOxV48jcr4KJsHl5Gi1ek8X0R3aC3fBxW5JR8jJXq3JbIcj6mHeFYjaHFPm7dWoZlovjV4Hnsksna9jNKsjtRu9wf79rmK_KedMrlug/s1920/DSC01652.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1920" data-original-width="1080" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiflfTxUgOPk6LePtfK5acXm5sNWzr7jM7-S8pB8GSJSyWWlsK0wZDdvXBquE0PK0IIklNf7IEQy_b6nFrvCm7tOxV48jcr4KJsHl5Gi1ek8X0R3aC3fBxW5JR8jJXq3JbIcj6mHeFYjaHFPm7dWoZlovjV4Hnsksna9jNKsjtRu9wf79rmK_KedMrlug/s320/DSC01652.JPG" width="180" /></a></div><br /><div><br /></div><div>DSC01652 showing the detail of the mounting tabs. The mounting holes on the left have not yet bee drilled. <span style="font-size: x-small;"> Updated 3/23/23</span></div><div><br /></div><div><br /></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgdHbK8AX07dPsQrLkCfeOwCFbRW7TR-HZZoDFWCuHr9EGHc-TtcA_paa4RXAyJBPmDsUeEhSfqB6QltoJNI1ItPAL_VlMWh8slAm5RCOblJu9PvHh5HFyIMdAsDpoo7wcjIe50el0SoxrhLC8FyUjRdwDXlUAAUuqZweT45-jfxQPHLPykkbbYbj2yXg/s1920/DSC01645.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgdHbK8AX07dPsQrLkCfeOwCFbRW7TR-HZZoDFWCuHr9EGHc-TtcA_paa4RXAyJBPmDsUeEhSfqB6QltoJNI1ItPAL_VlMWh8slAm5RCOblJu9PvHh5HFyIMdAsDpoo7wcjIe50el0SoxrhLC8FyUjRdwDXlUAAUuqZweT45-jfxQPHLPykkbbYbj2yXg/s320/DSC01645.JPG" width="320" /></a></div><br /><div><br /></div><div>DSC01645 showing the end on view of the support platform attached to the cradle. <span style="font-size: x-small;"> Edited 3/23/23</span></div><div><br /></div><div><br /></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhqV6D-IIZycYyL5JQZUJ-fU8ksNOZofyLSIZhFS9kTc5TVX0bNRLKBboluQpeL3lqkN55asILBu5PVs3KVvLuLBMsrb1qySJeyStxTgKRc0YLz-KJATOqVPNOWxEawLcSaK8TQttVS92Hb1o9i8O7euWaDyg2VRAhz9i_vWWt20f1lgpIOfsSUOa9kdw/s1920/DSC01646.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1920" data-original-width="1080" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhqV6D-IIZycYyL5JQZUJ-fU8ksNOZofyLSIZhFS9kTc5TVX0bNRLKBboluQpeL3lqkN55asILBu5PVs3KVvLuLBMsrb1qySJeyStxTgKRc0YLz-KJATOqVPNOWxEawLcSaK8TQttVS92Hb1o9i8O7euWaDyg2VRAhz9i_vWWt20f1lgpIOfsSUOa9kdw/s320/DSC01646.JPG" width="180" /></a></div><br /><div>DSC01646 showing Version 2.0 support platform mounted to the cradle. The bottom bolt is initially tightened to compress the cradle against the motor (or in this case the surrogate PVC motor) and after secure, the internal nut is tightened to secure the support platform to the cradle itself. <span style="font-size: x-small;"> Edited 3/23/23</span></div><div><span style="font-size: x-small;"><br /></span></div><div><br /></div><div><div class="separator" style="clear: both; text-align: center;"><br /></div></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEilnDvYYnv49ewKGS_GNaTfuXKe8_8-BRBHM5yKJW9m0RFiIjP29vkehMLotWlflg9XL32YRN8w0_l3qT0JX3t1axQHlPKrdxo-Zs_WQJPUA1inyI8dpGnTJLNGUhRFCFB8bTDgh5QBBFbcYVL6QLg3GQwL2_yr_cWK3qI2FW9U7DC9JGlnn5_A57ju_w/s1920/DSC01690.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEilnDvYYnv49ewKGS_GNaTfuXKe8_8-BRBHM5yKJW9m0RFiIjP29vkehMLotWlflg9XL32YRN8w0_l3qT0JX3t1axQHlPKrdxo-Zs_WQJPUA1inyI8dpGnTJLNGUhRFCFB8bTDgh5QBBFbcYVL6QLg3GQwL2_yr_cWK3qI2FW9U7DC9JGlnn5_A57ju_w/s320/DSC01690.JPG" width="320" /></a></div><br /><div><br /></div><div>DSC01690 showing the plasma cutting of a support plate from a 0.067" x 48" x 48" 5052-H32 Aluminum sheet. ($45 from Alro Metals). A Langmuir Systems - Crossfire Pro (at Bart's Precision Machinery and Fab) was used with a total cutting time of 93 seconds per piece. <span style="font-size: small;"> </span><span style="font-size: xx-small;">Updated 4/9/23</span></div><div><br /></div><div><br /></div><div><span style="font-size: large;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEhMCPaSHCdZCiFGbnhHaWRTnIw5EF4UIQPNYtwUqn1db51M6twLEVLlsVwnZA2SMJMLrwBfAyLhZybGs07KOQkhnkxJVsKS-odWsBeTuXDyWDi5Ch9kkXF25w4gPZlymf9Mi8hCNii9KWp2FbvjdlU6D--LAuYtSt3lmx5DTT-MRBvFBMZJSa9NDH5czg" style="margin-left: 1em; margin-right: 1em;"><img alt="" data-original-height="180" data-original-width="320" height="180" src="https://blogger.googleusercontent.com/img/a/AVvXsEhMCPaSHCdZCiFGbnhHaWRTnIw5EF4UIQPNYtwUqn1db51M6twLEVLlsVwnZA2SMJMLrwBfAyLhZybGs07KOQkhnkxJVsKS-odWsBeTuXDyWDi5Ch9kkXF25w4gPZlymf9Mi8hCNii9KWp2FbvjdlU6D--LAuYtSt3lmx5DTT-MRBvFBMZJSa9NDH5czg" width="320" /></a></div><br /><span style="font-size: medium;">DSC01646 showing Version 2.0 after being cut, but prior to drilling the fan mounting holes, and bending to shape. </span><span style="font-size: medium;"> </span></span></div><div><span style="font-size: large;"><br /></span></div><div><span style="font-size: large;"><br /></span></div><div><span style="font-size: large;"><span> </span><span> </span><span> </span><span> </span>Heat Sinks Mounted to the Controller Support</span></div><div><br /></div><div><br /></div><div><br /></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgIRpmuDrj1svcrW-k7JQ3coCN8v3ImqcJUB6_fgKU_tP1qwnD0Q7B_ZOi9tU74sEVMBvFk-1MTBRX5AVjG3-COhx4saN7QHS44Wg1SGwPkLHpw-Q6l1tl_NisEDQ_KrNHPHkbN8h5BMR4XXkvbpJHKSUPu1BMSx681lOQGmrjkr_uVHZssH-N6c-IBEg/s1920/DSC01569.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgIRpmuDrj1svcrW-k7JQ3coCN8v3ImqcJUB6_fgKU_tP1qwnD0Q7B_ZOi9tU74sEVMBvFk-1MTBRX5AVjG3-COhx4saN7QHS44Wg1SGwPkLHpw-Q6l1tl_NisEDQ_KrNHPHkbN8h5BMR4XXkvbpJHKSUPu1BMSx681lOQGmrjkr_uVHZssH-N6c-IBEg/s320/DSC01569.JPG" width="320" /></a></div><div><br /></div><div>DSC01569 showing the maximum length cooling heat sink (11.75" L x 7.25" W x 1.25" D with 1.0" fins) with both fans mounted externally. The fans do not clear the fins.</div><div><br /></div><div><br /></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhgihY9yDphI_Y0uoxW1Gy25E0S972xi6xbR1w0HN6zwo_Zbyb_8C6sOagOHTXCX2osC_XfM1_7K49-HxvoJSWOtDoHcumIYaN4A7_t8D0voO2-2cf-K7dgFdo7MS-yKOqxCbaxNkETOz46zdMtfj2clmfcavm-SqiWMerrozJ9uy4ntoNl3U6rlXFJ-w/s1920/DSC01575.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhgihY9yDphI_Y0uoxW1Gy25E0S972xi6xbR1w0HN6zwo_Zbyb_8C6sOagOHTXCX2osC_XfM1_7K49-HxvoJSWOtDoHcumIYaN4A7_t8D0voO2-2cf-K7dgFdo7MS-yKOqxCbaxNkETOz46zdMtfj2clmfcavm-SqiWMerrozJ9uy4ntoNl3U6rlXFJ-w/s320/DSC01575.JPG" width="320" /></a></div><div><br /></div><div>DSC01575 rear face of 11.75" x 8.375" heat sink after removing material to provide for fan clearance.</div><div><br /></div><div><br /></div><div><br /></div><div> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgKUiuBNBrJmXOqy5ky9leqNvETEP1OZAYE6miYf0tIwDojl_dkx_CFWIqck4-iatRGtAzjr5JfaeNm2R4_2eC1joW3LyL70aNF2E4R2XAwG1VVgRLgsrzbgBg-lVhGv_QbQLw1mQMdhMnt5D-kYU6834WnbpI8BvZqiDVsvouvJAZaXrNkl-9EngImAw/s1920/DSC01574.JPG" style="margin-left: 1em; margin-right: 1em; text-align: center;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgKUiuBNBrJmXOqy5ky9leqNvETEP1OZAYE6miYf0tIwDojl_dkx_CFWIqck4-iatRGtAzjr5JfaeNm2R4_2eC1joW3LyL70aNF2E4R2XAwG1VVgRLgsrzbgBg-lVhGv_QbQLw1mQMdhMnt5D-kYU6834WnbpI8BvZqiDVsvouvJAZaXrNkl-9EngImAw/s320/DSC01574.JPG" width="320" /></a></div><div><br /></div><div>DSC01574 front face of 11.75" x 8.375" heat sink after removing material to provide for fan clearance.</div><div class="separator" style="clear: both; text-align: center;"><br /></div><div><br /></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhwvl2X_rsrrWNGoTJ7mG4_uLs-J05f7SoaGv_Kjm-nyUlHsyEsXt37lSgASSNT2VVz_Yvowxoh9CA8HcOHsrlV879bOKoiZXAiCLNTHuY5fRfXjCUrx1TSh04wgcMA3Oejzj6I5UMks-xUy4ulCSoakQC11wq2C3GGFlykLwqwGcgL1v2Bpl30QZO5ZA/s1920/DSC01619.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhwvl2X_rsrrWNGoTJ7mG4_uLs-J05f7SoaGv_Kjm-nyUlHsyEsXt37lSgASSNT2VVz_Yvowxoh9CA8HcOHsrlV879bOKoiZXAiCLNTHuY5fRfXjCUrx1TSh04wgcMA3Oejzj6I5UMks-xUy4ulCSoakQC11wq2C3GGFlykLwqwGcgL1v2Bpl30QZO5ZA/s320/DSC01619.JPG" width="320" /></a></div><br /><div>DSC01619 view from the bottom of the "modified maximum length" heat sink in place. A wider heat could be used.</div><div><br /></div><div><br /></div><div>A more elegant heatsink was later machined from a second piece in which only the fins were removed in the area of the box fans. </div><div><br /></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjosvVzm64okoXbqNGZExEBCnc7HtXNFENhvoBn6w27bL6-LIBZ7ZunmLpC3GBaSLMjGU3XVdjjtvnHonkcwMaayzxLIudVoQDNdBWwLbLV7Xy1FRhUsQu5XXuSDpvX584AiuX-ee7DA08sRlaXLbj32cmci4zQkto1hFuhEpsYHvCjGMQkZPV4ttZl1w/s1920/DSC01571.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjosvVzm64okoXbqNGZExEBCnc7HtXNFENhvoBn6w27bL6-LIBZ7ZunmLpC3GBaSLMjGU3XVdjjtvnHonkcwMaayzxLIudVoQDNdBWwLbLV7Xy1FRhUsQu5XXuSDpvX584AiuX-ee7DA08sRlaXLbj32cmci4zQkto1hFuhEpsYHvCjGMQkZPV4ttZl1w/s320/DSC01571.JPG" width="320" /></a></div><div><br /></div>DSC01571 showing a smaller heat sink (7" L x 8.5" W x 1.25" D with 1.0" fins) which allows for both cooling fans to be located internally without modifying the heat sink (as in DSC01619 above). Replacement of the fans in this configuration would also be expected to be easier then in the case of DSC01619. <div><br /></div><div><span style="font-size: xx-small;">Edited 3/24/2023</span></div><div><br /></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhCQdaSJGXhgXN_OeOJW0wcxUuYp07hsPL0C-HfxkEzkwO8DKIn176Ky-sQFwFUkF7mEM0BzZ7TLPEYh-vcV5XKEkDbGSQDDZ52Q4-uVXreXrElE2wmBzOjs7Q-X2A_MN-mUBA_6bano5BRneuvDHI04gjaOK3PFaPLbx1e_Vxe79YqXRwBaT48sf_mgA/s1920/DSC01639.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhCQdaSJGXhgXN_OeOJW0wcxUuYp07hsPL0C-HfxkEzkwO8DKIn176Ky-sQFwFUkF7mEM0BzZ7TLPEYh-vcV5XKEkDbGSQDDZ52Q4-uVXreXrElE2wmBzOjs7Q-X2A_MN-mUBA_6bano5BRneuvDHI04gjaOK3PFaPLbx1e_Vxe79YqXRwBaT48sf_mgA/s320/DSC01639.JPG" width="320" /></a></div><br /><div>DSC01639 Closeup of the side of the heatsink shown in DSC01571 above. The heatsinks are generally not flat and there is a slight curvature. To obtain a precision contact surface between the heatsink and the controller base, the heatsinks must be machined perfectly flat prior to installation.</div><div>.</div><div><span style="font-size: x-small;">Edited 3/25/2023</span></div><div><br /></div><div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh5GcRqrLAAB0lvw9X0fS8OjH_9Gbb6o17_86iBBDSeGkFrjebNXL-FDwDRqVShQrpH6IVodjv9xS_w_zSV7QosWo7NZdNtDRNikuYd27HQa5J-e7-6E_qifApae0gE2c1G6VOMBvieUVXS87geiNvIMPFcA_J7MgOfR8avUvDIHI71RFDYUvzGPP6O5A/s1920/DSC01654.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh5GcRqrLAAB0lvw9X0fS8OjH_9Gbb6o17_86iBBDSeGkFrjebNXL-FDwDRqVShQrpH6IVodjv9xS_w_zSV7QosWo7NZdNtDRNikuYd27HQa5J-e7-6E_qifApae0gE2c1G6VOMBvieUVXS87geiNvIMPFcA_J7MgOfR8avUvDIHI71RFDYUvzGPP6O5A/s320/DSC01654.JPG" width="320" /></a></div><br />DSC01654 Closeup view of heatsink shown in DSC01571. The 1.25" x 1.25" x 0.125" Aluminum angle was cut to 9" length and drilled for attachment to the heatsink and the mounting surface. </div><div><br /></div><div><br /></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiJRv1S2tNDJL5VcX9m2vglTTiv2SugYzAUQ_4ipobHkugWVycEEpnHjwpRa8_YusnvVQRT1mFHymELRfabcJO6LU4RpU9KurrbGRfoRZRZ5a_HMthR56GJYOi4afGU-ompxy0kg_MZrzskn6vJMPBh_6GogMBk04uxWKzJReGmnLBT-Jragkvz_CJNBA/s1920/DSC01653.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiJRv1S2tNDJL5VcX9m2vglTTiv2SugYzAUQ_4ipobHkugWVycEEpnHjwpRa8_YusnvVQRT1mFHymELRfabcJO6LU4RpU9KurrbGRfoRZRZ5a_HMthR56GJYOi4afGU-ompxy0kg_MZrzskn6vJMPBh_6GogMBk04uxWKzJReGmnLBT-Jragkvz_CJNBA/s320/DSC01653.JPG" width="320" /></a></div><div><br /></div><div>DSC01653 Back side surface of heatsink shown in DSC01571 above. Heatsink base is is 9" x 7.25" and the overall height is about 1.305". </div><div><br /></div><div><br /></div>Williamhttp://www.blogger.com/profile/13072555311952861298noreply@blogger.com0tag:blogger.com,1999:blog-576268040829288449.post-27674697800631991342023-02-23T09:17:00.007-08:002023-02-23T10:16:40.265-08:00Motor Surrogate - 8" PVC Pipe<p>The Hyper9 weighs about 120 pounds and it is a challenge when moving it around the shop. The Hyper9 extruded Aluminum housing was measured to have an actual diameter of 22.0 cm (8.66 inches) and a body length (from edge of fins to edge of fins with the end caps removed) of 27.0 cm or 10.63 inches.</p><p>Standard 8" PVC pipe has an OD of about 8.625". Bushnell (847-297-4510 at 2110 Oxford Road, Des Plains, Illinois 60018) stocks 5 foot lengths of 8" PVC at $19.52 per foot and we were able to cut several 12" lengths for our own use. The weight of the surrogate and the pair of cradles is 12.44 pounds (5.65 kg).</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiT9qFfB4oG-Gi-9f88kHmJEEcjKTT3_6R3gBfdLBq8xzT7MKNW4TwCG-lZghen4ttH_u7IpjoGXX7zzVy5aXJ7Y58gasNyQNXThvJsq76w8VzJmVjVvG6sHzT3gNjhiN0OW8Bav_lE5esnW2lkZKuxo5vt57NK8ZbuJ7FT8vsvsQ5jqID__lmRcu0kwQ/s1920/DSC01618.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiT9qFfB4oG-Gi-9f88kHmJEEcjKTT3_6R3gBfdLBq8xzT7MKNW4TwCG-lZghen4ttH_u7IpjoGXX7zzVy5aXJ7Y58gasNyQNXThvJsq76w8VzJmVjVvG6sHzT3gNjhiN0OW8Bav_lE5esnW2lkZKuxo5vt57NK8ZbuJ7FT8vsvsQ5jqID__lmRcu0kwQ/s320/DSC01618.JPG" width="320" /></a></div><p>DSC01618 showing a Hyper9 PVC surrogate with attached cradle mounts (as shown it weighs 12.44 pounds). The surrogate can be positioned within the engine compartment using stiff wire or blocks of wood without the danger of dropping a heavy Hyper9. Estimates can then be made as to how the car's engine mounts (or frame) can be incorporated into the build. </p>Williamhttp://www.blogger.com/profile/13072555311952861298noreply@blogger.com0tag:blogger.com,1999:blog-576268040829288449.post-16620452501850806832023-02-22T11:01:00.002-08:002023-02-22T11:01:59.025-08:00Hyper9 SME Controller Box - 1<p> </p><p>A box measuring 12" (W) x 10.25" (D) x 6" (H) was fabricated using 0.067" <span color="inherit" face="Roboto, arial, sans-serif" style="background-color: white; font-size: 16px;">5052 H32 Aluminum</span>. The corners were welded and two lids were prepared, one solid and one transparent to allow for viewing.</p><p><br /></p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjzQtd_sFm-dsbfSL7Nx8hNUJEdXsMMyHZQ6CmcRFXX55cxoJI3OXNfegdmCz0CIldv35dLBEQtk_AWJ5W8ZKRjGtX4ICKc6gl_PDxKZ9NhbnWJvk072UqUXXPBOsu2MtvJnFnAiXZfIuCA1kQe8vRyGJFclpAzkSr_7-pcVR5UhgXJVRlNVLlVQf1yJw/s1920/DSC01603.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjzQtd_sFm-dsbfSL7Nx8hNUJEdXsMMyHZQ6CmcRFXX55cxoJI3OXNfegdmCz0CIldv35dLBEQtk_AWJ5W8ZKRjGtX4ICKc6gl_PDxKZ9NhbnWJvk072UqUXXPBOsu2MtvJnFnAiXZfIuCA1kQe8vRyGJFclpAzkSr_7-pcVR5UhgXJVRlNVLlVQf1yJw/s320/DSC01603.JPG" width="320" /></a></div><br />DSC01603 View from the top showing the Aluminum control box with the plastic window installed. The bus bars will penetrate the left side and a cowling will be added over the terminals to prevent a shock hazard. There is plenty of room within the box to include a contactor, main fuse, shut off, USB port (for communication and programming), and support wiring, etc. High voltage power to B+ and B- will be brought in through the side of the box with shielded cables and a water tight gland. A 350 amp plug/connector will allow for connection to the test workbench or connection to the battery pack in the car. <p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgQot08uQ6AKbPKEb8fi5fg9lxAWZwWsC5lP0idozUbKuYzQcQ0TnhB0t3Tep3NhCnwmOebNtYPpaz3RDk8wukuZ67Z71sCM1M11zJPfWMklf7vZTUJcA6uffHGm4Jn1yYlxADi0F4eUgkFPQ09MAXU9ZLWPSo6K7i3hQV3WHLBys7BaEkUjHnkl0HgYg/s1920/DSC01605.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1920" data-original-width="1080" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgQot08uQ6AKbPKEb8fi5fg9lxAWZwWsC5lP0idozUbKuYzQcQ0TnhB0t3Tep3NhCnwmOebNtYPpaz3RDk8wukuZ67Z71sCM1M11zJPfWMklf7vZTUJcA6uffHGm4Jn1yYlxADi0F4eUgkFPQ09MAXU9ZLWPSo6K7i3hQV3WHLBys7BaEkUjHnkl0HgYg/s320/DSC01605.JPG" width="180" /></a></div><br /><div class="separator" style="clear: both; text-align: center;">DSC01605 end on view of the control box.</div><div class="separator" style="clear: both; text-align: center;"><br /></div><div class="separator" style="clear: both; text-align: center;"><br /></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhQTAazRxmq0uX5WjdPLSxNEwBunXwoMJCJXKhaXQoStJ_gOHxI4kU97Qr5wOZrc4rhnc4BaUKOcY-ex54VwvitVOfuvNbTwlfAh2dVwfqzv8g9Ke9-Rz0obAkEg0GrGBb_4bdL9BnD3ipKpKskPkxtPYXpqBi_i8A-1C_ke80zUJOmmzSgfw7OgFb99A/s1920/DSC01606.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhQTAazRxmq0uX5WjdPLSxNEwBunXwoMJCJXKhaXQoStJ_gOHxI4kU97Qr5wOZrc4rhnc4BaUKOcY-ex54VwvitVOfuvNbTwlfAh2dVwfqzv8g9Ke9-Rz0obAkEg0GrGBb_4bdL9BnD3ipKpKskPkxtPYXpqBi_i8A-1C_ke80zUJOmmzSgfw7OgFb99A/s320/DSC01606.JPG" width="320" /></a></div><br /><p>DSC01606 oblique view of the control box. The lid is secured with eight 4-40 screws that use PEM steel press-fit nuts for sheet metal (McMaster 95185A125 at $12.68 for 50)</p><p><br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgPRf_sLdqLC96f_hnOu-bGicafRi1tyHiouZUX1TF_W9-A5oxvkVUgjo0V1a21bH3aaDbeN1Y83sjk6bKLPvVQhtXYO9nI-NKASDfVlehfElV4pZ2nwwdcBId1sqz4jc0lxWm8M6jqiJA2FWo2TrkUEP_e5Cq0pQIhf-KWUoE61y8SA-g1iaGAcX4xQA/s1920/DSC01607.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgPRf_sLdqLC96f_hnOu-bGicafRi1tyHiouZUX1TF_W9-A5oxvkVUgjo0V1a21bH3aaDbeN1Y83sjk6bKLPvVQhtXYO9nI-NKASDfVlehfElV4pZ2nwwdcBId1sqz4jc0lxWm8M6jqiJA2FWo2TrkUEP_e5Cq0pQIhf-KWUoE61y8SA-g1iaGAcX4xQA/s320/DSC01607.JPG" width="320" /></a></div><br /><p>DSC01607 closeup of the press fit female steel press-fit nuts that were used to secure the lids to the controller box. A shop press was used to insert the nuts. 4-40 is probably too small and in the next build a slightly larger bolt and press-fit nut will be used. </p>Williamhttp://www.blogger.com/profile/13072555311952861298noreply@blogger.com0tag:blogger.com,1999:blog-576268040829288449.post-9143736347057404192023-02-22T10:50:00.022-08:002023-05-20T09:31:01.908-07:00Wiring Options to Connect Hyper9 Controller to the Hyper9 Motor Using A Support<p></p><div class="separator" style="clear: both; text-align: center;"><br /></div><div><br /></div><div><br /></div><div><br /></div><div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj3cBaZc28X0rO_UzJWfsg73VDu1bHibnVxMKyPl75fusEb_gwwCPScoD6yWgw91rIqCkM8SZFWaTsxfe-2Kd6Mag83ug7AqUacnkVXc15uLJDLxMbEfY7H10SJTJ2N7mi4B8_MOJmomP7Pdx4dK1o3o1v7tlT5QbOVGbLP3I2AINkTfV9EyUAEZ3i8DQ/s1920/DSC01617.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj3cBaZc28X0rO_UzJWfsg73VDu1bHibnVxMKyPl75fusEb_gwwCPScoD6yWgw91rIqCkM8SZFWaTsxfe-2Kd6Mag83ug7AqUacnkVXc15uLJDLxMbEfY7H10SJTJ2N7mi4B8_MOJmomP7Pdx4dK1o3o1v7tlT5QbOVGbLP3I2AINkTfV9EyUAEZ3i8DQ/s320/DSC01617.JPG" width="320" /></a></div><br /></div><div>DSC01617 showing one of a pair of box fan covers that were added to the support (McMaster cat 19155K96, at $1.84 each). <span style="font-size: x-small;">edited 2/23/2023</span></div><div><span style="font-size: large;"><br /></span></div><div><span style="font-size: large;">Use of Copper Bus Bars and Rods - No Brake Press Required</span></div><div><span style="font-size: large;"><br /></span></div><div class="separator" style="clear: both; text-align: center;">In an effort to decrease the footprint of the power cables, copper bus bars were considered. One can either bend a series of bars, or use bus bars and 5/8" copper rods (standoffs) that elevate the motor terminals into the plane of the controller terminals.</div><br /><div><br /></div><div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjIp3Dz6dvDa8v1cZu2Oya8el2dOzW7VEo2vrqQqabHemFG8thNiAitKBPXi9sUlxQVnWth8WoIbbTiBdOu9YeXqVX3pjTGL4XF6XamrdyuzlITED_qVwyaJWPfiHESMpvzm3Kqa640yTQoM9abv9PfmWpN5s2z73UuXET7KbVCixxQoz6aF88Sf521-g/s1920/DSC01595.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1920" data-original-width="1080" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjIp3Dz6dvDa8v1cZu2Oya8el2dOzW7VEo2vrqQqabHemFG8thNiAitKBPXi9sUlxQVnWth8WoIbbTiBdOu9YeXqVX3pjTGL4XF6XamrdyuzlITED_qVwyaJWPfiHESMpvzm3Kqa640yTQoM9abv9PfmWpN5s2z73UuXET7KbVCixxQoz6aF88Sf521-g/s320/DSC01595.JPG" width="180" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><span style="text-align: left;">DSC01595 of the three 5/8" OD copper rods that were drilled and tapped for M10-1.5 with 13 mm depth at the bottom, and M8-1.25 with 13 mm depth at the top. M10-1.5 x 30 mm stainless steel studs (McMaster 93805A425 at $3.09 each) completed the bottom installation (25 mm length was found to be too short).</span></div></div><div class="separator" style="clear: both; text-align: center;"><span style="text-align: left;"><br /></span></div><div class="separator" style="clear: both; text-align: center;"><span style="text-align: left;"><br /></span></div><div><br /></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjhCDr6VEXpDqDqoO-IHf-Cw5T2OgEjxgevYlaq4Dxdghzkhg_fLQVjGrB6MHVlYDrlauQbu0EewgynbSfoQA2xlaPgZuWelGokcNlGOmjIp4eKnfU4lTbQvjR3X3VzIGpNSoGfzfpmp0eLxd5cWnQr9I4mfOvP8qr6CWGVK678UZnJikOZSTUWDyD04g/s1920/DSC01599.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjhCDr6VEXpDqDqoO-IHf-Cw5T2OgEjxgevYlaq4Dxdghzkhg_fLQVjGrB6MHVlYDrlauQbu0EewgynbSfoQA2xlaPgZuWelGokcNlGOmjIp4eKnfU4lTbQvjR3X3VzIGpNSoGfzfpmp0eLxd5cWnQr9I4mfOvP8qr6CWGVK678UZnJikOZSTUWDyD04g/s320/DSC01599.JPG" width="320" /></a></div><br /><div>DSC01599 showing a mock up of possible bus bars that would be "L" shaped. Even with the excess copper at the corners trimmed off, the corners extend significantly out to the side and they will be more difficult to enclose later.</div><div><br /></div><div><div><span style="font-size: xx-small;">Edited 2/28/2023</span></div><div><br /></div><div>Purchased a remnant of 0.125" Copper plate that was 2.25 x 24.0" (ALRO Outlet for $25.08 includes $7.00 cut charge.)</div><div><br /></div><div>Using the Copper Rods and Bus bar design above, cut out a pair of cardboard templates and trial fit them to the motor. Laid out the templates on the Coper plate to maximize the use of the smooth factory edge (DSC01620)</div></div><div><br /></div><div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgmltGanaMaVRs36AfcTS3VZWp2C5gQBLR6E0SEG9OATZLptLdlxrq0quUmTdPBAKN8ISx-nBSMPFbfNlRDO1K6m1qKGYcQ_zCN1_AyQDmNTxuUmrDI6rtvMQ0uAG9GfMwyao_30b1IZmXQaOhNL1je2T5ketROLo7KPPTHC1vEId_bS4RnURfxknEfYg/s1920/DSC01620.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="225" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgmltGanaMaVRs36AfcTS3VZWp2C5gQBLR6E0SEG9OATZLptLdlxrq0quUmTdPBAKN8ISx-nBSMPFbfNlRDO1K6m1qKGYcQ_zCN1_AyQDmNTxuUmrDI6rtvMQ0uAG9GfMwyao_30b1IZmXQaOhNL1je2T5ketROLo7KPPTHC1vEId_bS4RnURfxknEfYg/w400-h225/DSC01620.JPG" width="400" /></a></div><br /><div>DSC01620 showing the cardboard templates positioned on the Copper plate prior to bandsaw cutting.</div></div><div><br /></div><div><br /></div><div><div>Attached Avery TrueBlock Shipping Label 5165 sheet to Copper plate for ease of marking part outline. </div><div><br /></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjBw21qG6-yoBtob0lVr68Vu5UjN_IK15_YpV8K1aaaHqGpkpEpLAfq3I4p5JIahyUIhWtSZ1MeP7uT35qVLwRnhq84so7Ffwz4fZFy1EhhlwPH0OVx1flZDYz8cq4eW9oUGF48CmlhVeVPTf2GRigu-bTSeKxZGAEJ5F2FHHb7ooyHtxaeTR1-Mzwa5g/s1920/DSC01621.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="360" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjBw21qG6-yoBtob0lVr68Vu5UjN_IK15_YpV8K1aaaHqGpkpEpLAfq3I4p5JIahyUIhWtSZ1MeP7uT35qVLwRnhq84so7Ffwz4fZFy1EhhlwPH0OVx1flZDYz8cq4eW9oUGF48CmlhVeVPTf2GRigu-bTSeKxZGAEJ5F2FHHb7ooyHtxaeTR1-Mzwa5g/w640-h360/DSC01621.JPG" width="640" /></a></div><br /><div><br /></div><div>DSC01621 closeup of the Copper plate after drawing part outline. Longest length (upper right) positioned to take advantage of the smooth factory edge </div><div><br /></div><div><br /></div><br /><div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj1DzWU5qBdg_OarJXOHzsWsm8nQoo79ZCbU9x426SZRV4VHptD6DJ_EUnmMtQOyVKPP6ztgf48OSk7fTNz_jHxdpfkQ4Atg22_DluOo5wdjD-Pc0tcs0bRHpzhPNCOAkZGHp6E8HAnIynnB3aMmyBTAx2RFfTNs7Yi8mPanYSOHEFqdrMTm9lXB_FEoA/s1920/DSC01753.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="360" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj1DzWU5qBdg_OarJXOHzsWsm8nQoo79ZCbU9x426SZRV4VHptD6DJ_EUnmMtQOyVKPP6ztgf48OSk7fTNz_jHxdpfkQ4Atg22_DluOo5wdjD-Pc0tcs0bRHpzhPNCOAkZGHp6E8HAnIynnB3aMmyBTAx2RFfTNs7Yi8mPanYSOHEFqdrMTm9lXB_FEoA/w640-h360/DSC01753.JPG" width="640" /></a></div><br /></div><div>DSC01753 Line drawing of Copper bus bar. <span style="font-size: x-small;">Updated 4/29/2023</span></div></div><div><br /></div><div><br /></div><div><br /></div><div><br /></div><div><span> </span><span> </span><span> </span><span> </span><span> </span><span> </span><span> </span><span> </span><span> </span><span> </span><span> </span><span> </span><span> </span><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhis3YMKmDNnxIdjsWt1XuYz6yqIeyjzhMLDC4UE6EkU8e5PGCwJ_tE1ObeM0cqVpthnOSEfJSEFUiLkN_SQu9uVCo3AetdnQ32RsJKCTf_wqeifhPJ1RrepTpXcr0-Ye6KLOUHLei8DVekeLqtTEUfdNqTYdh2gjUQOMzUJ7MRHL6LTIY5fqztnTlJyg/s1920/DSC01597.JPG" style="margin-left: 1em; margin-right: 1em; text-align: center;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhis3YMKmDNnxIdjsWt1XuYz6yqIeyjzhMLDC4UE6EkU8e5PGCwJ_tE1ObeM0cqVpthnOSEfJSEFUiLkN_SQu9uVCo3AetdnQ32RsJKCTf_wqeifhPJ1RrepTpXcr0-Ye6KLOUHLei8DVekeLqtTEUfdNqTYdh2gjUQOMzUJ7MRHL6LTIY5fqztnTlJyg/s320/DSC01597.JPG" width="320" /></a></div><div><br /></div><div>DSC01597 showing one of a series of manila folder templates that were cut out and tested during trial fittings. </div><div><br /></div><div><br /></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjHDJL1CLIeA-Js4BaGo8fTjXrlxobwXojviNTGxMVEX43DYs2Y84IOJXPquhDUbbe5FIogDyzEE3A2Z2Jav_PoKIpk3CXk6jEJYYjQEN9wOSs6fwdcePHOLosqKb51jdxifW2gPSyijQg1bozamIsUwCEgrzOeo3OhYV14JsRXNyPOwxelTZeLEXXeWA/s1920/DSC01615.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjHDJL1CLIeA-Js4BaGo8fTjXrlxobwXojviNTGxMVEX43DYs2Y84IOJXPquhDUbbe5FIogDyzEE3A2Z2Jav_PoKIpk3CXk6jEJYYjQEN9wOSs6fwdcePHOLosqKb51jdxifW2gPSyijQg1bozamIsUwCEgrzOeo3OhYV14JsRXNyPOwxelTZeLEXXeWA/s320/DSC01615.JPG" width="320" /></a></div><br /><div>DSC01615 view showing the three bus bars installed. </div><div><br /></div><div><br /></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgKkJqhlW9ZpMSzXwFWgci08G0-cx_SrKaz3VPagAXOLye4emVCk7fA6fhFARzJd7lh_KArCVk9qXJ_V-bz7W5S2yMlj8FpRezurQVgT6DcjypfAupl0bklvjFD_CBpUGYNSu-LUHIObwtReKLyrSTrpOPovcLFoMaA50EkX2U8r7a05zeWj30TE31Ylw/s1920/DSC01613.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1920" data-original-width="1080" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgKkJqhlW9ZpMSzXwFWgci08G0-cx_SrKaz3VPagAXOLye4emVCk7fA6fhFARzJd7lh_KArCVk9qXJ_V-bz7W5S2yMlj8FpRezurQVgT6DcjypfAupl0bklvjFD_CBpUGYNSu-LUHIObwtReKLyrSTrpOPovcLFoMaA50EkX2U8r7a05zeWj30TE31Ylw/s320/DSC01613.JPG" width="180" /></a></div><br /><div>DSC01613 end view of bus bars and rods. If used, the corners will later be rounded.</div><div><br /></div><div><br /></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjAMonumIHzvoUoE84wGiKjCqPjCx7vEZaYmQypTtoUhspj_0nGCI074l5L9_o5eUxRskpXwgAcheKHVP7EMmHY1okoRUd9p6XSizbrAzrcojhxig1NIVUSBs6XXHFWpe6TG2Cofdm2YYaMTjn8hGfg78efBqkq0PH_dYxBk_KzCzWLD2dgSu30LKhVFw/s1920/DSC01614.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjAMonumIHzvoUoE84wGiKjCqPjCx7vEZaYmQypTtoUhspj_0nGCI074l5L9_o5eUxRskpXwgAcheKHVP7EMmHY1okoRUd9p6XSizbrAzrcojhxig1NIVUSBs6XXHFWpe6TG2Cofdm2YYaMTjn8hGfg78efBqkq0PH_dYxBk_KzCzWLD2dgSu30LKhVFw/s320/DSC01614.JPG" width="320" /></a></div><br /><div>DSC01614 top view of Copper bus bars and rods. These "angled" bus bars do not extend excessively from the midline. A box enclosure will be added that is mounted to the top of the motor, the side of the controller box, and the Aluminum support plate. Before installation the bus bars will be tinned, covered with heat shrink tubing as needed, and then slipped into fiberglass insulation. </div><div><br /></div><div><br /></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgdIHYQWVWlh1pdCqULsCPp2od28xZF8tvqk3Z8G--ht0IJxBFmw40k-DIGTxSIt7goO31dgr8jurry54VyE-dHCp0GM17UlwY6CDkWAbWGnt6AWDla2AujPwUgl_nR5B5xzLyLy61itkr4y67llm9dKFaSs0JrJTP4CSzcPK60meO-xAGDLVqCid6cvA/s1920/DSC01765.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgdIHYQWVWlh1pdCqULsCPp2od28xZF8tvqk3Z8G--ht0IJxBFmw40k-DIGTxSIt7goO31dgr8jurry54VyE-dHCp0GM17UlwY6CDkWAbWGnt6AWDla2AujPwUgl_nR5B5xzLyLy61itkr4y67llm9dKFaSs0JrJTP4CSzcPK60meO-xAGDLVqCid6cvA/s320/DSC01765.JPG" width="320" /></a></div><div><br /></div><div>DSC01765 showing the Aluminum test pieces.</div><div><br /></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhnlDjqr6__BHKyGkGhhqj4kpvmLT10CkEbIDaYh_m4K9o1TYmiOa4Il2lAAyap050SkIirRV8m6ke7vN5VaieZ86idlT2Q-bgmBj5og7j_N7OlhlLavXQlZG9GeH4h23YiHJfY_neGZCwaVtk5U4vx97Pc3u-2S1g7lx4RJDhxhzSoODfOjBo9QqYL_A/s1920/DSC01767.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhnlDjqr6__BHKyGkGhhqj4kpvmLT10CkEbIDaYh_m4K9o1TYmiOa4Il2lAAyap050SkIirRV8m6ke7vN5VaieZ86idlT2Q-bgmBj5og7j_N7OlhlLavXQlZG9GeH4h23YiHJfY_neGZCwaVtk5U4vx97Pc3u-2S1g7lx4RJDhxhzSoODfOjBo9QqYL_A/s320/DSC01767.JPG" width="320" /></a></div><div><br /></div><div>DSC01767 close up of the angle in the Aluminum test pieces. <span style="font-size: x-small;">updated 5/16/2023</span></div><div><br /></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhl9dCyNwjmbcHuOE6yhEiEhVNKKoKdT4Q5NMNCf1WeNTfZ7sJnNEfoqTpPu9DHn8g12VxdV1L4jdDnM8KDQkSOrbQBWScYFb7vf121hCnJUQouBRRvFw39HEH5YuJGknvfjQ5FBxUkypn5iYzJVap8QZ-BlwuSduFbofGmhrPLH3S7aeIyNjZQf83BYA/s4032/IMG_6590%20%20PB%20Copper%20Bus%20Bar%20Prep.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhl9dCyNwjmbcHuOE6yhEiEhVNKKoKdT4Q5NMNCf1WeNTfZ7sJnNEfoqTpPu9DHn8g12VxdV1L4jdDnM8KDQkSOrbQBWScYFb7vf121hCnJUQouBRRvFw39HEH5YuJGknvfjQ5FBxUkypn5iYzJVap8QZ-BlwuSduFbofGmhrPLH3S7aeIyNjZQf83BYA/s320/IMG_6590%20%20PB%20Copper%20Bus%20Bar%20Prep.jpeg" width="320" /></a></div><br /><div>IMG-6590 of the Copper plate on the plasma cutting table. <span style="background-color: white; color: #222222; font-family: Arial, Tahoma, Helvetica, FreeSans, sans-serif; font-size: 13.2px;">( Bart's Precision Machinery and Fab )</span></div><div> </div><div><br /></div><div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEidF52gxqGpaWu-sdopLyCQIh9XrrLU-b7C95AEW3Q67R3ZQw3zwY8CgYviwsrJEMI3FVt0iZt8l7x-sEmjZK85YPRbN8_z4zsn-OEVggAPVHHxRHDlH7vfDvNGR6XBcj0Ksh-mfFMPExKMWWZBc26X-EtJ8En4SQb0GIxoULt_qpQJrWS_r3h3lB2Lig/s1920/DSC01790.JPG" style="margin-left: 1em; margin-right: 1em; text-align: center;"><img border="0" data-original-height="1080" data-original-width="1920" height="225" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEidF52gxqGpaWu-sdopLyCQIh9XrrLU-b7C95AEW3Q67R3ZQw3zwY8CgYviwsrJEMI3FVt0iZt8l7x-sEmjZK85YPRbN8_z4zsn-OEVggAPVHHxRHDlH7vfDvNGR6XBcj0Ksh-mfFMPExKMWWZBc26X-EtJ8En4SQb0GIxoULt_qpQJrWS_r3h3lB2Lig/w400-h225/DSC01790.JPG" width="400" /></a></div><div><br /></div><div><div><br /></div><div><div>DSC01790 The holes in the 0.125" thick Copper washers (picture IMG-6590 above) for the M8-1.25 bolts were drilled to 5/16" and the holes in the Copper washers for M10-1.5 bolts were drilled to 13/32". <span style="font-size: x-small;">updated 5/16/2023</span></div></div><div><br /></div><div><br /></div><div>Copper washers were plasma cut from scrap 0.125" Copper plate (picture IMG-6590 above). M8 washers can be used to correct for a vertical bus bar height that is too long, and the M10 Copper washers can correct for a bus bar whose vertical height is too short. <span style="font-size: x-small;">updated 5/18/2023</span></div><div class="separator" style="clear: both; text-align: center;"><br /></div></div><div><br /></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgGPY93mZ8eGL8ib5Si-IgSy80_fWBZdL0IYw5hbW5a6DBk2ulyTiLaeW5-TQAOhsQO13G5wAVrkLuYKZCyuJI_NldJIBvammSmsGVRixl5WhQOZxfqx2vIQhrCwy0Eap4EOqoVP-D7gPQZwqyJv7A9cTbfmd2LFVjdQENo-hsD1sSFVlxe1HkhsrvnpA/s1920/DSC01768.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgGPY93mZ8eGL8ib5Si-IgSy80_fWBZdL0IYw5hbW5a6DBk2ulyTiLaeW5-TQAOhsQO13G5wAVrkLuYKZCyuJI_NldJIBvammSmsGVRixl5WhQOZxfqx2vIQhrCwy0Eap4EOqoVP-D7gPQZwqyJv7A9cTbfmd2LFVjdQENo-hsD1sSFVlxe1HkhsrvnpA/s320/DSC01768.JPG" width="320" /></a></div><div><br /></div><div>DSC01768 </div><div><br /></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgQJiX1AO4edoIXnxQbOOwfV1elcHo8vUsckEZRERvnDubWuqOMf4zdBZgzwcp8J66q2mON9_nxCN-rDYfeWO3a8SFPZH2uiifXd3yN0pvCP-VAb5bbhWGlMmjuNDdeHkxJFATgE1Hb20d4RIMDKItw4m4JP5Z6lzhPb40mf1kwq2TaapmLRxeMjORweA/s1920/DSC01775.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgQJiX1AO4edoIXnxQbOOwfV1elcHo8vUsckEZRERvnDubWuqOMf4zdBZgzwcp8J66q2mON9_nxCN-rDYfeWO3a8SFPZH2uiifXd3yN0pvCP-VAb5bbhWGlMmjuNDdeHkxJFATgE1Hb20d4RIMDKItw4m4JP5Z6lzhPb40mf1kwq2TaapmLRxeMjORweA/s320/DSC01775.JPG" width="320" /></a></div><br /><div>DSC01775 showing the area covered by the long bus bars.</div><div><br /></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi6Pi5DfE97Rlq4dPTZOD7ARs0uNVErm_Taj7hbPUjuKBx62cE5vylW3IcOj3kRnkud0nmYT6WcxQf1PKVur3nf3NzFLQsBR5NwUaQDpqtglkk7vI7MhVNPDRfRUJF3GPDCVtH84vH-jbiPw3hqr6dpw7xOmBEsMH2lhzXEWehMfWIWSf-bCvH2IQoSLA/s1920/DSC01778.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi6Pi5DfE97Rlq4dPTZOD7ARs0uNVErm_Taj7hbPUjuKBx62cE5vylW3IcOj3kRnkud0nmYT6WcxQf1PKVur3nf3NzFLQsBR5NwUaQDpqtglkk7vI7MhVNPDRfRUJF3GPDCVtH84vH-jbiPw3hqr6dpw7xOmBEsMH2lhzXEWehMfWIWSf-bCvH2IQoSLA/s320/DSC01778.JPG" width="320" /></a></div><br /><div>DSC01778 showing the use of short bus bars. These bars do not need to cross over the top of the controller and each one uses less Copper. But, these short bars would require that the motor terminals U and W be reprogrammed prior to use.</div><div><br /></div><div><br /></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjLG2EyOWy3AIMAv7-YPEz2uG8ytheQR_2-Wg0Iw3a17_nQCL3EVQPXjT1eQEQWPv6xweCi_Fer1bYA0EBDpXP-UNJ4IQN5sL0wCn65-Wvp-MLcSJl_RKR3BrIIWyQRrZ3fRlyJfD3GzzZRPiLkdTjjakrvRR4p1EILheAwJqACBDKQGJGNtpgkqu_Rtw/s1920/DSC01779.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjLG2EyOWy3AIMAv7-YPEz2uG8ytheQR_2-Wg0Iw3a17_nQCL3EVQPXjT1eQEQWPv6xweCi_Fer1bYA0EBDpXP-UNJ4IQN5sL0wCn65-Wvp-MLcSJl_RKR3BrIIWyQRrZ3fRlyJfD3GzzZRPiLkdTjjakrvRR4p1EILheAwJqACBDKQGJGNtpgkqu_Rtw/s320/DSC01779.JPG" width="320" /></a></div><br /><div>DSC01779 showing that the existing pre-charge terminal would be covered by the short bus bars. If the pre-charge terminal can be relocated to a vacant area of the controller, then these short bus bars might be used. </div><div><br /></div><div><br /></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEihSk4UVA6ELOYb-gsm1fud0DLqaoOtIHeP1w83r59ZqlmLMZ5QpUF2usOj4QaRvo6NS_135SaBQ5ls1guMEfqwim1MjHvYlWXIWRuHk1Mrkl9naTbfGb7IQRfJMWMXmltYBIXlQ9t_pdjw4UkBbpHlKJyL_yUKCIosIr_L_gnHzYT0f20pVPrwBRiHUQ/s1920/DSC01816.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="360" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEihSk4UVA6ELOYb-gsm1fud0DLqaoOtIHeP1w83r59ZqlmLMZ5QpUF2usOj4QaRvo6NS_135SaBQ5ls1guMEfqwim1MjHvYlWXIWRuHk1Mrkl9naTbfGb7IQRfJMWMXmltYBIXlQ9t_pdjw4UkBbpHlKJyL_yUKCIosIr_L_gnHzYT0f20pVPrwBRiHUQ/w640-h360/DSC01816.JPG" width="640" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><br /></div><div>DSC01816 showing the terminal block found at the power end of the motor. The bottom block in the picture (when viewed from the end of the motor) is the OEM supplied orientation. During software installation and the motor set up process, the motor can be reprogrammed to reverse terminals W and U. The OEM “U” terminal becomes the new “W” terminal, and the
OEM “W” terminal becomes the new “U” terminal. A later post will discuss this process. To avoid confusion, the four bolts that secure the terminal block can be removed and the terminal block rotated 180 degrees to correspond to the new software assignments.</div><div><br /></div><div> </div><div><br /></div><div><br /></div><div><span style="font-size: x-large;">Use of Copper Bus Bars - Using a Brake Press</span></div><div><br /></div><div><br /></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhezfoJo3wJouUPljBOGp1d-swgc-y4MLUDNraeZq7HMXyvu__fWZAjgxl6Z-zyvl6hP6oP_25y8HDvPcukGUYmAvlbuSPmgfhi51owZYlLTvDhu8fvafcY2SkOfC5gm0QyQfwN2jAII2P30zvxsZz8fWH_9tJ0ECuhF4oamDekKSqhm_Nk2UDLhek7kA/s1920/DSC01804.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhezfoJo3wJouUPljBOGp1d-swgc-y4MLUDNraeZq7HMXyvu__fWZAjgxl6Z-zyvl6hP6oP_25y8HDvPcukGUYmAvlbuSPmgfhi51owZYlLTvDhu8fvafcY2SkOfC5gm0QyQfwN2jAII2P30zvxsZz8fWH_9tJ0ECuhF4oamDekKSqhm_Nk2UDLhek7kA/s320/DSC01804.JPG" width="320" /></a></div><br /><div>DSC01804 An Eastwood brake attachment ( https://www.eastwood.com/eastwood-press-brake-attachment.html ) was combined with a Premium Products 12 Ton Press ( provided by Peter Kola).</div><div><br /></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjJV44xzy_sHD-0z4EtrqdCeOZQRH6JUVUb9mr-fiqlR6hIkXCB3mxB1TPfuLEjntcZ5VXjucvfekdwPNmhn0QvAsYiM7uqXmPZAIXPpXKiVEoSikAi_eg_4P67go-wFGNGsixp_uNbrad7OUSePc631W4jM8srvJl6_ZFXgLzXUgnhCUjSFbwa2Ik3Xg/s1920/DSC01810.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1920" data-original-width="1080" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjJV44xzy_sHD-0z4EtrqdCeOZQRH6JUVUb9mr-fiqlR6hIkXCB3mxB1TPfuLEjntcZ5VXjucvfekdwPNmhn0QvAsYiM7uqXmPZAIXPpXKiVEoSikAi_eg_4P67go-wFGNGsixp_uNbrad7OUSePc631W4jM8srvJl6_ZFXgLzXUgnhCUjSFbwa2Ik3Xg/s320/DSC01810.JPG" width="180" /></a></div><br /><div>DSC01810 end view of the installed and contoured bus bars.</div><div><br /></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjq50FCDz5uuzIpAZ1MZAhx9lYEFUNMR2ipWJDhd4_b4G1GcUeDZIpfQIrnNba6mg5_yZvYmGZureMzoCdRNhqjmhxCRB6PXyul5or4TyL5zEpfl4KHabUL7W8BywM1ULFb3fprCcpiLfkGnSKxVL5XfSwg79-kjHDGxQHmcYutn85etllw_Ix3u9j6mA/s1920/DSC01811.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjq50FCDz5uuzIpAZ1MZAhx9lYEFUNMR2ipWJDhd4_b4G1GcUeDZIpfQIrnNba6mg5_yZvYmGZureMzoCdRNhqjmhxCRB6PXyul5or4TyL5zEpfl4KHabUL7W8BywM1ULFb3fprCcpiLfkGnSKxVL5XfSwg79-kjHDGxQHmcYutn85etllw_Ix3u9j6mA/s320/DSC01811.JPG" width="320" /></a></div><br /><div>DSC01811 top view of the installed and contoured bus bars.</div><div><br /></div><div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjpzeYS4EUWAwvIDqwNav4jZHu06hiUgzyGkFC0DIXb36nSCvZDdbvXrBvC-y3wiJR6x0E_ojtiZw1LE2D72RKH73ettrjEpgcsvo-TefUlKm1dNDWMblVkP6LT9XpyWm2_1MZb47RCiSntuKsJsysbStavHkrXiMWYSLoD7EwJw4FtaijULplYdu45kg/s1920/DSC01763.JPG" style="margin-left: 1em; margin-right: 1em; text-align: center;"><img border="0" data-original-height="1080" data-original-width="1920" height="360" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjpzeYS4EUWAwvIDqwNav4jZHu06hiUgzyGkFC0DIXb36nSCvZDdbvXrBvC-y3wiJR6x0E_ojtiZw1LE2D72RKH73ettrjEpgcsvo-TefUlKm1dNDWMblVkP6LT9XpyWm2_1MZb47RCiSntuKsJsysbStavHkrXiMWYSLoD7EwJw4FtaijULplYdu45kg/w640-h360/DSC01763.JPG" width="640" /></a></div><div><br /></div><div>DSC01763 showing the outlines of the required cuts on the Avery 5165 label paper. These cuts will allow the bus bars to pass though the side of the enclosure. </div><div><br /></div><div><br /></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj9VOTyNT-3EQPdza9basJ4UClA01qCv01JUvqguEIwiFlEJbNThBCwtR7QsgaSTJt6XNv5F70O0Ybo3vnAg1AgAgWumrmau5Os-cHidY40zyBOsnnrB8xM6Y9wPjM82iGvkrQzkceCQqHXJnnB_AWq4Nn4zzllVx6dbcCXCXM_9zuSdKll-YPsDOQOrg/s1920/DSC01813.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj9VOTyNT-3EQPdza9basJ4UClA01qCv01JUvqguEIwiFlEJbNThBCwtR7QsgaSTJt6XNv5F70O0Ybo3vnAg1AgAgWumrmau5Os-cHidY40zyBOsnnrB8xM6Y9wPjM82iGvkrQzkceCQqHXJnnB_AWq4Nn4zzllVx6dbcCXCXM_9zuSdKll-YPsDOQOrg/s320/DSC01813.JPG" width="320" /></a></div><br /><div>DSC01813 of the end caps (one was used) that were made from 0.063" Aluminum 5052.</div><div><br /></div><div><br /></div><div><br /></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj5O09y544CFAZivGuNPLVVycc-JKF5HgpzKfCWyhjOjNUHZjX3UbosZUmbq6wGqjAiR3tbYYjp797sLQOTS4OWiN4SpEpnoZpw8X0B2hNTw8932XDwumKMJ9wYNrICDnct2eeFk3yg2jA4HCXzYYDWitmoapSNM6gSRoqQHs_8ff3wNN4k2lkPB910mg/s1920/DSC01814.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1920" data-original-width="1080" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj5O09y544CFAZivGuNPLVVycc-JKF5HgpzKfCWyhjOjNUHZjX3UbosZUmbq6wGqjAiR3tbYYjp797sLQOTS4OWiN4SpEpnoZpw8X0B2hNTw8932XDwumKMJ9wYNrICDnct2eeFk3yg2jA4HCXzYYDWitmoapSNM6gSRoqQHs_8ff3wNN4k2lkPB910mg/s320/DSC01814.JPG" width="180" /></a></div><div class="separator" style="clear: both; text-align: center;"><span style="text-align: left;"><br /></span></div><div class="separator" style="clear: both; text-align: center;"><span style="text-align: left;">DSC01814 showing the external view. The end caps were 3.375" wide, 2.375" deep, and 7.25" in height. Top seams were welded.</span></div><div><br /></div><div><br /></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgTLBV2eDJsvUYqLjxcU9KZqj_FvB-RZpjxCtBRGtR85vL9wWI2vStbiCtws8bCPtgttyRrTxY35Mp5ZMHXfNvgYJcu9fbmTgbNTM86sYFxrRFK8pDIWYVBVC6px1TPQKEr1wug0rz06EPnVjKoD8RGWNJmbiKwDTTg8oqXz_8h982JH-2yr_QThOM_3A/s1920/DSC01815.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgTLBV2eDJsvUYqLjxcU9KZqj_FvB-RZpjxCtBRGtR85vL9wWI2vStbiCtws8bCPtgttyRrTxY35Mp5ZMHXfNvgYJcu9fbmTgbNTM86sYFxrRFK8pDIWYVBVC6px1TPQKEr1wug0rz06EPnVjKoD8RGWNJmbiKwDTTg8oqXz_8h982JH-2yr_QThOM_3A/s320/DSC01815.JPG" width="320" /></a></div><br /><div>DSC01815 top view of the enclosure end cap..</div><br />Williamhttp://www.blogger.com/profile/13072555311952861298noreply@blogger.com0tag:blogger.com,1999:blog-576268040829288449.post-11148928344752537482023-02-22T10:07:00.008-08:002023-04-26T16:31:51.218-07:00Hyper9 Motor Support and Cradle - Version 3 Bracket<p><br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjq7MMmE0NVzCe5LGwTQukNQbq_AhQy0bwFtHVVIDMn-iAZsqys9h1PoOwz_7tiP9dUx8Nr1tpeh04NBIiKIZtuYF7OgNtCDZUxOFHE8y72iumO3sLi1f8b_Uos3pyOU89N3MxVrCCBuZbxRtPOwMeB2puZsjsLGLzgxYkTs0OSkKjlaER8eKmnpSE9BQ/s1920/DSC01610.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjq7MMmE0NVzCe5LGwTQukNQbq_AhQy0bwFtHVVIDMn-iAZsqys9h1PoOwz_7tiP9dUx8Nr1tpeh04NBIiKIZtuYF7OgNtCDZUxOFHE8y72iumO3sLi1f8b_Uos3pyOU89N3MxVrCCBuZbxRtPOwMeB2puZsjsLGLzgxYkTs0OSkKjlaER8eKmnpSE9BQ/s320/DSC01610.JPG" width="320" /></a></div><br /><p>DSC01610 of the previously reported (1/7/2023 this blog) Mounting Bracket Version 2.</p><p><span style="font-size: xx-small;">Edited 3/9/2023</span></p><p>1/2"-20 x 3.5" fully threaded bolts from distributor Miller Industrial (Hillman 25 pieces for $28.99) and 1/2"-13 nuts, (Hillman 50 pack for $10.49).</p><p><br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgnaQQ8vuHMSfjxeTmNUDKrcXELRu8IeGpDbqa1SfekkOCLEXzEd9R71M_0pSD-Th46CCrPDorOqBQZ6vglyND-Eid4AGK-CTkIkdPqQNae0AGKLjST1KDQ8xntOoAdNzru0Kpe1pztOsUKHZ6QbIzrWyhA5p45On5e7-mXLVLKFA8BCub_vtojGlD5pg/s1920/DSC01609.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgnaQQ8vuHMSfjxeTmNUDKrcXELRu8IeGpDbqa1SfekkOCLEXzEd9R71M_0pSD-Th46CCrPDorOqBQZ6vglyND-Eid4AGK-CTkIkdPqQNae0AGKLjST1KDQ8xntOoAdNzru0Kpe1pztOsUKHZ6QbIzrWyhA5p45On5e7-mXLVLKFA8BCub_vtojGlD5pg/s320/DSC01609.JPG" width="320" /></a></div><br /><p>DSC01609 showing the OEM bracket on the left (with rubber cushions removed) and the Version 2 bracket on the right. When working with the right hand bracket, it was found that the closure bolts needed to be inserted from the bottom, as there was not clearance to insert them from the top.</p><p><br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiZ3APnJBqV2gP_gC56th1SYm47_D5MZ113_f5Mmt3OHZQ2Bbu4VtfCWvhJJj0S0ENUrm-ecS9OdgW0jkhd7hwa-wEbrWtpQLouUDkPG02oZppIjq_9rExwK2XvtfBEQrcImyaI4B9DBN73TN_gjY1BctjPe5JxvjtT8thTiah4YP7Z2AfEWhi-CyLCgg/s1920/DSC01740.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiZ3APnJBqV2gP_gC56th1SYm47_D5MZ113_f5Mmt3OHZQ2Bbu4VtfCWvhJJj0S0ENUrm-ecS9OdgW0jkhd7hwa-wEbrWtpQLouUDkPG02oZppIjq_9rExwK2XvtfBEQrcImyaI4B9DBN73TN_gjY1BctjPe5JxvjtT8thTiah4YP7Z2AfEWhi-CyLCgg/s320/DSC01740.JPG" width="320" /></a></div><p>DSC01740 Showing the slip roll former that was used to create the 9" diameter curvature in the rings.</p><p><span style="font-size: x-small;">Edited 4/26/2023</span></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEigslYRSXdoL4wsUzUrGcdFlrMzT4XKoClzu-jp5NN9c3prjJkoEGP2bZfG9p2pDe5zbIlAwECkdmbnDNGrpj5x7O8-GAgZh2i6Pqby1-EQQYGrDol1yEw2LPa-mzVYLJotCjfyQ3P0A7Z0COcxhBTB0FG1VmnMukXttT3afbm0300CYQk7TiRIs8yKjg/s1920/DSC01611.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1920" data-original-width="1080" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEigslYRSXdoL4wsUzUrGcdFlrMzT4XKoClzu-jp5NN9c3prjJkoEGP2bZfG9p2pDe5zbIlAwECkdmbnDNGrpj5x7O8-GAgZh2i6Pqby1-EQQYGrDol1yEw2LPa-mzVYLJotCjfyQ3P0A7Z0COcxhBTB0FG1VmnMukXttT3afbm0300CYQk7TiRIs8yKjg/s320/DSC01611.JPG" width="180" /></a></div><br /><p>DSC01611 showing (at the bottom) the previous Version 2 design that has a 7.75" mounting surface. The Version 3 bracket is at the top (the mounting surface has not yet been welded to place). Note how the top bracket will allow for simple insertion of the closure bolts without interference with the anticipated mounting plate or surfaces.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhhCb5QrweMJoXsDgTRv40rgkGnf5gtso6XmQguOfRIY_ux60IWpqF6QF9ZZJG0PvyCcwwtHnn9jobrfCx7xxol1vROFAZ9ADC2O9ZMPB8yuw3Ipamb9IfV7kJ0nKz1J7R0JeIvAqiO7MqmssHSSKWyKrfu8VZ_BXvEWo1VREACDUXCTTyBu9l2WVQ5-Q/s1920/DSC01612.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhhCb5QrweMJoXsDgTRv40rgkGnf5gtso6XmQguOfRIY_ux60IWpqF6QF9ZZJG0PvyCcwwtHnn9jobrfCx7xxol1vROFAZ9ADC2O9ZMPB8yuw3Ipamb9IfV7kJ0nKz1J7R0JeIvAqiO7MqmssHSSKWyKrfu8VZ_BXvEWo1VREACDUXCTTyBu9l2WVQ5-Q/s320/DSC01612.JPG" width="320" /></a></div><p>DSC01612 this Version 3 design will allow for a mounting surface that is now 8.75" across.</p><p><span style="font-size: xx-small;">Edited 3/8/2023</span></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjVPVcibLKb5ZOD5ASjWvXqBwdgRz61fwEgHdddeuOOuDoMi-Vfh9LVPUq-f7dO4juiMjnNic46mPVJF09rK77IpOW3lzqrqBfEpXBdBJT2oAVNoip0rHgxZ8tMmsZHcozNFTgLyMfUx-PAVPyHefiGn0CXosO-_mSrjMWbhv5e4s_qwpIDKmWGYCkdEw/s1920/DSC01636.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1920" data-original-width="1080" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjVPVcibLKb5ZOD5ASjWvXqBwdgRz61fwEgHdddeuOOuDoMi-Vfh9LVPUq-f7dO4juiMjnNic46mPVJF09rK77IpOW3lzqrqBfEpXBdBJT2oAVNoip0rHgxZ8tMmsZHcozNFTgLyMfUx-PAVPyHefiGn0CXosO-_mSrjMWbhv5e4s_qwpIDKmWGYCkdEw/w225-h400/DSC01636.JPG" width="225" /></a></div><br /><p><span style="font-size: xx-small;">Edited 3/16/2023</span></p><p>DSC01636 showing the Neoprene Rubber edge trim (cushion) added to the cradle. (McMaster-Carr catalog 8507K16, at $1.80/ foot, 30" required for each cradle.) Note the single mounting hole at the horizontal base of the cradle.</p><p>Two additional mounting holes were added on the sides of the base.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj9-mbfINCOZ2U-PJdk0XFaKJZzkvXmd7-KKYl0zvrL4zKmGaavljn2bx3fpLzUfjtAxB2gW02MW3f1SNvEk2G-jOicrXFN-dVJjWrFQl2F-WHDFR6KzfSlrupkdVYyjiOAMNjP1xmn5u5GMWP4ISN0xoZiIj64dZK_fq5tWunKmI_74H20_qzcOgB2kw/s1920/DSC01699.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj9-mbfINCOZ2U-PJdk0XFaKJZzkvXmd7-KKYl0zvrL4zKmGaavljn2bx3fpLzUfjtAxB2gW02MW3f1SNvEk2G-jOicrXFN-dVJjWrFQl2F-WHDFR6KzfSlrupkdVYyjiOAMNjP1xmn5u5GMWP4ISN0xoZiIj64dZK_fq5tWunKmI_74H20_qzcOgB2kw/s320/DSC01699.JPG" width="320" /></a></div><span style="font-size: x-small;">Edited 4/10/2023</span><br /><p>DSC01699 showing the additional set of mounting holes that were added to the vertical portion of the cradle. The OEM clamp only had two mounting holes on the bottom of the base. </p><p>To prevent rusting, several of the clamp sets were sent off for Zinc plating (picture DSC01699 (above) and DSC01696 (below)). A standard 0.0001" Zinc layer with clear chromate coating was applied. (ThreeJ's Industries, Elk Grove Village, Illinois, 847-640-6080). The clear chromate treatment provides a protective layer over the soft Zinc layer and it leaves behind a <span face="Roboto, arial, sans-serif" style="background-color: white; color: #202124; font-size: 16px;">slightly iridescent blue</span><span face="Roboto, arial, sans-serif" style="background-color: white; color: #202124; font-size: 16px;"> color. </span></p><div class="separator" style="clear: both; text-align: center;"><br /></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhWvqoVfEAFUafD7okRYSSqmYvs2QF_mNqVma5cduVXsSGrKmkPU-DQSJv5NbyPP-6-Db7DfJJot47kkDioUXcrYS7bIMNJFW9TOn8HhRUUctcmf81IszF44zcrYyWM1VwV2HyIKxD92Lw10NR1qIVVKKZuFw9ABpgbhQLJseZNVuj123_2WYUhMCCJHw/s1920/DSC01696.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhWvqoVfEAFUafD7okRYSSqmYvs2QF_mNqVma5cduVXsSGrKmkPU-DQSJv5NbyPP-6-Db7DfJJot47kkDioUXcrYS7bIMNJFW9TOn8HhRUUctcmf81IszF44zcrYyWM1VwV2HyIKxD92Lw10NR1qIVVKKZuFw9ABpgbhQLJseZNVuj123_2WYUhMCCJHw/s320/DSC01696.JPG" width="320" /></a></div><div><br /></div><div><br /></div>DSC01696 showing the raw steel (no plating) clamp (center), the Zinc plated clamp (far right), and the plated with rubber trim piece (far left).<br /><p><br /></p><p><br /></p>Williamhttp://www.blogger.com/profile/13072555311952861298noreply@blogger.com0tag:blogger.com,1999:blog-576268040829288449.post-87183755193667838492023-02-22T08:02:00.002-08:002023-02-23T13:29:34.579-08:00SME Controller and Motor Terminal Blocks - 2<p><span face="Helvetica, -apple-system, BlinkMacSystemFont, "Helvetica Neue", "Segoe UI", Arial, sans-serif, "Apple Color Emoji", "Segoe UI Emoji", "Segoe UI Symbol"" style="letter-spacing: -0.23px;">We were initially unable to find the 90 degree terminal units shown in picture DSC01549. </span></p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhRB6xvAl-3JCfAnDp5ga_gYlUrL2jWe4YGUXUIGpaZei9XqNxEdVwNdP0UZ6YN6mH2oqXB9rlLUWHpQXQLVtspLLQTDuuYXbuHZsAd-R2P2FF-FCAMMDoQbBjZ2OmuOnLgcewysqFA2Ag_cqiRsEpLkHErUQykEop7Lo0hVmp-l2PIWICDUFZqX_V6Tg/s1920/DSC01549.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhRB6xvAl-3JCfAnDp5ga_gYlUrL2jWe4YGUXUIGpaZei9XqNxEdVwNdP0UZ6YN6mH2oqXB9rlLUWHpQXQLVtspLLQTDuuYXbuHZsAd-R2P2FF-FCAMMDoQbBjZ2OmuOnLgcewysqFA2Ag_cqiRsEpLkHErUQykEop7Lo0hVmp-l2PIWICDUFZqX_V6Tg/s320/DSC01549.JPG" width="320" /></a></div><span face="Helvetica, -apple-system, BlinkMacSystemFont, "Helvetica Neue", "Segoe UI", Arial, sans-serif, "Apple Color Emoji", "Segoe UI Emoji", "Segoe UI Symbol"" style="letter-spacing: -0.23px;"><p><span style="letter-spacing: -0.23px;">DSC01549 of a commercial 90 degree terminal lug that is crimped to secure the 2/0 Copper stranded wire.</span></p></span><p></p><p><span face="Helvetica, -apple-system, BlinkMacSystemFont, "Helvetica Neue", "Segoe UI", Arial, sans-serif, "Apple Color Emoji", "Segoe UI Emoji", "Segoe UI Symbol"" style="letter-spacing: -0.23px;">Initially, to obtain a terminal lug that allowed the 2/0 wires to exit vertically from the controller, I </span><span face="Helvetica, -apple-system, BlinkMacSystemFont, "Helvetica Neue", "Segoe UI", Arial, sans-serif, "Apple Color Emoji", "Segoe UI Emoji", "Segoe UI Symbol"" style="letter-spacing: -0.23px;">used 3/4" Copper hex bar stock and cut to </span><span face="Helvetica, -apple-system, BlinkMacSystemFont, "Helvetica Neue", "Segoe UI", Arial, sans-serif, "Apple Color Emoji", "Segoe UI Emoji", "Segoe UI Symbol"" style="letter-spacing: -0.23px;">length, drilled out one end with a 15/32" drill for the 2/0 stranded wire, then drilled and threaded the other end for a M8-1.25 stud. The terminal wire, when crimped (or Silver soldered) into the copper Hex, now exits the controller perpendicular t</span><span face="Helvetica, -apple-system, BlinkMacSystemFont, "Helvetica Neue", "Segoe UI", Arial, sans-serif, "Apple Color Emoji", "Segoe UI Emoji", "Segoe UI Symbol"" style="letter-spacing: -0.23px;">o the controller housing. The other end of the 2/0 cable would need to be trial fitted, and that terminal lug crimped in the correct orientation so that there is not a kink in the wire itself.</span></p><p><span face="Helvetica, -apple-system, BlinkMacSystemFont, "Helvetica Neue", "Segoe UI", Arial, sans-serif, "Apple Color Emoji", "Segoe UI Emoji", "Segoe UI Symbol"" style="letter-spacing: -0.23px;"><br /></span></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjvUIKpQ2qgw0WonoEKCwjeQFlez1ZWz3VTag0tFuXQl4Kjq_Ko6XpRJzimIUe2hWVfVIsTKfrQJMeJxkf38eg0lvvAbiuANKmtfl4_HAD8KJl1mj6L0gpLQNYCEkW9jsjjAmg0ywsJ3FKhvPhyd9UflzhO8nGWa4plwkJymLLTkQHpWfXDvecpf2pyrQ/s1920/DSC01582.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjvUIKpQ2qgw0WonoEKCwjeQFlez1ZWz3VTag0tFuXQl4Kjq_Ko6XpRJzimIUe2hWVfVIsTKfrQJMeJxkf38eg0lvvAbiuANKmtfl4_HAD8KJl1mj6L0gpLQNYCEkW9jsjjAmg0ywsJ3FKhvPhyd9UflzhO8nGWa4plwkJymLLTkQHpWfXDvecpf2pyrQ/s320/DSC01582.JPG" width="320" /></a></div><br /><div class="default-style" style="font-family: Helvetica, -apple-system, BlinkMacSystemFont, "Helvetica Neue", "Segoe UI", Arial, sans-serif, "Apple Color Emoji", "Segoe UI Emoji", "Segoe UI Symbol"; letter-spacing: -0.23px;">DSC01582 The bottom of the image shows a 2/0 cable inserted into the hex bar stock. This cable can either be crimped or Silver soldered to place. </div><div class="default-style" style="font-family: Helvetica, -apple-system, BlinkMacSystemFont, "Helvetica Neue", "Segoe UI", Arial, sans-serif, "Apple Color Emoji", "Segoe UI Emoji", "Segoe UI Symbol"; font-size: 12.5px; letter-spacing: -0.23px;"><br /></div><div class="default-style" style="font-family: Helvetica, -apple-system, BlinkMacSystemFont, "Helvetica Neue", "Segoe UI", Arial, sans-serif, "Apple Color Emoji", "Segoe UI Emoji", "Segoe UI Symbol"; font-size: 12.5px; letter-spacing: -0.23px;"><br /></div><div class="default-style" style="font-family: Helvetica, -apple-system, BlinkMacSystemFont, "Helvetica Neue", "Segoe UI", Arial, sans-serif, "Apple Color Emoji", "Segoe UI Emoji", "Segoe UI Symbol"; font-size: 12.5px; letter-spacing: -0.23px;"><br /></div><div class="default-style" style="font-family: Helvetica, -apple-system, BlinkMacSystemFont, "Helvetica Neue", "Segoe UI", Arial, sans-serif, "Apple Color Emoji", "Segoe UI Emoji", "Segoe UI Symbol"; font-size: 12.5px; letter-spacing: -0.23px;"><br /></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg8RzS-4Z8Q5bIazQw-1-Y-XnZZxRGVgMOct7vRcxunm0MV9H4lV15167e4Yv5KHVeaXFb0DBOuigEV8WYR5RM0hotXtIj3I4T6Yr5IiIcwqCUbGUDWcbUoPY_DZhw4fJU1vGTZWpYsExl9zaJAvQjyI2FQgGzNi-UNICRJC46O0HWGJtOV02EYmMp2BA/s1920/DSC01583.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg8RzS-4Z8Q5bIazQw-1-Y-XnZZxRGVgMOct7vRcxunm0MV9H4lV15167e4Yv5KHVeaXFb0DBOuigEV8WYR5RM0hotXtIj3I4T6Yr5IiIcwqCUbGUDWcbUoPY_DZhw4fJU1vGTZWpYsExl9zaJAvQjyI2FQgGzNi-UNICRJC46O0HWGJtOV02EYmMp2BA/s320/DSC01583.JPG" width="320" /></a></div><div><br /></div><div><br /></div><div>DSC01583 closeup view of the cut hex bar stock (McMaster 89985K927 at 12" for $98.15) with 15/32" drill and bevel (far left) for the 2/0 battery cable. The M8-1.25 with 13 mm depth terminal end for the stainless steel M8-1.25 x 25 mm stud (McMaster 93805A355, pack of 10 for $15.06). Far right shows fully assembled terminal lug. </div><div><br /></div><div class="default-style" style="font-family: Helvetica, -apple-system, BlinkMacSystemFont, "Helvetica Neue", "Segoe UI", Arial, sans-serif, "Apple Color Emoji", "Segoe UI Emoji", "Segoe UI Symbol"; font-size: 12.5px; letter-spacing: -0.23px;"><br /></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiZce89LrUP4Kd-t0p-j0TfgBLB-H3Ua81m8DV9x5cwh55booYvn4KsCO0UOFa-W09Bml_DAbT2mLfDFoUCQHdqLAw0eiVJldKxDIS1JC7_8XjtgUFP0TTfcHWHq1gbZDg6fEJStYF2ueVODK_kwEqtFnYq2kMafXmyFcKiQeISp3EEVrgzy05y7clyxQ/s1920/DSC01581.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1920" data-original-width="1080" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiZce89LrUP4Kd-t0p-j0TfgBLB-H3Ua81m8DV9x5cwh55booYvn4KsCO0UOFa-W09Bml_DAbT2mLfDFoUCQHdqLAw0eiVJldKxDIS1JC7_8XjtgUFP0TTfcHWHq1gbZDg6fEJStYF2ueVODK_kwEqtFnYq2kMafXmyFcKiQeISp3EEVrgzy05y7clyxQ/s320/DSC01581.JPG" width="180" /></a></div><br /><div><br /></div><div>DSC01581 showing the controller mounted on its side. This configuration might be used if the controller was attached to the car firewall or to the side of the motor compartment. If heat shrink tubing is used on these terminals, then there will be no exposed power voltages. </div><div><br /></div><div><br /></div><div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh85A8QId_k9IzgbnYjt1rAmym9uE6YA9UzJr5kiVbyOrcvRhn2Xd3Q1cU4mqGfPoBkcUoFfI-2NQXNYj4yI_OkeDAD4X40dXJDHZhGOegPaWbVmIJtaYeotrbh_QGjYIbtyPMsZVQ5SZju5GQ9Z5WDFt1Kdu3AE9LyFEFBrRQfRTctNZpwXA0tMTMfDg/s1920/DSC01586.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh85A8QId_k9IzgbnYjt1rAmym9uE6YA9UzJr5kiVbyOrcvRhn2Xd3Q1cU4mqGfPoBkcUoFfI-2NQXNYj4yI_OkeDAD4X40dXJDHZhGOegPaWbVmIJtaYeotrbh_QGjYIbtyPMsZVQ5SZju5GQ9Z5WDFt1Kdu3AE9LyFEFBrRQfRTctNZpwXA0tMTMfDg/s320/DSC01586.JPG" width="320" /></a></div><br /></div><div>DSC01586 with added connections to the battery.</div><div><br /></div>Williamhttp://www.blogger.com/profile/13072555311952861298noreply@blogger.com0tag:blogger.com,1999:blog-576268040829288449.post-45894355049161524372023-02-05T15:39:00.004-08:002023-02-07T10:12:11.616-08:00SMS Controller and Motor Terminal Blocks - 1<p>There are multiple possible cable lugs and terminal blocks to choose from. In all cases the 2/0 multi-strand wire it is a challenge to slide into the fitting without bending back some of the wires (DSC01512 below).</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiIlJhdUAAqTO45pdVBqPwgl6AWVyBr-LRUfpc3WeolxTbLhBmINkj6nwC6A8YnNUjIBYJ4EsJRvs6r0ieQJZr9y0Z-db9BSwLM_cCP-GnVgFOkbfldyFvZ219vUPMlpGRjqoc1FSgyEZTsEbbYsOYn5BOg8q9qI40orkHigVoxlJ_9mWudSxEpPOwlTA/s1920/DSC01510.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiIlJhdUAAqTO45pdVBqPwgl6AWVyBr-LRUfpc3WeolxTbLhBmINkj6nwC6A8YnNUjIBYJ4EsJRvs6r0ieQJZr9y0Z-db9BSwLM_cCP-GnVgFOkbfldyFvZ219vUPMlpGRjqoc1FSgyEZTsEbbYsOYn5BOg8q9qI40orkHigVoxlJ_9mWudSxEpPOwlTA/s320/DSC01510.JPG" width="320" /></a></div><p>DSC01510 of the commercially available mechanical lugs purchased from Home Depot (two per pack at $3.75). These lugs are 5/8" wide and 1.5" long and 13/16" tall and they have an opening for the 2/0 wire of 0.4435" (11.26 mm). It takes patience to insert the 2/0 wire into the opening without bending back some of the wires. (see DSC01512).</p><p>The Aluminum set screws are 0.5950" long and rounded contact (convex), are 7/16"-20 thread, use require a 3/16" hex key to tighten. An alternative would be to use 18-8 Stainless Steel Cone Point Set Screws that are M8 x 1.25 mm thread, and 16 mm long (McMaster cat 91217A315, $7.85 for 10). </p><p><br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj3O-wMBOL0UBpQTRsFCPVhC63Y6pTVwM1Ug-WAmirC436uFRK1WYe263q1dYDjLOuYT11g6DeTCi3t8x5cmD8_1gDugPEJk-3qGbgYU6ijX-zDLcp8e-Iz4fmDfjGKPNkKhIvbG3mm2Uc-mD0Ar4b1KOJrI-ITDPv4FkkV1kU7_Jwn58sjNcFk4Kik4g/s1920/DSC01512.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj3O-wMBOL0UBpQTRsFCPVhC63Y6pTVwM1Ug-WAmirC436uFRK1WYe263q1dYDjLOuYT11g6DeTCi3t8x5cmD8_1gDugPEJk-3qGbgYU6ijX-zDLcp8e-Iz4fmDfjGKPNkKhIvbG3mm2Uc-mD0Ar4b1KOJrI-ITDPv4FkkV1kU7_Jwn58sjNcFk4Kik4g/s320/DSC01512.JPG" width="320" /></a></div><div><br /></div>DSC01512 showing the orientation of the 2/0 wires parallel to the axis of the motor and the difficulty in preventing some of the wires from bending back during insertion. The Hyper9 bolts are M10-1.5 x 16 mm. Without washers and locknuts, the threads must not insert more then 16 mm. <div><br /></div><div><br /></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhcht8fOgYzMmHSazBqeBOhx54csmIRIoh4ATM3PiCW_lr3-3h0knmCQrJHlRs596ovSmYhXsHVlkje_9c68wWPfFyUSALhFio2MuXi8kaHoiQHn0835Cun6yuXkcsoVBtLdhCMXu9DWePAWqFOfARU4mtz9hbtx0fJVahEd-aMDCOmT33YhneE03q1aQ/s1920/DSC01515.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhcht8fOgYzMmHSazBqeBOhx54csmIRIoh4ATM3PiCW_lr3-3h0knmCQrJHlRs596ovSmYhXsHVlkje_9c68wWPfFyUSALhFio2MuXi8kaHoiQHn0835Cun6yuXkcsoVBtLdhCMXu9DWePAWqFOfARU4mtz9hbtx0fJVahEd-aMDCOmT33YhneE03q1aQ/s320/DSC01515.JPG" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;">DSC01515 picture of Odyssey Battery Copper "L" Adapter Terminal Brackets Kit (Yamaha Rhino / BMW) purchased from Seven Saturdays Motorsports (714-523-4357) for $14.99 . The brackets are copper and 0.1245" thick and 0.502" wide. The legs are 0.9285 (long) and 0.7656" (short). Although for battery use, these brackets were too small for our application. They were used as templates for the larger "L" brackets that were later made. </div><div class="separator" style="clear: both; text-align: center;"><br /></div><div class="separator" style="clear: both; text-align: center;"><br /></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEguvBFDanYs6PpDAh77rgxPvbCIxH4rrEFf_xkLhx29BZbaLPg1oNqyonBOvP_uNmjgCPx4Tb1cheziK9OjaNBwqiHSrBYYlgO0_7TvCHuuitGpMmYsyqKhSSIU4m1d4MJ6ZGpO2s5vhTjZmjx4VSqyHpiqZZ-qHMAcj_knRvHNrn7UwjvID2G1WrUTFA/s1920/DSC01526.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEguvBFDanYs6PpDAh77rgxPvbCIxH4rrEFf_xkLhx29BZbaLPg1oNqyonBOvP_uNmjgCPx4Tb1cheziK9OjaNBwqiHSrBYYlgO0_7TvCHuuitGpMmYsyqKhSSIU4m1d4MJ6ZGpO2s5vhTjZmjx4VSqyHpiqZZ-qHMAcj_knRvHNrn7UwjvID2G1WrUTFA/s320/DSC01526.JPG" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;">DSC01526 of the EVWest RING-2/0-1/2 lug.</div><div class="separator" style="clear: both; text-align: center;"><br /></div><div class="separator" style="clear: both; text-align: left;">Commercial heavy duty ring terminal lugs were purchased from EVWest. Part numbers RING-2/0-1/2 (1/2" of M12) and RING-2/0-5/16 (5/16" or M8). Both sizes of terminals were priced at $2.90 each so there is not financial motivation for reinventing them. </div><div class="separator" style="clear: both; text-align: left;"><br /></div><div class="separator" style="clear: both; text-align: left;"><span> </span><span> </span><span> </span><span> </span><span> </span><span> </span><span> </span><span> </span><span> </span><span> </span><span> </span><span> </span><span> </span><span> </span><span> </span><span> </span><span> </span><span> </span><span> </span><br /></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgX1GpCsJQzitaw-o9w-ZFBLJd2VXMtwoYnRJM2wxplWrjz5U7_FBGpqTH0AlTck5vyov78W2PaZNcESSWzUo77woR9ldCJKpASQuYExfgC4H497m0ThH8H81xpSQjKRWCO6zPSZPOYvsVI-ATO1G5HqLL6vokx4tg71hH4lofRwzYkNsqm1jQ-XXYPUA/s1920/DSC01525.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgX1GpCsJQzitaw-o9w-ZFBLJd2VXMtwoYnRJM2wxplWrjz5U7_FBGpqTH0AlTck5vyov78W2PaZNcESSWzUo77woR9ldCJKpASQuYExfgC4H497m0ThH8H81xpSQjKRWCO6zPSZPOYvsVI-ATO1G5HqLL6vokx4tg71hH4lofRwzYkNsqm1jQ-XXYPUA/s320/DSC01525.JPG" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: left;"><span> </span><span> </span><span> </span><span> </span><span> </span><span> </span><span> </span><span> </span><span> </span><span> </span><span> </span><span> </span><span> </span><span> </span><span> </span><span> </span>DSC01525 <span style="text-align: center;">of the RING-2/0-1/2 lug.</span></div><div class="separator" style="clear: both; text-align: left;"><br /></div><div class="separator" style="clear: both; text-align: left;">The OD of the 2/0 tubing section is on average 16.44 mm and the inner ID is on average about 11.88 mm (the tube is slightly oblong). This opening is slightly larger then the Home Depot lugs (DSC01510 above) making the 2/0 wires easier to install.</div><div class="separator" style="clear: both; text-align: left;">Overall length is 59.3mm for 2/0-1/2, or 53.29 mm for 2/0-5/16</div><div class="separator" style="clear: both; text-align: left;">Tab is 23.04 wide by 25.0 mm long</div><div class="separator" style="clear: both; text-align: left;">Tab thickness is 4.54 mm.</div><div class="separator" style="clear: both; text-align: left;">Bolt Holes available in 3/8" or 5/16" or 1/2".</div><div class="separator" style="clear: both; text-align: left;"><br /></div><div class="separator" style="clear: both; text-align: left;">The lugs appear to have been made from a 2.2-2.3 mm wall thickness copper tubing that was then crimped flat at one end (note the seam at the edge in the far left image of DSC01525), drilled for passage of the attachment bolt, the tab end rounded, and Tin plating applied either by plating or hot dip. The 2/0 wire entry is beveled, and since all of the lugs are slightly oval, it is probable that the edges were beveled prior to pressing.</div><div class="separator" style="clear: both; text-align: left;"><br /></div><div class="separator" style="clear: both; text-align: left;"><br /></div><div class="separator" style="clear: both; text-align: left;"><br /></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhgvMlELejlwe_dbfb1lU7E9FM88IkikZDynDn1ciPHs1AK-QdCXPxx0JBztIgwWbkb3SIDoIrbvg0Elm964EdZGQ1T6_iRD12M2Jgs-QxW23JotMMtOt7Xf-t1A1wIJEZImfyYc-SLtWY2ZC-LFUEQtrpo_75IH_xNBOeDLoKoAUdHpEsD1SlfzeBz2Q/s1920/DSC01529.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhgvMlELejlwe_dbfb1lU7E9FM88IkikZDynDn1ciPHs1AK-QdCXPxx0JBztIgwWbkb3SIDoIrbvg0Elm964EdZGQ1T6_iRD12M2Jgs-QxW23JotMMtOt7Xf-t1A1wIJEZImfyYc-SLtWY2ZC-LFUEQtrpo_75IH_xNBOeDLoKoAUdHpEsD1SlfzeBz2Q/s320/DSC01529.JPG" width="320" /></a></div><div><br /></div>DSC01529 showing both the plane of the base of the fitting and the score line just to the right of center. If the fitting was pressed flat one might expect the tab on the left to be in the center line of the tubing. Instead, there must be a fixture that holds the tubing in place and allows the press to asymmetrically compress the tubing on the left side. The score line suggests contact on the edge of a clamping fixture.<br /><div class="separator" style="clear: both; text-align: left;"><br /></div><div class="separator" style="clear: both; text-align: left;"><br /></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgZ1zkse7ggYZ_R1c62g8Fo5ZgutjuIJSOCbKYIqWSbNHLWSBUlXWA7jyct5lXHpikDRKPG5voCIjD2W7CQdsY4Tl-YMgFWnNV652z4wbszd1oVMb5CbY9-YI-bs05iwY2HWNtsO3K0RErNXNkQENaCEB3RTb_VIQ5c6BG3ZIIXo9r9y-lx94xFNnR84g/s1920/DSC01531.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgZ1zkse7ggYZ_R1c62g8Fo5ZgutjuIJSOCbKYIqWSbNHLWSBUlXWA7jyct5lXHpikDRKPG5voCIjD2W7CQdsY4Tl-YMgFWnNV652z4wbszd1oVMb5CbY9-YI-bs05iwY2HWNtsO3K0RErNXNkQENaCEB3RTb_VIQ5c6BG3ZIIXo9r9y-lx94xFNnR84g/s320/DSC01531.JPG" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><br /></div><div class="separator" style="clear: both; text-align: left;">DSC01531 showing the score line (middle right) on the underside of the fitting that was probably caused by the fixture that the tubing was clamped to during the press operation. There appears to be a similar crease line internally suggesting that a rod was inserted prior to pressing.</div><div class="separator" style="clear: both; text-align: left;"><br /></div><div class="separator" style="clear: both; text-align: left;"> The 2/0 wire has a practical bending radius of about 2" and depending upon the orientation of the controller relative to the motor, the straight out lugs can pose some challenges. Alternatively, one may use 45 or 90 degree 2/0 lugs (DSC01550 and DSC1549 below) for greater flexibility in the orientation of the cables. </div><div class="separator" style="clear: both;"><br /></div><div class="separator" style="clear: both; text-align: left;"><br /></div><div class="separator" style="clear: both; text-align: left;"><div class="separator" style="clear: both; text-align: center;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgpFxmmsBH40JJyMFEObVhhF9PXe_JX2M5q65TtAF7Yl7HW00Q2DDp05ZBR9Cc0O42_PErHBQBljR1IwRBJbGFvus3VWkhDLwDa1bTV7iUVjPwfVV0alkl3fD4hfiIRtUJgaF5-nkybCCi4Ic4MW-vcPF6w53ubzRwMRNOyXpPIuCC8UQzEoWfBIRe85A/s1920/DSC01550.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgpFxmmsBH40JJyMFEObVhhF9PXe_JX2M5q65TtAF7Yl7HW00Q2DDp05ZBR9Cc0O42_PErHBQBljR1IwRBJbGFvus3VWkhDLwDa1bTV7iUVjPwfVV0alkl3fD4hfiIRtUJgaF5-nkybCCi4Ic4MW-vcPF6w53ubzRwMRNOyXpPIuCC8UQzEoWfBIRe85A/s320/DSC01550.JPG" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;">DSC01550 of the 45 degree terminal lug.</div></div></div><div class="separator" style="clear: both; text-align: left;"><br /></div><div class="separator" style="clear: both; text-align: left;"><br /></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjZsXh7Lp4JNwZGeQULfariR6ga8aW3oL9I705cty2OXwIv143oY2BWqAWyhO4vco_WqSoipcehiq6Qoh8e7fr00dPKE_CBdmgLuT8IUMkawCvw6fTrmGAw7jKMcgnit8liOoMyPM5bjRTFpg_DE9jtrr6Z9fxYkrrpUMx15eH0YvmxrjKNg4t1_gHJWA/s1920/DSC01549.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjZsXh7Lp4JNwZGeQULfariR6ga8aW3oL9I705cty2OXwIv143oY2BWqAWyhO4vco_WqSoipcehiq6Qoh8e7fr00dPKE_CBdmgLuT8IUMkawCvw6fTrmGAw7jKMcgnit8liOoMyPM5bjRTFpg_DE9jtrr6Z9fxYkrrpUMx15eH0YvmxrjKNg4t1_gHJWA/s320/DSC01549.JPG" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: left;"><span> </span><span> </span><span> </span><span> </span><span> </span><span> </span><span> </span><span> </span><span> </span><span> </span><span> </span><span> </span><span> </span>DSC0549 of the 90 degree terminal lug.</div><div class="separator" style="clear: both; text-align: left;"><br /></div><div class="separator" style="clear: both; text-align: left;"><br /></div><div class="separator" style="clear: both; text-align: left;"><span> </span><span> </span><span> </span><span> </span><span> </span><span> </span><span> </span><span> </span><span> </span><span> </span><span> </span><span> </span><span> </span><span> </span><span> </span><span> </span><span> </span><span> </span><span> </span><span> </span><span> </span><br /></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEirdVqcS60hmwii9PxGFe7NN7-BUPANEnLBPLefGNuCudc7ZhX1NVn6Yi1llBs4ZpEZN78K_Yqk8nmWwB5M7ox14EFSNkMRYyUpeVqp_4Y7Qt34GkHL4TivnL6tTiu8c6JNPCBYHQhmrxp-qomaUMuO6ObqFzubu_HLEBUvH6P7ygcaw3W1xG-99nzozw/s1920/DSC01527.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEirdVqcS60hmwii9PxGFe7NN7-BUPANEnLBPLefGNuCudc7ZhX1NVn6Yi1llBs4ZpEZN78K_Yqk8nmWwB5M7ox14EFSNkMRYyUpeVqp_4Y7Qt34GkHL4TivnL6tTiu8c6JNPCBYHQhmrxp-qomaUMuO6ObqFzubu_HLEBUvH6P7ygcaw3W1xG-99nzozw/s320/DSC01527.JPG" width="320" /></a></div><div><br /></div><span> </span><span> </span>DSC01527 of model YQK-120 EVWest hexagonal crimper (catalog number CRIMP at $68.00).<div><br /></div><div><b style="background-color: white; color: #7f7f7f; font-family: Arial, Helvetica, sans-serif; font-size: 13.2px; outline: none;">Model:</b><span face="Arial, Helvetica, sans-serif" style="background-color: white; color: #7f7f7f; font-size: 13.2px;"> YQK-120</span><br style="background-color: white; color: #7f7f7f; font-family: Arial, Helvetica, sans-serif; font-size: 13.2px; outline: none;" /><b style="background-color: white; color: #7f7f7f; font-family: Arial, Helvetica, sans-serif; font-size: 13.2px; outline: none;">Crimping Force:</b><span face="Arial, Helvetica, sans-serif" style="background-color: white; color: #7f7f7f; font-size: 13.2px;"> 12T</span><br style="background-color: white; color: #7f7f7f; font-family: Arial, Helvetica, sans-serif; font-size: 13.2px; outline: none;" /><b style="background-color: white; color: #7f7f7f; font-family: Arial, Helvetica, sans-serif; font-size: 13.2px; outline: none;">Crimping Type:</b><span face="Arial, Helvetica, sans-serif" style="background-color: white; color: #7f7f7f; font-size: 13.2px;"> Hexagonal crimping</span><br style="background-color: white; color: #7f7f7f; font-family: Arial, Helvetica, sans-serif; font-size: 13.2px; outline: none;" /><b style="background-color: white; color: #7f7f7f; font-family: Arial, Helvetica, sans-serif; font-size: 13.2px; outline: none;">Stroke:</b><span face="Arial, Helvetica, sans-serif" style="background-color: white; color: #7f7f7f; font-size: 13.2px;"> 14mm</span><br style="background-color: white; color: #7f7f7f; font-family: Arial, Helvetica, sans-serif; font-size: 13.2px; outline: none;" /><b style="background-color: white; color: #7f7f7f; font-family: Arial, Helvetica, sans-serif; font-size: 13.2px; outline: none;">Length:</b><span face="Arial, Helvetica, sans-serif" style="background-color: white; color: #7f7f7f; font-size: 13.2px;"> 425mm</span><br style="background-color: white; color: #7f7f7f; font-family: Arial, Helvetica, sans-serif; font-size: 13.2px; outline: none;" /><b style="background-color: white; color: #7f7f7f; font-family: Arial, Helvetica, sans-serif; font-size: 13.2px; outline: none;">Package:</b><span face="Arial, Helvetica, sans-serif" style="background-color: white; color: #7f7f7f; font-size: 13.2px;"> Plastic case</span><br style="background-color: white; color: #7f7f7f; font-family: Arial, Helvetica, sans-serif; font-size: 13.2px; outline: none;" /><b style="background-color: white; color: #7f7f7f; font-family: Arial, Helvetica, sans-serif; font-size: 13.2px; outline: none;">Crimping Range:</b><span face="Arial, Helvetica, sans-serif" style="background-color: white; color: #7f7f7f; font-size: 13.2px;"> 10-120mm</span><br style="background-color: white; color: #7f7f7f; font-family: Arial, Helvetica, sans-serif; font-size: 13.2px; outline: none;" /><b style="background-color: white; color: #7f7f7f; font-family: Arial, Helvetica, sans-serif; font-size: 13.2px; outline: none;">AWG Crimping Range:</b><span face="Arial, Helvetica, sans-serif" style="background-color: white; color: #7f7f7f; font-size: 13.2px;"> 6 AWG - 4/0 AWG</span><br style="background-color: white; color: #7f7f7f; font-family: Arial, Helvetica, sans-serif; font-size: 13.2px; outline: none;" /><b style="background-color: white; color: #7f7f7f; font-family: Arial, Helvetica, sans-serif; font-size: 13.2px; outline: none;">Dies:</b><span face="Arial, Helvetica, sans-serif" style="background-color: white; color: #7f7f7f; font-size: 13.2px;"> 10, 16, 25, 35, 50, 70, 95, 120mm</span></div><div><span face="Arial, Helvetica, sans-serif" style="background-color: white; color: #7f7f7f; font-size: medium;"><br /></span></div><div><span face="Arial, Helvetica, sans-serif" style="background-color: white; color: #7f7f7f; font-size: medium;"> </span><span face="Arial, Helvetica, sans-serif" style="background-color: white; color: #7f7f7f; font-size: xx-small;">(updated 2/7/2023) </span><span face="Arial, Helvetica, sans-serif" style="background-color: white; color: #7f7f7f; font-size: medium;"> EVWest indicates that they use the 95 mm die for crimping 2/0 wire.</span></div><div><span face="Arial, Helvetica, sans-serif" style="background-color: white; color: #7f7f7f; font-size: 13.2px;"><br /></span></div><div><span face="Arial, Helvetica, sans-serif" style="background-color: white; color: #7f7f7f; font-size: 13.2px;"><br /></span></div><div><br /></div><div><div class="separator" style="clear: both; text-align: center;"><br /></div></div>Williamhttp://www.blogger.com/profile/13072555311952861298noreply@blogger.com0tag:blogger.com,1999:blog-576268040829288449.post-53469139926319500352023-02-05T10:25:00.003-08:002023-05-02T15:47:11.065-07:00HyPer-9 Chiller Plate Design Evolution<p></p><div class="separator" style="clear: both; text-align: left;"> </div><div class="separator" style="clear: both; text-align: center;"><br /></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj_hTo8hyrW9bmxBchxOeebKEvPG4wNlrXXmJTYyH7dpxylpg2Bx5x0xOfv6QVHS6oCMwskE2TDgrPwzVXeWZsz1n3QmBAgaokSYH39m8kFx6pVDjdp-WkwfbSFFvfO-3M9Lg3KluopvlY7/" style="margin-left: 1em; margin-right: 1em;"><img alt="" data-original-height="240" data-original-width="320" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj_hTo8hyrW9bmxBchxOeebKEvPG4wNlrXXmJTYyH7dpxylpg2Bx5x0xOfv6QVHS6oCMwskE2TDgrPwzVXeWZsz1n3QmBAgaokSYH39m8kFx6pVDjdp-WkwfbSFFvfO-3M9Lg3KluopvlY7/" width="320" /></a></div><div class="separator" style="clear: both; text-align: center;"><br /></div><div class="separator" style="clear: both; text-align: center;"><span style="text-align: left;">Chiller plate Version 1.0 with 1.25" wide channels. The plate is 0.6490" thick and it weighs 711.64 grams.</span></div><div class="separator" style="clear: both; text-align: center;"><br /></div><p></p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEis2nigIXkep-AKtHlmm4GyRYgecgFAQafTtAV-X9zx-V6Y3x3ioPnSoDlYSBCO5SU7LzAiN7IVg-Za9B-OpYbEgGqsoZpvESXQjMsA7t-KtA_z4YRHLRUsKQebjp5bKtOYom2xAVwVt3Ip/" style="margin-left: 1em; margin-right: 1em;"><img alt="" data-original-height="240" data-original-width="320" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEis2nigIXkep-AKtHlmm4GyRYgecgFAQafTtAV-X9zx-V6Y3x3ioPnSoDlYSBCO5SU7LzAiN7IVg-Za9B-OpYbEgGqsoZpvESXQjMsA7t-KtA_z4YRHLRUsKQebjp5bKtOYom2xAVwVt3Ip/" width="320" /></a></div><p><span> </span><span> </span><span> </span><span> </span><span> </span><span> </span><span> </span><span> </span><span> </span>The 0.125" NPT (1/8"-27) inlet and outlet ports are 1.50" center to center and were pilot drilled 21/64" drill bit.</p><p><br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgYcZxrBqibBLz1HjjG3maZJptbQx5La00K-Gf2JKyN0r-t3iVXO2_TW0z04UWqOmum9-y63H7bTdNkgUrD2-UcRi1zRBNjeiP1Gj1Hkqm4SygCqSf72izOBlX58ZNt9fRX0-xia3PicHqG/" style="margin-left: 1em; margin-right: 1em;"><img alt="" data-original-height="240" data-original-width="320" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgYcZxrBqibBLz1HjjG3maZJptbQx5La00K-Gf2JKyN0r-t3iVXO2_TW0z04UWqOmum9-y63H7bTdNkgUrD2-UcRi1zRBNjeiP1Gj1Hkqm4SygCqSf72izOBlX58ZNt9fRX0-xia3PicHqG/" width="320" /></a></div><br /> Design 2.0 Chiller plate that is 0.6480" thick and has narrower channels (0.75" wide) and inlet outlet spacing of 1.0" center to center.<div><br /><p></p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiyslJZaE2c4drUa6E86RKFiE2p5jsnSACdYowwyeLKvjfyQfs_mGWGru6dIlgacyF4lj3TRECkONE6PJfGDVZ8Lx-yY4MV7SK4cbThVeLzMUaJtvuZdcev7If-oJY7B7G-jbAA9GTXfP26/" style="margin-left: 1em; margin-right: 1em;"><img alt="" data-original-height="240" data-original-width="320" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiyslJZaE2c4drUa6E86RKFiE2p5jsnSACdYowwyeLKvjfyQfs_mGWGru6dIlgacyF4lj3TRECkONE6PJfGDVZ8Lx-yY4MV7SK4cbThVeLzMUaJtvuZdcev7If-oJY7B7G-jbAA9GTXfP26/" width="320" /></a></div><br />Edge view of Design 2.0 showing the inlet and outlet port separation of 1.0". This picture shows a test unit that has additional NPT ports located on opposite side for addition of optional sensors. <div><br /></div><div><br /></div><div><br /></div><div>Design 2.1 showing the increased separation of inlet and outlet after increasing to 2.0" to allow for 90 degree elbow nipples. (McMaster Carr part # ). The inlet and outlet threads were also made deeper. </div><div><p></p><p> (McMaster Carr part # ) </p><p><br /></p><p><br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEicKvwcV63bxhsrjX3sjPv5bE2w6-yvh-fba9XCjP7r9UULShXV3JCwsB8K2RsLgAOj4NBGYaga4Z6sFYvHJBWsDkLo_MNzrHNO7TJssHaba4c6rcEpbCsjSzG06AthsvxY4SfpE-yiDdVQ/s1920/DSC01206.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEicKvwcV63bxhsrjX3sjPv5bE2w6-yvh-fba9XCjP7r9UULShXV3JCwsB8K2RsLgAOj4NBGYaga4Z6sFYvHJBWsDkLo_MNzrHNO7TJssHaba4c6rcEpbCsjSzG06AthsvxY4SfpE-yiDdVQ/s320/DSC01206.JPG" width="320" /></a></div><br /><p>DSC01206 of Design 2.2 that shows more rounded internal corners at each of the mounting holes to allow for a greater sealing area or the placement of an O-Ring. There is now a uniform 10 mm landing area for the application of sealant. These chill plates weigh 743.68 grams.</p><p><br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg95wLBywV1Y8Q14oGZXf41p_ua6YbidOQRWoD1MhgZMcSj9EdgGUXSRdkQLjMeLLU26cd-V1aM4mMyo7wwBkeYajPTnW7hrODDqG82TmtfjxZB4kac_s9fiNTVkvra1QFqLQpXSyx8mxZ3/s1920/DSC01205.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg95wLBywV1Y8Q14oGZXf41p_ua6YbidOQRWoD1MhgZMcSj9EdgGUXSRdkQLjMeLLU26cd-V1aM4mMyo7wwBkeYajPTnW7hrODDqG82TmtfjxZB4kac_s9fiNTVkvra1QFqLQpXSyx8mxZ3/s320/DSC01205.JPG" width="320" /></a></div><p>DSC01205 Close up showing the difference between the older designs 2.0 and 2.1 (left side with 0.2870" of landing area for silicone sealant at the corners) and the newer design 2.2 (right side with 0.4425" of landing area). This larger area may also allow for the possible future addition of an O-ring. The corner mounting holes remain the same on both plates at 6.5 mm (0.2559").</p><p>Design 2.3 incorporates a longer length by 2 mm (1 mm longer at each end) The drill pattern remains the same and the smaller width (160 mm) remains the same. Increased length necessary to accommodate the latest versions of controllers as supplied by SME.</p><p><span style="font-size: xx-small;">Edited 3/7/2022</span></p><div class="separator" style="clear: both; text-align: center;"><br /></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiR5J7cODe5jXz_K-MHZjPPoKHot1yRsib4bYanYEkGWkVtsd1nxatbIOElFHpsrrnrphEFmUBWknwqvLwM_-PxfRZzXW3fV5Fm04tfqLsk_nmx24mew51LDtZ549QXX_jtqaJhyphenhyphen_zfAXK-/s1920/DSC01207.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiR5J7cODe5jXz_K-MHZjPPoKHot1yRsib4bYanYEkGWkVtsd1nxatbIOElFHpsrrnrphEFmUBWknwqvLwM_-PxfRZzXW3fV5Fm04tfqLsk_nmx24mew51LDtZ549QXX_jtqaJhyphenhyphen_zfAXK-/s320/DSC01207.JPG" width="320" /></a></div><p>DSC01207 picture of longer design 3.242 with longer overall dimensions of 9.50" (242 mm) length and 6.25" width. All previous designs were 8.25" long and 6.25" wide. The 3.0 chill plates weigh 974.82 grams</p><p><span style="font-size: x-small;">updated 3/31/2023</span></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjHtTSTJlZje4Sb51-FylXyz-noRpCPvKH4EVadRzijiHz-jGB4OCDqSLYxEqPtQaYGU2eeMhKceCS16i46khQMydDAof8u8_DfMocSqElm6zhypBwbrEBH213AoPbJfc-aN-4kuPvpyzsO/s1920/DSC01213.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjHtTSTJlZje4Sb51-FylXyz-noRpCPvKH4EVadRzijiHz-jGB4OCDqSLYxEqPtQaYGU2eeMhKceCS16i46khQMydDAof8u8_DfMocSqElm6zhypBwbrEBH213AoPbJfc-aN-4kuPvpyzsO/s320/DSC01213.JPG" width="320" /></a></div><p>DSC01213 side view of Design 3.242 with the inlet/outlets on opposite side away from the terminals. In this case the M6-1.00 x 45 mm cap head bolts extend below the chiller plate. The outer diameter of the cap head bolts is 9.85 mm (0.3878") and the shank length of the heads is 6.05 mm (0.2382")</p><p><br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhrcwdJeVq0NjOjGZaVE7vbKR_4smjMSWPFxPS_WE77QsKw6XOEGjvwg6iU2OZ8OnYPo8Pdz_Zty39pvwJ17bMe-MqDAm-lUhZdoXL9faZtdGFp-hHij1dh_nqawIweLPPCUc-wBV0G6A1M/s1920/DSC01209.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhrcwdJeVq0NjOjGZaVE7vbKR_4smjMSWPFxPS_WE77QsKw6XOEGjvwg6iU2OZ8OnYPo8Pdz_Zty39pvwJ17bMe-MqDAm-lUhZdoXL9faZtdGFp-hHij1dh_nqawIweLPPCUc-wBV0G6A1M/s320/DSC01209.JPG" width="320" /></a></div><br /><p>DSC01209 closeup picture of Design 3.242 (242 mm length) corners showing the 0.625" wide mounting area that now extends beyond the edge of the controller base. This additional shelf area now allows for direct and independent attachment of the chiller controller to any mounting surface.</p><p>This chiller pate was elongated from 242 mm to 244 mm for use in the controller box first described in this blog <span style="font-size: x-small;">2/22/2023</span>. The four controller mounting holes in the chill plate were tapped for M6-1.0 x 30 mm cap head screws. This allows for the chill plate to rest flat on the surface of the base of the controller box. It also allows for the custom drilling of mounting holes (to box or chassis) that are independent of the factory supplied mounting holes.</p><div class="separator" style="clear: both; text-align: center;"><br /></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi0gn8e6Pbc_Dmwyuu4qeCNqOPgGJ4q14iJx4lN40ATIoy3c3--vWViHR89y6rbV8RAH9K0wa2HR_y_esTCSFhg2Vvi6eNLrsDgCMg6n5unMRbAUzz3olNd9L_4ChZe1X9zHIeo-_jm_8TTeEEkVSyHIhJGvNsjZnFH8lF_Slv_TneL6E1_iA7l5cCF0A/s1920/DSC01661.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi0gn8e6Pbc_Dmwyuu4qeCNqOPgGJ4q14iJx4lN40ATIoy3c3--vWViHR89y6rbV8RAH9K0wa2HR_y_esTCSFhg2Vvi6eNLrsDgCMg6n5unMRbAUzz3olNd9L_4ChZe1X9zHIeo-_jm_8TTeEEkVSyHIhJGvNsjZnFH8lF_Slv_TneL6E1_iA7l5cCF0A/s320/DSC01661.JPG" width="320" /></a></div><br /><p>DSC01661 showing the longer chill plate (version 3.244T) and the M6-1.0 tapped mounting holes.</p><p><br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiEmzpX5WB5SaAH7HjMBhxx_e2NvufLu2ZaE-IdsFR3m9blPRakn9vVqOEmXwE7teDyDcu_dZbEDGDx-QpFK1T6-kAPOCNEDpe7OV06Fo-rFTPh5QFYO_gD20Uoveshi-ItbgAaVT0USvx6uzNz8mOJaYP-vNBNvsR4kuxO_3PiU7E6L2Shgk_6c2oytA/s1920/DSC01663.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiEmzpX5WB5SaAH7HjMBhxx_e2NvufLu2ZaE-IdsFR3m9blPRakn9vVqOEmXwE7teDyDcu_dZbEDGDx-QpFK1T6-kAPOCNEDpe7OV06Fo-rFTPh5QFYO_gD20Uoveshi-ItbgAaVT0USvx6uzNz8mOJaYP-vNBNvsR4kuxO_3PiU7E6L2Shgk_6c2oytA/s320/DSC01663.JPG" width="320" /></a></div><br /><p>DSC01663 showing the cap head screws do not extend beyond the base of the controller chill plate.</p><p><span style="font-size: xx-small;">updated 3/31/2023</span></p><p><span style="font-size: x-small;">updated 5/2//2023</span></p><p><br /></p><p> </p></div></div>Williamhttp://www.blogger.com/profile/13072555311952861298noreply@blogger.com0tag:blogger.com,1999:blog-576268040829288449.post-57355940734290621542023-01-07T10:26:00.005-08:002023-03-23T10:09:36.616-07:00Mounting the Water Cooled SME Controller directly to the Hyper9 AC Motor (Version 2 Bracket)<p></p><div class="separator" style="clear: both; text-align: center;"><span style="font-size: large;"><br /></span></div><div class="separator" style="clear: both; text-align: center;"><span style="font-size: large;"><br /></span></div><div class="separator" style="clear: both; text-align: center;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh8BobPSEkcQcCRyhEaBL6nr24AtIU44bpAbrBp5RrEs-_igiA4MA9BfvMprms5uFezrOMwMiudJq0Fthku_HYzdwU2MAme27qowO1RJXJiiupcCiJGJHnmlojGn-B8y_x1rPFqT433G7IceYNZs_j7q-KB-SaPHCAKbDrMQvL3KpqIo9MPzXdtW_MjuQ/s1920/DSC01489.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh8BobPSEkcQcCRyhEaBL6nr24AtIU44bpAbrBp5RrEs-_igiA4MA9BfvMprms5uFezrOMwMiudJq0Fthku_HYzdwU2MAme27qowO1RJXJiiupcCiJGJHnmlojGn-B8y_x1rPFqT433G7IceYNZs_j7q-KB-SaPHCAKbDrMQvL3KpqIo9MPzXdtW_MjuQ/s320/DSC01489.JPG" width="320" /></a></div><span style="text-align: left;"><div class="separator" style="clear: both; text-align: center;"><span style="text-align: left;"><br /></span></div>DSC01489 showing the motor resting in the NetGain cradle. If the cradle is then mounted on a dolly, it can be moved around the shop with ease.</span></div><div class="separator" style="clear: both; text-align: center;"><br /></div><p></p><div class="separator" style="clear: both; text-align: center;"><p style="text-align: left;"><br /></p><div class="separator" style="clear: both;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiW-Mu8O8vLAtf8WLEgGsl9IcG1W_I6tl5xYNb_sPqvOxadTTnT85KNBisb-jqrG70b-VvisjugxLQAIvoLo9rMgcD0X61tVt6LZ3k8gS0nDlI7_rLBnJkfVKv4mfW65bEdT5Vb-nLN5EH64BCqvmDckv4nCbRFcI5ZnTbla-5oGN3To2HVAbsw6XeBFw/s1920/DSC01398.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="225" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiW-Mu8O8vLAtf8WLEgGsl9IcG1W_I6tl5xYNb_sPqvOxadTTnT85KNBisb-jqrG70b-VvisjugxLQAIvoLo9rMgcD0X61tVt6LZ3k8gS0nDlI7_rLBnJkfVKv4mfW65bEdT5Vb-nLN5EH64BCqvmDckv4nCbRFcI5ZnTbla-5oGN3To2HVAbsw6XeBFw/w400-h225/DSC01398.JPG" width="400" /></a></div><p style="text-align: left;">DSC01398 showing the Version 2 welded bracket. The steel bracket was fabricated from a piece of 12 gauge HR metal plate that was cut to 14" x 1.25". The length of each leg is 4.75" and the horizontal surface is 7.75" (the SME controller base is 6.25" x 8.25"). This bracket is version 2.</p><p style="text-align: left;"><span style="font-size: xx-small;">Edited 3/23/2023</span></p><div class="separator" style="clear: both;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjXeewjZJVeJqv770J-R04cpqBAfjBxTzZ8JNj_FNgt-ZkU7bQZ1_ryw3YydHTRxdP2QcFAvocwFQGnLu2NyWXOiYqc5U_Li5A13s34HX9eUQgPuFXbfmNgVqpR0K4exTga_YoMKJQwL4abHoEv3ZiS-Wr0DeqXY6QgHOAWPbTDd4hu4pBCyJU0h81XRQ/s1920/DSC01402.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1920" data-original-width="1080" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjXeewjZJVeJqv770J-R04cpqBAfjBxTzZ8JNj_FNgt-ZkU7bQZ1_ryw3YydHTRxdP2QcFAvocwFQGnLu2NyWXOiYqc5U_Li5A13s34HX9eUQgPuFXbfmNgVqpR0K4exTga_YoMKJQwL4abHoEv3ZiS-Wr0DeqXY6QgHOAWPbTDd4hu4pBCyJU0h81XRQ/s320/DSC01402.JPG" width="180" /></a></div><div style="text-align: left;"><br /></div><span style="text-align: left;">DSC01402 Closeup of the welded bracket on the top section of the cradle. Note that the maximum horizontal surface is about 7.75". The 3" OEM supplied bolts can no longer be inserted from the top and must now be inserted from the bottom along with an additional nut at the top. Alternatively, if the cradle is slightly bent outward, then the bolts can be preinstalled on the bench, and the cradle can then be gently bent back to its original configuration. <span style="font-size: xx-small;"> (1/26/23)</span> The nuts are 1/2"-13 and the bolts are 3.5" long. </span></div><div class="separator" style="clear: both; text-align: center;"><span style="text-align: left;"><br /></span></div><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhMUowo4unfGTBZj1cm7U0Kd6woieAQanQz_oaLsu84tzBDn72RZ79BYv18LdM1RDiSsMwOgnno10DzNYoH_AbTwM9v6ffYteoWeTtTlmLSV3vcBhRvwMl4GywNsO3LBW1bFU5i67aKo3Gmubdf7aHz4JkuB3qkcKmuiuiRz4yzscIxrFSOpdwx-cwz0Q/s1920/DSC01400.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="225" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhMUowo4unfGTBZj1cm7U0Kd6woieAQanQz_oaLsu84tzBDn72RZ79BYv18LdM1RDiSsMwOgnno10DzNYoH_AbTwM9v6ffYteoWeTtTlmLSV3vcBhRvwMl4GywNsO3LBW1bFU5i67aKo3Gmubdf7aHz4JkuB3qkcKmuiuiRz4yzscIxrFSOpdwx-cwz0Q/w400-h225/DSC01400.JPG" width="400" /></a></div><div class="separator" style="clear: both; text-align: center;"><span style="text-align: left;"><br /></span></div><div class="separator" style="clear: both; text-align: center;"><span style="text-align: left;">DSC01399 showing the attached Controller mount on the body of a NetGain Hyper9 AC motor. The way that the cradle is factory designed, the line of draw for the bolts is inward toward the midline. A better design would be to have the bolts of the cradle vertical. This would allow for a maximum mounting surface and easier assembly.</span></div><div class="separator" style="clear: both; text-align: center;"><span style="text-align: left;"><br /></span></div><div class="separator" style="clear: both; text-align: center;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgWKhh0P5VyN-y6aM_bwMKzQOZGUsxoq9zFrWTIDI6L0pgrs2xqvJf5DUD088kZu2tQCWIuaZtyo1fTIQtdA3oIL4ydBJjQDO6v1vpprVbDgBYRg2opRelNXaYYRalm__GfY7Y1xZQUwphuTIxfdYxr2ldqZg_RidnyD-u5b2REVOAZ-zAqLV0E3wD7oA/s1920/DSC01493.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgWKhh0P5VyN-y6aM_bwMKzQOZGUsxoq9zFrWTIDI6L0pgrs2xqvJf5DUD088kZu2tQCWIuaZtyo1fTIQtdA3oIL4ydBJjQDO6v1vpprVbDgBYRg2opRelNXaYYRalm__GfY7Y1xZQUwphuTIxfdYxr2ldqZg_RidnyD-u5b2REVOAZ-zAqLV0E3wD7oA/s320/DSC01493.JPG" width="320" /></a></div><br /><span style="text-align: left;"><br /></span></div><div class="separator" style="clear: both; text-align: center;"><span style="text-align: left;">DSC01493 with both welded cradles (version 2) attached. The useful distance between the mounted brackets is about 19.5 cm. </span></div><div class="separator" style="clear: both; text-align: center;"><span style="font-size: large;"><br /></span></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgSRR2GhE-6NiZyG8l67Cem_ArhQ3KVC6PmX3xltTCct8ly5vdtTvE7NEMezPPxCTgI5F57Cupx5o8Exjxffop00kV0zPdlFMdBaz3p-rRUkfXIojTFjqXlQ7CKGUzSr_bLSxthvbVEdorO69ok5jwC3mXg6OlZ7K_Mh5cvkWfby_aNzm-UloA7ITPfTg/s1920/DSC01406.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1920" data-original-width="1080" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgSRR2GhE-6NiZyG8l67Cem_ArhQ3KVC6PmX3xltTCct8ly5vdtTvE7NEMezPPxCTgI5F57Cupx5o8Exjxffop00kV0zPdlFMdBaz3p-rRUkfXIojTFjqXlQ7CKGUzSr_bLSxthvbVEdorO69ok5jwC3mXg6OlZ7K_Mh5cvkWfby_aNzm-UloA7ITPfTg/w225-h400/DSC01406.JPG" width="225" /></a></div><div class="separator" style="clear: both; text-align: center;"><span style="font-size: large;"><br /></span></div><div class="separator" style="clear: both; text-align: center;"><span style="text-align: left;">DSC01406 End view of the welded cradles and the water cooled SME controller both directly mounted to the cradle. The controller and chiller plate weight about 9.4 pounds. Vibration damping mounts of 0.625" diameter (1/4" - 20) with stud and inserts were purchased (McMaster 93945K11, $5.82 each) that are rated at 15 pounds each. The downward directed stud thread length is 1/2". The upper female threaded portion is 1/4"-20 and 0.25" deep. Zinc plated steel threaded rods (McMaster 95475A551, 2.25" length at $19.60 for 50). 7/8" long coupling nuts were used to secure the controller to the studs to allow easy socket wrench access. No mounting plate in this assembly.</span></div><div class="separator" style="clear: both; text-align: center;"><span style="text-align: left;"><br /></span></div><div class="separator" style="clear: both; text-align: center;"><span style="text-align: left;">The next generation mounting plate should be min. 0.25" taller to allow for air cooled fins to have adequate clearance above motor housing. The upper surface of the steel mounting surface should be min 22 mm from highest point (center of motor).</span></div><div class="separator" style="clear: both; text-align: center;"><br /></div><div class="separator" style="clear: both; text-align: center;"><span style="font-size: large;">Water cooled SME controller on a mounting plate.</span></div><div class="separator" style="clear: both; text-align: center;"><br /></div><div class="separator" style="clear: both; text-align: center;">In both configurations below, a wiring harness will be needed that has tight bends. Possibly a braided strap or a flex braid or a copper buss bar or buss bar ground braid or a pair of custom mechanical lugs that are joined with a flexible 2/0 jumper. </div><div class="separator" style="clear: both; text-align: center;"><br /></div><div class="separator" style="clear: both; text-align: center;"><br /></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgFOjQDEV7XphA8Jo7WHXwdXGvmFHcWW3vTFC2bFlxQXcFcfN-JtBcTVPtbrdTfHKh9t4NXmoZ3j_DZmc0T2CY-6Mh9JjD3Cc-njdM1Vahv4MtMSRiv7_mo5qhK_Y6tSPIqeBwfp9QS1CZFtNirodNBeOJT_yf99Us9KkRy6EviFWwxAaMz6HsvFV_iHg/s1920/DSC01497.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgFOjQDEV7XphA8Jo7WHXwdXGvmFHcWW3vTFC2bFlxQXcFcfN-JtBcTVPtbrdTfHKh9t4NXmoZ3j_DZmc0T2CY-6Mh9JjD3Cc-njdM1Vahv4MtMSRiv7_mo5qhK_Y6tSPIqeBwfp9QS1CZFtNirodNBeOJT_yf99Us9KkRy6EviFWwxAaMz6HsvFV_iHg/s320/DSC01497.JPG" width="320" /></a></div><p>DSC01497 with the SME controller located for power cables on the side. This 6061 plate is 0.125"x7.75"x10.375". Three plates were cut from a scrap piece 20" x 20" x 0.125" plate that was purchased for $29.01. </p><p><br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhbczMq8ZrAcFoNZXCnM3-g-4ctpswfMqD8RsxG-hzx2U6rygXNhL3AEIBmqv0IJ3ch7wGgzHCsqrIS1VxYwP1T9b3yKuJTLgH9HLiCVJoxtdVAQKLvk8l0RGv0mB12c9sGEnHTRI28UITfJBJ3n_gx234g80ydB9pUr69O8B75-GfHtOWwWVNZVLPxhw/s1920/DSC01498.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhbczMq8ZrAcFoNZXCnM3-g-4ctpswfMqD8RsxG-hzx2U6rygXNhL3AEIBmqv0IJ3ch7wGgzHCsqrIS1VxYwP1T9b3yKuJTLgH9HLiCVJoxtdVAQKLvk8l0RGv0mB12c9sGEnHTRI28UITfJBJ3n_gx234g80ydB9pUr69O8B75-GfHtOWwWVNZVLPxhw/w294-h180/DSC01498.JPG" width="294" /></a></div><p> DSC01498 The 6061 plate (0.125" x 7.75" x 10.375") with the SME controller mounted with the power cables on the side. </p><div class="separator" style="clear: both; text-align: center;"><br /></div><div class="separator" style="clear: both; text-align: center;"><br /></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEidi1qZtEAtcMRw-Cwj0Hd4l4-VeMqLeZA39qiMV-CgbgIjS1kZqVQOvJthhnDfvZ70rDpaeOUUOSZO6n7fWWptTnwyX_xZ1arsl-RMz9h0JSU5OzbNtPXVJXzr9cTjSnIAw9F2ePe3OJLJ3PnsQbt80whsmnUyzU4zfmrMuMTvFkfgAL0BrX4cQz4lMg/s1920/DSC01501.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEidi1qZtEAtcMRw-Cwj0Hd4l4-VeMqLeZA39qiMV-CgbgIjS1kZqVQOvJthhnDfvZ70rDpaeOUUOSZO6n7fWWptTnwyX_xZ1arsl-RMz9h0JSU5OzbNtPXVJXzr9cTjSnIAw9F2ePe3OJLJ3PnsQbt80whsmnUyzU4zfmrMuMTvFkfgAL0BrX4cQz4lMg/s320/DSC01501.JPG" width="320" /></a></div><br /> DSC01501 with the SME controller located for power cables at the end. This larger 6061 mounting plate (0.125" x 9" x 10.5") is wide enough that the SME controller can be rotated so that the terminals align with the motor terminals. The connections in this orientation are misaligned. The U1 controller terminal goes to W on the motor, the V1 of controller goes to V on the motor, and the W1 of the controller goes to U on the motor. This alignment results in the motor direction being reversed. A software alteration will be possible to wire in this fashion.<p></p><p><br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhQKlmBECm1K4H0iyFR-rletLiSzdGG9bcYkaxF9zH59JMq8kRkL9mlOHhp_b6a4l3LV0NTOiOq9FNRw7stvM3xaxjD08HE6p5F7r8HEFsw9jBo5TpP1LSqIo_OurRbqrBPgpi8So2q5ap3H9zyy-3bc0_3JNHlQAjeLH-wp7Yv2ZXWfqCWqhITtzVBNw/s1920/DSC01502.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhQKlmBECm1K4H0iyFR-rletLiSzdGG9bcYkaxF9zH59JMq8kRkL9mlOHhp_b6a4l3LV0NTOiOq9FNRw7stvM3xaxjD08HE6p5F7r8HEFsw9jBo5TpP1LSqIo_OurRbqrBPgpi8So2q5ap3H9zyy-3bc0_3JNHlQAjeLH-wp7Yv2ZXWfqCWqhITtzVBNw/s320/DSC01502.JPG" width="320" /></a></div><p>DSC01502 with the SME controller located for power cables at the end.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEif-t0uxbPvtck9cZL55Yd9ib_Q5SG7fwfjLpg6FOm5EolQwQoN-0OrPv9O3n6QTKP3krnJxz-yA7xAfCyGs87wgFcDUia-HJTb90EHKvwVHgT4PVSr7AP9psuC0fwu_5ahz_1M0PujarzrI1yEJblWtlC8iUYq-uEzP0dgt0aHkbnXDeoZecz_WP06vA/s1920/DSC01504.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEif-t0uxbPvtck9cZL55Yd9ib_Q5SG7fwfjLpg6FOm5EolQwQoN-0OrPv9O3n6QTKP3krnJxz-yA7xAfCyGs87wgFcDUia-HJTb90EHKvwVHgT4PVSr7AP9psuC0fwu_5ahz_1M0PujarzrI1yEJblWtlC8iUYq-uEzP0dgt0aHkbnXDeoZecz_WP06vA/s320/DSC01504.JPG" width="320" /></a></div><p>DSC01504 side view of the SME controller oriented for power cables at the end. In this picture, larger 1" vibration damping mounts of 1" diameter were used. (McMaster-Carr 93945K117 at $8.94 each). They are rated at 40 pounds each. </p><p><br /></p><p><span> </span><span> </span><span> </span><span> </span></p>Williamhttp://www.blogger.com/profile/13072555311952861298noreply@blogger.com0tag:blogger.com,1999:blog-576268040829288449.post-1681248201696903182022-07-01T16:26:00.007-07:002023-03-31T07:40:46.772-07:00Hyper9 Motor Support and Cradle - Version 1<p>Purchased a Stainless Steel motor cradle from NetGain Motors (part MC-H9225 for $112.50).</p><p>The pair of galvanized steel clamping bolts are 3.5" long and 1/2"-13 coarse thread (3/4" socket head). Stainless Steel replacement bolts for $3.13 each are available from McMaster-Carr ( https://www.mcmaster.com/93190A726/ ).</p><p><span style="font-size: xx-small;">updated 7/15/2022</span></p><div class="separator" style="clear: both; text-align: center;"><br /></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhtuHhbxDkrTdrhBlI3bUiPDKeuXC_I5k-u0q-R_BTlOmpm0WUhT6tsu91wJzKFWNqDjOqQTxiOcnjXpB7yVRPi8zKVXZI-Jl4yhWit48xhF1B1dcYkO6j9hu8WZnYdFnZuEwmfYIcmHTReN8UGsPa3pxoILEqldnzEXPflUBu4koH2z2lT7FRyWVwEAw/s1920/DSC01363.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="225" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhtuHhbxDkrTdrhBlI3bUiPDKeuXC_I5k-u0q-R_BTlOmpm0WUhT6tsu91wJzKFWNqDjOqQTxiOcnjXpB7yVRPi8zKVXZI-Jl4yhWit48xhF1B1dcYkO6j9hu8WZnYdFnZuEwmfYIcmHTReN8UGsPa3pxoILEqldnzEXPflUBu4koH2z2lT7FRyWVwEAw/w400-h225/DSC01363.JPG" width="400" /></a></div><p>DSC01363 Side view of the 9" ID motor cradle. </p><p><br /></p><p>The engineering drawing for this cradle can be found here:</p><p>https://www.go-ev.com/PDFs/MC_H9225_Information.pdf </p><p><span style="font-size: xx-small;">updated 3/3/2023</span></p><p><br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjIbwKOrolpkhAV6KhpCH7I4j_5DO73t3vkf5pu3RNzjajYEkK3th-GfNjQEJBopvL7vbJIpctNHXHYEEA46hFE-xdNv-h7_ntRD91d0HxrTdQW22Se0lZZmwH_2OMIDM4QFpQ2hB9lXu7bT7GMhFwuJ3kt3uXYIURma9Pji94qZYiQyUnnEEpMNwT-tw/s1920/DSC01366.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1920" data-original-width="1080" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjIbwKOrolpkhAV6KhpCH7I4j_5DO73t3vkf5pu3RNzjajYEkK3th-GfNjQEJBopvL7vbJIpctNHXHYEEA46hFE-xdNv-h7_ntRD91d0HxrTdQW22Se0lZZmwH_2OMIDM4QFpQ2hB9lXu7bT7GMhFwuJ3kt3uXYIURma9Pji94qZYiQyUnnEEpMNwT-tw/s320/DSC01366.JPG" width="180" /></a></div><p>DSC01366 Closer view of 1/2" bolt assembly of the cradle. The bottom of the cradle uses a pair of steel narrow-base weld nuts, 1/2"-13 thread size (McMaster 90594A033, 25 units for $22.27). It is important to align the bolts correctly to engage the lower threads and not cross thread them.. The top fitting is just a thick washer that is crimped fit to the top of the cradle (no threads).</p><p><span style="font-size: xx-small;">Updated 2/17/23</span></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhuFePBlhaiZULx6Ct8ckw1rT6H_eSx7lA3fusk0juoa6hMZAqEmAOveB2jf5GVRXXIoHmEQHtYDiojh1equ8D7rrImLyeUr9Uz2Z_WOdhed8IGnrGbz6zWaEolTchPLNsgLm_Ft9fSdenEpNap-y-BTpwtg_26lyZLALwbzpOllpsp6w0JpfX_njwCLw/s1920/DSC01364.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhuFePBlhaiZULx6Ct8ckw1rT6H_eSx7lA3fusk0juoa6hMZAqEmAOveB2jf5GVRXXIoHmEQHtYDiojh1equ8D7rrImLyeUr9Uz2Z_WOdhed8IGnrGbz6zWaEolTchPLNsgLm_Ft9fSdenEpNap-y-BTpwtg_26lyZLALwbzpOllpsp6w0JpfX_njwCLw/s320/DSC01364.JPG" width="320" /></a></div><div><br /></div><div>DSC01366 Top view of the cradle showing the metal band. The steel band is 1.25" wide and when covered with the rubber bushing the total width is 1.50". </div><div> </div><div><br /></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEikzRgn4jIdFVZdJ0lkJz1V9SuuXHhVC7ww0acjlOHFqXL4WpOMAVCGpH3_fRo07luo6xbTNPv8apMfxg-tOugH0dyNvkqTnNLvhYB9MiBkC466EyCu0VPAuJO62ttPKjp3IJ84hYzADuG7ZNGLH04PCe5vY5zwOc1cv7LdqjKbT_lGm-eue0VBz_qHhQ/s1920/DSC01365.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEikzRgn4jIdFVZdJ0lkJz1V9SuuXHhVC7ww0acjlOHFqXL4WpOMAVCGpH3_fRo07luo6xbTNPv8apMfxg-tOugH0dyNvkqTnNLvhYB9MiBkC466EyCu0VPAuJO62ttPKjp3IJ84hYzADuG7ZNGLH04PCe5vY5zwOc1cv7LdqjKbT_lGm-eue0VBz_qHhQ/s320/DSC01365.JPG" width="320" /></a></div><div><br /></div>DSC01366 Bottom view of the base of the cradle. The metal band is 3 mm thick and 37.75 mm wide (about 1.485"). The pair of mounting holes have a diameter of 0.59" (15.0 mm) and either a 9/16" or 14 mm bolt will pass freely. The mounting holes are 215 mm (about 8 7/16") center to center.<div><br /></div><div><br /></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgPcVZSPpb6OI8MyXlp-_-7iStkx1CWvWtSyc5azju9EC8qTOObXTCah2-IIBLDxzrRt0rFdYcbLipkmneHNFAmbBb899vOpUw0gGZp6FgxHAtpUaicOSQcXhFiRB8L2ipBlmjChXpuGOCYLtrNtLK2BJD2hBmn2YxGI7KrKQTwbOuv7ygSUo5ZJOjTsg/s1920/DSC01375.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgPcVZSPpb6OI8MyXlp-_-7iStkx1CWvWtSyc5azju9EC8qTOObXTCah2-IIBLDxzrRt0rFdYcbLipkmneHNFAmbBb899vOpUw0gGZp6FgxHAtpUaicOSQcXhFiRB8L2ipBlmjChXpuGOCYLtrNtLK2BJD2hBmn2YxGI7KrKQTwbOuv7ygSUo5ZJOjTsg/s320/DSC01375.JPG" width="320" /></a></div><br /><div>DSC01375 Picture showing a Hyper9 body clamped within the NetGain support Cradle.</div><div><div><br /></div><div><br /><p><br /></p></div></div>Williamhttp://www.blogger.com/profile/13072555311952861298noreply@blogger.com0tag:blogger.com,1999:blog-576268040829288449.post-73177574167260938802022-06-28T09:51:00.007-07:002022-07-15T11:12:28.087-07:00Air Cooled Hyper-9 Chill Plate<p>If one is not interested in installing a glycol/water based cooling system along with the Hyper9 controller, then an air based cooling system may be an alternative. If properly constructed and mounted directly over the Hyper9 motor, then accompanied with a forced air fan, it may also be possible to gain some cooling for the motor at the same time.</p><p>In review, the dimensions of the Hyper9 controller are 8.25" by 6.25", and the overall length of the Hyper9HV is about 14" with a maximum width of 9".</p><p>Several sample chill plates were purchased and modified and they are shown in picture DSC01355. All of these chill plates are extruded 6063 alloy and they are manufactured in the USA. The sizes shown are 14" x 8.5" (top left), 14' x 7.25" (top right), 7.25" x 9" (bottom left and center left), and about 8.5" x 7" (bottom right and center right). All of the chill plates have a fin height of 1.0" and an overall thickness of about 1.30".</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh47Z8XT1oGedbflHp-sctj5yPmfNrc8gvotRis7Q1G1y6s3-QNiiZXL4icfL-U0gKG46MzvoEAJN3XXBTH3_OKGIMHxCzIcDhEkpW49EVcoJJ7u-W4e2qWC-FnGe4XCTtU53gvrh9oOBtNvJRSP58wSXZXB4KUXx75ZDryYwQGeEEBjE4g7M-_ueZQrw/s1920/DSC01355.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh47Z8XT1oGedbflHp-sctj5yPmfNrc8gvotRis7Q1G1y6s3-QNiiZXL4icfL-U0gKG46MzvoEAJN3XXBTH3_OKGIMHxCzIcDhEkpW49EVcoJJ7u-W4e2qWC-FnGe4XCTtU53gvrh9oOBtNvJRSP58wSXZXB4KUXx75ZDryYwQGeEEBjE4g7M-_ueZQrw/s320/DSC01355.JPG" width="320" /></a></div><div><br /></div><div>DSC01355 showing the selection of air cooled chill plates that were selected for testing.</div><div><div class="separator" style="clear: both; text-align: center;"><br /></div></div><div><br /></div><div><span> </span><span> </span><span> </span><span> </span><span> </span><span> </span><span> </span><span> </span><span> </span><span> </span><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjZHrg14xLknRKTGgU0HrKs6U4E321xlyKQGYwlG0F6oOvu6Nvgn74v8lYlDxmEqG7E09Lj7w-PGFS-9vGY8PWwnQuuU4XSr93W0eQMN2SM83_1MQ1N0s3w0kMuJMK2M2apdfErrovHxRayvmicagr1b_eWBObxwsecs0awZyhK4V-7Kp6UCsrlCyiV-A/s1920/DSC01358.JPG" style="margin-left: 1em; margin-right: 1em; text-align: center;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjZHrg14xLknRKTGgU0HrKs6U4E321xlyKQGYwlG0F6oOvu6Nvgn74v8lYlDxmEqG7E09Lj7w-PGFS-9vGY8PWwnQuuU4XSr93W0eQMN2SM83_1MQ1N0s3w0kMuJMK2M2apdfErrovHxRayvmicagr1b_eWBObxwsecs0awZyhK4V-7Kp6UCsrlCyiV-A/s320/DSC01358.JPG" width="320" /></a></div><div><br /></div><div><br /></div><div>DSC01358 with a paper template of the controller on top of the fins of the chill plate. These fins run perpendicular to the long length of the controller. The picture shows the template on the same side as the fins, but actually the controller would be on the flat opposite side. We plan to also use a heat transfer paste between the flat surface of the controller and the flat surface of the Chill Plate (to be reported later). </div><div><br /></div><div><span style="font-size: xx-small;">updated 7/15/2022</span></div><div><br /></div><div><span> </span><span> </span><span> </span><span> </span><span> </span><span> </span><span> </span><span> </span><span> </span><span> </span><span> </span><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiBMhdbcczsTb03WfT8kcTnqAhOAeIIduGXDQxXeZj09c0mimi73n_2DOu_Q1IcmlFK_sUgYCK1wHcVeIYV5D3EicZ95wABOA7aQSPwnyIeS8tKG65joM4JSwsYuBRr4flQIFNGz3JK-RiudISfFaekOVGGqpyF6QAf5MtHMBpec4ZHMmcGxg8dxVsMow/s1920/DSC01360.JPG" style="margin-left: 1em; margin-right: 1em; text-align: center;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiBMhdbcczsTb03WfT8kcTnqAhOAeIIduGXDQxXeZj09c0mimi73n_2DOu_Q1IcmlFK_sUgYCK1wHcVeIYV5D3EicZ95wABOA7aQSPwnyIeS8tKG65joM4JSwsYuBRr4flQIFNGz3JK-RiudISfFaekOVGGqpyF6QAf5MtHMBpec4ZHMmcGxg8dxVsMow/s320/DSC01360.JPG" width="320" /></a></div><div><br /></div><div>DSC01360 side view of the mounted 8.5" x 7" chill plate shown in picture DSC01358 in which the fins run perpendicular to the long length of the controller.</div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhkCAD_2fZiUM_Ka75fSLUCik4Gquh2vccR1p8KgZSyrlrJ076LYQ4ARxH_6bYzWCF89oRwqOHsttDxAUW-yf0V_dk98DgjR_2mkD6BzjKEwk7OafXc9vHTirah_vlMINDySxzE3dY6FYur-6O-82Z-Id4y5OrKKIkyLpx1sksQ1XTrmMOL4jZXyKau2w/s1920/DSC01359.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhkCAD_2fZiUM_Ka75fSLUCik4Gquh2vccR1p8KgZSyrlrJ076LYQ4ARxH_6bYzWCF89oRwqOHsttDxAUW-yf0V_dk98DgjR_2mkD6BzjKEwk7OafXc9vHTirah_vlMINDySxzE3dY6FYur-6O-82Z-Id4y5OrKKIkyLpx1sksQ1XTrmMOL4jZXyKau2w/s320/DSC01359.JPG" width="320" /></a></div><div><br /></div><div>DSC01359 with a paper template of the controller on top of the fins of the 7.25" x 9" chill plate. The fins run parallel to the long length of the controller.</div><div><br /></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgNacp_5m_G9wQ32vHqRLoKL7T0tSBNg6L_fHfxd-Rpj26plcngjEkPxYd8bnxi4cy1O4-qgZbcliFsC9IzAzlAQbPv2geeVW9-BzeI-wYZtChuI54cCgOZiHVWeLccecczA2AHQBQP24q06SlO5MgGCdsycBmsOs8TfQDdD2mGi6YSguzh0ztmZuBS6Q/s1920/DSC01361.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgNacp_5m_G9wQ32vHqRLoKL7T0tSBNg6L_fHfxd-Rpj26plcngjEkPxYd8bnxi4cy1O4-qgZbcliFsC9IzAzlAQbPv2geeVW9-BzeI-wYZtChuI54cCgOZiHVWeLccecczA2AHQBQP24q06SlO5MgGCdsycBmsOs8TfQDdD2mGi6YSguzh0ztmZuBS6Q/s320/DSC01361.JPG" width="320" /></a></div><p>DSC01361 side view of the 7.25" x 9" chill plate shown in DSC01359 showing the controller mounted to the face of the chill plate and with the fins running parallel to the long length of the controller.</p><p><br /></p><p><span> </span><span> </span><span> </span><span> </span><span> </span><span> </span><span> </span><span> </span><span> </span><span> </span><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgeZQ5QKrpKUSZfF0xRRmlWDYm4rWNpt1Ydk2nKIhjpTuwgoaMaYbKkE1UkAiVsp4qqY8znzzDne_aKGBXwP6GXm0D3XJ6V5P-M9lv57In_v8R13micpuHqQfX97S7-BSGoGGryV3yqkcLXJXB7LvZ6lIyc7GfVd0gjXdSUZWL-C9W2jqmyW4jzxkN3ug/s1920/DSC01362.JPG" style="margin-left: 1em; margin-right: 1em; text-align: center;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgeZQ5QKrpKUSZfF0xRRmlWDYm4rWNpt1Ydk2nKIhjpTuwgoaMaYbKkE1UkAiVsp4qqY8znzzDne_aKGBXwP6GXm0D3XJ6V5P-M9lv57In_v8R13micpuHqQfX97S7-BSGoGGryV3yqkcLXJXB7LvZ6lIyc7GfVd0gjXdSUZWL-C9W2jqmyW4jzxkN3ug/s320/DSC01362.JPG" width="320" /></a></p><p>DSC01362 top view of the 14' x 7.25" chill plate with paper template of the controller in place to demonstrate the range of location that is possible. This plate is equivalent to the 7.25" x 9" plate shown in DSC01359, but it is longer and it allows for greater variation in the placement of the controller. </p><p><br /></p><p> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiz-RVm1tMn35PgiaM9jjyPu7NouJTIOk6B_zERaeiC-xORsxJdSMZQ7rvr8_xapaEfpQ3AyY0oLwT5YdrPFn3bST6KSFh6_gNtmSAwAp-eZtGI7nfXmcYwr-TXdVCW9--WGQsc0CGIfvSahlu1IkiBMJWZp7bLzXO-XDaqZW8HXOrb5BTquYxuCIIXvA/s1920/DSC01357.JPG" style="margin-left: 1em; margin-right: 1em; text-align: center;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiz-RVm1tMn35PgiaM9jjyPu7NouJTIOk6B_zERaeiC-xORsxJdSMZQ7rvr8_xapaEfpQ3AyY0oLwT5YdrPFn3bST6KSFh6_gNtmSAwAp-eZtGI7nfXmcYwr-TXdVCW9--WGQsc0CGIfvSahlu1IkiBMJWZp7bLzXO-XDaqZW8HXOrb5BTquYxuCIIXvA/s320/DSC01357.JPG" width="320" /></a></p><div>DSC01357 of a chill plate that is 14" x 8.5". This size can allow for a pair of controllers to be mounted on the same surface. The fins run perpendicular to the long dimension of the controller.</div><p><br /></p><p><br /></p><p><br /></p>Williamhttp://www.blogger.com/profile/13072555311952861298noreply@blogger.com0tag:blogger.com,1999:blog-576268040829288449.post-44035769267682774702021-08-11T12:42:00.004-07:002021-09-18T12:26:44.210-07:00NetGain HyPer 9-DHV Motor Controller <p> A Hyper9HV controller was improperly wired by an end user resulting in the failure of an internal capacitor. The four T10 Torx screws that secure the black plastic housing to the Aluminum base were removed and the controller opened so that some pictures could be taken of the internals. SME S.p.A. has very efficiently designed this unit and it is much more compact then the Soliton DC controller that was previously used to control the Warp 11. <span style="font-size: x-small;">updated 8-20-21</span></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiZvbtT-DHtfVmnLUQEvv6y_AYluPoRXKpj9kLL8GhiRX5BG3TYynW1lUWFRgQ-sG26w91d25mk7545A-XnxZI7v8cVv_QJ8-Y6FcFaQzrKj7XNZwMpA9_y7yzTDSbAA153SRlKDD8c6Fv9/s640/IMG_0012.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" height="276" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiZvbtT-DHtfVmnLUQEvv6y_AYluPoRXKpj9kLL8GhiRX5BG3TYynW1lUWFRgQ-sG26w91d25mk7545A-XnxZI7v8cVv_QJ8-Y6FcFaQzrKj7XNZwMpA9_y7yzTDSbAA153SRlKDD8c6Fv9/w368-h276/IMG_0012.jpg" width="368" /></a></div><br /><p>Picture AIMG-0012 Top view showing the pair of cable connectors (upper left and middle far right) and the -B and +B (center) terminals and the U1 and V1 and W1 terminals at the bottom. The +B pre-charge is the small terminal at the bottom to the right of center. <span style="font-size: xx-small;">updated 8-19-21</span></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEilxUIknkGJpO7nd7SgEtD2B3M00djwAFkS2xJGdbIFu0uJ7GyVk35kwe0fueb1kAfiM0i17GtkB3XONc-XHuccD8tnTIZhyphenhyphen60F0PKKwwBcnbqXSPmi34CxSD68zcVfdG4QaiySImVzYL-F/s2048/IMG_0016.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1536" data-original-width="2048" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEilxUIknkGJpO7nd7SgEtD2B3M00djwAFkS2xJGdbIFu0uJ7GyVk35kwe0fueb1kAfiM0i17GtkB3XONc-XHuccD8tnTIZhyphenhyphen60F0PKKwwBcnbqXSPmi34CxSD68zcVfdG4QaiySImVzYL-F/s320/IMG_0016.JPG" width="320" /></a></div><div><br /></div><div>Picture AIMG-0016 End Side View showing the small cable connector (K3) at the top left. The IGBTs are at the bottom and they appear to be directly mounted to the Aluminum base. The Aluminum heat sink base is 160.41 mm x 210.20 mm x 18.23 mm thick. <span style="font-size: x-small;">updated 9-18-21</span></div><div><br /></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh4nT3vosC_gkBuSfiGEgTiI8S_b6AfXCVDh9pbxAwpimTMDTG9RzhgPL3X3B3M2AyehHkrR1niL6vAIxdWFdatl3dHdMMFwa2pwxVbR4cVZESTUNpJU6AiZ-ZLS2Wc-hYW6ZX8Ukoeo3Or/s2048/IMG_0013A.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1536" data-original-width="2048" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh4nT3vosC_gkBuSfiGEgTiI8S_b6AfXCVDh9pbxAwpimTMDTG9RzhgPL3X3B3M2AyehHkrR1niL6vAIxdWFdatl3dHdMMFwa2pwxVbR4cVZESTUNpJU6AiZ-ZLS2Wc-hYW6ZX8Ukoeo3Or/s320/IMG_0013A.JPG" width="320" /></a></div><div><br /></div><div>Picture AIMG-0013A Long Side View adjacent to terminals U1, V1, and W1. Note that each terminal is provided with red o-rings that provide a dust seal between the terminals and black plastic housing.</div><div><br /></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjZ0rwR8wfPvK1TYzmL7u2JW3CPzRw1GKtXtzKnFeaS2CSrnUUmADbtqSzMUgxNjnzHpFdSt5Le_BVYUPREBT1qj5d01hK05QmeqkTityq7LCLLqMuJEz8kYvQD9CEzRgMRwVVERjfJM4xk/s2048/IMG_0015.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1536" data-original-width="2048" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjZ0rwR8wfPvK1TYzmL7u2JW3CPzRw1GKtXtzKnFeaS2CSrnUUmADbtqSzMUgxNjnzHpFdSt5Le_BVYUPREBT1qj5d01hK05QmeqkTityq7LCLLqMuJEz8kYvQD9CEzRgMRwVVERjfJM4xk/s320/IMG_0015.JPG" width="320" /></a></div><br /><p>Picture AIMG-0015 End Side View showing the main cable connector (K1).</p>Williamhttp://www.blogger.com/profile/13072555311952861298noreply@blogger.com0tag:blogger.com,1999:blog-576268040829288449.post-51946081765191984942019-12-14T11:31:00.009-08:002023-06-08T08:03:10.897-07:00NetGain HyPer 9-DHV Motor Controller and Kit.<br />
The product description for the HyPer 9-DHV controller is as follows:<br />
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Type: ACX1T50000100<br />
Model: AC-1X 120/144 V 500 A 112 SWS<br />
SN: 9735730003<br />
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The controller can operate in the range of 90 to 180 volts. This 1992 BMW 325i build will operate at a nominal 144 volts.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjyW_D2saQUAZ-RRKzvvML77SsL_7rv6w8ytaPjS-np4vRjZRqwZ2hX6Ew79TasNGtxXNZF6-vpfmcHEFx6OYJ_PwwCAjlJSyppoT6pez6iCerf6XIbLuyumdQ8926Yg_SolLO0GutRbWLV/s1600/DSC06595.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjyW_D2saQUAZ-RRKzvvML77SsL_7rv6w8ytaPjS-np4vRjZRqwZ2hX6Ew79TasNGtxXNZF6-vpfmcHEFx6OYJ_PwwCAjlJSyppoT6pez6iCerf6XIbLuyumdQ8926Yg_SolLO0GutRbWLV/s320/DSC06595.JPG" width="320" /></a></div>
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DSC06595 Top view of the controller. Terminal bolts are in the plastic bag.<div><br /></div><div><br /></div><div><br /></div><div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi7YlOS-3Sn5PLjRrXLrdHWkkIxHeOIL7O8rmHLvSXCp-CsRKvjzioYmMAVshBktMYMv47TV9fkxNhjgW5uYZxjfXkbxmmCypQwFjTZpF910bRUJSxxDNlT8-YZ7w6F3cSToJN1bq8kWfD5/s1920/DSC01163.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi7YlOS-3Sn5PLjRrXLrdHWkkIxHeOIL7O8rmHLvSXCp-CsRKvjzioYmMAVshBktMYMv47TV9fkxNhjgW5uYZxjfXkbxmmCypQwFjTZpF910bRUJSxxDNlT8-YZ7w6F3cSToJN1bq8kWfD5/s320/DSC01163.JPG" width="320" /></a></div><br />DSC01163 Detail picture of supplied hardware which includes five M8-1.25x20 hex head bolts (torque to 15Nm max)with washer and lock washers. These are used for the -B, +B, U1,V1, and W1 terminals. Also included is a M4-0.7x10 bolt (torque to 2.5Nm max)with both washers. This is used for the +B pre-charge terminal. The outer diameter of the M8x20 Zinc plated bolts was measured to be 7.82 mm. </div><div>Lock washer ID = 8.29mm, flat washer ID = 8.44mm. <span style="font-size: xx-small;">Updated 6-22-2021</span></div><div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiIMBlMQY4KSJ0_lIbkbFTfGHuo5ZORIlm5GtDYekRnXA0Jch5eh82uoo0lnDJ0gCGH1hRMmS9fVn6z8HAq7pp_60gR6pfDKkl8zHuAVO78CJ-rMchxx40MTkOhmcG8JZ8n9XZHfTeVii9x/s1600/DSC06598.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiIMBlMQY4KSJ0_lIbkbFTfGHuo5ZORIlm5GtDYekRnXA0Jch5eh82uoo0lnDJ0gCGH1hRMmS9fVn6z8HAq7pp_60gR6pfDKkl8zHuAVO78CJ-rMchxx40MTkOhmcG8JZ8n9XZHfTeVii9x/s320/DSC06598.JPG" width="320" /></a></div>
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DSC06598 side end view of controller. The black plastic housing is attached to the Aluminum heat sink (base) with four T10 Torx bits (two are shown in the picture). <span style="font-size: x-small;">Updated 9-15-2021</span><br />
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DSC06597 of the 35 pin connector.</div><div><br /></div><div><span style="font-size: xx-small;">Edited 6/8/2023</span></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj8pj63i-wuENMFbivEJeUgwCjGSO3mVlEQ41-unPsv5qpUotrWNdHs7jtFmOtFDRIUyyF4QCs08kfGclbSrQQdjp-eOVrcXP6JWlmFYcELYYyGtwpbM1YtvQrlrO_j-xIqh18DfT0zBKnB8V0oqvGY_bQUVrXBY3wjwe20whlIphKtd8RWxW2Syn194A/s1920/DSC01891.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1080" data-original-width="1920" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj8pj63i-wuENMFbivEJeUgwCjGSO3mVlEQ41-unPsv5qpUotrWNdHs7jtFmOtFDRIUyyF4QCs08kfGclbSrQQdjp-eOVrcXP6JWlmFYcELYYyGtwpbM1YtvQrlrO_j-xIqh18DfT0zBKnB8V0oqvGY_bQUVrXBY3wjwe20whlIphKtd8RWxW2Syn194A/s320/DSC01891.JPG" width="320" /></a></div><br /><div>DSC01891 showing a <span style="background-color: white; color: #2a2a2a; font-family: "Atlas Grotesk Web"; font-size: 16px;">dust cap that was printed for the K1 port on the SME AC-X1 (or X144) Controller/Inverter. Ken (a member of the electric auto club FVEAA) made the cap with a Ender Pro 3 and he has posted the file here:</span></div><div><span style="background-color: white; color: #2a2a2a; font-family: "Atlas Grotesk Web"; font-size: 16px;"><br /></span></div><div><span style="background-color: white; color: #2a2a2a; font-family: "Atlas Grotesk Web"; font-size: 16px;"> </span><a href="https://www.printables.com/model/500848-sme-ac-x1-k1-port-cover" rel="noopener" style="font-family: Helvetica, -apple-system, BlinkMacSystemFont, "Helvetica Neue", "Segoe UI", Arial, sans-serif, "Apple Color Emoji", "Segoe UI Emoji", "Segoe UI Symbol"; font-size: 13px; word-break: break-word;" target="_blank">https://www.printables.com/model/500848-sme-ac-x1-k1-port-cover</a> </div><div><br /></div><div>The cap fits perfectly. We added a few small drops of bathtub Silcone sealer on the inside edges of the cap to further increase the grip of the cap while we are working with the controller. </div><div><br />
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DSC06601 showing the mounting holes at the corners of the base of the controller's Aluminum heat sink. The mounting holes are 6.5 mm diameter and are 197 mm and 147 mm center to center.<br />
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The kit purchased from NetGain included the following:<br />
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HyPer 9-DHV 3 phase motor (pictures shown previously in 9/24/19 blog posting)<br />
Hyper-Drive X144 controller (for up to 144 volts operation) Serial number 9735730003<br />
500 Amps with Standard Ampseal Wire Harness<br />
Gigavac GV200PA-1 contactor<br />
HTS: 8501.32.4500<br />
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DSC06593 of the components included in the kit in addition to the motor and controller. In the center of the picture is the bag of terminal pins for the motor encoder and motor thermistor plugs attached to the motor. Starting at 12:00, the black plastic 3 phase terminal cover, pre-charge relay, Gigavac main contactor relay, computer cable (bottom right), USB to cable, and wire cable bundle with red Ampseal 35 pin connector.<br />
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DSC06596 Picture of the 35 pin Ampseal connector. <span style="font-size: x-small;">Updated 9-18-2021</span></div><div><span style="font-size: x-small;"><br /></span></div><div>A full description of how the crimped wires are installed in the AMPSEAL connector can be found here: <a class="moz-txt-link-freetext" href="https://www.youtube.com/watch?v=uXTkm_XV2OY" rel="noopener" style="color: #3c61aa; font-family: -apple-system, BlinkMacSystemFont, "Helvetica Neue", "Segoe UI", Arial, sans-serif; font-size: 13px; word-break: break-word;" target="_blank">https://www.youtube.com/watch?v=uXTkm_XV2OY</a></div><div><br /></div><div>It appears that this video ( https://www.youtube.com/watch?v=v157tIIQGEc ) discusses the crimping tool used for the AMPSEAL 16 contacts. <span style="font-size: small;">Updated 10-5-2021</span></div><div><br /></div><div><br /></div><div><br />
(picture of Gigavac to be added)<br />
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DSC0 of the Givac 500 amps main contactor relay.<br />
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DSC06677 Top view of the pre-charge relay.<br />
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DSC06678 Side view of the pre-charge relay.<br />
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The HyPer 9-DHV user manual can be found here:<br />
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<a href="https://www.go-ev.com/PDFs/HyPer_9HV_IS_User_Manual_REV08.pdf">https://www.go-ev.com/PDFs/HyPer_9HV_IS_User_Manual_REV08.pdf</a> <br />
<br /></div>Williamhttp://www.blogger.com/profile/13072555311952861298noreply@blogger.com3tag:blogger.com,1999:blog-576268040829288449.post-3245762655844212252019-12-12T22:45:00.003-08:002021-09-07T16:39:09.595-07:00Chiller Plate Fabrication Part 2- Machining Steps<br />
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DSC06687 Picture showing the Aluminum chill plate version 1.0 after the majority of the CNC work had been completed.<br />
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DSC06686 During fabrication a small layer of Aluminum was left on the bottom of the plate which when eventually removed provided a brilliant smooth surface on both the top and bottom faces of the plate.<br />
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The final chiller plate dimensions match the controller base dimensions and they are described in the previous post.<br />
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DSC06602 The 1.25" wide channels allow for good flow and contact surface. The final weight of chill plate version 1.0 was 708.23 grams.<br />
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DSC06627 Showing the internal view of the 0.125" NPT inlet and outlet ports on the side of the chiller plate. <span style="font-size: xx-small;">updated 2/7/2020 </span>Pilot holes drilled with 0.332" (Q) drill ($7.19) and tapped with 1/8-27 NPT tap ($6.19). <span style="font-size: xx-small;">updated 3/18/21</span> The center to center spacing was initially 38.1mm, but later chill plate version 2.2 provided an increased center to center distance of 50.8 mm to accommodate larger footprint 90 degree elbow fittings. <span style="font-size: xx-small;">updated 9/7/21</span><br />
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<br /><span style="font-size: xx-small;">updated 3/18/21</span><br /><div>
DSC06628 Gasket adhesive that was used to secure the Chiller Plate to the base of the controller. One source is Advanced Auto Parts part number 22072 at $4.49. EVWest indicates that white silicone should not be used as it degrades over time. <br />
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To mount the chiller plate to the controller, the bottom surface of the controller and the top surface of the chiller plate are cleaned (brake cleaner or solvent) and then Gasket Maker is applied to the top surface of the chiller plate. The bolt holes are aligned and the two parts are clamped together for curing for 24 hours. Any excess silicone can then be trimmed from the sides. During fabrication of the chiller plate, if a small beveled edge is machined onto one of the top outer edges of the chiller plate, the bevel can allow for insertion of a chisel so that a mallet can then be used to separate the two parts later if needed.<br />
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<strong>Alternative Chill Plate Design - Faster Flow Design</strong><br />
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The inlet inner diameter of a 1/8" NPT hose nipple is 0.307" (thin wall schedule 10) and 0.269" (standard wall schedule 40). Thus for a schedule 40 pipe fitting, the cross sectional area is 0.227 square inches. This cross sectional area will define the flow rate at a given inlet pressure. Once the cooling fluid enters the plate, the larger cross sectional area (rectangle 1.25" wide and 0.50" tall, 0.625 square inches ) results in a flow rate that is only 36.3% of the inlet flow. It is not known how much heat must be removed from the controller when it is under full load. It is possible that a different design with only 0.75" channel width and the same 0.50" depth, will not have any material impact upon performance, but we will make one and test it. This design is much simpler, although tedious to fabricate, when manually operating a Bridgeport.<br />
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DSC06698 Showing the smaller 0.75" width channels in an alternate design chill plate version 2.0. The final weight of this design is 708.41 grams.<br />
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DSC06697 Edge on view showing the input and output NPT threaded holes for version 2.0 at the far side and on this plate the addition of two extra threaded ports holes at the front edge for optional sensors.<br /><span style="font-size: xx-small;">updated 2/7/2020</span><br />
<span style="font-size: xx-small;"></span><span style="font-size: xx-small;">updated 9/7/21</span><br />
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DSC06782 Edge on view showing placement of 0.125" brass plugs installed into sensor ports of version 2.0 with sensor.</div><div><span style="font-size: x-small;">updated 9/7/21</span><br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg60kKyOTuncvs_vNQLWqR7LH-71hhcNPVdugt-_mszSRMKqLoJYzSZtCgYe3XqlrlYrztB7CgPrJiEG3UPop8D1mkPHgITjOG1LoilwGgvOOMfHgnIEGjXOMJSAum0HHxnwLEDSn-SIX2J/s1600/DSC06795.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg60kKyOTuncvs_vNQLWqR7LH-71hhcNPVdugt-_mszSRMKqLoJYzSZtCgYe3XqlrlYrztB7CgPrJiEG3UPop8D1mkPHgITjOG1LoilwGgvOOMfHgnIEGjXOMJSAum0HHxnwLEDSn-SIX2J/s320/DSC06795.JPG" width="320" /></a></div>
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DSC06795 Multiple copies of these plates version 2.0 were fabricated and they are available to others by contacting William at <a href="mailto:sales@narchem.com">sales@narchem.com</a> . <br />
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<span style="font-size: xx-small;">updated 2/19/2020</span><br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj5VFd3pgVxOscXOSFiC1DMf_fT8bkTazwnekPJl5QL7gZbVcdBWV9auke2A6AtwlMJBXBVm3B8V2AEz_pGHkFgJZjFgQqMaphiR27N9tEK2P8669F9VrnD0UY8lvjcQGZ0WxXmpz5Tr5rh/s1600/DSC06792.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj5VFd3pgVxOscXOSFiC1DMf_fT8bkTazwnekPJl5QL7gZbVcdBWV9auke2A6AtwlMJBXBVm3B8V2AEz_pGHkFgJZjFgQqMaphiR27N9tEK2P8669F9VrnD0UY8lvjcQGZ0WxXmpz5Tr5rh/s320/DSC06792.JPG" width="320" /></a></div>
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DSC06792 Picture of McMaster Carr (part 5346K13, $1.19 ea.) straight brass barbed for 1/4" hose ID that was used when the center to center holes was only 1.0" (chill plate version 2.0). The ID of the straight fitting is 0.18".</div><div><span style="font-size: xx-small;">updated 9/7/21</span></div><div><br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgLmaT6X6uFhQIy9Z9vUABNNCi4bdItQqPXPnfHgkGD7aGc0YkvQgUXSa1_N-qUKYIgVVoZ0MdJZ213wC50M83I_mIgQCUzeu92QfV5eXwIOTn3QAv1sy5aLtA3vc8nql2sdj15yE1b1OTC/s1600/DSC06794.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgLmaT6X6uFhQIy9Z9vUABNNCi4bdItQqPXPnfHgkGD7aGc0YkvQgUXSa1_N-qUKYIgVVoZ0MdJZ213wC50M83I_mIgQCUzeu92QfV5eXwIOTn3QAv1sy5aLtA3vc8nql2sdj15yE1b1OTC/s320/DSC06794.JPG" width="320" /></a></div>
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DSC06794 Picture of McMaster Carr (part 53525K11, $2.67 ea) of the 90 degree elbow brass barbed for 1/4" hose ID that was used when the center to center holes was 1.50" (chill plate version 2.1) and there was additional space for rotation of the fitting during installation. The ID of the 90 degree elbow is 0.18".</div><div><span style="font-size: x-small;">updated 9/7/21</span><br />
<br /></div>Williamhttp://www.blogger.com/profile/13072555311952861298noreply@blogger.com4