diff --git a/mechanical/README.md b/mechanical/README.md index c3be4f3..09bcbb9 100644 --- a/mechanical/README.md +++ b/mechanical/README.md @@ -1,3 +1,75 @@ # /mechanical -Mechanical design including enclosures and 3D files. \ No newline at end of file +Mechanical design files for all physical components and sub-assemblies. + +## Purpose +This directory contains mechanical design files for the complete physical system, including multiple sub-assemblies, enclosures, mounting hardware, and mechanical interfaces. + +## Directory Structure +- `cad/` - Editable CAD models and assemblies +- `drawings/` - 2D technical drawings and specifications +- `enclosure/` - Housing and case designs +- `stl/` - 3D printable files for all components + +## Sub-Assembly Organization +For projects with multiple mechanical sub-assemblies, organize by function: + +``` +mechanical/ +├── cad/ +│ ├── main-assembly/ # Complete system assembly +│ ├── pcb-mount/ # PCB mounting and brackets +│ ├── sensor-housing/ # Sensor enclosures and mounts +│ ├── connector-panel/ # Connector panels and interfaces +│ ├── cooling/ # Heat sinks, fans, thermal management +│ └── fasteners/ # Custom bolts, spacers, hardware +├── drawings/ +│ ├── assembly-drawings/ # Overall assembly drawings +│ ├── detail-drawings/ # Individual part drawings +│ ├── interface-drawings/ # Mating part specifications +│ └── manufacturing-drawings/ # Fabrication specifications +├── enclosure/ +│ ├── main-housing/ # Primary enclosure +│ ├── sub-enclosures/ # Secondary housings +│ └── covers-panels/ # Removable covers and access panels +└── stl/ + ├── enclosure-parts/ # 3D printable enclosure components + ├── mounting-hardware/ # Custom brackets and mounts + ├── prototyping/ # Prototype and test fixtures + └── tooling/ # Assembly jigs and fixtures +``` + +## File Types +- **CAD Files**: Native CAD formats (.sldprt, .step, .iges, .f3d) +- **Drawings**: PDF technical drawings and DXF files +- **3D Models**: STL files for 3D printing, STEP for manufacturing +- **Assembly Files**: Complete system assemblies and sub-assemblies + +## Design Considerations +- **Modularity**: Design for easy assembly and maintenance +- **Manufacturing**: Consider fabrication methods and tolerances +- **Materials**: Document material specifications and requirements +- **Interfaces**: Define mechanical interfaces between sub-assemblies +- **Thermal**: Account for heat dissipation and airflow +- **Accessibility**: Ensure access for assembly, service, and repair + +## CAD File Management +- Use consistent naming conventions across all files +- Maintain assembly hierarchy and relationships +- Include material properties and finish specifications +- Document design intent and critical dimensions +- Version control CAD files with descriptive commit messages + +## Manufacturing Integration +- Coordinate with PCB dimensions and mounting holes +- Consider assembly sequence and tooling requirements +- Define tolerances and critical dimensions +- Specify surface finishes and treatments +- Include inspection and quality requirements + +## Documentation Requirements +- Assembly instructions and procedures +- Bill of materials for mechanical components +- Interface specifications and mating requirements +- Manufacturing and fabrication notes +- Testing and validation procedures diff --git a/mechanical/cad/README.md b/mechanical/cad/README.md index b8cfc64..74019b5 100644 --- a/mechanical/cad/README.md +++ b/mechanical/cad/README.md @@ -1,3 +1,79 @@ # /mechanical/cad -Editable CAD files (e.g., FreeCAD, Fusion360). \ No newline at end of file +Editable CAD models and assemblies for all mechanical components. + +## Purpose +This directory contains the source CAD files for all mechanical components and sub-assemblies in the project. These are the master files used for design, modification, and manufacturing preparation. + +## Organization by Sub-Assembly +Organize CAD files by functional sub-assemblies: + +``` +cad/ +├── main-assembly/ # Complete system assembly +│ ├── system-assembly.sldasm +│ ├── system-layout.dwg +│ └── assembly-bom.xlsx +├── pcb-mount/ # PCB mounting and support +│ ├── pcb-bracket.sldprt +│ ├── standoffs.sldprt +│ └── mounting-plate.sldprt +├── sensor-housing/ # Sensor enclosures and protection +│ ├── sensor-mount.sldprt +│ ├── protective-cover.sldprt +│ └── cable-gland.sldprt +├── connector-panel/ # External interfaces +│ ├── front-panel.sldprt +│ ├── connector-cutouts.dxf +│ └── panel-assembly.sldasm +├── cooling/ # Thermal management +│ ├── heat-sink.sldprt +│ ├── fan-mount.sldprt +│ └── thermal-interface.sldprt +└── fasteners/ # Custom hardware + ├── custom-screws.sldprt + ├── spacers.sldprt + └── washers.sldprt +``` + +## File Types +- **Part Files**: Individual components (.sldprt, .prt, .ipt) +- **Assembly Files**: Multi-part assemblies (.sldasm, .asm, .iam) +- **Drawing Files**: 2D technical drawings (.slddrw, .dwg, .idw) +- **Neutral Formats**: STEP, IGES for cross-platform compatibility + +## CAD Standards +- **Units**: Use consistent units (preferably metric) +- **Materials**: Assign appropriate materials to all parts +- **Properties**: Include mass, volume, and center of gravity +- **Features**: Use parametric modeling with design intent +- **Configurations**: Use configurations for part variations + +## File Naming Convention +- Use descriptive, consistent naming +- Include version numbers for major revisions +- Examples: + - `PCB-Mount-Bracket_v2.1.sldprt` + - `Main-Housing-Assembly_v1.3.sldasm` + - `Connector-Panel-Front_Rev-C.sldprt` + +## Design Documentation +- Include design intent in feature names +- Document critical dimensions and tolerances +- Specify manufacturing processes and materials +- Include assembly notes and special requirements +- Reference related electrical and thermal requirements + +## Version Control +- Commit CAD files with descriptive messages +- Tag major design milestones +- Include PDF drawings with CAD file commits +- Document design changes in commit messages +- Use branching for experimental design variations + +## Manufacturing Preparation +- Generate STEP files for manufacturing +- Create technical drawings with GD&T +- Specify surface finishes and treatments +- Include material specifications +- Document assembly sequences and tooling requirements diff --git a/mechanical/drawings/README.md b/mechanical/drawings/README.md index 0615562..d3b6be0 100644 --- a/mechanical/drawings/README.md +++ b/mechanical/drawings/README.md @@ -1,3 +1,137 @@ # /mechanical/drawings -2D mechanical drawings (e.g., DXF, PDF). \ No newline at end of file +2D technical drawings and specifications for all mechanical components. + +## Purpose +This directory contains 2D technical drawings, specifications, and documentation for manufacturing, assembly, and quality control of all mechanical components and sub-assemblies. + +## Drawing Organization +Organize drawings by type and sub-assembly: + +``` +drawings/ +├── assembly-drawings/ # Overall system and sub-assembly drawings +│ ├── main-assembly-drawing.pdf +│ ├── pcb-mount-assembly.pdf +│ ├── sensor-housing-assembly.pdf +│ └── connector-panel-assembly.pdf +├── detail-drawings/ # Individual part drawings +│ ├── machined-parts/ +│ ├── sheet-metal-parts/ +│ ├── molded-parts/ +│ └── standard-hardware/ +├── interface-drawings/ # Mating part specifications +│ ├── pcb-interface-spec.pdf +│ ├── connector-interface-spec.pdf +│ ├── mounting-interface-spec.pdf +│ └── cable-interface-spec.pdf +└── manufacturing-drawings/ # Fabrication specifications + ├── machining-drawings/ + ├── sheet-metal-drawings/ + ├── molding-drawings/ + └── 3d-printing-drawings/ +``` + +## Drawing Types + +### Assembly Drawings +- **Overall Assembly**: Complete system with all sub-assemblies +- **Sub-Assembly**: Individual functional groups +- **Exploded Views**: Component relationships and assembly sequence +- **Section Views**: Internal construction and interfaces +- **Installation Drawings**: Mounting and positioning requirements + +### Detail Drawings +- **Part Drawings**: Individual component specifications +- **Fabrication Drawings**: Manufacturing process details +- **Inspection Drawings**: Quality control and measurement points +- **Modification Drawings**: Engineering changes and updates + +### Interface Drawings +- **Mechanical Interfaces**: Mating surfaces and clearances +- **Electrical Interfaces**: Connector positions and orientations +- **Thermal Interfaces**: Heat transfer surfaces and requirements +- **Fluid Interfaces**: Sealing and flow requirements + +## Drawing Standards + +### Dimensioning and Tolerancing +- **GD&T**: Geometric dimensioning and tolerancing per ASME Y14.5 +- **Critical Dimensions**: Identify key functional dimensions +- **Tolerance Stack-up**: Analysis of cumulative tolerances +- **Inspection Requirements**: Measurement methods and equipment + +### Drawing Format +- **Title Block**: Part number, revision, date, approvals +- **Drawing Scale**: Appropriate scale for clarity +- **View Selection**: Minimum views to fully define geometry +- **Section Views**: Internal features and construction +- **Detail Views**: Enlarged views of critical features + +### Material Specifications +- **Material Callouts**: Specific material grades and specifications +- **Heat Treatment**: Required thermal processing +- **Surface Finish**: Roughness and appearance requirements +- **Coating/Plating**: Protective and decorative finishes +- **Hardware Specifications**: Fastener grades and specifications + +## Manufacturing Information + +### Machining Drawings +- **Setup Instructions**: Workholding and fixturing requirements +- **Tool Requirements**: Cutting tools and parameters +- **Inspection Points**: Critical dimensions and tolerances +- **Surface Finish**: Machining quality requirements + +### Sheet Metal Drawings +- **Bend Allowances**: Material deformation calculations +- **Forming Operations**: Bending, punching, and cutting sequences +- **Weld Symbols**: Welding specifications and requirements +- **Finishing Operations**: Deburring, cleaning, and coating + +### Molding Drawings +- **Draft Angles**: Mold release requirements +- **Parting Lines**: Mold separation surfaces +- **Gate Locations**: Material injection points +- **Ejector Pin Locations**: Part removal mechanisms + +### 3D Printing Drawings +- **Print Orientation**: Optimal build direction +- **Support Requirements**: Support material locations +- **Post-Processing**: Required finishing operations +- **Material Specifications**: Filament or resin requirements + +## Quality Control + +### Inspection Drawings +- **Measurement Points**: Critical dimension locations +- **Inspection Methods**: Required measurement techniques +- **Acceptance Criteria**: Pass/fail specifications +- **Documentation Requirements**: Inspection record keeping + +### Testing Specifications +- **Functional Testing**: Performance verification requirements +- **Environmental Testing**: Temperature, humidity, vibration +- **Durability Testing**: Lifecycle and wear requirements +- **Safety Testing**: Regulatory compliance verification + +## File Management + +### Drawing Revisions +- **Revision Control**: Systematic revision tracking +- **Change Documentation**: Engineering change orders (ECOs) +- **Approval Process**: Design review and sign-off procedures +- **Distribution Control**: Controlled document distribution + +### File Formats +- **PDF**: Standard format for manufacturing and inspection +- **DWG/DXF**: CAD-compatible formats for editing +- **Native CAD**: Original drawing files for modifications +- **Archive Formats**: Long-term storage and retrieval + +## Documentation Standards +- **Drawing Numbers**: Systematic part numbering system +- **Revision Letters**: Alphabetical revision tracking +- **Date Formats**: Consistent date representation +- **Approval Signatures**: Required design approvals +- **Distribution Lists**: Controlled document recipients diff --git a/mechanical/enclosure/README.md b/mechanical/enclosure/README.md index d3a83c1..fc7731d 100644 --- a/mechanical/enclosure/README.md +++ b/mechanical/enclosure/README.md @@ -1,3 +1,93 @@ # /mechanical/enclosure -STL/STEP files for 3D-printable enclosures. \ No newline at end of file +Housing and enclosure designs for the complete system. + +## Purpose +This directory contains enclosure and housing designs that protect and contain the electronic and mechanical components. Enclosures may include multiple housings, covers, and panels depending on system complexity. + +## Enclosure Types +Organize by enclosure function and hierarchy: + +``` +enclosure/ +├── main-housing/ # Primary system enclosure +│ ├── base-housing.sldprt +│ ├── top-cover.sldprt +│ ├── gaskets-seals.sldprt +│ └── housing-assembly.sldasm +├── sub-enclosures/ # Secondary or modular housings +│ ├── sensor-module-housing/ +│ ├── power-supply-housing/ +│ ├── interface-module-housing/ +│ └── expansion-module-housing/ +└── covers-panels/ # Removable access components + ├── access-panels/ + ├── connector-panels/ + ├── display-bezels/ + └── ventilation-grilles/ +``` + +## Design Considerations + +### Environmental Protection +- **IP Rating**: Define ingress protection requirements +- **Sealing**: Gaskets, O-rings, and weatherproofing +- **Drainage**: Water management and condensation control +- **Ventilation**: Airflow and thermal management + +### Mechanical Requirements +- **Structural Integrity**: Load bearing and impact resistance +- **Mounting**: Wall mount, panel mount, or free-standing +- **Access**: Service panels and component accessibility +- **Cable Management**: Entry points and strain relief + +### Manufacturing Considerations +- **Material Selection**: Plastic, metal, composite materials +- **Manufacturing Process**: Injection molding, machining, sheet metal +- **Tolerances**: Fit and finish requirements +- **Surface Treatment**: Painting, anodizing, texturing + +### Electrical Integration +- **EMI/RFI Shielding**: Electromagnetic compatibility +- **Grounding**: Electrical safety and noise reduction +- **Cable Entry**: Glands, connectors, and feedthroughs +- **Heat Dissipation**: Thermal interface to internal components + +## File Organization + +### Main Housing Files +- **Base/Bottom**: Primary structural component +- **Cover/Top**: Removable or hinged access +- **Sides/Walls**: Structural walls and mounting surfaces +- **Internal Structure**: Mounting posts, ribs, and supports + +### Sub-Enclosure Files +- **Modular Housings**: Self-contained sub-assemblies +- **Protective Covers**: Component-specific protection +- **Interface Panels**: User interaction surfaces +- **Mounting Brackets**: Attachment to main housing + +### Hardware and Fasteners +- **Screws and Bolts**: Fastening hardware specifications +- **Hinges and Latches**: Access mechanism components +- **Gaskets and Seals**: Environmental protection components +- **Inserts and Threads**: Threaded fastening points + +## Material Specifications +Document material requirements for each component: +- **Mechanical Properties**: Strength, flexibility, durability +- **Environmental Resistance**: UV, chemical, temperature +- **Electrical Properties**: Conductivity, dielectric strength +- **Regulatory Compliance**: UL, CE, RoHS requirements + +## Assembly Instructions +- **Assembly Sequence**: Order of component installation +- **Torque Specifications**: Fastener tightening requirements +- **Sealing Procedures**: Gasket installation and verification +- **Quality Checks**: Dimensional and functional verification + +## Testing and Validation +- **Environmental Testing**: Temperature, humidity, vibration +- **Ingress Protection**: Water and dust resistance verification +- **EMC Testing**: Electromagnetic compatibility validation +- **Mechanical Testing**: Drop, impact, and load testing diff --git a/mechanical/stl/README.md b/mechanical/stl/README.md index a61f137..962cbdf 100644 --- a/mechanical/stl/README.md +++ b/mechanical/stl/README.md @@ -1,3 +1,121 @@ # /mechanical/stl -Exported STL files ready for printing. \ No newline at end of file +3D printable files for all mechanical components and sub-assemblies. + +## Purpose +This directory contains STL files ready for 3D printing, organized by functional categories. These files support prototyping, custom tooling, replacement parts, and production components. + +## Organization by Function +Organize STL files by their intended use and sub-assembly: + +``` +stl/ +├── enclosure-parts/ # 3D printable enclosure components +│ ├── housing-prototypes/ +│ ├── custom-panels/ +│ ├── mounting-brackets/ +│ └── access-covers/ +├── mounting-hardware/ # Custom brackets and mounting solutions +│ ├── pcb-mounts/ +│ ├── sensor-brackets/ +│ ├── cable-management/ +│ └── standoffs-spacers/ +├── prototyping/ # Prototype and development parts +│ ├── concept-models/ +│ ├── fit-test-parts/ +│ ├── functional-prototypes/ +│ └── design-iterations/ +├── tooling/ # Assembly and manufacturing aids +│ ├── assembly-jigs/ +│ ├── test-fixtures/ +│ ├── alignment-tools/ +│ └── handling-fixtures/ +├── replacement-parts/ # Service and maintenance components +│ ├── wear-parts/ +│ ├── consumables/ +│ └── field-replaceable/ +└── custom-components/ # Project-specific mechanical parts + ├── actuator-parts/ + ├── interface-components/ + ├── structural-elements/ + └── specialty-hardware/ +``` + +## File Naming Convention +Use descriptive names that include key specifications: +- `PCB-Mount-Bracket_M3-Holes_v2.1.stl` +- `Sensor-Housing-Top_IP65_ABS.stl` +- `Cable-Gland_PG16_TPU-Flexible.stl` +- `Assembly-Jig_Main-PCB_PLA.stl` + +## Print Settings Documentation +Include recommended print settings for each component: + +### Material Recommendations +- **PLA**: Prototyping, non-critical parts, tooling +- **PETG**: Mechanical parts, chemical resistance +- **ABS**: Structural components, higher temperature resistance +- **TPU**: Flexible parts, gaskets, vibration dampening +- **ASA**: Outdoor use, UV resistance +- **PC**: High strength, high temperature applications + +### Print Quality Settings +Document recommended settings for each part: +- **Layer Height**: 0.1mm (fine), 0.2mm (standard), 0.3mm (draft) +- **Infill**: 10-20% (light), 40-60% (standard), 80-100% (structural) +- **Support**: Required/not required, support type +- **Orientation**: Optimal print orientation for strength/finish +- **Post-Processing**: Required finishing operations + +## Quality Control +### Print Validation +- **Dimensional Accuracy**: Critical dimensions and tolerances +- **Surface Finish**: Required surface quality +- **Mechanical Properties**: Strength and durability requirements +- **Fit and Function**: Assembly and mating requirements + +### Testing Procedures +- **Fit Testing**: Verify assembly with mating parts +- **Functional Testing**: Confirm operational requirements +- **Durability Testing**: Lifecycle and wear testing +- **Environmental Testing**: Temperature and chemical resistance + +## Manufacturing Notes +### Production Considerations +- **Print Time**: Estimated printing duration +- **Material Usage**: Filament consumption estimates +- **Batch Production**: Multiple part printing strategies +- **Quality Assurance**: Inspection and acceptance criteria + +### Alternative Manufacturing +Document when injection molding or machining might be preferred: +- **Volume Thresholds**: When to consider other processes +- **Material Limitations**: Properties not achievable with 3D printing +- **Tolerance Requirements**: Precision beyond 3D printing capabilities +- **Surface Finish**: Requirements for smooth or textured surfaces + +## File Management +### Version Control +- Include version numbers in filenames +- Document changes in commit messages +- Tag releases for production parts +- Maintain design history and rationale + +### Source File References +- Link STL files to source CAD files +- Document any modifications made for 3D printing +- Include original design intent and specifications +- Reference assembly drawings and instructions + +## Print Instructions +### Setup Requirements +- **Printer Specifications**: Minimum build volume and capabilities +- **Material Preparation**: Drying and storage requirements +- **Bed Preparation**: Adhesion and leveling requirements +- **Environmental Conditions**: Temperature and humidity control + +### Post-Processing +- **Support Removal**: Techniques and tools required +- **Surface Finishing**: Sanding, smoothing, or coating +- **Assembly Preparation**: Drilling, tapping, or fitting operations +- **Quality Inspection**: Dimensional and visual checks