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Update mechanical folder structure for multiple sub-assemblies

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- Refactor mechanical/ directory to support multiple sub-assemblies instead of just enclosures
- Update mechanical/README.md with comprehensive sub-assembly organization examples
- Enhance mechanical/cad/README.md with detailed sub-assembly structure (PCB mounts, sensor housing, connector panels, cooling, etc.)
- Expand mechanical/enclosure/README.md to cover main housing, sub-enclosures, and removable panels
- Improve mechanical/stl/README.md with broader 3D printing categories including tooling, prototyping, and custom components
- Update mechanical/drawings/README.md with comprehensive technical drawing organization for all mechanical components
- Add detailed manufacturing considerations, quality control procedures, and file management guidelines
- Support complex projects with multiple mechanical sub-systems and assemblies
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Alexander Grabowski
2025-08-04 14:30:36 +07:00
parent 046f66f6eb
commit a0c843204d
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mechanical/README.md
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# /mechanical # /mechanical
Mechanical design including enclosures and 3D files. 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

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mechanical/cad/README.md
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# /mechanical/cad # /mechanical/cad
Editable CAD files (e.g., FreeCAD, Fusion360). 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

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# /mechanical/drawings # /mechanical/drawings
2D mechanical drawings (e.g., DXF, PDF). 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

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# /mechanical/enclosure # /mechanical/enclosure
STL/STEP files for 3D-printable enclosures. 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

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# /mechanical/stl # /mechanical/stl
Exported STL files ready for printing. 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