Chassis I/O Panels
These panels were designed to interface with our chassis to allow the integration of mechanical and electrical components
Design Goal
The engineering problem I was given the task of solving was to create panels that would fit into the chassis and give the functionalities for I/O components needed in specific areas of the assembly.
Fastening the Panels
The last step was to engineer a method for both locating and securing the panels to the chassis. Our existing design for the cutouts in the chassis had clearance holes, so I used pem nuts in the opposite face of the side panels to allow bolts to secure it in place.
Sheet Metal
Given the components I needed to include in each of the panels, I decided to use sheet metal design to make the parts. This choice was made as the panels would be easy to bend from a 2D frame, and for more efficient manufacturing.
Once I made the outline of each of the panels. I used the CAD models and drawings of the desired components to design extruded cuts for the necessary parts.
Hard Decisions
Part of the design process for these pieces included some critical design decisions for the function and assembly. A key change made was using a recessed panel for the power switches and the e-stops to ensure they were unable to be switched accidentally. In addition, some of the placement of the extruded cuts were altered after an assembly of the pieces were made to ensure the components used were not interfering with other parts of the chassis, and for cable management.
Final Assembly
I used the part models to make engineering drawings for sheet metal, ensuring the gussets and bends were notated correctly, and contacted a manufacturer for fabrication. Eventually these parts were mounted on the chassis and worked as designed.
