Day 4 Curriculum

​

• 4 Projects:
• Light Dimmer - Rectify + Pulse Control (Arduino + Transistor)
• Motor controller (maybe), but definitely 120V power tool controller
• ​
• Welder
• Battery Pack
• Take 6 batteries, baggem up!
• Use off-the-shelf charge controller or individual power supply.
• Power Panel
• PWM Power Control Doc
• Arduino PWM Power Control Tutorial
• [[DIY Welding Electrode Holder]]
• https://www.facebook.com/marcin.jakubowski.378/posts/10218309464825166
• ​

Battery Charger

​

​

• Use circuit

​

charger

Power supply, 18V

Light Dimmer

​

• Bridge Rectified
• Arduino controlled light dimmer
• IGBT
• 3D printed socket - design exercise
• Concept: screws clamp down on bulb contacts, as we modify the bulb socket

Welder Design and Build

​

Awesome 3D printed design project: ground clamp with dinosaur (need to open source) + 2 set screws and spring mounth

​

Terminal on Power Panel or at battery bank

​

Ground Clamp

​

• Initial Welder design Doc
• Modules:
• Ground Clamp
• Electrode Holder
• Battery Pack
• Power Board

​

​

Power Panel Concept

​

• 15” x 6” 3D printed panel?
• 4D print
• Heat Gun - to flatten
• Power Panel - riddled with 10 mm holes for mounting components
• Mount circuit boards and terminals and components through the quick-attach holes
• Peg with slit, put it in hole - snaps in
• Insulated structure - it’s plastic
• Components - all components snap in - like a 2-dimensional DIN rail - let’s call it QuickPeg^TM - power electronics unpatent number 1
• Funcional modules snap in on pegs

Function Module

15”

Power Panel Design

​

• 15” x 6” 3D printed panel?
• 4D print
• Heat Gun -
• Power Panel - riddled with ⅜” holes
• Mount circuit boards and terminals and components through the quick-attach holes
• Peg with slit, put it in hole - snaps in
• Insulated structure

TERMINAL BLOCK

ARDUINO

IGBT with Fan and heatsink

RECTIFIER

Gate driver circuit

BAT CHARGER CIRCUIT - ADD TRANSFORMER TO KIT. Needs feedback.

Motor controller with either batteries or transformer. No beedback

Pot Module

Light Dimmer Module

Power Panel Module

​

Empty on Bottom. Perspective view

​

Stack of 2 vertically

​

Stack of 2 horizontally

​

Empty on Bottom. Perspective view

​

• Modular, scalable design
• Use Squares of a size that handles practical components
• Stackable for multiple layers of components
• Like multi-layer PCBs for space optimization
• On Standoffs
• Infinitely Extensible - stackable vertically and horizontally in all directions
• Standoffs for
• Have thickness - 20 mm or enough so quickpeg has grip
• Feature modules
• Standoff
• Foot
• Side-to-side connector
• Hole functions:
• Wire routing
• Peg insertion
• Mounting

Base panel possibilities

​

3 mm thick

​

sandwich

​

Box sandwich

​

Cap

​

Springiness for holding components

​

Types:

• 3 mm thick flat sheet
• Sandwich
• Springiness for holding components
• Cap

Features

​

Standoff

​

Standoffs can also be used for stacking:

Standoffs:

Power Element Module

​

Power Element CAD

​

Heatsink with IGBT

Power Terminal

Power Terminal

Small Terminal

Functional Elements

​

• Quickpeg connected to an Arduino holder 3d printed piece

• Power element holder

Heatsink with IGBT

Power Terminal

Power Terminal

Small Terminal

CAD

​

• Power Panel Parts List
• ​
• Panel
• Terminals - 6 mm set screw
• IGBT holder

fan

heatsink

Mount

​

​

​

​

​

screw

screw

screw

screw

IGBT

Terminal

Terminal

Sig Term.