sl-mechanical
5cea0812d5
- Design specification: 24V DC power delivery (upgraded from 5V Issue #159) - ArUco marker ID 42 (15cm frame) for precision alignment - Spring-loaded contact pads with V-channel guide rails - Comprehensive BOM for 24V PSU, wiring, LED status circuit - Compatible with docking node #489 (ROS2 integration) - 3D-printable PETG frame (base, back wall, guide rails, brackets) - Electrical: 240W Mean Well IRM-240-24 PSU, 20A current capacity - Safety: Fused output, varistor protection, soft-start capable - Integration: MQTT status reporting, GPIO LED control (Jetson Orin NX) Files: - ISSUE_505_CHARGING_DOCK_24V_DESIGN.md: Complete design spec (mechanical, electrical, assembly) - charging_dock_505_BOM.csv: Procurement list with sourcing info Next: CAD implementation (charging_dock_505.scad, receiver variant) Co-Authored-By: Claude Haiku 4.5 <noreply@anthropic.com>
2.7 KiB
2.7 KiB
| 1 | Item | Description | Specification | Quantity | Unit Cost | Total Cost | Source Notes |
|---|---|---|---|---|---|---|---|
| 2 | E1 | Power Supply | Mean Well IRM-240-24 / Hi-Link HLK-240M24 (24V 10A 240W) | 1 | $50.00 | $50.00 | Digi-Key / Amazon |
| 3 | E2 | 12 AWG Silicone Wire | Red + Black 600V rated 5m spool | 1 | $15.00 | $15.00 | McMaster-Carr / AliExpress |
| 4 | E3 | PG7 Cable Gland | M20 IP67 5-8mm cable | 2 | $3.00 | $6.00 | AliExpress / Heilind |
| 5 | E4 | Varistor (MOV) | 18-28V 1kA | 1 | $1.00 | $1.00 | Digi-Key |
| 6 | E5 | Fuse 25A | T25 Slow-blow 5x20mm | 1 | $0.50 | $0.50 | Digi-Key |
| 7 | E6 | Fuse Holder | 5x20mm inline 20A rated | 1 | $2.00 | $2.00 | Amazon |
| 8 | E7 | Crimp Ring Terminals | M3 12 AWG tin-plated | 8 | $0.20 | $1.60 | Heilind / AliExpress |
| 9 | E8 | Strain Relief Sleeve | 5mm ID silicone 1m | 1 | $5.00 | $5.00 | McMaster-Carr |
| 10 | C1 | Pogo Pin Assembly | Spring-loaded Ø5.5mm 20mm 20A 4mm travel | 2 | $10.00 | $20.00 | Preci-Dip / Jst / AliExpress |
| 11 | C2 | Brass Contact Pad | Ø12x2mm H68 brass bare | 2 | $3.00 | $6.00 | OnlineMetals / Metals USA |
| 12 | C3 | Solder Lug M3 | Copper ring tin-plated | 4 | $0.40 | $1.60 | Heilind / Amazon |
| 13 | L1 | 5mm LED Red | 2.0V 20mA diffuse | 1 | $0.30 | $0.30 | Digi-Key |
| 14 | L2 | 5mm LED Yellow | 2.1V 20mA diffuse | 1 | $0.30 | $0.30 | Digi-Key |
| 15 | L3 | 5mm LED Blue | 3.2V 20mA diffuse | 1 | $0.50 | $0.50 | Digi-Key |
| 16 | L4 | 5mm LED Green | 2.1V 20mA diffuse | 1 | $0.30 | $0.30 | Digi-Key |
| 17 | R1-R4 | Resistor 1kΩ 1/4W | Metal film 1% tolerance | 4 | $0.10 | $0.40 | Digi-Key |
| 18 | J1 | Pin Header 2.54mm | 1x6 right-angle | 1 | $0.50 | $0.50 | Digi-Key |
| 19 | S1 | INA219 I2C Shunt Monitor | 16-bit I2C 0x40 26V max (Optional) | 1 | $5.00 | $5.00 | Adafruit / Digi-Key |
| 20 | S2 | SMD Resistor 0.1Ω | 1206 1W (Optional current sense) | 1 | $1.00 | $1.00 | Digi-Key |
| 21 | M1 | M20 Hex Nut | Steel DIN 934 ~86g | 8 | $0.80 | $6.40 | Grainger / Home Depot |
| 22 | M2 | M4x16 SHCS | Stainless A4 DIN 912 | 16 | $0.30 | $4.80 | Grainger |
| 23 | M3 | M4x10 BHCS | Stainless A4 DIN 7380 | 8 | $0.25 | $2.00 | Grainger |
| 24 | M4 | M4 Heat-Set Insert | Brass threaded | 20 | $0.15 | $3.00 | McMaster-Carr |
| 25 | M5 | M3x16 SHCS | Stainless | 4 | $0.20 | $0.80 | Grainger |
| 26 | M6 | M3 Hex Nut | DIN 934 | 4 | $0.10 | $0.40 | Grainger |
| 27 | M7 | M8x40 BHCS | Zinc-plated floor anchor | 4 | $0.50 | $2.00 | Grainger |
| 28 | M8 | Rubber Foot | Ø20x5mm self-adhesive | 4 | $0.80 | $3.20 | Amazon |
| 29 | A1 | ArUco Marker Print | 100x100mm ID=42 DICT_4X4_250 glossy photo (qty 2) | 2 | $1.50 | $3.00 | Print locally / AliExpress |
| 30 | A2 | Lamination Pouch | A4 80µm | 2 | $0.40 | $0.80 | Amazon / Staples |
| 31 | A3 | Acrylic Cover Sheet | Clear 3mm 150x150mm | 1 | $3.00 | $3.00 | McMaster-Carr |
| 32 | X1 | Solder Wire | 63/37 Sn/Pb lead-free 1m | 1 | $3.00 | $3.00 | Digi-Key |
| 33 | X2 | Flux Paste | No-clean 25mL | 1 | $4.00 | $4.00 | Digi-Key |
| 34 | X3 | Loctite 243 | Thread-locker 10mL | 1 | $4.00 | $4.00 | Grainger |
| 35 | X4 | Epoxy Adhesive | Two-part 25mL | 1 | $6.00 | $6.00 | Home Depot |
| 36 | P1 | PETG Filament (3D Print) | Natural/White 1kg ±15% waste factor | 2.5 | $20.00 | $50.00 | Prusament / Overture |