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Accessible Water Resistance Enclosure System
The design consists of four major components:
80/20 Substructure
Battery Mount and Water-Resistant Shroud
Three-point Mounting (a fore nipple + two aft couplings)
Electrical Enclosure (Electronic + Power Distribution)
Animated View
80/20 Substructure
Extruded Aluminum Modular Structure
Extruded Aluminum Modular Structure
80/20 extruded aluminum was used for the substructure material, acting as the central mounting frame for the electrical enclosures, batteries, and cabling. The substructure is 56”x42” and is attached below the roof to the WAM-V beams by the three-point mounting method described below. The 80/20 mounting structure prioritizes a modular solution to mounting the enclosures and battery structure. Fine tuning, repositioning, and design iteration are leveraged with this approach. Mounting of this substructure to under the roof of the WAM-V allows for easier accessibility to the system's components.
Three-point Mounting
Fore Mount
Fore Mount
The fore mount consists of a 2-part assembly machined from 6061 Aluminum and press-fit together. The design provides both high strength and quick mounting to the front of the boat. The fore mount fits within a round tube with inner diameter of 0.99in. There are four 1/4"-20 holes to affix the mount to the 80/20 structure. The fore mount position is horizontally adjustable across the length of the attached 80/20. The factor of safety for this piece is 15, therefore allowing a great amount of tolerance for the weight of the system.
Aft Mount
Aft Mount
Two aft mounts attach the substructure to boat's rear under-roof bracing bar.
There are two components comprising a singular aft mount: a 2 inch ID coupling and the 80/20 mounting bracket.
The couplings are machined from 6061 Aluminum. It will be used to clamped on a 2 inch powder coated steel round tube with two stainless steel 3/8" - 16 SHCS. The bracket is fabricated from 6" x 4" x 0.25" L stock 6061 aluminum and connected to the coupling with the ability to adjust horizontally to the 80/20 structure, where there are 4 slots to provide adjustment vertically. The factor of safety for these pieces is 3.76 which is less than that of the fore mount, however it is still viable.
Analysis
Analysis
Parameter
Static load of 113 kg (250 lbs)
Impact of 2.5 kN
Electrical Enclosure
Aluminum Trailer Box Enclosures
Aluminum Trailer Box Enclosures
The design of both electronic and power distribution boxes are 90% identical. The power distribution components are separated from the electrical components into their own enclosures in order to improve organization of the system and reduce signal interference between the components. The main different is that the internal components in each require different numbers of I/O connectors and wiring types. The use of back plates for mounting components within the enclosures allows for changes of the specific layouts for future iterations within each box. Each enclosure is designed with 50% expandability for future additions if expansion is necessary.
Both boxes are 30" x 16" x 14" 6061 anodized aluminum. The enclosures are team-verified as IP65 rated, per IEC 60529 standard. The enclosure water-resistance is a high-priority feature due to the ocean faring operating conditions of the RobotX boat.
The design of each enclosure consists of an internal reinforcement frame and mounting brackets. The internal reinforcement consists of three 6061 aluminum bars welded together that will run along the back wall to the top wall of the box. The mounting brackets are made from 2.5" x 2.5" x 0.25" L stock 6061 aluminum, directly connected the internal reinforcement frame. The framing and attachment design ensures the framing supports the primary mechanical loading of the boxes' internals, not the sheeting that makes up the enclosures.
Additionally, IPS65+ cable glands and connectors will not go directly on the wall panel. They are mounted to an adaptive acrylic plate set up. [Show this (image)]
Electronic Enclosure
Electronic Enclosure
The Electronic Enclosure is less weight but requires more cutout features for connecting sensors, cameras, motors, antennas, etc. This separation from the power distribution enclosure allows for organization of each individual component for higher modularity of the overall system.
Power Distribution
Power Distribution
The Power Distribution Enclosure is heavier in weight and contains high power components that create signal noises. In order to minimize signal interference, the power distribution components are separated from the electrical components into their own enclosure.
Analysis
Analysis
Parameter
Static load of 18 kg (40 lbs) for power distribution enclosure
Impact of 2.5 kN
Analysis
Analysis
Parameter
Max Heat Flow 208 W
Constant Convection at 18 W/(m^2℃) with ambient temperature 22 ℃
Become steady state at 33.447℃
Battery Holder
Battery Holder
The battery holder is required to carry two (2) Torqueedo batteries that weight 25.4 kg (56 lbs) each. The terminal connections need to be accessible but protected from direct contact with water.
The Design:
Two (2) 0.125" 5052 aluminum are the support holding the batteries in place separately and ratchet strapped.
The cover is made from 0.063" 5052 aluminum to protect water splashing on terminals and removable for easy access with two (2) quick release pins hold in place.
The support structure consists of multiple parts.
2x1 80/20 aluminum extrusion support the weight on the bottom
Trapezoidal .25" 6061 aluminum connected the 80/20 extrusion and a 2" aluminum square tube
Two (2) machined 6061 aluminum sets of clamps to mount the battery holder system to the 80/20 substructure.
Analysis
Analysis
Battery Holder should:
Carry at least 54 kg (120 lbs)
Withstand a 2 kN impact force due to wave dropped
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