diff --git a/docs/hardware.md b/docs/hardware.md index ef15cf0..2d8edbe 100644 --- a/docs/hardware.md +++ b/docs/hardware.md @@ -31,9 +31,15 @@ Same on every current `v1` shell (Ethernet, DC jack, power button). Old USB-C re | 2 or 4 each | M2.5 insert | Each of **3 Adafruit module bays** you populate (skip empty bays) | | 10 | M3×8 / M3×10 / M3×12 | Mount screen + lower front to the shell | | 4 | M3 insert | **Adjustable feet only** — omit if using solid feet | +| 2 | M3 screw + nut, or M3 self-tapper | **Ethernet coupler only** — the flange screws into the two Ø4.0 mm rear holes, 27.0 mm apart. No insert: the holes are clearance, not insert pockets | Adafruit total if all three bays are used: **6 or 12** extra M2.5 inserts (2 or 4 per bay). +The rear DC jack and power button clamp into their own Ø12.5 mm holes with the +nuts they ship with — no screws or inserts. See +[Rear I/O openings](parts/shell.md#rear-io-openings) for every rear hole +dimension and what fits it. + ### Screen bezel | Variant | M3 inserts | diff --git a/docs/parts/shell.md b/docs/parts/shell.md index 0063fc5..048dfe6 100644 --- a/docs/parts/shell.md +++ b/docs/parts/shell.md @@ -2,14 +2,105 @@ The rear body. Pick one board-specific file. Every current `v1` shell has the same rear I/O: -- **Ethernet** through the rear -- **Barrel DC jack** for power -- **Power button** +- **Ethernet** — 16.0 × 14.0 mm opening with two Ø4.0 mm screw holes +- **Barrel DC jack** — Ø12.5 mm +- **Power button** — Ø12.5 mm + +Full dimensions and what fits them: [Rear I/O openings](#rear-io-openings). USB-C rear shells are **EOL** (USB-C spec compatibility) — see [`stls/shell/eol/`](../../stls/shell/eol/README.md). ![Pi and UPS mounted in the shell](../drawings/assy-01-boards.png) +## Rear I/O openings + +Every current `v1` shell carries the same three openings on one sloped rear +face, so these numbers apply to `Shell-x1202`, `Shell-x1206` and +`Shell-x12-a1` alike. + +**The face is 3.0 mm thick.** That is the panel thickness a threaded connector +has to clamp, so check that each part's panel-thickness range covers 3 mm +before you buy it. Many panel connectors are cut for thin sheet metal and will +not close on 3 mm of plastic. + +| Opening | Size | Centre (model X) | +| --- | --- | --- | +| **Ethernet** | **16.0 × 14.0 mm** rectangular cut-out (16.0 across the shell, 14.0 up the face), plus **two Ø4.0 mm screw holes 27.0 mm apart**, on the cut-out's horizontal centreline | 40.0 mm | +| **DC power** | **Ø12.5 mm** round | 73.0 mm | +| **Power button** | **Ø12.5 mm** round | 161.8 mm | + +All three centres sit at the same height on the face. Across the 200 mm-wide +shell they run Ethernet, then DC jack, then power button: 33.0 mm from the +Ethernet centre to the DC centre, and 88.8 mm from the DC centre to the button +centre. Measured from the release STLs. + +### What fits the Ethernet opening + +A **panel-mount RJ45 feed-through coupler with a two-screw flange** — the kind +that takes a patch lead on each side, not a punch-down keystone. Check three +numbers on the datasheet before ordering: + +1. the part of the body that passes through the panel is **no larger than + 16.0 × 14.0 mm**; +2. the flange screw holes are **27.0 mm apart** and take **M3** screws — the + shell's Ø4.0 mm holes are clearance, so an M3 screw with a nut behind, or an + M3 self-tapper into the plastic, both work; +3. it is rated for a **3 mm** panel. + +> [!NOTE] +> **Do not buy from the reference model for this opening.** +> [`reference-models/connectors/Ethernet_Panel_Coupler.step`](../../reference-models/connectors/Ethernet_Panel_Coupler.step) +> is a **round coupler with a 21.7 mm thread**, contributed in +> [#8](https://github.com/open-flight/openflight-enclosure/pull/8) as a +> dimensional reference for *other* enclosure projects. This shell has no +> round Ethernet bore at all — its opening is the 16.0 × 14.0 mm rectangle +> above — so that part does not fit a `v1` shell. Match the three numbers +> instead; no specific product is endorsed here. + +### What fits the DC opening + +A **panel-mount DC barrel jack** with: + +- a threaded barrel of **Ø12 mm or less** — the common 12 mm-thread panel jack + is the snug fit; an M11 jack also goes in, with 0.75 mm of slop per side that + its flange covers; +- a **flange or bezel wider than Ø12.5 mm**, so it seats against the face; +- a **panel thickness rating that reaches 3 mm**; +- a **5.5 × 2.1 mm** socket, if you are feeding a Geekworm X1202 or X1206 — + that is the barrel size those boards use. + +Buy one that comes **pre-wired with a flying lead**. This build keeps soldering +to a minimum, and a jack with solder tags adds a joint you would otherwise not +have to make. You will still need an iron for the heat-set inserts, as +[Required hardware](../hardware.md) says. + +Unlike the Ethernet one, the +[reference DC jack](../../reference-models/connectors/DC_5.5x2.1_Panel_Jack.step) +is representative: it is a round jack with an Ø11 mm threaded barrel behind an +Ø15.5 mm flange, 18.5 mm long overall. That drops into the Ø12.5 mm hole with +0.75 mm of slop per side, which the flange covers. + +> [!WARNING] +> **Barrel-jack polarity — get this wrong and you can destroy the Pi, the UPS +> and the radars at once.** A 5.5 × 2.1 mm plug carries no keying: a +> centre-negative supply mates perfectly with a centre-positive jack and +> reverses the rail. The Geekworm **X1202 and X1206 both expect centre pin +> positive (+)** — confirmed by Geekworm in +> [this exchange](https://github.com/open-flight/openflight/pull/273#issuecomment-5779406632); +> their wiki pages do not state it either way, so do not go looking there. +> When you wire the panel jack, the **centre/tip contact goes to +** and the +> sleeve to −, and the supply you plug in must also be centre positive. Buzz +> the jack out with a multimeter before the first power-up rather than +> trusting wire colour. The openflight +> [power guide](https://github.com/open-flight/openflight/blob/main/docs/get-started/power.md) +> covers the wiring end to end. + +### What fits the button opening + +A **12 mm panel-mount momentary push button**. It must be **momentary** +(spring-back): the X1202/X1206 read how long the button is held, so a latching +or toggle switch will not work. + ## Board-specific shells | Board | STL |