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Albin Varghese edited this page Nov 18, 2024 · 2 revisions

HydroLink Plus 3D Printed Case Documentation

Table of Contents

  1. Introduction
  2. Case Design Overview
  3. Materials and Tools
  4. 3D Printing Instructions
  5. Case Assembly
  6. Exploded View Diagram
  7. Testing and Validation
  8. Conclusion

Introduction

The 3D-printed case for HydroLink Plus ensures a compact, robust, and weatherproof housing for all hardware components. Designed with ease of assembly and outdoor durability in mind, the case facilitates safe operation of the smart water meter under various environmental conditions.

Case Design Overview

The HydroLink Plus case design includes compartments for the ESP32 microcontroller, sensors, power supply, and additional modules, ensuring secure fitting and efficient cable management.

Features

  1. Compact Design:

    • Dimensions: 150mm (L) x 100mm (W) x 70mm (H).
    • Fits all hardware components, including sensors and battery.

  2. Weatherproofing:

    • Includes gaskets and waterproof seals to protect internal components.
    • Drainage holes for water egress in case of leaks.

  3. Easy Access:

    • Removable lid for hardware installation and maintenance.
    • Dedicated slots for cables, valves, and connectors.

  4. Mounting Options:

    • Wall mounting slots and pipe clamps for flexible installation.
    • Solar panel attachment point.

Materials and Tools

Recommended Materials

  1. Filament: PETG or ABS (preferred for outdoor use due to heat and UV resistance).
  2. Gasket Material: Silicone or rubber strips for sealing edges.
  3. Screws: Stainless steel screws for durability.

Required Tools

  • 3D Printer (FDM type preferred).
  • Screwdriver set.
  • Sandpaper (for post-processing edges).
  • Silicone adhesive for waterproofing.

3D Printing Instructions

Printer Settings

  • Layer Height: 0.2mm for balanced quality and print speed.
  • Infill: 50% (recommended for structural integrity).
  • Material: PETG/ABS.
  • Supports: Enabled for overhangs.
  • Bed Temperature: 80°C (for PETG) or 110°C (for ABS).
  • Nozzle Temperature: 240°C (PETG) or 250°C (ABS).

STL File Preparation

  1. Download STL files from the repository: HydroLink Plus 3D Case Files.
  2. Slice the files using software like Cura or PrusaSlicer:
    • Ensure proper orientation for minimal support usage.
    • Preview layers to identify potential issues.

STL File Components

  • Main Body: Houses all hardware components.
  • Lid: Protects internal components and allows easy access.
  • Cable Ports: Slots for power and sensor cables.
  • Mounting Brackets: Supports wall or pipe installation.

Case Assembly

Component Placement

  1. ESP32 Mounting:

    • Secure the ESP32 module using screws in the designated slots.
    • Route cables through the side openings.

  2. Sensor Placement:

    • Attach sensors to their respective holders with secure clips.
    • Ensure the flow sensor aligns with the water pipe inlet and outlet.

  3. Battery and Solar Module:

    • Place the battery in the bottom compartment with foam padding.
    • Use the solar panel mount point for secure placement.

Waterproofing

  1. Apply silicone adhesive around all edges of the lid and cable ports.
  2. Attach rubber gaskets to the lid edges before securing it to the main body.
  3. Verify all screws are tightly sealed to prevent water ingress.

Exploded View Diagram

graph TD;
    A[Case Lid] --> B[Main Body];
    B --> C[ESP32 Mounting Plate];
    B --> D[Sensor Holders];
    B --> E[Battery Compartment];
    D --> F[Flow Sensor];
    D --> G[pH Sensor];
    D --> H[Turbidity Sensor];
    E --> I[Li-ion Battery];
    I --> J[Solar Charger Module];
Loading

Diagram Description

  • The case lid securely fastens onto the main body, providing access to the ESP32 mounting plate and sensor holders.
  • The battery compartment houses the Li-ion battery and the solar charger module, while cable ports allow for organized wiring.

Testing and Validation

  1. Fit Test:

    • Verify all components fit snugly within their compartments.
    • Check for cable clearance in ports and ensure they are not pinched.

  2. Waterproofing Test:

    • Submerge the case in water up to the cable ports for 30 minutes.
    • Inspect for any signs of leakage.

  3. Temperature Test:

    • Place the case in a simulated outdoor environment.
    • Monitor for structural changes under high temperatures (>50°C).

  4. Installation Test:

    • Mount the case on a wall or pipe and verify stability.
HydroLink Plus 2024
HydroLink Plus ©2024

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