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Update mounting holes and nut seats to match M4 hardware dimensions #37

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EfficiencyJunky opened this issue Jan 6, 2021 · 3 comments
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3D Model Parts that need to be modeled LED Sticks Issues related to the physical sticks Part Update when parts need to be updated

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@EfficiencyJunky
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EfficiencyJunky commented Jan 6, 2021

We want to test if M4 hardware works better than the previous 10-32 hardware for mounting bolts

Things to adjust:

  1. Mounting Bolt hole diameter -> 4mm
  2. Mounting Bolt Head Diameter -> 8mm + Gap
  3. Mounting Nut Width -> 7mm
  4. Mounting Nut Depth -> 3.2mm + Gap
  5. D-Ring clearance -> drop the height of the outer shell from 1mm to 0.2mm -> Add 2mm fillet to inside lip
@EfficiencyJunky EfficiencyJunky added 3D Model Parts that need to be modeled Part Update when parts need to be updated LED Sticks Issues related to the physical sticks labels Jan 6, 2021
@EfficiencyJunky EfficiencyJunky self-assigned this Jan 6, 2021
@EfficiencyJunky EfficiencyJunky added this to To do in Physical Design via automation Jan 6, 2021
@EfficiencyJunky EfficiencyJunky moved this from To do to In progress in Physical Design Jan 6, 2021
@EfficiencyJunky
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EfficiencyJunky commented Jan 6, 2021

10-32 Bolt and nut dimensions:
10-32 Bolt Diameter: 0.19 inch -> mounting_bolt_diameter
10-32 Clearance hole diameter: 5mm -> mounting_bolt_clearance_hole_diameter_10_32
10-32 Nut width: 8mm -> nut_10_32_width
10-32 Nut height: 2.8mm -> nut_10_32_height
10-32 Bolt Head Diameter: 9.5mm -> mounting_bolt_head_diameter
Thickness of plastic from d-ring cutout to head hole == 1mm

M4 Bolt and nut dimensions:
Bolt: https://www.mcmaster.com/92005A242/
Nut: https://www.mcmaster.com/91828A231/

M4 Bolt Diameter: 4mm (3.8mm measured)
M4 Clearance hole diameter: 4mm -> M4_mounting_bolt_clearance_hole_diameter
M4 Nut width: 7mm -> M4_mounting_nut_width
M4 Nut height: 3.2mm -> M4_mounting_nut_height
M4 Bolt Head Diameter: 8mm -> M4_mounting_bolt_head_diameter
Thickness of plastic from d-ring cutout to head hole == 1.8mm

@EfficiencyJunky
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EfficiencyJunky commented Jan 7, 2021

TOP FOUNDATION INSERT

  • Mounting Bolt Hole cutout (from sketch on aluminum bar) (originally 5mm): M4_mounting_bolt_clearance_hole_diameter (4mm)

TOP SHEETH (COVER) -- finished top mounting hole and nut updates and fillet on d-ring cutout in V115

  • Mounting Bolt Head diameter (originally 9.9): M4_mounting_bolt_head_diameter + gap * 3 (8.6mm)
  • Mounting Nut half width (originally 4mm): M4_mounting_nut_width / 2 (3.5mm)
  • extrusion depth for Mounting Nut (originally 3.2): M4_mounting_nut_height + gap (3.4)
  • D-Ring Fillet: 2mm
  • extra height on extrusion (originally 1): 1mm

@EfficiencyJunky
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All M4 Updates complete in V117

Physical Design automation moved this from In progress to Done Jan 7, 2021
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3D Model Parts that need to be modeled LED Sticks Issues related to the physical sticks Part Update when parts need to be updated
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