This is not the last blog for this project, but it is perhaps the main blog because it showcases how well the Hammond box works to house the project. I had fun designing the interior chassis to hold all the subsystems in position.
What is in the box...
This is a quick top-view metamorphosis of how it all goes together before I dive into the design:
Mechanical CAD Design
The next video shows how each 3D printed part was designed and animates them from all angles:
Assembly of the System
Then we get into the main assembly video which is a contender for the centerpiece of this whole project because this project is all about Hammond cases.
Hammond makes an outstanding number of case types in an extremely large number of case sizes, so they always seem to have a case that fits, and there is no question that this particular case is perfect for my application.
Discussion
I am just tickled at how well everything fits and the functionality of each chassis piece. When things go together this well, it is deceptively simple, but knowing how many pitfalls could have happened makes one appreciate the design disproportionately to the amount of apparent effort. Of course it did take lots of time and meticulous design work to make it happen, but that would be really boring to try and include in a video. The design required some calculated risks to be taken (or just plain old luck) for example the super capacitors didn't have a complete data sheet with complete dimensions when I ordered them. If they had been a few mm larger, they may not have fit in the space available.
Project Status
The mechanical design is complete.
The CCA assembly is complete.
The initial mechanical assembly is complete.
The wiring and cabling is complete.
The capacitor voltage monitoring circuit has been tested and calibrated.
The custom booster pack circuitry has been tested it is all functional.
Preliminary firmware to place data on the LCD has been updated and tested.
Power control has been programmed and tested. (Turns off Bluetooth power and sensor power when not needed)
Four project blogs are complete.
Issues
The temperature sensor is not working, although the interface circuit and firmware to read it are working. This sensor was purchased from a suspect source and the part seems to be mis-labelled. More sensors have been ordered. I am not too fussed about this issue since the main challenge for me is to see if the MCU will run all night off the super capacitors. The temperature sensor function will happen when the new parts arrive.
Next Steps
Test the super capacitors and their protection circuit
Write Bluetooth firmware for the MCU
Write an android app to get data via Bluetooth
Replace the temperature sensor when new parts arrive
Test and debug the software
Test the system outside to see if the super capacitors are sufficient
Relevant Links
Just Encase Solar Super Capacitor Experiment - Blog 1
Just Encase Solar Super Capacitor - Project Outline - Blog 2
Just Encase Super Capacitor Solar Weather Station - Design - Blog 3
Just Encase Super Capacitor Solar Weather Station - Assembly - Blog 4
Just Encase Super Capacitor Solar Weather Station - Bluetooth - Blog 5
Just Encase Super Capacitor Solar Weather Station - Indoor Operation - Blog 6
Just Encase Solar Super Capacitor Weather Station - Outdoor Tests - Blog 7
Just Encase Design Challenge
Tube Amp using Hammond transformers
GPS location and distance tracking using LoRa on a MKR WAN 1300
