Questions tagged [mechanical-assembly]

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38
votes
4answers
11k views

Why did Axial Capacitors Fall Out of Use in the Industry?

When inspecting the boards from electronics made in 1980s and earlier, one distinct feature is the extensive use of axial, electrolytic capacitors as power supply filter. Axial ceramic decoupling ...
18
votes
3answers
3k views

How to secure cables to a PCB

What is a good way to secure cables to a PCB? There are some good advice in the following post, but the application is slightly different: Securing electrical cables to holes in enclosures? In this ...
0
votes
1answer
96 views

Avoiding mechanical shock damage on a PCB

I'm currently working on a PCB design that will have to go in a plastic enclosure. This plastic enclosure will have to endure severe shocks (dropped from 2m to ground) so I'm looking for ways to ...
1
vote
1answer
67 views

Power Cable Strain Relief Solution Needed for Restoring Vintage Electronics

I recently acquired a vintage Tektronix active probe from 1969, and I'm in the process of restoring and modding it for modern scopes. The unit is in good shape, but the connector is no longer in ...
3
votes
3answers
146 views

PCB surface shim

We have a PCB with a detector that must be positioned at a particular height above a mounting surface. Our plastic parts are slightly undersized, so we must add some space (0.4 mm) between our PCB ...
0
votes
2answers
146 views

How to keep users from breaking push button switches

I'm designing an enclosure for a device with a push button switch. The external button on the enclosure is physically large so I am concerned people will apply too much force and break the switch or ...
0
votes
1answer
62 views

Board soldered airtight capsule

Mechanical Engineer here, not an EE. I have some environmental sensors that need to be a part of a flow path. It occurred to me that it might be possible to have a metal "can" that sealed to the ...
0
votes
0answers
42 views

Robotic tool changer functionality

Have you any idea how is a changeable end-of-arm tool powered when is interfaced with an ATI tool changer or something similar ? My first thought is that on both sides of parts is a F/M connectors ...
1
vote
2answers
91 views

Is there a motor design where a rotor gradually moves into a stater? [closed]

I was wondering if there is a motor/generator design where the rotor moves gradually in and out of the stator along the axis of rotation, or the stator over the rotor, but the primary motion is rotary,...
4
votes
1answer
223 views

How do I assemble the mechanical parts of panel mount switch? (lock ring, lock washer, nut, etc)

I'm sure this is a very simple question, but I'm not familiar with the different mechanical parts of a simple switch. For example, I've purchased this switch and it includes: Switch "Lockwasher" ("...
0
votes
0answers
75 views

Vibration and Maintenance friendly way to stack multiple PCBs

For a design stacking pcbs on top of each other, using a a smt interconnect, what is the best way to mechanically hold the PCBs together without using the enclosure. Focusing on: Vibration resistant ...
0
votes
2answers
69 views

How to automatically assemble lithium polymer battery?

I'm redesigning a product for automatic assembly (DFA / DFX). The current product includes a lithium polymer battery with solderable leads, very similar to this: Right now the leads are hand-...
1
vote
2answers
291 views

mounting orientation for Meanwell enclosed power supply

I am building a small system that includes two Meanwell LRS-100 series power supplies: https://www.meanwell.com/Upload/PDF/LRS-100/LRS-100-SPEC.PDF Note the photograph on the first page of the data ...
1
vote
2answers
225 views

How is the shaft of a motor fixed in its position?

Consider for example a brushed DC motor. 1- Is the shaft of the motor (which is rotor in this case), actually floating mid-air because of magnetic field of stator? Why doesn't it fall down due to ...
1
vote
1answer
458 views

best adhesive for FR4 to aluminum

I am making my own LED bulbs (for wedge-base sockets in a low-voltage application). A key construction detail requires me to cement a small (roughly 3/8" x 1") piece of FR4 circuit board (which plugs ...
0
votes
1answer
57 views

Glue used to adhere cellphone / laptop components (not screen)

What type of glue is used to adhere cellphone (or laptop) components (excluding the screen which has its own speciality glue)? I'm talking about the sticky, but not too sticky glue used to hold things ...
0
votes
4answers
147 views

Which type of DC electric motor is the best suited for driving a mechanical clock?

I want to drive a clock mechanism with a motor. In order to get acceptable accuracy I need a motor that can deliver a certain rpm very precisely, is low on vibrations, noise and power consumption, and ...
1
vote
3answers
117 views

Unobtrusive panel mounting for controls

I'm in the middle of a "living room acceptable" project, and I'm looking to capture the spirit of a 1970s preamplifier (Quad 34, see below). My design has 6 LEDs, 4 push buttons, a latching mains ...
0
votes
1answer
325 views

gear motor can be used as generator

I am in doubt with a motors operation, I am not sure whether this question could be asked here, I have a car wiper motor with two speed operation,It uses a PM dc motor with worm gear inside, so it is ...
4
votes
1answer
906 views

What is the usable area (for connectors) of a PCI Express card bracket?

I have a number of awkwardly shaped connectors that I need to cram into a single PCI Express slot metal bracket without any of them colliding with the host PC case's metalwork. The connectors are a ...
2
votes
3answers
1k views

Costs of Conductive Silicone/Rubber Keypad vs. Mechanical Switches?

I am toying around with some new mechanical design ideas. One thing I've never looked at it is the rubber keypads with the conductive "pucks" underneath. I've always used mechanical switches, or ...
8
votes
4answers
635 views

Colliding fasteners in electronics retrofit project

I have a mechanical problem with securing a Mini PCIe card into an adapter which then goes into a legacy product's connector. Look carefully at the orange PCB in the picture below and you'll notice ...
4
votes
2answers
1k views

Motor that allows threaded rod to pass through

Is there a motor that can travel linearly up and down a threaded rod. I already know that you can attach a motor to the end of a threaded rod and make a nut travel along the threaded rod but this is ...
1
vote
1answer
57 views

Control of motor engagement with shaft

I am using servo and stepper motors for the first time, and have been searching for a solution to this basic problem: I want to drive a shaft with a motor, whereby this shaft also has a ‘neutral’ ...
0
votes
1answer
70 views

Bolting a steel ring terminal to a steel tab on IGBT?

This is a similar question to one answered here: what are the best practices for bolting a ring terminal to a steel panel? However, the main difference is that I am not attaching a ring terminal to a ...
1
vote
1answer
376 views

what are the best practices for bolting a ring terminal to a steel panel?

i have made several new bolted grounding points in project boxes and in my car. i don't have data on how long they last, but i been following a strategy like this to connect a ring terminal: drill a ...
2
votes
1answer
416 views

Indicator LED to Case - mechanical design

I got a board for which I need several indicator LEDs and I cant decide on the best solution for the mechanical design of these. The board and the casing currently have a gap of 15mm to each other. ...
3
votes
1answer
135 views

Electromagnetic energy harvesting designing problems

We designed a very simple energy harvester made of a little magnet that moves inside a coil. We have a vibrating environment moving at 12 Hz with 10 millimeters peak-to-peak. Our pcb will be ...
3
votes
3answers
113 views

What is the easiest way to stagger a signal chain on a stack of identical boards?

I am designing a stack of identical boards that each generate an analog signal. What I am trying to do is take the signal from the board above, mix it with the signal from this board, and then send it ...
1
vote
2answers
194 views

Suitable FFC socket for this LCD module

I've ordered this LCD module, and I'm trying to find a suitable connector for it. It's 26 pins with pitch of 0.8mm, but as you can see, the right hand side is "sticking out" of the connector. Is this ...
0
votes
2answers
128 views

Can't recognize circuit element in old clock mechanism

I am spending my free time thinking of how to make an old clock in my hometown working again. Here is a picture of the mechanism. I can't recognize the marked parts. Hope somebody of you can. In this ...
1
vote
4answers
1k views

Standard way to tension a string using a motor?

I am dealing with a design that requires me to tension a small string, about 5 inches long with a diameter of about 1-2 mm, and then keep it under tension (lock it in place) without the use of ...
-1
votes
2answers
157 views

Mechanically securing PCB with imaging sensor

I designed a PCB with an imaging sensor that is mechanically coupled to a lens assembly using four 2-56 screws. The lens/mechanical design realizes an image that is smaller than the imaging sensor (e....
4
votes
1answer
840 views

Which side should I place a TO-220 transistor on a heat sink?

On TO-220 heat sinks, there are usually two sides, on which the transistor fits easily. One side is more narrow, surrounding the transistor. The other side is more open. Which of these sides is ...
1
vote
1answer
1k views

What's a good way to mount an OLED display to a glass/acrylic window?

I have a graphic OLED display I'm using for a project and need to mount it in a chassis. I was planning on using some sort of clear window in an aluminum panel. Perhaps acrylic or glass. I'm ...
0
votes
2answers
892 views

LED to mount securely in little space (< 5mm)?

The picture shows a 2mm wooden board, 4.63mm deep and 9.86mm wide. Below the board there is 3mm clearance for wires. Above the board, there is 5mm of free "air space". Behind the wooden board is a 2×...
-1
votes
2answers
380 views

screws and nuts [closed]

I recently bought such screw: and I would like to use that screw to mount some items on a PCB. Would it be possible to use any type of nut with such type of screws? If it is not the case, it is for ...
5
votes
4answers
4k views

How are air-core inductors typically constructed?

I'm considering learning to build air-core inductors for power applications. For example, I presently want a .5-1 mH choke capable of handling 50 amps for two seconds. Winding my own air-core seems ...
5
votes
3answers
8k views

Are there strong but insulative screws?

Common through-hole power semiconductor devices, like TO-220 and TO-247, can be mounted to a heatsink by running a screw through the hole in the device. However, on TO-220 the hole is often ...
5
votes
2answers
2k views

OK to connect ring terminals directly to a PCB?

I am designing a PCB board and was wondering if there is a reason not to use ring terminals directly to a PCB. The PCB could have a pad surrounding a hole like I often see as ground connections. A ...
14
votes
2answers
4k views

How is this design for a basic PCB pick and place?

I have zero experience with any serious mechanical design, but out of necessity and curiosity, I'm attempting to build a pick and place machine (for my hobby projects as well as low-volume PCB ...
9
votes
2answers
5k views

Is there an insulation compound for exposed leads on a PCB?

The top of the enclosure I am building is going to be the PCB. The PCB has a 7-segment LCD and the leads are somewhat exposed. Is there an insulation material I can brush on or squeeze on that will ...
1
vote
1answer
955 views

Assembly a custom mini-B USB connector

I've bought packages of this connector from Digikey. However, according to the manufacturer, the crimp tool for the USB cable onto these connectors are no longer sold. For the DIY hobbyists out there, ...
1
vote
1answer
278 views

I twisted a L200CV in Pentawatt package; what kind of damage can I expect?

I was installing a heatsink which didn't quite fit and after installing it, I noticed that I've twisted the L200CV about 5° when looking from above the chip. What kind of damage, if any, can I expect?
3
votes
2answers
3k views

How to assemble male USB A connector?

This one should be obvious, but I'd rather ask here then get some unexpected surprises. One of my friends fried a proprietary USB cable which has male USB A connector at one end and TRS connector at ...