Quadbike Project (Part 07)

Links to other parts:

Getting off the breadboard

Now that i've tested the throttle and steering circuits/code, i need to get this stuff into an enclosure.

Motor Controllers

For the enclosure, i've decided to use two cast-aluminum boxes instead of one. My thoughts were that the motor speed controllers may emit a fair amount of EMF, so separating them would be a good idea.

esc_top

I'm using two motor speed controllers, one for steering control and the other for the brake motor.

The motor controllers fit quite well in the enclosure however the terminals were the wrong way around. esc_terminals

I was able to de-solder and reverse the terminal pins to allow for the wires to fit in the box. These green terminals were reversed to point the other way.

esc enclosure It was a tight fit getting both motor controllers inside the case.

I de-soldered the header pins and soldered the wires directly to the board. i used a combination of Hot glue, dielectric tape and Sikaflex to help prevent anything from moving around.

For cable choice i used 7-core trailer wire for the high-power side and for the signalling wires i used one of those USB-C cables used to connect a laptop to a laptop dock.

Turns out that USB-C cables are a great source of thin but strong cable that is heavily shielded and has plenty of cores (close to 20-cores if i recall).


Arduino and the rest.

I added the throttle circuit components to a breadboard. The board is also hosting "interconnects" that sit between the arduino and the wiring harness.

throttle_board

I've never been able to create a breadboard circuit without it becoming spaghetti. i hope to replace this with a custom printed PCB in the future.

The Arduino was added to another breadboard with all the wires connected. Thankfully the USB-C cable has color coded shielding.

arduino_board

The arduino, throttle breadboard, RC receiver and power regulator were all crammed into the enclosure.

arduino_enclosure

Just like the motor controller enclosure, i used a combo of Sikaflex, Hot glue and high-strength double-sided table to hold everything in place.

I tested everything after installing in the enclosure and it looks good!!


Part 8 Coming soon....

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