Difference between revisions of "Creating an enclosure to mount a PCB"

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==Select components to mount in enclosure==
 
==Select components to mount in enclosure==
−
#Source the components you want to mount in your enclosure<br>[[File:photo-mini-ITXPCB.png|250px|left|thumb|Mini-ITX PCB]][[File:photo-fan-60mm.png|100px|left|thumb|60mm Fan]][[File:photo-powersupply.png|200px|left|thumb|Power Supply]]<br>
+
#Source the components you want to mount in your enclosure.<br>
 +
#:''Mini-ITX PCB''
 +
#:[[File:photo-mini-ITXPCB.png|250px]]  
 +
#:''60mm Fan''
 +
#:[[File:photo-fan-60mm.png|100px]]
 +
#:''Power Supply''
 +
#:[[File:photo-powersupply.png|200px]]
  
 
==Determine mounting specifications for components==
 
==Determine mounting specifications for components==
 
The figures below are rough sketches of the example components with their measurements. All dimensions (given in inches) are measured using mechanical calipers.
 
The figures below are rough sketches of the example components with their measurements. All dimensions (given in inches) are measured using mechanical calipers.
−
#Determine the mounting hole and cutout dimensions and locations for all the components.<br><br>
+
#Determine the mounting hole and cutout dimensions and locations for all the components.
−
[[File:sketch-powersupply-pcb.jpg|600px|thumb|center|Top view: Sketch of power supply and PCB mounting dimensions]]<br>
+
#:''Top view: Sketch of power supply and PCB mounting dimensions''
−
[[File:sketch-powersupply-pcb-rear.jpg|600px|thumb|center|Rear view: Sketch of power supply and PCB mounting dimensions]]<br>
+
#:[[File:sketch-powersupply-pcb.jpg|600px]]
−
{{Note|Mounting dimensions are not needed for the 60mm fan, since a built-in cutout for the fan will be used.
+
#:''Rear view: Sketch of power supply and PCB mounting dimensions''
−
}}{{Note|It is important to properly understand how to mount each component, including any required clearances.
+
#:[[File:sketch-powersupply-pcb-rear.jpg|600px]]
−
}}
+
'''Notes'''
 +
:*Mounting dimensions are not needed for the 60mm fan, since a built-in cutout for the fan will be used.
 +
:*When mounting each component, include any required clearances.
  
 
==Determine mounting locations for components==
 
==Determine mounting locations for components==
−
{{Procedure|
 
 
#Determine mounting location for all components.
 
#Determine mounting location for all components.
 
#Determine cutout, mounting hole, and self-clinching fastener sizes to mount all components.
 
#Determine cutout, mounting hole, and self-clinching fastener sizes to mount all components.
−
#Create a sketch of all required mounting dimensions.<br><br>[[File:sketch-mounting-dimensions.jpg|600px|thumb|center|Top view: Sketch of power supply and PCB mounting dimensions]]<br>[[File:sketch-mounting-dimensions-rear.jpg|600px|thumb|center|Rear view: Sketch of power supply and PCB mounting dimensions]]<br>
+
#Create a sketch of all required mounting dimensions.
−
}}{{Note|Dimensions are always measured from the absolute origin shown on the OUTSIDE of the base of the enclosure, and therefore you must factor in the thickness of the enclosure.}}<br>
+
#:''Top view: Sketch of power supply and PCB mounting dimensions''
 +
#:[[File:sketch-mounting-dimensions.jpg|600px|]]
 +
#:''Rear view: Sketch of power supply and PCB mounting dimensions''
 +
#:[[File:sketch-mounting-dimensions-rear.jpg|600px]]
 +
{{Note|Dimensions are always measured from the absolute origin shown on the OUTSIDE of the base of the enclosure, and therefore you must factor in the thickness of the enclosure.}}<br>
  
 
===Tips on positioning components and cutouts===
 
===Tips on positioning components and cutouts===
Line 36: Line 47:
  
 
==Create enclosure from template==
 
==Create enclosure from template==
−
{{Procedure|
 
 
#Open Protocase Designer and click '''New File''', or, if Protocase Designer is already open, click '''New''' in the '''File''' menu,  
 
#Open Protocase Designer and click '''New File''', or, if Protocase Designer is already open, click '''New''' in the '''File''' menu,  
−
#Click '''Rackmount Enclosures''', then click '''Rackmount'''.<br><br>[[File:window-newassembly-rackmount-color.png|500px|thumb|centre|New Assembly window]]<br>
+
#Click '''Rackmount Enclosures''', then click '''Rackmount'''.
 +
#:The New Assembly window opens.
 +
#:[[File:window-newassembly-rackmount-color.png|500px]]
 
#Enter a '''Depth''' of 15 (inches) and '''Height''' of 2 (U).
 
#Enter a '''Depth''' of 15 (inches) and '''Height''' of 2 (U).
 
#Select a color for each panel, as desired and then click '''OK'''.
 
#Select a color for each panel, as desired and then click '''OK'''.
 
#Select 14 (.075) for all thicknesses.
 
#Select 14 (.075) for all thicknesses.
−
#On the '''View''' menu, click '''Show/Hide Parts'''.<br><br>[[File:dialogbox-showhideparts-rackmount.png|300px|thumb|centre|Show/Hide Parts dialog box]]<br>
+
#On the '''View''' menu, click '''Show/Hide Parts'''.
−
#Click to clear the '''Cover''' check box. This will hide the cover, letting you view the inside of the enclosure.<br><br>[[File:window-main-rackmount-nocover.png|400px|thumb|centre|3D View window: rackmount enclosure with cover hidden]]
+
#:The Show/Hide Parts dialog box opens.
−
}}
+
#:[[File:dialogbox-showhideparts-rackmount.png|300px]]
 +
#Click to clear the '''Cover''' check box. This hides the cover, letting you view the inside of the enclosure.
 +
#:[[File:window-main-rackmount-nocover.png|400px]]
 +
 
  
 
==Add PCB and power supply cutouts to rear panel==
 
==Add PCB and power supply cutouts to rear panel==
−
This enclosure requires two rectangular cutouts on the rear panel to accommodate the mini-ITX PCB and power supply.
+
This enclosure requires two rectangular cutouts on the rear panel to accommodate the mini-ITX PCB and power supply.<br>
−
{{Procedure|
+
#On the '''Standard''' toolbar, click '''Edit Face''' [[File:button-editface.png|40px|bottom]], then click the rear face.
−
#On the '''Standard''' toolbar, click '''Edit Face''' [[File:button-editface.png|40px|bottom]], then click the rear face. The '''Face Editor''' window opens.<br><br>[[File:window-faceeditor-rackmount-rear.png|600px|thumb|center|Face Editor window: rackmount rear face]]<br>
+
#:The '''Face Editor''' window opens.
 +
#:[[File:window-faceeditor-rackmount-rear.png|600px]]
 
#On the '''Drawing''' toolbar, select the '''Rectangle''' tool. [[File:tool-rectangle.png|40px|bottom]]
 
#On the '''Drawing''' toolbar, select the '''Rectangle''' tool. [[File:tool-rectangle.png|40px|bottom]]
−
#Draw two rectangles at approximate mounting locations.<br><br>[[File:window-faceeditor-rackmount-rear-rectangles.png|600px|thumb|center|Face Editor Window: rectangle cutouts on rackmount rear face]]<br>
+
#Draw two rectangles at approximate mounting locations.
 +
#:[[File:window-faceeditor-rackmount-rear-rectangles.png|600px]]<br>
 
#On the '''Drawing''' toolbar, select the '''Circle''' tool. [[File:tool-circle.png|40px|bottom]]
 
#On the '''Drawing''' toolbar, select the '''Circle''' tool. [[File:tool-circle.png|40px|bottom]]
−
#Draw two circles on each side of the right rectangle.<br><br>[[File:window-faceeditor-rackmount-rear-circles.png|600px|thumb|center|Face Editor Window: circle cutouts on rackmount rear face]]<br>
+
#Draw two circles on each side of the right rectangle.
 +
#:[[File:window-faceeditor-rackmount-rear-circles.png|600px]]<br>
 
#On the '''Drawing''' toolbar, select the '''Edit''' tool. [[File:tool-edit.png|40px|bottom]]
 
#On the '''Drawing''' toolbar, select the '''Edit''' tool. [[File:tool-edit.png|40px|bottom]]
 
#Select each cutout and update the origin, width, and height as follows:
 
#Select each cutout and update the origin, width, and height as follows:
Line 73: Line 91:
 
#:Origin(X): 1.35
 
#:Origin(X): 1.35
 
#:Origin(Y): 1.2
 
#:Origin(Y): 1.2
−
#:Diameter: 0.125<br><br>[[File:window-faceeditor-rackmount-rear-circle-origin.png|600px|thumb|center|Face Editor Window: updating circle origin]]<br>
+
#:Diameter: 0.125
−
}}
+
#:[[File:window-faceeditor-rackmount-rear-circle-origin.png|600px]]<br>
  
 
==Add built-in fan cutout to rear panel==
 
==Add built-in fan cutout to rear panel==
−
Protocase Designer offers a library of cutouts for common components including fans of various sizes.
 
−
{{Procedure|
 
 
#On the '''Cutout Library and Fasteners''' menu, point to '''Fans''', '''General''', then click '''60mm'''.
 
#On the '''Cutout Library and Fasteners''' menu, point to '''Fans''', '''General''', then click '''60mm'''.
−
#Click on the face to place the fan cutout at the approximate mounting location.<br><br>[[File:window-faceeditor-rackmount-rear-fan-placing.png|600px|thumb|center|Face Editor window: placing fan cutout]]<br>
+
#Click on the face to place the fan cutout at the approximate mounting location.
 +
#:[[File:window-faceeditor-rackmount-rear-fan-placing.png|600px]]<br>
 
#On the '''Drawing''' toolbar, select the '''Edit''' tool. [[File:tool-edit.png|40px|bottom]]
 
#On the '''Drawing''' toolbar, select the '''Edit''' tool. [[File:tool-edit.png|40px|bottom]]
 
#Select the fan cutout and update the origin as follows:
 
#Select the fan cutout and update the origin as follows:
 
#*Fan cutout
 
#*Fan cutout
 
#:Origin(X): 7.5
 
#:Origin(X): 7.5
−
#:Origin(Y): 1.5<br><br>[[File:window-faceeditor-rackmount-rear-fan-origin.png|600px|thumb|center|Face Editor window: rack mount with rectangle cutouts and fan cutout]]<br>
+
#:Origin(Y): 1.5<br>
−
#On the '''Standard''' toolbar, click '''Accept & Close'''. [[File:button-acceptclose.png|40px|bottom]]
+
#:The fan cutout is complete.
−
}}
+
#Click '''Accept & Close'''. [[File:button-acceptclose.png|40px|bottom]]
  
 
==Add self-clinching fasteners to chassis==
 
==Add self-clinching fasteners to chassis==
−
{{Procedure|
 
 
#On the '''Standard''' toolbar, click '''Edit Face''' [[File:button-editface.png|40px|bottom]], then click the chassis (bottom) of the enclosure. The '''Face Editor''' window opens.
 
#On the '''Standard''' toolbar, click '''Edit Face''' [[File:button-editface.png|40px|bottom]], then click the chassis (bottom) of the enclosure. The '''Face Editor''' window opens.
 
#On the '''Standard''' toolbar, click '''Inside''' [[File:button-inside.png|60px|middle]] to change the view to the inside of the chassis.
 
#On the '''Standard''' toolbar, click '''Inside''' [[File:button-inside.png|60px|middle]] to change the view to the inside of the chassis.
−
#On the '''Cutout Library and Fasteners''' menu, click '''Place Self Clinching Fasteners'''.<br><br>[[File:dialogbox-pem-studs-440-500.png|300px|thumb|center|Self Clinching Fastener dialog box: selecting studs, 4-40 x .500" long]]
+
#On the '''Cutout Library and Fasteners''' menu, click '''Place Self Clinching Fasteners'''.
−
#Select Studs, 4-40 x .500 long and click '''Place PEM'''.
+
#:[[File:dialogbox-pem-studs-440-500.png|300px]]
−
#Click on the face to place two studs at the approximate mounting location for the power supply.<br><br>[[File:window-faceeditor-rackmount-chassis-studs.png|600px|thumb|center|Face Editor Window: placing studs, 4-40 x .500" long]]
+
#Select '''Studs, 4-40 x .500 long''' and click '''Place PEM'''.
−
#On the '''Cutout Library and Fasteners''' menu, click '''Place Self Clinching Fasteners'''.<br><br>[[File:dialogbox-pem-standoffs-440-375.png|300px|thumb|center|Self Clinching Fastener dialog box: selecting standoffs, 4-40 x .375" long]]
+
#Click on the face to place two studs at the approximate mounting location for the power supply.
 +
#:[[File:window-faceeditor-rackmount-chassis-studs.png|600px]]
 +
#On the '''Cutout Library and Fasteners''' menu, click '''Place Self Clinching Fasteners'''.
 +
#:[[File:dialogbox-pem-standoffs-440-375.png|300px]]
 
#Select Standoffs, 4-40 x .375" long and click '''Place PEM'''.
 
#Select Standoffs, 4-40 x .375" long and click '''Place PEM'''.
−
#Click on the face to place four standoffs at the approximate mounting location for the PCB (on the right).<br><br>[[File:window-faceeditor-rackmount-chassis-standoffs.png|600px|thumb|center|Face Editor window: placing standoffs, 4-40 x .375" long]]
+
#Click on the face to place four standoffs at the approximate mounting location for the PCB (on the right).
 +
#:[[File:window-faceeditor-rackmount-chassis-standoffs.png|600px]]
 
#On the '''Drawing''' toolbar, select the '''Edit''' tool.  [[File:tool-edit.png|40px|bottom]]
 
#On the '''Drawing''' toolbar, select the '''Edit''' tool.  [[File:tool-edit.png|40px|bottom]]
 
#Select each standoff and stud and update their origins as follows:
 
#Select each standoff and stud and update their origins as follows:
Line 118: Line 138:
 
#*Standoff 4
 
#*Standoff 4
 
#:Origin(X): 15.65
 
#:Origin(X): 15.65
−
#:Origin(Y): 8<br><br>[[File:window-faceeditor-rackmount-chassis-pems-origin.png|600px|thumb|center|Face Editor Window: studs and standoffs placed in proper locations]]
+
#:Origin(Y): 8
−
#On the '''Drawing toolbar''', click '''Accept & Close'''. [[File:button-acceptclose.png|40px|bottom]]<br><br>[[File:window-main-rackmount-pems.png|600px|thumb|center|Main window: rack mount with studs and standoffs added]]
+
#:The studs and standoffs are now placed.
−
}}
+
#:[[File:window-faceeditor-rackmount-chassis-pems-origin.png|600px]]
−
You can now customize your enclosure further by adding additional cutouts, graphics, and hardware to the other faces and then request an instant quote.
+
#On the '''Drawing toolbar''', click '''Accept & Close'''. [[File:button-acceptclose.png|40px|bottom]]
 +
#:The rackmount with studs and standoffs is completed.
 +
#:[[File:window-main-rackmount-pems.png|600px]]<br>
 +
You can now customize your enclosure further by adding additional cutouts, graphics, and hardware to the other faces, and then get an instant quote.

Revision as of 16:07, 8 September 2015

One of the most common uses for Protocase Designer is to design a custom enclosure to mount a PCB (Printed Circuit Board) and associated components. This tutorial will guide you through the process of creating a custom rackmount enclosure to mount a mini-ITX PCB using self-clinching fasteners, and create cutouts for the PCB, power supply, and fan.

Select components to mount in enclosure

  1. Source the components you want to mount in your enclosure.
    Mini-ITX PCB
    Photo-mini-ITXPCB.png
    60mm Fan
    Photo-fan-60mm.png
    Power Supply
    Photo-powersupply.png

Determine mounting specifications for components

The figures below are rough sketches of the example components with their measurements. All dimensions (given in inches) are measured using mechanical calipers.

  1. Determine the mounting hole and cutout dimensions and locations for all the components.
    Top view: Sketch of power supply and PCB mounting dimensions
    Sketch-powersupply-pcb.jpg
    Rear view: Sketch of power supply and PCB mounting dimensions
    Sketch-powersupply-pcb-rear.jpg

Notes

  • Mounting dimensions are not needed for the 60mm fan, since a built-in cutout for the fan will be used.
  • When mounting each component, include any required clearances.

Determine mounting locations for components

  1. Determine mounting location for all components.
  2. Determine cutout, mounting hole, and self-clinching fastener sizes to mount all components.
  3. Create a sketch of all required mounting dimensions.
    Top view: Sketch of power supply and PCB mounting dimensions
    Sketch-mounting-dimensions.jpg
    Rear view: Sketch of power supply and PCB mounting dimensions
    Sketch-mounting-dimensions-rear.jpg
Note: Dimensions are always measured from the absolute origin shown on the OUTSIDE of the base of the enclosure, and therefore you must factor in the thickness of the enclosure.


Tips on positioning components and cutouts

  • If the board needs to be mounted close to a wall of the enclosure, do not place the mounting holes too close to the edge of the board. The example below shows two boards, each with two mounting holes and a DB-9 panel mount connector. On the board on the left (A), the connector holes are located 0.150” from the edge of the board. On the board on the right (B), the mounting holes are placed well back from the edge of the board. The difficulty with the board on the left is the fact that since it has a DB-9 panel connector, the board must be placed sufficiently close to the rear panel of the enclosure so as to allow the DB-9 to pass through the enclosure rear panel. In order to get the board close enough to the vertical side of the enclosure to accommodate the DB-9 connector, the required mounting hardware for the board must be installed so close to the edge of the enclosure that it will interfere with the enclosure bend radius, making it difficult to manufacture, if not impossible. With the board on the right, there is no problem because the mounting holes are far enough back to prevent any interference. A good rule of thumb is to leave at least 0.375" between the centre of the mounting hole and the edge of the board.
Pcb-example1.png
  • Always mount panel mount connectors so that they are not flush with the edge of the board. In the example below, the board on the left (A) has the connector mounted so close to the edge of the board that the board will have to be mounted with its edge just touching the vertical side of the enclosure so that it can accommodate the connector. Allowing for manufacturing tolerances means that the board might be jammed into position when it is mounted, thus inducing stress on the board and compromising its electrical integrity. The board on the right (B) is done properly.
Pcb-example2.png
  • When determining the locations for the connectors, it is essential to find the height of the cutouts by counting the height of the standoff, board, and gap between connector, as shown in the following example for a DB-9 cutout.
The top view, showing the important dimensions including the mounting holes, the cutout, and the connectors:
Pcb-figure a.png
The height of the connector:
Pcb-figure b.png
The height of 0.85", to which you would add a height clearance of 0.15". Thus the total height would be 1" (= 0.85" + 0.15"):
Pcb-figure c.png
The dimension of the DB-9 cutout, which helps you locate the center point on the board:
Pcb-figure d.png

Create enclosure from template

  1. Open Protocase Designer and click New File, or, if Protocase Designer is already open, click New in the File menu,
  2. Click Rackmount Enclosures, then click Rackmount.
    The New Assembly window opens.
    Window-newassembly-rackmount-color.png
  3. Enter a Depth of 15 (inches) and Height of 2 (U).
  4. Select a color for each panel, as desired and then click OK.
  5. Select 14 (.075) for all thicknesses.
  6. On the View menu, click Show/Hide Parts.
    The Show/Hide Parts dialog box opens.
    Dialogbox-showhideparts-rackmount.png
  7. Click to clear the Cover check box. This hides the cover, letting you view the inside of the enclosure.
    Window-main-rackmount-nocover.png


Add PCB and power supply cutouts to rear panel

This enclosure requires two rectangular cutouts on the rear panel to accommodate the mini-ITX PCB and power supply.

  1. On the Standard toolbar, click Edit Face Button-editface.png, then click the rear face.
    The Face Editor window opens.
    Window-faceeditor-rackmount-rear.png
  2. On the Drawing toolbar, select the Rectangle tool. Tool-rectangle.png
  3. Draw two rectangles at approximate mounting locations.
    Window-faceeditor-rackmount-rear-rectangles.png
  4. On the Drawing toolbar, select the Circle tool. Tool-circle.png
  5. Draw two circles on each side of the right rectangle.
    Window-faceeditor-rackmount-rear-circles.png
  6. On the Drawing toolbar, select the Edit tool. Tool-edit.png
  7. Select each cutout and update the origin, width, and height as follows:
    • PCB rectangle cutout (on left)
    Origin(X): 10
    Origin(Y): 0.375
    Width: 6.25
    Height: 1.75
    • Power Supply rectangle cutout (on right)
    Origin(X): 1.5
    Origin(Y): 0.4
    Width: 3.2
    Height: 1.6
    • Power Supply circle cutout 1
    Origin(X): 4.85
    Origin(Y): 1.2
    Diameter: 0.125
    • Power Supply circle cutout 2
    Origin(X): 1.35
    Origin(Y): 1.2
    Diameter: 0.125
    Window-faceeditor-rackmount-rear-circle-origin.png

Add built-in fan cutout to rear panel

  1. On the Cutout Library and Fasteners menu, point to Fans, General, then click 60mm.
  2. Click on the face to place the fan cutout at the approximate mounting location.
    Window-faceeditor-rackmount-rear-fan-placing.png
  3. On the Drawing toolbar, select the Edit tool. Tool-edit.png
  4. Select the fan cutout and update the origin as follows:
    • Fan cutout
    Origin(X): 7.5
    Origin(Y): 1.5
    The fan cutout is complete.
  5. Click Accept & Close. Button-acceptclose.png

Add self-clinching fasteners to chassis

  1. On the Standard toolbar, click Edit Face Button-editface.png, then click the chassis (bottom) of the enclosure. The Face Editor window opens.
  2. On the Standard toolbar, click Inside Button-inside.png to change the view to the inside of the chassis.
  3. On the Cutout Library and Fasteners menu, click Place Self Clinching Fasteners.
    Dialogbox-pem-studs-440-500.png
  4. Select Studs, 4-40 x .500 long and click Place PEM.
  5. Click on the face to place two studs at the approximate mounting location for the power supply.
    Window-faceeditor-rackmount-chassis-studs.png
  6. On the Cutout Library and Fasteners menu, click Place Self Clinching Fasteners.
    Dialogbox-pem-standoffs-440-375.png
  7. Select Standoffs, 4-40 x .375" long and click Place PEM.
  8. Click on the face to place four standoffs at the approximate mounting location for the PCB (on the right).
    Window-faceeditor-rackmount-chassis-standoffs.png
  9. On the Drawing toolbar, select the Edit tool. Tool-edit.png
  10. Select each standoff and stud and update their origins as follows:
    • Stud 1
    Origin(X): 1.15
    Origin(Y): 6.675
    • Stud 2
    Origin(X): 4.65
    Origin(Y): 6.675
    • Standoff 1
    Origin(X): 9.4
    Origin(Y): 14
    • Standoff 2
    Origin(X): 15.65
    Origin(Y): 14
    • Standoff 3
    Origin(X): 9.4
    Origin(Y): 8
    • Standoff 4
    Origin(X): 15.65
    Origin(Y): 8
    The studs and standoffs are now placed.
    Window-faceeditor-rackmount-chassis-pems-origin.png
  11. On the Drawing toolbar, click Accept & Close. Button-acceptclose.png
    The rackmount with studs and standoffs is completed.
    Window-main-rackmount-pems.png

You can now customize your enclosure further by adding additional cutouts, graphics, and hardware to the other faces, and then get an instant quote.

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