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KJC Design Solutions has worked on a number of projects involving electrical components, that either involve packaging the components into an enclosure, or the wiring of an electrical component to another electrical component, or a combination of both mechanical – electrical design tasks.

Housed in a bespoke aluminum enclosure the product that we needed to design would provide a complete monitoring solution for engineers to provide further feedback on the performance of the overall mechanical assembly to which it would be fitted to.

The design of the product required that a number of components needed to be packaged inside a bespoke electrical enclosure. A selection of these components included Printed Circuit Boards (PCBs), Microprocessor Boards, Surface Mount Connectors, and Vibration & Heat Sensors.

There were many design issues that required resolving from a functional perspective and from a material standpoint. The environment which the electrical enclosure would operate in, required that the assembly must withstand environmental and manufacturing issues:

  • Medium to High temperatures
  • The enclosure would be subjected to vibration in use
  • The enclosure should be tough but to be of a reasonable weight for handling
  • Easily manufactured and assembled on production lines

Further considerations were that the components within the enclosure were also very sensitive and expensive, and required to be protected at all costs. Therefore the components within enclosure would need to be encased in an epoxy resin, which required a further manufacturing process to be taken into consideration.

Working alongside the electronic engineers, an envelope was decided for the size and shape of the printed circuit boards. With this information, an IDF file was generated and imported into SolidWorks, which gave us a starting point for the overall space that we had to work with.

From this information we designed an aluminium enclosure that would allow each PCB to be connected to each other and fitted to the enclosure using a combination of standoff’s and fasteners.

Aluminium covers would be then fitted to each side of the enclosure which would provide added protection of the components. A further removable connector block was added to complete the design, to enable access for retrieving the monitored data.

Our design was successfully used as a prototype for testing the overall device prior to going to manufacture of the production units’