This is my second Instructable on a outdoor robot based on Drone Robot Workshop DB1, I am truly standing on the shoulders of giants.
This is my first ever robot. Hope is for a robot to help in outdoor chores thus the need for a waterproof electronic enclosure.
Step 1: Enclosure
Not having any idea how large my enclosure would need to be I went BIG. This 14" x 12" enclosure should be large enough for the battery and electronics. polycase makes a wonderful product, so much better than my first attempt with cheap cases on eBay with broken edges upon delivery.
Step 2: Plywood Mounting
polycases have internal mounting holes for the plywood used for attaching the power distribution.
My Home Depot only had 1/8" ply and it is working but the 1/4" would be better. They will cut to 12"x13.5" leaving you with a few small corner cuts to fit in the box.
By applying a generous amount of black ink with a sharpie and pressing the ply down hard you will mark the holes needed to install the ply with the 10/32 screws.
Step 3: Attach Power Distribution Connection Strips
The robot will need power directly from the battery (12-36v), 12v, 5v and 3.3v so power distribution will be needed. I modified Drone Robot's excellent idea down to four banks of screw terminal strips. The busbars were trimmed to eight equal red and black (if you watch Drone Robot this will make sense).
As the strips must be above the battery, I first marked it's height, evenly distributed the strips and attached to the plywood.
Step 4: Attach Wire Entry and Exhaust
Although I need my electronics to be dry they will be controlling items outside this box such as motors and arms and receiving information from LIDAR and cameras. These 90 degree 1" electrical box connections will work well after trimming off the end. The robot will be operating outside and could get quite hot. I'm planning a fan at the top of the enclosure and a 1" straight electrical box connector with waterproof cap will keep the inside dry.
First trim the edge of both 90 degree connectors. Mark suitable locations for the wire entry/exit sites and the top exhaust site. No need to trim edge of the the top connector. Drill a 1/8" pilot hole before the 1 1/4" holes with circular drill.
You need to temporarily remove the ply to install the 90 degree connectors.
Here is a picture back on HUNIE.
Step 5: Cover Vent
This vent cover will hopefully keep the electronics from drowning from the exhaust vent. I attached with silicone instead of glue but will let you know if I pull it off accidentally...
Step 6: Paint
My wife choose brown as my first chore for HUNIE is picking up dog poop.
Step 7: Attach to Robot
Using 3/8 x 1" bolts (3/4" might be better), washers and locking nuts from ACE Hardware, I attached to HUNIE frame. You will see extra holes drilled in the bottom for ventilation.
Next step, complete the enclosure with power on/off for battery and electronics and shelves for the battery and electronics.
This is an entry in the