Replacement Relay Socket Panel, Updated: Version 3 - Solid State Relays and Fuse Panel Replacement |
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Replacement Relay Socket Panel, Updated: Version 3 - Solid State Relays and Fuse Panel Replacement |
Evan0 |
Apr 30 2017, 10:12 AM
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#1
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Newbie Group: Members Posts: 44 Joined: 13-February 17 From: Southern California Member No.: 20,837 Region Association: Southern California |
Update 3 Post
I've been rewiring my car for the last few weeks and part of that was replacing the factory fuse panel with one that uses modern fuse from JWest Engineering. I was unhappy with the existing relay sockets that I found. As a result of that, I designed and printed a monolithic fuse socket for all the relays, buzzer, and flasher unit. (IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-20837-1493568735.1.jpg) After mounting it to the fuse panel. The buzzer is a Hella H35394001. The horn, blower, and fog relays are Hella 933332051. The flasher unit is a Hella 009492101. The head light relay is a modern reproduction of the VW one. Still waiting on the flasher unit to ship. (IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-20837-1493568735.2.jpg) I'll be posting the STL files, Bill of Materials, and instructions after I've worked out a few kinks. I would love any feedback or suggestions on improvements. |
Spoke |
Aug 16 2017, 06:48 AM
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#2
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Jerry Group: Members Posts: 6,978 Joined: 29-October 04 From: Allentown, PA Member No.: 3,031 Region Association: None |
Beautiful design. Looks really well thought out. Lots of good feedback from the guys too.
One question on the placement of SSR U6 for the low beam: Why is it turned around WRT to the other SSRs? With it's positioning, its exposed pad is not against the heatsink. Was this done for isolation? What is the theta-JC from junction to the EP versus junction to top of case? |
Evan0 |
Aug 16 2017, 10:33 AM
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#3
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Newbie Group: Members Posts: 44 Joined: 13-February 17 From: Southern California Member No.: 20,837 Region Association: Southern California |
One question on the placement of SSR U6 for the low beam: Why is it turned around WRT to the other SSRs? With it's positioning, its exposed pad is not against the heatsink. Was this done for isolation? What is the theta-JC from junction to the EP versus junction to top of case? I'm regretting the placement of U6 and it going to get flipped around for the next revision. I'll need to move a couple other components around to make that happen. I had it in that orientation originally to simplify routing. 7mm thick traces on both side are required to meet my current and temperature requirements, so routing was a bit of an issue. Thermal resistance junction to case is 0.3°C/W and junction to ambient is 33°C/W. The heatsink is approximately 28°C/W. I'm going to run a thermal test with a thermal camera with three of the relays carrying 12A, which should reflect worse case real world use. I'll incorporate anything learned from that test in the next revision. Wondering...what is intended for a fuse panel cover? The stock cover indicates the functions of each fuse. Thanks for answering my question. If its not critical to the connecting terminals, I think i will straighten it out to make injection molding much easier and cheaper. Is there a source for the stock cover? If reproductions are available, I would like to go with those to maintain some look of originality. |
Spoke |
Aug 16 2017, 04:18 PM
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#4
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Jerry Group: Members Posts: 6,978 Joined: 29-October 04 From: Allentown, PA Member No.: 3,031 Region Association: None |
I'm regretting the placement of U6 and it going to get flipped around for the next revision. Very few products make it to production with Rev 1. I recently did a PCB for the people mover trains at Newark Airport where I reversed the coil leads for 6 relays. (IMG:style_emoticons/default/dry.gif). Fixed it in Rev 2. |
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