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. |
Evan0 |
Aug 26 2017, 02:40 PM
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#2
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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 8/26/2017
Been on vacation for the last couple weeks so not much progress. I did get around to doing a thermal test of the relay board. Here's a picture of the test setup. (IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-20837-1503780005.1.jpg) A 12V 600W power supply provides the juice to drive current through the solid state relays. Three 1Ω 200W resistors provide the load for the test. The fog, air fan, and low beam relays were chosen to as the test subjects since they are the high current draw items. The resistors actually measured about 1.2Ω so with 12V it should provide 10A through each of the relays. Left it running for about 20 minutes to reach steady state. (IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-20837-1503780005.2.jpg) The max measured temperature was about 91°F, 15°F above ambient. Looks like the heatsink is doing its job correctly. The load resistors did get quite toasty during the test run. (IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-20837-1503780005.3.jpg) With 30A passing through the PCB and the relays, there doesn't seem to by any issues. With these results I'll get to work with Rev B and figuring out how to mass produce these at a reasonable cost. |
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