DC Motor Controller Box

thingiverse

DC Motor Controller Box This box houses a DC motor controller to control speed and direction of a DC motor. The controller bolts on the bottom with four M3 x 6mm long screws, securely fastening it in place. The lid bolts onto the top of the box with eight M3 x 6mm long screws, providing a sturdy closure. I used heat-set brass thread inserts for the mounting threads to ensure a reliable connection. On the controller, a yellow light indicates "on," while two red lights signal "forward" and "reverse." To make these indicators visible from outside, I designed tubes that transfer light from LEDs through cover lenses. A rocker switch allows users to set the motor's direction to forward, reverse, or off, and a potentiometer controls the motor speed. For external power connections, I used panel mount female DC panel mount barrel jacks from a reliable supplier. Assembly Instructions: To assemble this controller box, start by attaching the LED tubes to the cover plate using super glue. Next, secure the lenses to the tubes with glue. Using a soldering iron, install heat-set inserts into the empty holes in the housing – there are 12 holes total. Remove the knob and nut from the potentiometer and install it into the cover plate. Disconnect the wires from the rocker switch and install it on the cover plate, then rewire the switch back to the controller. Solder wires onto the DC barrel jacks and install them in the housing. Secure the controller in the housing using four M3 screws. Connect the wires from the DC barrel jacks to the controller, ensuring proper power connection to avoid damaging the controller. The outlet power phases to the motor do not matter. Finally, attach the cover plate to the box, completing the assembly. Required Components: Motor Controller PN: A16090700UX0248 Manufacturer: Uxcell Voltage: 10-30vdc/ 3amp You can find this motor controller on Uxcells' website or purchase it from Amazon for $10: https://amzn.to/2E5YtVt DC GearMotor (optional) Any motor under 3amps will work, but I used this one: PN: A16051100UX0484 Manufacturer: Uxcell Voltage: 24vdc/ 1amp RPM: 200 (20-1000 available same gearmotor) You can find it on Uxcells' site or purchase it from Amazon for $14: https://amzn.to/2Sgtucq Panel Mount DC Barrel Jack Size: 2.1mm x 5.5mm Panel Hole Size: 7.8mm Quantity: 3 I purchased these barrel jacks on eBay, where they were available in packs of ten for $1. You can also find them on Amazon. Thread Inserts M3x0.5mm thread, 5.6mm od x 3.8mm lg. brass Quantity: 12 You can find threaded inserts on Amazon: https://amzn.to/2P7NMCV Power Supply Any power supply from 10-30vdc will work as long as it has a 5.5mm x 2.1mm barrel connector. I purchased a 24vdc x 3 amp power supply for $12 on Amazon: https://amzn.to/2QvaHgg Double Male Adapter Cable You'll need a cable with 2.1mm x 5.5 male plugs on both ends to connect the controller to the motor cap housing. I found five of these cables on eBay for $3. Required hardware: M3 X .5 X SOCKET HEAD CAP SCREW 6M LG – 4X M3 X .5 X BUTTON HEAD CAP SCREW 6M LG – 8X https://youtu.be/7sirsHA1HLo Print Settings: Printer: Monoprice Select Mini Rafts: No Supports: No Notes: No supports are required! I used a second color on the cover. If you wish to do so, the cover thickness is 0.1" (2.54mm), and the letters are 0.4" (2mm) high. For better results when printing the LED tubes, turn down the heat slightly since they are small.