Parametric PowerPole Breakout Box

thingiverse

A universal PowerPole breakout/distribution box lets multiple devices share one power supply efficiently. The standard for connecting power to equipment are Anderson PowerPoles commonly used by Amateur Radio operators and emergency teams. This STL upload isn't rendering smoothly; I'm disabling customizers temporarily while adding a single STL file, representing a 4 position box (one side connection plus four top connections). You can create other configurations by opening the included OpenSCAD script. For build specifics see: http://wordpress.uark.edu/rso-w5ym/2014/07/07/parametric-powerpole-break-out-boxes/ Per your request in the comments, STL files have been added for boxes with 3, 4 and 5 PowerPoles on top; each comes in three files: box halves only, just "top", just "bottom". These simplify printing if you want different colors. New files function similarly to originals, yet original files remain in-place due to archival needs. Instructions Libraries For a custom rendering using the OpenSCAD script, get "pins" library; available here: https://github.com/tbuser/pin_connectors/blob/master/pins.scad A newer version (3) might work but you've been warned; for this script version 2 is being used. Printing It was printed with a MakerBox 2X using 0.2mm layer thickness, ABS and 10% infill initially. Testing higher infills found slight improvement in rigidity, although marginal. Assembly "Standard" 15/30/45 amp PowerPole housings should be used with PCB contacts; the exact part is Mouser number 879-1336G1. Place the housings loaded together inside and mate into printed shells; connect them by soldering the PCBs; make sure there's no damage (short/opens); now put the other half shell into place. Its intended purpose is having power connection enter on one side with plugged devices entering through holes on top. Hints To overcome contact spring stress or a poorly fit device at ends, small amount of glue applied beforehand may resolve this. The quality and fitting should allow contacts (for example regular crimp wire connections) implementation of which will remain in your responsibility. The final item, as any project with personal variation due to builder skills may result with poor performance so I urge to act wisely when use for non-harm. More project updates and further detailed instructions is found here: http://w5ym.org