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| -rw-r--r-- | mechanical-specifications.typ | 385 | ||||
| -rw-r--r-- | pictures/chassis-module-loading.svg | 895 | ||||
| -rw-r--r-- | preamble.typ | 8 |
3 files changed, 1288 insertions, 0 deletions
diff --git a/mechanical-specifications.typ b/mechanical-specifications.typ index 40cc933..ae5c04e 100644 --- a/mechanical-specifications.typ +++ b/mechanical-specifications.typ @@ -886,3 +886,388 @@ least $qty(4, "mm")$ height. Jack labels should be at least $qty(2, "mm")$ height. == Chassis <chassis> + +=== Overview <chassis-overview> + +The chassis provides the mechanical and electrical infrastructure for housing +modules. It includes: +- Structural enclosure with EMI shielding, +- Cassette rail system for module installation and removal, +- Power distribution board with backplane connectors, +- Front panel with reference outputs and system controls, +- Thermal management provisions. + +This specification defines interface requirements that any compliant chassis +must meet. Chassis may vary in capacity (number of module positions), form +factor (rack-mount, desktop, portable), and mounting style. The reference +implementation (#ref(<reference-implementation-chassis>)) describes a +$qty(19, "inch")$ $qty(4, "U")$ rack-mount chassis with $8$ module positions. + +=== Dimensional requirements <chassis-dimensional-requirements> + +#figure( + image("pictures/chassis-module-loading.svg"), + caption: [Chassis module loading dimensional requirements], +) <figure-chassis-dimensional-requirements> + +==== Module interface dimensions <chassis-module-interface-dimensions> + +All chassis must accommodate standard SAME cassettes. The following dimensions +are mandatory: + +#figure( + table( + columns: (auto, auto, auto), + table.header([Parameter], [Value], [Notes]), + [Module pitch], [$qty(38.1, "mm")$ ($qty(1.5, "inch")$)], [Center-to-center spacing], + + [Module opening height], [$qty(177.8, "mm")$ ($qty(4, "U"), qty(7, "inch")$)], [Panel visible area], + + [Module body clearance], [$qty(165.2, "mm")$], [Between top and bottom rails], + + [Module depth], [$qty(152.5, "mm")$], [Front panel to rear connector], + [Rail-to-rail width], [$qty(38.1, "mm")$ ($qty(1.5, "inch")$)], [Center-to-center spacing], + ), + caption: [Module interface dimensions], +) <table-chassis-module-interface-dimensions> + +==== Capacity <chassis-capacity> + +Chassis capacity is defined by the number of module positions. There is no +minimum or maximum, but the following constraints apply: + +#figure( + table( + columns: (auto, auto, auto), + table.header([Capacity], [Power budget], [Notes]), + [Per module], [$qty(185, "mA") at plus.minus qty(15, "V")$], [Maximum per position], + + [Per module], [$qty(100, "mA") at plus.minus qty(5, "VD")$], [Maximum per position], + + [Total], [Scales with capacity], [Power distribution must support all positions], + ), + caption: [Chassis capacity power requirements], +) <table-chassis-capacity> + +Designers should consider thermal dissipation when determining maximum capacity. + +==== Clearances + +The rear clearance (behind cassette) should be at least $qty(25, "mm")$, to +account for the DB-25 connector and cable bend radius. + +=== Structural requirements <chassis-structural-requirements> + +==== Material <chassis-material> + +#figure( + table( + columns: (auto, auto), + table.header([Parameter], [Requirement]), + [Material], [Steel (recommended) or aluminum], + [Minimum thickness], [$qty(1.5, "mm")$ (steel) or $qty(2.0, "mm")$ (aluminum)], + + [Finish], [Black powder coat or anodization, conductive areas masked], + ), + caption: [Chassis material requirements], +) <table-chassis-material> + +Steel is preferred for magnetic shielding. Aluminum may be used where weight is +critical, with reduced magnetic shielding performance. + +==== EMI shielding <chassis-emi-shielding> + +A fully loaded chassis must form a continuous shielded enclosure: + +#figure( + table( + columns: (auto, auto), + table.header([Parameter], [Requirement]), + [Shielding effectiveness], [$gt qty(20, "dB"), qtyrange(80, 1000, "MHz")$], + [Panel joints], [Metal-to-metal contact of conductive gasket], + [Ventilation openings], [\ Maximum slot dimensions: $qty(10, "mm") times qty(2, "mm")$], + + [Cable entry], [Shield connectors or filtered feedthroughs], + ), + caption: [Chassis EMI shielding requirements], +) <table-chassis-emi-shielding> + +==== Grounding <chassis-grounding> + +#figure( + table( + columns: (auto, auto), + table.header([Parameter], [Requirement]), + [Chassis earth bonding], [All panels bonded to single earth point], + [Earth impedance], [$gt qty(0.1, "ohm")$ between any two chassis points], + [Safety earth], [Connected to mains earth via IEC inlet], + [Module earth path], [Via DB-25 shell and pin 25], + ), + caption: [Chassis grounding requirements], +) <table-chassis-grounding> + +=== Cassette rails <chassis-cassette-rails> + +The rail system guides cassette insertion and provides retention. + +==== Geometry <chassis-cassette-rails-geometry> + +#figure( + table( + columns: (auto, auto, auto), + table.header([Parameter], [Value], [Notes]), + [Rail height], [$qty(6.35, "mm")$ ($qty(0.25, "inch")$)], [Matches cassette lip height], + + [Channel width], + [$qty(38.1, "mm")$ ($qty(1.5, "inch")$) $plus 0.2 "/" minus qty(0.0, "mm")$], + [Accepts cassette body with clearance], + + [Channel depth], [$qty(5, "mm")$ minimum], [Guides cassette during insertion], + + [Rail length], [Full chassis depth], [Front to rear], + ), + caption: [Chassis cassette rails geometry], +) <table-chassis-cassette-rails-geometry> + +==== Retention <chassis-cassette-rails-retention> + +Cassettes must be retained to prevent accidental ejection during operation or +transport. + +#figure( + table( + columns: (auto, auto), + table.header([Method], [Requirement]), + [Friction fit], [Acceptable for stationary installations], + [Positive retention], [Required for portable or vibration-prone environments], + + [Front panel screws], [Optional, into chassis front rail], + ), + caption: [Chassis cassette retention requirements], +) <table-chassis-cassette-rails-retention> + +Positive retention may be achieved via: +- Spring clips engaging cassette lips, +- Latching mechanisms. + +==== Material <chassis-cassette-rails-material> + +The rails must be of the same metal as the chassis, with a smooth, burr-free +finish; and bond to chassis earth. + +They contribute to EMI shielding by closing the gap between cassette lips and +chassis structure. + +=== Thermal management <chassis-thermal-management> + +==== Cooling method <chassis-cooling-method> + +Passive convection cooling is the baseline requirement. Forced-air cooling may +be added for high-density configurations. + +#figure( + table( + columns: (auto, auto), + table.header([Method], [Requirement]), + [Passive (convection)], [Minimum for all chassis], + [Active (forced air)], [Optional, for high-capacity or enclosed installations], + ), + caption: [Chassis cooling method requirements], +) <table-chassis-cooling-method> + +==== Ventilation <chassis-ventilation> + +Chassis ventilation must align with cassette ventilation slots to enable +chimney-effect airflow. + +#figure( + table( + columns: (auto, auto), + table.header([Parameter], [Requirement]), + [Bottom ventilation], [Required, aligned with cassette bottom vents], + [Top ventilation], [Required, aligned with cassette top vents], + [Slot dimensions], [$lt.eq qty(10, "mm") times qty(2, "mm")$ for EMI compliance], + + [Open area], [$gt.eq qty(20, "percent")$ of cassette footprint area], + ), + caption: [Chassis ventilation requirements], +) <table-chassis-ventilation> + +==== Thermal limits <chassis-thermal-limits> + +Inside the chassis cassette chamber, internal ambient temperature must not go +over $qty(50, "dC")$. If passive cooling cannot maintain thermal limits at full +capacity, forced-air cooling or reduced capacity is required. + +=== Power distribution board <chassis-power-distribution-board> + +The power distribution board generates and distributes all power rails to +module positions. + +==== Functions <power-distribution-board-functions> + +#figure( + table( + columns: (auto, auto), + table.header([Function], [Requirement]), + [AC-DC conversion], + [Mains input to $plus.minus qty(15, "V")$, $plus.minus qty(5, "VD")$ rails. Can be external or internal], + + [Reference generation], [$plus.minus qty(10.0000, "V")$ precision references], + + [Master oscillator generation], [Generation of the $qty(10, "MHz")$ sine wave reference], + + [Distribution], + [ + - One female DB-25 connector per module position, + - One female isolated BNC connector per module position + ], + + [Calibration], [Front-panel accessible switches], + [Protection], [Overcurrent, overvoltage, thermal shutdown], + ), + caption: [Power distribution board functional requirements], +) <table-power-distribution-board-functions> + +==== Power entry <power-distribution-board-power-entry> + +#figure( + table( + columns: (auto, auto), + table.header([Parameter], [Requirement]), + [Mains connector], [IEC C14 (with integrated fuse) or regional equivalent], + [Voltage range], + [$qtyrange(100, 240, "VAC"), 50 "/" qty(60, "Hz")$ (universal) recommended. Factory setup accepted], + + [Safety], [Compliant with IEC 60950-1 or IEC 62368-1], + ), + caption: [Power entry requirements], +) <table-power-distribution-board-power-entry> + +==== Master oscillator <power-distribution-board-master-oscillator> + +To support the metrologic tier time-domain computations, the chassis must +include a precision clock source. + +/ Oscillator: Oven Controlled Crystal Oscillator (OCXO). + / Recommended part: AOCJY4A-10.0000MHZ-SW (or equivalent with + $plus.minus qty(10, "ppb")$ stability). +/ Buffering: The oscillator output must be filtered to remove harmonics and + buffered to drive the $qty(50, "ohm")$ distribution network. + / Metrologic tier buffer: LM7171 (high speed, high voltage operational + amplifier) or equivalent, configured to drive $qty(50, "ohm")$ loads with + high slew rate and low distortion. +/ Signal level: $qty(1.0, "Vpp") plus.minus qty(10, "percent")$ into + $qty(50, "ohm")$. +/ Waveform: Sine wave. +/ Fan-out: The oscillator distribution network must ensure port-to-port + isolation $gt qty(40, "dB")$ to prevent oscillator line crosstalk between + modules. + +=== Front panel <chassis-front-panel> + +The chassis front panel provides system-level controls and reference inputs and +outputs. + +==== Elements <chassis-front-panel-elements> + +#figure( + table( + columns: (auto, auto, auto), + table.header([Element], [Type], [Function]), + [SAME logo], [Label], [N/A], + [SAME license], [Label], [Legal], + [Power switch], [Rocker or toggle], [Mains on/off], + [Standby switch], [Toggle], [Maintains reference ovens temperature], + [Power indicator], [LED], [Indicates power state], + [Standby indicator], [LED], [Indicates standby state], + [$plus qty(10.0000, "V")$ output jack], [4mm banana, yellow], [Reference voltage output], + + [$qty(-10.0000, "V")$ output jack], [4mm banana, blue], [Reference voltage output], + + [$plus qty(10.0000, "V")$ input jack], [4mm banana, white], [Reference voltage input], + + [$qty(-10.0000, "V")$ input jack], [4mm banana, white], [Reference voltage input], + + [AGND jack], [4mm banana, black], [Analog ground reference], + [Dual $qty(10, "MHz")$ sine oscillator output jacks $plus.minus qty(1, "V")$], + [4mm banana, light blue], + [Master oscillator output (independent paths, to allow verification - see #ref(<the-time-invariant>))], + + [$qty(10, "MHz")$ sine oscillator input jack], [4mm banana, white], [Master oscillator input], + + [Calibration coarse], [Rotary or DIP switch], [Reference voltage coarse adjust], + + [Calibration fine], [Rotary or DIP switch], [Reference voltage fine adjust], + ), + caption: [Chassis front panel elements], +) <table-chassis-front-panel-elements> + +- Case designers may add other elements as they see fit (fuse holders, voltage + selectors, sensors, etc.), +- Reference jacks should be grouped together, on a $qty(0.75, "inch")$ grid, +- All controls and jacks must have an associated label. + +=== Electrical safety <chassis-electrical-safety> + +==== Mains isolation <chassis-mains-isolation> + +#figure( + table( + columns: (auto, auto), + table.header([Parameter], [Requirement]), + [Isolation voltage], [$gt.eq qty(3000, "VAC")$ mains to SELV], + [Creepage / Clearance], [Per IEC 60950-1 or IEC 62368-1], + [Fusing], [Primary slide, appropriately rated], + [Earth bonding], [Continuous, $lt qty(0.1, "ohm")$ to mains earth], + ), + caption: [Mains isolation requirements], +) <table-chassis-mains-isolation> + +==== SELV circuits <selv-circuits> + +All module-facing voltages ($plus.minus qty(15, "V")$, $plus.minus qty(10, "V")$, $plus.minus qty(5, "V")$) are Safety Extra-Low Voltage (SELV): + +#figure( + table( + columns: 2, + table.header([Parameter], [Requirement]), + [Maximum voltage], [$lt qty(60, "VDC")$], + [Isolation from mains], [Required], + [User accessible], [Yes (banana jacks)], + ), + caption: [SELV circuits requirements], +) <table-selv-circuits> + +==== Protective earth <protective-earth> + +#figure( + table( + columns: 2, + table.header([Parameter], [Requirement]), + [Earth continuity], [$lt qty(0.1, "ohm")$ from any exposed metal to mains earth], + + [Earth current capacity], [Per fuse rating], + [Chassis bonding], [All panels bond], + ), + caption: [Protective earth requirements], +) <table-protective-earth> + +=== Compliance <chassis-compliance> + +Chassis must comply with applicable safety and EMS standards for the target +market: + +#figure( + table( + columns: 3, + table.header([Region], [Safety], [EMC]), + [EU], [IEC 62368-1], [EN 55032, EN 55035], + [USA], [UL 62368-1], [FCC Part 15], + [International], [IEC 62368-1], [CISPR 32, CISPR 35], + ), + caption: [Chassis compliance requirements], +) <table-chassis-compliance> + +Compliance testing and certification are the responsibility of the chassis +manufacturer. diff --git a/pictures/chassis-module-loading.svg b/pictures/chassis-module-loading.svg new file mode 100644 index 0000000..47e5449 --- /dev/null +++ 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y="9.4249802" + font-size="13px" + font-weight="700" + id="text34">FRONT ELEVATION</text> + <text + x="833.54004" + y="24.42498" + font-size="10px" + id="text35">Module Pitch & Slot Interface Alignment</text> + <rect + x="823.54004" + y="115.42498" + width="280" + height="410" + fill="none" + class="thick-line" + id="rect35" /> + <rect + x="828.54004" + y="125.42498" + width="270" + height="390" + fill="none" + class="medium-line" + id="rect36" /> + <line + x1="880.44006" + y1="100.42498" + x2="880.44006" + y2="530.42505" + class="center-line" + id="line36" /> + <line + x1="964.24005" + y1="100.42498" + x2="964.24005" + y2="530.42505" + class="center-line" + id="line37" /> + <line + x1="1048.04" + y1="100.42498" + x2="1048.04" + y2="530.42505" + class="center-line" + id="line38" /> + <rect + x="839.04004" + y="125.42498" + width="82.800003" + height="390" + fill="#ffffff" + class="medium-line" + id="rect38" /> + <circle + cx="880.44006" + cy="132.17499" + r="2.5" + class="thin-line" + id="circle38" /> + <circle + cx="880.44006" + cy="508.67499" + r="2.5" + class="thin-line" + id="circle39" /> + <text + x="880.44006" + y="155.42499" + font-size="10px" + font-weight="700" + text-anchor="middle" + id="text39">Module 1</text> + <circle + cx="860.44006" + cy="185.42499" + r="5" + class="thin-line" + id="circle40" /> + <circle + cx="900.44006" + cy="185.42499" + r="5" + class="thin-line" + id="circle41" /> + <circle + cx="860.44006" + cy="215.42499" + r="5" + class="thin-line" + id="circle42" /> + <circle + cx="900.44006" + cy="215.42499" + r="5" + class="thin-line" + id="circle43" /> + <circle + cx="880.44006" + cy="265.42496" + r="12" + class="medium-line" + id="circle44" /> + <rect + x="922.84003" + y="125.42498" + width="82.800003" + height="390" + fill="#ffffff" + class="medium-line" + id="rect44" /> + <circle + cx="964.24005" + cy="132.17499" + r="2.5" + class="thin-line" + id="circle45" /> + <circle + cx="964.24005" + cy="508.67499" + r="2.5" + class="thin-line" + id="circle46" /> + <text + x="964.24005" + y="155.42499" + font-size="10px" + font-weight="700" + text-anchor="middle" + id="text46">Module 2</text> + <circle + cx="944.24005" + cy="185.42499" + r="5" + class="thin-line" + id="circle47" /> + <circle + cx="984.24005" + cy="185.42499" + r="5" + class="thin-line" + id="circle48" /> + <circle + cx="964.24005" + cy="245.42499" + r="10" + class="medium-line" + id="circle49" /> + <rect + x="1006.64" + y="125.42498" + width="82.800003" + height="390" + fill="#ffffff" + class="thin-line" + id="rect49" /> + <rect + x="1006.64" + y="125.42498" + width="82.800003" + height="13.5" + class="medium-line" + id="rect50" /> + <rect + x="1006.64" + y="501.92499" + width="82.800003" + height="13.5" + class="medium-line" + id="rect51" /> + <text + x="1048.04" + y="315.42499" + font-size="10px" + font-weight="700" + text-anchor="middle" + id="text51">Empty slot</text> + <text + x="1048.04" + y="327.42499" + font-size="10px" + font-weight="700" + text-anchor="middle" + id="text52">(Rails visible)</text> + <line + x1="880.44006" + y1="115.42498" + x2="880.44006" + y2="80.42498" + class="dim-ext" + id="line52" /> + <line + x1="964.24005" + y1="115.42498" + x2="964.24005" + y2="80.42498" + class="dim-ext" + id="line53" /> + <line + x1="880.44006" + y1="79.42498" + x2="964.24005" + y2="79.42498" + class="dim-line" + id="line54" /> + <text + x="892.34003" + y="69.42498" + font-size="9px" + id="text54">38.1 mm (1.5")</text> + <line + x1="964.24005" + y1="115.42498" + x2="964.24005" + y2="80.42498" + class="dim-ext" + id="line55" /> + <line + x1="1048.04" + y1="115.42498" + x2="1048.04" + y2="80.42498" + class="dim-ext" + id="line56" /> + <line + x1="964.24005" + y1="79.42498" + x2="1048.04" + y2="79.42498" + class="dim-line" + id="line57" /> + <text + x="976.14001" + y="69.42498" + font-size="9px" + id="text57">38.1 mm pitch</text> + <line + x1="1098.54" + y1="125.42498" + x2="1148.54" + y2="125.42498" + class="dim-ext" + id="line58" /> + <line + x1="1098.54" + y1="515.42505" + x2="1148.54" + y2="515.42505" + class="dim-ext" + id="line59" /> + <line + x1="1148.54" + y1="125.42498" + x2="1148.54" + y2="515.42505" + class="dim-line" + id="line60" /> + <text + x="320.97528" + y="-1157.3979" + font-size="9px" + id="text60" + transform="rotate(90)">177.8 mm</text> + <!-- ================================================================= --> + <!-- VIEW C: DETAILED CASSETTE RAIL PROFILE (ENLARGED SECTION) --> + <!-- Scale: ~6.0 px / mm --> + <!-- ================================================================= --> + <text + x="129.54004" + y="565.42505" + font-size="13px" + font-weight="700" + id="text61">CASSETTE RAIL GEOMETRY & RETENTION</text> + <text + x="129.54004" + y="580.42505" + font-size="10px" + id="text62">Cross-Section of Rail Guide Channel (Scale Enlarged)</text> + <path + d="m 179.54007,715.425 h 400.00001 v 10 H 179.54007 Z" + class="medium-line" + id="path62" /> + <path + d="m 199.54007,715.425 v -50 h 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