openinverter forum

I thought it might make sense to create a new thread for contributions of 3D printed parts to go with the Gen 3 inverter rather than filling the support thread with them.

So far we have a few nice designs from @Konstantin (not sure how you tag users on this forum?) (viewtopic.php?f=14&t=488&start=100#p11671) and a couple of my own contributions, attached here.

The first one is a simple blanking plate for one of the round connections (battery? air con?). This requires an R26 O-ring to seal against the hole and is just push-fit.

The second is a two-part piece for Damien's AMPSEAL connector daughterboard for the gen 3 inverter. I've dropped the original sealing ring on this one because it would have required a very thick backplate to keep that and recess the pcb. I'll just use a skim of silicone when I install it permanently. My IDC cable has enough slack for the inverter case to be removed if necessary without taking it off again.

Nice work:)

I've printed both, they fit perfectly. Thanks

Bigpie wrote: ↑Tue Jun 16, 2020 12:04 pm I've printed both, they fit perfectly. Thanks

Fab! More to come when I get a chance.

One more simple blanking plate for the smaller round hole. This one needs an R24 O-ring.

Right, the complicated one. This is my first pass at a 3D printed part(s) to house and seal in the battery connectors in the new location, using Damien's machined brass standoffs. It's not perfect yet but prints and fits together nicely.

Three parts:

- Base plate should slot in to the rebate around the oval hole. The two brass standoffs then slot into this. I'm using threaded bar at the moment so I can thread these in to hold it all on while I do the rest. There's a space for an M6 threaded insert to screw the cover down but I'm still waiting on these for testing.
- Cable grommet is designed to seal around 35mm2 welding wire, though I don't have mine yet so I'm working off official dimensions rather than the real thing. There are slots inside the grommet to take two R10 O-rings that should seal against the wire. This slides onto the base plate and the terminals can be bolted down. Should be easy to do different versions of this 'grommet' for different diameters of wire.
- The locking cover then slides over the top and two ridges on each side locate in the base plate and grommet and hold them together. This is screwed down into the M6 threaded insert on the base plate

Might be a bit overkill but I figured we want to keep those HV connections shielded.

IMPORTANT THINGS I DON'T KNOW: LOTS! I've not been able to electrically test this. Mine is printed in PETG, which seems to have very high electrical resistance, and I can't see any obvious issues in the design, but moisture ingress would worry me a bit. Feedback very welcome if you can see issues with this design.

I'll carry on testing it and likely do some cosmetic tweaks in the coming weeks, which I will post here. Note that there was a slight issue in the printing of the cover in the pics and the version below has been tweaked for ease of printing. Shouldn't need support on any of the parts and I printed at 20% infill - seems very strong.

Oh, and I know the terminals are the wrong size but my 6mm ones haven't arrived yet.

Looks pretty good. I'll get one printed off this week and check it out.

Sorry this might be a bit late for you @Bigpie but made some revisions after the M6 inserts arrived. They have a bigger o/d than expected and are slightly deeper so have added a mil to the width and depth of the hole, thickened the wall around them, and redesigned the cover to match. Mine is on the printer now. New files in the attached zip.

Grommet remains the same for now. If anyone wants one with smaller cable diameter then let me know the o/d and I'll sketch one up.

I've not printed the battery connector yet, will give it a go. Cheers.

I'd be happy to pay for a cover if someone wants to print an extra

I've printed the battery connector off, fits well. I think the 1st post is also going to need to come out too for using it as a charger?

Ah maybe - I haven't looked at that side of things yet. Thought it would come in through MG1 and back out through the same two?

Glad it fits for now. Printed one myself and have the thread insert in. Fits much better now. Will have to think about where to place the screw if we need to open up the other connection as well.

MG1 will be rectifying mains on to the DC bus that the RHS terminal is connected to, the battery will need to be disconnected from the during charging and moved to the other side of the buck/boost module.

Ah - gotcha. That makes sense. Hence control for additional contactors. Does mean you'll (I'll) need another brass standoff for connecting the charger.

I guess so. If just got some brass round stock. Was just going to cut to length and drill a hole down centre. I'll have some spare if you need a piece.

Bigpie wrote: ↑Mon Jul 13, 2020 3:41 pm I guess so. If just got some brass round stock. Was just going to cut to length and drill a hole down centre. I'll have some spare if you need a piece.

Thanks. I have some threaded standoffs I got before I received the ones from Damien but they're fractionally too wide (20mm). Could turn the bottoms down with a drill &file but really I need something a little narrower. Surprisingly cheap on eBay though. That said, I'm going to be spending a fair amount of time (and money) at the metal merchants anyway!

Don't suppose you can share the fusion 360 files for the power connector? Want add a 3rd hole for my stand off. Mine will likely differ from yours, especially as I've so far failed to get the hold dead centre. My drill press is a crappy drill mount from eBay so has loads of play.

Bigpie wrote: ↑Mon Jul 13, 2020 4:33 pm Don't suppose you can share the fusion 360 files for the power connector? Want add a 3rd hole for my stand off. Mine will likely differ from yours, especially as I've so far failed to get the hold dead centre. My drill press is a crappy drill mount from eBay so has loads of play.

Absolutely: https://a360.co/2OiNlYJ

Though adding a third hole is on my plans for tonight. I'm going to see if I can tie into some of the other holes on the inverter casing for the cover.

Sounds like you need a tweaked version though!

Due to the location of my inverter ending up very close to the firewall, I've had to redesign the housing for the AMPSEAL connector to swing it around 180 degrees. This is very much in the testing phase but let me know if this would be useful for you.

Also means I have a spare straight shroud for the AMPSEAL if anyone wants it. If you're in the UK or relatively close, let me know and I'll stick it in the post.

bobby_come_lately wrote: ↑Wed Oct 21, 2020 5:29 pm Due to the location of my inverter ending up very close to the firewall, I've had to redesign the housing for the AMPSEAL connector to swing it around 180 degrees. This is very much in the testing phase but let me know if this would be useful for you.

Also means I have a spare straight shroud for the AMPSEAL if anyone wants it. If you're in the UK or relatively close, let me know and I'll stick it in the post.
ampseal_shroud_180.jpg

Looks good, got a cad file I can check out/tweak?

https://github.com/jamiejones85/Gen3Pri ... ter3DParts

I've put files bobby_come_lately and Konstantin on github, stls and fusion360 files.

Hi folks, I have an offer to print some parts for my Yaris inverter. I can imagine the the AMPSEAL is pretty much the same as the Gen3 but can anyone confirm that the other parts are also compatible? Also any change in preference for material and infill% from the PETG at 20% that Bobby-come-lately used initially?
Thanks,
Chris

I am looking for gen3 plate V3.stl, I found it on Github, but it doesn't have a download button like the rest of the stl's?

I think @Konstantin designed the part you are after

Does anyone have drawings for the battery cable standoffs for use with battery_connector_v2?