Wireless PIR Sensor Enclosure

thingiverse

This enclosure features a PIR sun sheild, 3D printed circuit board, and battery compartment with battery door. The circuit board is designed for an Adafruit Pro Trinket (5V) and Adafruit RFM69HCW Transceiver Radio Breakout. The exterior of the enclosure has raised digital camouflage type pattern and side handles for temporary mounting with small bungee cords. The PIR cover has a sun shield that also helps protects the PIR lens when transporting the sensor. As always I have included the 123D design files you can use to make modifications to meet your project needs. This is part of a larger project still in progress. This is being shared for others who may be looking for an enclosure for similar components. See http://www.instructables.com/id/Sensor-Array-and-Monitor/ for more of this project. Thumb Screw Heads for the battery cover can be found here:http://www.thingiverse.com/thing:1764416 Digital Camo Stencils for painting can be found here:http://www.thingiverse.com/thing:1765630 Print Settings Printer Brand: Printrbot Printer: Simple Black Rafts: No Supports: Yes Resolution: 2.6 mm Infill: 30% Post-Printing Remove support material and clean up any artifacts. All interconnecting parts should be cleaned up carefully and all parts test fit before final assembly. Holes should be checked and drilled to the correct size if required. Here is an Instructable I made on custom circuit boards: http://www.instructables.com/id/Custom-Circuit-Boards/ Circuit Board: Assemble the components on the circuit board. The Pro Trinket can be attached to the board with small screws, but I used small pieces of filament melted on each end. I secured the RFM69HCW to the circuit board with a few drops of super glue on contact points. I wired the pins with wire wrap wire and wire wrap tool. The battery clip was soldered. The antenna wire strain relief can be glued on the printed board in the locations shown. I glued the wire into the notch on the top of the strain relief block. Enclosure Top: The hole for the PIR needs to be cut out. The print has a thin layer with a wedge shaped support for the battery cover nut holder. Auto supports did not work well so I added these supports. They may be a little difficult to cut, so use a sharp knife and take care cutting this out. Put a 6-32 Nut into the battery cover slot on the top and two 6-32 nuts in the hex indents on each side for the side handles. They can be held in place with a few drops of super glue. Slide the circuit board into the enclosure top slots. PIR Enclosure cover: The PIR is attached to the cover with fasteners. On the Adafruit PIR, the holes are very close to other components and be careful a metal fastener does not short any components. I used small pieces of filament melted on the ends to secure the PIR to cover. The PIR and cover can be assembled to the Enclosure Top using small metal screws. The Enclosure top has slotted holes for the screw to thread into, nuts are not required. Enclosure Bottom: The bottom consists of the battery compartment and battery door. The enclosure is made for an 8 AA battery pack from Radio Shack. Test fit the battery door. It may require a little filing of the edges so the battery door works easily. There are hex indents for two 6/32 nuts. A few drops of super glue will hold these nuts in place. Press the enclosure bottom to the enclosure top. These do not need to be glued, they are held together by the side handles. The battery door can be held closed by a 6/32 x ¾” screw. Handles: The two handles are screwed to the sides using 4 6/32 x ¾” screws. The handles also secure the enclosure top half and bottom half.