Panel-mount Fuseholder Holder

Under ordinary circumstances, a fuseholder mounts in a square-ish panel cutout, but there’s no convenient panel to be found in the repurposed GX270 case. So now there’s a holder for the fuseholder stuck to the side of the power supply inside the case:

Fuseholder - installed
Fuseholder – installed

The square tube covers the entire fuseholder, with the quick-connect tabs protruding from the back, to provide enough surface area for the double-stick foam tape.

Looking down into the solid model, you can see the reduced width near the back end:

Fuseholder Holder
Fuseholder Holder

The black fuseholder contains a 5 A fast blow fuse, which should be entirely adequate for normal operation. In the event that a wire breaks loose and contacts the metal shell surrounding the whole chassis, it will pop instantly. That won’t disable the power supply, but it will remove line voltage from the entire motor controller chassis.

Remember that the source power line goes to the center QC tab, thus burying the always-hot contact deep in the fuseholder.

The OpenSCAD source code:

// Fuseholder mount
// Ed Nisley - KE4ZNU - August 2014

//- Extrusion parameters must match reality!

ThreadThick = 0.20;
ThreadWidth = 0.40;

HoleWindage = 0.2;			// extra clearance

Protrusion = 0.1;			// make holes end cleanly

AlignPinOD = 1.70;			// assembly alignment pins: filament dia

function IntegerMultiple(Size,Unit) = Unit * ceil(Size / Unit);

//----------------------
// Dimensions

Shell = [25.0,25];						// outside = bezel size + some stiffening

Mount = [17.3,15.7,21.0];					// mount section = slight compression in X
Base = [13.5,15.7,17.0];					// clearance over crimped contact

OAL = Mount[2] + Base[2];

//----------------------
// Useful routines

module PolyCyl(Dia,Height,ForceSides=0) {			// based on nophead's polyholes

  Sides = (ForceSides != 0) ? ForceSides : (ceil(Dia) + 2);

  FixDia = Dia / cos(180/Sides);

  cylinder(r=(FixDia + HoleWindage)/2,
           h=Height,
           $fn=Sides);
}

module ShowPegGrid(Space = 10.0,Size = 1.0) {

  RangeX = floor(100 / Space);
  RangeY = floor(125 / Space);

	for (x=[-RangeX:RangeX])
	  for (y=[-RangeY:RangeY])
		translate([x*Space,y*Space,Size/2])
		  %cube(Size,center=true);

}

//----------------------
// Build it

ShowPegGrid();

difference() {
	translate([0,0,OAL/2])
		cube([Shell[0],Shell[1],OAL],center=true);
	translate([0,0,Base[2] + Mount[2]/2])
		cube(Mount + [0,0,2*Protrusion],center=true);
	translate([0,0,Base[2]/2])
		cube(Base + [0,0,2*Protrusion],center=true);
}