SOC-Meter Kit DIY Assembly

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garygid

Well-known member
Joined
Apr 21, 2010
Messages
12,469
Location
Laguna Hills, Orange Co, CA
CAUTION: Do not attempt this DIY assembly unless you are sufficiently skilled to do it SAFELY.

This is a finished SOC-Meter, without the new Filter Holder.
DSCF0172-SOC-20.jpg

The Assembly Instructions for the DIY SOC-Meter Kit have been
improved and "Rev 8" is now available for download as a pdf file from:
http://www.wwwsite.com/puzzles/socmeter/" onclick="window.open(this.href);return false;

Thanks, Gary
 
garygid said:
There are three main steps:

1. Prepare the Enclosure:
Make 5 holes and one rectangular slot in the plastic box. I intend to provide a paper template to tape over the box.

2. Solder wires:
a. 6 connections on one toggle switch.
>>>>>>>>
3. Physical Assembly:
a. Install the two push-buttons through holes in the "top" of the meter box.
>>>>>>>>>

This all looks reasonably doable by me. This will take me back to my "Heathkit" days. I have a good temperature-controlled soldering iron and other tools. Are you providing color-coded wiring that we cut and strip? It would be helpful if you would list the wire length required for each connection. I am a little worried I might not have the tools to cleanly cut a rectangular hole.

I am glad this project does not require precision surface-mount soldering like that exhibited by the EVSE project guy (sorry, I could find his name), because I don't think I could do that.

For those who are not up to assembling the kit, perhaps we could find some students whom we could train to build some kits for modest pay.
 
Yes, I intend color coding in the wires.

Yes, the only "difficult" part is the rectangular hole for the Display.
My Hole-Template ".pdf" should help, found at:
www.wwwsite.com/puzzles/socmeter/

Everything else is "a section of pastry".
 
When you are ready to ship, I am ready to wire!

Tom

garygid said:
Yes, I intend color coding in the wires.

Yes, the only "difficult" part is the rectangular hole for the Display.
My (yet to exist) template should help.

Everything else is "a section of pastry".
 
Gary,

My suggestion is to include the parts that you plan to put in the Kit, number them, and use that in the instructions. That way all the kit information is in one place. The parts thread can continue to evolve listing multiple options.
 
A Numbered Parts List for the SOC-Meter Kit has
been added to the first post of this thread.

If you see errors, please let me know.
the Assembly is not yet complete, but ... improving.
 
The first 4 SOC-Meter Kits will be available tomorrow at the
SoCal LEAF-Gathering in Santa Ana, two with a Blue Display,
and two with a Red Display.

I have ordered the parts for 10 more Kits, all with Blue Displays.

The color choice for the Display is a remaining issue, and we should be able to see the Green and Yellow working tomorrow. The Red, Blue, and Yellow all seem to be fine in anything except direct sunlight.

Since the Blue is a nice accent color for the LEAF interior, I decided to order more Blue Displays.

I also hope to make a 4-display "Demo" box, with one of each color display, to better compare possible more-subtle differences.
 
Our first SOC-Meter Kit was delivered yesterday.
Hooefully I will get some good feedback about the Assembly procedure.

I will continue to update the in-forum Assembly Instructions
(see the first post in this thread) on Tuesday afternoon.
 
A suggestion: Actual dimensions for the holes, cutout, etc. on the template would be helpful. Trying to scale them from just the rulers is difficult if you are planning to use real numbers on a CNC or the like.

garygid said:
SOC-Meter Wiring Diagram and Hole Template are available (pdf) at:
http://www.wwwsite.com/puzzles/socmeter/
 
OK, I will try and add dimensions tomorrow.

Do you have easy access to a Computerized Numerical Controlled milling machine?

I wish there was one nearby that I could use to do these boxes. I have about 20 to do now.

Thanks for the suggestion.
Cheers, Gary

Do you have all the parts and a/the box for the SOC-Meter?

You were intending to use a different display?

Let me know if I can send anything to you.
 
garygid said:
Do you have easy access to a Computerized Numerical Controlled milling machine?
I wish there was one nearby that I could use to do these boxes. I have about 20 to do now.
Harvey Mudd College has at least one or two Computerized Numerical Controlled milling machines. I live only about a mile away. There is a chance that I could get access to one before the school year gets underway Aug 30. I am friends with some of the faculty, but I don't know who controls that lab. I would have to convince them the SOC project was non-commercial.

Does anyone on the forum know how to program NC ? How easy is it to program a rectangular hole cut ?
 
I have a neighbor a few houses down that has one in his garage that he uses for his prototyping business. It's an old one but should be just fine for this purpose. I'm going to see if he will let me use it.

garygid said:
OK, I will try and add dimensions tomorrow.

Do you have easy access to a Computerized Numerical Controlled milling machine?

I wish there was one nearby that I could use to do these boxes. I have about 20 to do now.
 
I thought there were a couple places where you could submit orders online and get this done pretty quickly/easily. Never used any, myself, though.
 
I will have a stern chat with the Quality Control Department!

I checked the other "Red" and the black wire is there.
I will check the 2 Blue Kits tomorrow.
Thanks!

I will try to cut some boxes tomorrow, and build a Blue Kit myself.

I got more displays today, but they did not mark the color on 3 of them!
I will have to power them ON just to check the color.
Perhaps I can set their Baud Rate to 57600 while I am at it.

Did you notice the SOC-Meter Cluster meeting this Saturday
(6 Aug) at HTB in Santa Ana?
 
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