Building Ronja AUI Forte

Description

The electronics is placed in a metal box. The body is made of tin-plated steel tin of thickness about 0.5mm. The lid is from tin-plated steel tin, or aluminium or copper tin. They are connected with 10 M4x6 galvanized bolts with hex head and 10 M4 galvanized nuts.

Postscript / PDF / EPS / BIG png / DXF (qcad)

Box

Cut out the body and lid shape from tin, drill the holes. Form the tin into depicted shape. Use the 20x20x3 steel L-sections fastened in vice for bending.

Solder the tin together in corners. Place the lid over the body and drill through with 4.3mm bit, securing the already drilled holes against movement by inserting M4 bolts.

Grommets, wire nut

Insert the grommets.

Place the wire nut near the 8mm grommet (10.5mm hole).
Drill with 3.3mm bit through all five holes of the nut. Use inserted M3 bolts to keep the nut in position during drilling.
And attach with 5 M3x15 bolts,5 M3 washers, and 5 M3 nuts. Place bolt heads inside the box. Tighten firmly.
Note: the pictures are of old prototype with only 4 wire nut terminals instead of correct 6.

AUI Cable

Cut a 1 meter long piece of shielded 4-conductor cable. Solder the AUI connector (CANON 15-pin male) on one end of the cable together with a 39R resistor (see the schematic, the closed box in the upper right corner.

Postscript / PDF / EPS / BIG png / SVG (Inkscape)

Cutting cables

Cut two 10cm long pieces of shielded single-conductor cable. Strip all ends of the cables and cover them with solder.

Postscript / PDF / EPS / BIG png / SVG (Inkscape)

RX/TX Cables

Install the three cables into the AUI box and solder one shield to the ground according to the drawing.

Postscript / PDF / EPS / BIG png / SVG (Inkscape)

Stubs

Solder four 4mm^2 hard wires (uninsulated) on the remaining ends of the cable.

Postscript / PDF / EPS / BIG png / SVG (Inkscape)

Insulation

Stick coloured strips of insulating tape on the box as on the drawing
Insulate wire ends with corresponding colour and plug into the wire nut and tighten down.

Populating with components

Semiconductor components will be installed according to the placement plan.
Semiconductors will be wired together using wires, resistors, capcitors, diodes etc.

There are arrows labeled "P*" where "*" varies. Those are not real components, just measurement points.

Postscript / PDF / EPS / BIG png / SVG (Inkscape)

Placing components

Place components according to the plan. Before placing each integrated circuit, carve the part number (for example 74HCT132) on the bottom side using sharp metal stylus or stick a sticker and write it on. Write a refdes (e. g. U51) beside the IC on the tin using fine-tip permanent waterproof marker.

Some of the following example photos have pins pointing towards the tin. Recommended way is to make pins point away from the tin.

		PostScript	PostScript + Gzip	PDF
Color	Dark	aui_forte_01.ps	aui_forte_01.ps.gz	aui_forte_01.pdf
	Light	aui_forte_00.ps	aui_forte_00.ps.gz	aui_forte_00.pdf
	Small	aui_forte_02.ps	aui_forte_02.ps.gz	aui_forte_02.pdf
B/W	Dark	aui_forte_11.ps	aui_forte_11.ps.gz	aui_forte_11.pdf
	Light	aui_forte_10.ps	aui_forte_10.ps.gz	aui_forte_10.pdf
	Small	aui_forte_12.ps	aui_forte_12.ps.gz	aui_forte_12.pdf

aui_forte.sch (gschem)

Component lists

Seznamy součástek

Soldering

Wire up the remainder of the circuit in this priority:

Remaining components
Remaining wires

Correctness check

Take the schematic and a multimeter and do a check. Check that the topology is OK (i. e. the wires lead where they should lead). Check every resistor - either read the value, decode the strip code or measure the resistor with a multimeter (sometimes it will show less if there is a current path around). Check every capacitor visually where the value is visible. Check every diode and transistor junction with diode measuring function of the multimeter. Scrawl out every part and wire you check on the schematic with a pencil.

Postscript / PDF / EPS / BIG png / SVG (Inkscape)

Labeling

Print out the "small print" schematic (see Soldering above) on a laser printer. Overwrite part numbers where different parts or equivalents were used. Glue the paper on the inner side of the lid.

Print out the Ronja AUI Forte label. Fill in the label and glue the label on the outer side of the lid.