A Redesign of the DRO-350/DPU-550 Case

Let me begin by stating that the comments and analysis contained herein are in noway a critism of the original design for the DRO-350 case. At the time that case was designed, the DPU-550 was not even a dream. But my experience with the DPU-550 has convinced be that a redesign of the DRO-350/DPU-550 case is in order.

The construction of the DRO-350/DPU-550 differs from a "Plain Jane" DRO-350 in several ways.

First, there can be up to four Aux/Tach/Edge inputs. The DRO-350 has only one. Next, although not a change, the DB-9 connector, although changing from a connector for the JDM programmer to a connector for a true RS-232 connection, still occupies "real estate" on the case.

We then add the capability to increase the number of possible scale (Mini-Din) inputs from 3 to 5. Then we have added the openings for the USB connector and the programming switch. And of course, we have to have the power jack.

The additional openings unto themselves would not be a particular problem if we still had all the room that is available inside the "Plain Jane" DRO-350 case. But the DPU-550 occupies space inside the case and restricts the potential locations for the additional openings. Plus, the position of the USB and Programming Switch openings are dictated by the location of these components on the DPU-550.

The instructions on the ShumaTech web site assume that a DPU-550 is being added to an existing DRO-350, and that the original DRO-350 case will be retained. If shows the locations for the USB and Programming Switch openings, but makes no suggestions for the expansion allowed by a DPU-550 Full daughter board.

I have taken the approach that rather than dealing with an upgrade to an existing DRO-350, we are building a DRO-350/DPU-550 from the ground up. Variations of my design can be used to expand the capabilities of the original DRO-350 case when upgrading to a DPU-550.

The primary driving force behind my belief that a redesign was in order, was the crowding of the scale input cables that occurs beneath the DPU-550 daughter board. Because of the location and orientation of the X, Y and Z input connectors on the DRO-350 processor board, coupled with the placement of the openings for the Mini-Din connectors along the bottom edge of the rear of the case, it is difficult to route the scale cables away from the area of the LED displays. Although there has been debate on whether moving the scale cables away from the LED displays and the associated circuitry, reduces jitter, there has been no evidence that routing the scale cables away from that area presents any problems in the operation of the DRO-350 or DRO-350/DPU-550. So my design errs on the side of caution.

The photo above shows the new design with three scale connector openings located over the keypad area of the DRO-350 processor board and two Aux/Tach/Edge connector openings along the top rear of the case. This design allows for easier routing of the scale cables away from display area of the DRO-350 processor board and the higher frequency (40 mhz) ARM7 MPU on the DPU-550 daughter board.  The power receptacle remains in approximately the same location.  Also seen are the openings for the USB connector and the programming switch.

 

The next photo shows the rear case cover from the inside. Visible in this photo are the pilot holes and reliefs milled for the purpose of expanding the number of scales and/or Aux/Tach/Edge connectors. These additional openings can be created with a simple drill and utility knife. Cases delivered without the RS-232 DB-9 opening also have this opening outlined and piloted.

(Please excuse the lack of clarity in these photos.)

The Aux/Tach/Edge connectors delivered with the Wildhorse Innovations kits are slightly different from those specified in the ShumaTech BOM. These connectors (both Wildhorse's and ShumaTech's) are merely 10mm Stereo Jacks.  Their jacks have the nut on the inside so the wires must be soldered with the assembly in the case.  Ours (Wildhorse) have the nuts on the outside so the soldering can be done before installing into the case.

The threaded "neck" of the Wildhorse jacks are slightly short for the thickness of the case.  They can be installed, but the number of threads engaged by the nut is insufficient.  The nut can be tightened down with pliers, compressing into the plastic.

Our cases have a relief milled into the inside of the cover for the stereo jacks, allowing more threads to be exposed.  These reliefs are also milled for the "piloted" areas provided for additional Aux/Edge/Tach openings.

An additional difference is that our jacks have a slightly smaller neck than the ones specified in the BOM.  Ours require a  0.250" opening.  The ones called for in the BOM require using an "O" letter size drill.

Some additional dimensions:
Bolt holes for Mini-Din connectors and RS-232 jack - 0.125".
Openings for Mini-Din connectors - 0.500"

If you are install the RS-232 (DB-9) receptacle, using the pilot hole in the center of the DB-9 outline, drill a #10 or 25/64 hole.  Then use an exacto knife, following the outline milled into the case, to create the final shape.

As usual, all coments are welcome.  We hope our new case design meets with your approval.