RuggedPOD Proto 1 bugs SDS team Wolfe Engineering

Liquid Leak Hypothesis – Liquid leak is coming from poor welding between panels – We did not experienced liquid leak on our early prototypes welded in France Panel material: AS7G03 – European aluminum alloy for die casting. Is it available in the US ? – Welded successfully in France with the following procedure – Pre-heating to C with a welding torch to remove oxidation, improve welding grip and reduce gas emission during welding process – Use TIG process with Argon and AG3 filler Rod – Is this ROD available in the US ? – Keep the material pre-heated during the process Liquid leak due to premature failure The original design was using locking mechanism between panel (see the following top view) This locking system was on top part of the panel and has been removed by the machining process reducing potential material to material contact and pushing the pressure support to the weld. Extreme forces on cube edge without locking mechanism which could probably led to weld failure if they are not strongly attached French proto style have in die casting rail support increasing thickness by 5 mm on some area making the panel much stronger

Gas Leak The top plate was misaligned on the prototype, not sharing the same plane than its support containing the Oring. We do not really know from where this misalignment is coming from, but it could be perhaps from the welding process of the support to the tank, which has involved some twisting of the support. Can we check ? One work around could be to use a thicker oring.

3 Pails doesn’t fit We need 3 Pails of 5 Gallons oil Oil is available as Pail or drum. Drum are much less expensive but contain 45 Gallons. Can we have a single drum of 15 Gallons compliant with oil ?

Blade bending Move to stainless steel material

Screw doesn’t fit SSD mounting hole

Wire length (bug 6/7/8/9/10) Before After Change wire routing, and add some wire strapping. (position will be transferred on sept 22th)

Wire length (bug 6/7/8/9/10) Before After Change wire routing, and add some wire strapping. (position will be transferred on sept 22th)

Wire length 5v/12V to DCDC cable lenght : 65mm DCDC power cable lenght : 75mm AC/DC to backplane cable lenght : 85mm Backplane to ethernet switch : 4x60mm Raspberry to ethernet switch : 100mm Switch power cable : 35mm All dimensions doen't inculde connectors head length

Soldered connection on Fisher are exposed We need to find a kind of threaded cork to hide the wires. Fisher do not seem to provide it and the threaded is a custom one. We didn't find something that fit at this time but can continue the dev program without it through thermal shrink protection Maybe the solution will be to make a custom one

Top cover cables are not guided

Raspberry PI mounting holes Standoff are now M2.5

Backplane PCB mounting screws Will be changed for next pass

USB power cable for RPI not pluggable after backplane positionned We can use this type of USB cable

Cables on Blade are loose

Need a slot for an optional Vacuum Pump Robinair Vacuum pump 1.5CFM/min Warning: Missing cable between vacuum inlet to POD. We need the vacuum cable Intake fitting: ¼ inch flare and ½ inch Acme intake port Voltage: 110V More info : Can Jabil supply us this pump ?

Need a slot for an optional oil transfer pump Bio-Diesel-Gas-Transfer-Pump-W-Meter-Hose- Nozzle-/ Bio-Diesel-Gas-Transfer-Pump-W-Meter-Hose- Nozzle-/ Can Jabil supply us this pump ?

Impossible to fully empty a POD

When serial is connected to a motherboard we observed some random POST failure on MSI core i7 board MSI board wiring Connectic board wiring COM 1 TX RX J52 RX TX Connect RX (com1) on RX(J52) and TX (com1) on TX (J52) This was a bad wiring approach

POD is hard to move (handle positioning)

Label on electronics part need to be withdrawn Will be done for next batch

Top cover not aligned with support We believe that this is a duplicate of Gas leak bug and that we can close this one. The main target is to avoid any gas leak

Mechanical conflict between raspberry pi, wires and power supply We will use right angle connectors to avoid collision, the raspberry positioning has been changed,

Define a sealing test procedure

Explain in documentation how to position O-ring

Lots of screws, deliver pods with electrical screwdriver

Mechanical conflict between ethernet wires and cover We can use this type of RJ45 cable 1

Mechanical conflict between power supply and rails The rail must be shortned by 15 mm

Add a cable guide for every internal cable even on blades

Add a GFCI to every ruggedpod We need to find one for north america market and one for european market

Blade collision with PSU

Add a network switch support