Custom adapter enclosure designed to interface xNAV650 GPS/INS system with Ouster LiDAR sensors. The project includes complete PCB design, 3D-printable enclosure with precise mounting specifications, and comprehensive assembly documentation. Features integrated power regulation, signal conditioning, and PPS synchronization for precise time-stamped LiDAR point clouds.
This design demonstrates practical embedded systems integration, mechanical CAD skills, and understanding of high-precision sensor synchronization requirements for autonomous vehicle applications.
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| Element | Dim X | Dim Y | Dim Z | Notes |
|---|---|---|---|---|
| External dimensions | 90mm | 60mm | 20mm | Wall thickness 2mm |
| Internal space | 86mm | 56mm | 18mm | Clear working space |
| PCB standoffs | 60mm spacing | 40mm spacing | 10mm height | M3 holes, 4 pieces |
| Micro-D hole | - | 20mm | 10mm | Left side, centered |
| DC Jack hole | - | Ø8mm | - | Left side, 10mm from top |
| Cable output | 20mm | - | 8mm | Rear wall, centered |
| LED hole | - | Ø5.5mm | - | Front wall, upper right |
| Element | Dimension | Notes |
|---|---|---|
| External dimensions | 90×60×10mm | Wall thickness 2mm |
| Mounting groove | 86×56×2mm | Fits bottom part |
| Screw holes | 4× M3 | Corners, 5mm from edge |
| Vent slots | 6× (1×15mm) | Sides, for heat dissipation |
Print or draw template at 1:1 scale. Secure with tape to enclosure. Use center punch to mark hole centers before drilling.
DC Jack (Ø8mm): Drill from outside to inside. Start with 3mm pilot, then gradually increase (5mm, 6mm, 8mm).
LED (Ø5.5mm): 5.5mm hole, press-fit LED with holder.
Micro-D 15: Best cut with sharp knife or use file to shape.
For Ouster wires: drill 6mm hole, then expand with file to 8×20mm rectangle. Use rubber grommet for cable protection.
Ø3.2mm drill for free M3 screw passage. For threading in plastic, use Ø2.5mm and tap M3 thread.
Remove all burrs with file or sandpaper. Clean enclosure from debris. Check fit of all connectors before assembly.
| Hole | Position | Size | Tool |
|---|---|---|---|
| DC Jack (J3) | Left wall, X=0, Y=30mm, Z=20mm | Ø8mm | 8mm drill bit |
| Micro-D 15 (J1) | Left wall, X=0, Y=30mm, Z=10mm | 20×10mm rect | Knife/file |
| LED (green) | Front wall, X=75mm, Y=5mm | Ø5.5mm | 5.5mm drill |
| Ouster cables | Rear wall, X=45mm, Z=15mm | 20×8mm rect | 6mm drill + file |
| Ventilation (6×) | Lid sides, evenly spaced | 1×15mm slots | Drill + file/mill |
| Lid mount (4×) | Corners, 5mm from edge | Ø3.2mm | 3.2mm drill |
If 3D printing: clean supports, smooth surfaces with P400-P800 sandpaper. If using off-the-shelf: drill all holes according to template from "Drilling" tab.
Screw 4× M3 standoffs (10mm height) to enclosure bottom in 60×40mm pattern. Use M3×6mm screws from outside. Ensure alignment with PCB holes.
J3 (DC Jack): Insert from outside, tighten nut from inside.
J1 (Micro-D): Mount connector in hole, secure with screws (if has mounting ears).
LED: Press-fit LED in Ø5.5mm hole, secure with drop of hot glue.
Connect wires from J1 and J3 to corresponding PCB points (check electrical schematic). Place PCB on standoffs and secure with M3×6mm screws. Don't overtighten!
Thread 3 wires (green, white, black) through rear wall opening. Solder to PCB per schematic. Install rubber grommet in hole for cable protection.
⚠️ CRITICAL! Before closing enclosure:
1. Connect 12V power, verify LED lights
2. Multimeter check: 5V at LM7805 output
3. Verify LM7805 heatsink temp (max 60°C)
4. Ensure all connections are solid
Place lid, ensure groove fits properly. Secure with 4× M3×12mm screws at corners. If lid won't close, check for protruding components.
For outdoor use: apply thin silicone bead around lid perimeter before screwing. Use clear acetylene silicone. Allow 24h cure before use.
Connect xNAV650 and Ouster. Power on. Verify:
• LED illuminated (green light)
• Ouster receives NMEA signal (check web interface)
• PPS synchronizes correctly
• Enclosure doesn't overheat (max 50°C)
| Criteria | Hammond 1591XX | 3D Print (PETG) | IP65 Box |
|---|---|---|---|
| 💰 Cost | $8-12 | $2-25 | $5-10 |
| ⏱️ Lead Time | 1-3 days | 4-6h (self) / 2-3d (service) | Immediate (stock) |
| 🔧 Difficulty | Medium (drilling) | Easy (pre-made holes) | Medium (drilling) |
| 🌧️ Waterproof | IP54 (with gasket) | IP20-40 (needs sealing) | IP65 (factory) |
| ✨ Appearance | Professional | Varies by print | Industrial |
| 📝 Customization | Low | Full (logos, text) | Low |
| 🏆 Recommendation | ⭐⭐⭐⭐⭐ | ⭐⭐⭐⭐ | ⭐⭐⭐ |
| Parameter | Value | Notes |
|---|---|---|
| Material | PETG | Alternative: ABS (needs heated bed) |
| Nozzle temp | 230-240°C | For PETG, depends on filament |
| Bed temp | 70-80°C | Important for adhesion |
| Layer height | 0.2mm | Sweet spot speed/quality |
| Infill | 30-40% | Sufficient strength |
| Infill pattern | Gyroid or Grid | Best for mechanical strength |
| Print speed | 40-50mm/s | Slower = better quality |
| Supports | YES | For side wall holes |
| Brim/Raft | Brim 5mm | Prevents warping |
| Cooling | 50-75% | For PETG not too much! |
| Print time | 4-6h | Depends on printer |
Ready-to-print models in multiple formats
Compatible with: Cura, PrusaSlicer, Simplify3D, FreeCAD, Fusion 360
This adapter enables precise time-synchronized LiDAR point clouds for autonomous vehicle mapping and SLAM applications. The xNAV650 GPS/INS provides accurate positioning and timing via PPS signal, which synchronizes Ouster LiDAR measurements to GPS time. This ensures consistent timestamps across sensor modalities, critical for sensor fusion and mapping accuracy.
The design is optimized for robotic platforms requiring reliable outdoor operation, with consideration for vibration, thermal management, and weatherproofing.