Faraday Cage

PROJECT OVERVIEW:

Srushty engineered the sheet metal enclosure for stacking 3 different power module one by one into it which is connected internally into the enclosure. This product is used in the server room where the cage enclosure mounted in a 2U rack.

WORK FLOW:

Research:

We did a complete study on the dimension of the product which can be fit into the 2U size rack with 3 modules kept uniformly into it. And also on the wire routing in the enclosure and also in the front fascia which has the plugin to connect for servicing.

Frugal Prototype:

We tested the dimension of the cage with thermocol mock- ups where the modules were physically arranged in the cage to know:

  • the possible size of the cage for easy fittings of its modules
  • the difficulty in assembling and disassembling & servicing &
  • how to stack up the modules within the cage based on the given height of 2U size rack.

MECHANICAL ENGINEERING:

Mechanical Engineering was done based on the planning made after considering the test result of the mock- up.

  • EMI/EMC requirement:

As the modules are electronic components, so the EMI/EMC test becomes essential we tested the conductivity inside the enclosure between modules and also from the door to each module.

We also eliminated some EMI/EMC issues such as we made sure that in the server room many other electronic devices were present should not produce any electrical disturbance with signals and radiations to the enclosure and also the electrical signals inside the enclosure should not affect the other devices.

  • CAD:

We develop the 3D CAD model of each component of the enclosure such as front slide tray, plugin in the front fascia, air pieces for mounting, etc. as well as models of the modules to check the fitment and feel of the device and conclude on the height, width, air piece size and slot, pitch gap between the holes.

ASSEMBLING:

Process the engineering design based on the internal component placement and wire routing between the modules while keeping EMI & EMC in mind. At last, packaging was done completely to avoid any signal or interference to pass through the enclosure.

 

CHALLENGES:

There were certain challenges present while doing this product such as:

  • Packing the modules into the 2U rack size when the module size is itself taking too much space, leaving very less place for the enclosure this can lead difficulty in assembling and disassembling & servicing of the device.
  • Difficult to select the connectors for ensuring the conduction of every part electrically for the continuous signal. And to avoid any electrical disturbance with signals and radiations to the enclosure.

SOLUTIONS:

We used Ethernet wire so that every connector in the front fascia has got EMI/EMC compliance type cable connectors and also we masked some area before powder coating to create conductivity within the enclosure. The metals after powder coated to become non-conductive and cause no interface outside the enclosure. A slide tray was available in the front to replace the modules.

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