138 lines
11 KiB
Markdown
138 lines
11 KiB
Markdown
# 2020 Aluminum Extrusion Skeleton Blueprint & Structural Specifications
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**System:** 6U 19-Inch Open-Source Tri-Mode Storage Array
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**Document ID:** MECH-SPEC-01
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**Compliance Standard:** EIA-310-D / IEC 60297-3-100 (19-Inch Rack Cabinets)
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**Frame Material:** 6063-T5 Anodized Aluminum 2020 T-Slot Extrusion (6mm Slot, Series 20)
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---
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## 1. Dimensional Envelope & EIA-310-D Compliance
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The 6U chassis is engineered to maximize internal compute and storage density while guaranteeing seamless insertion into standard 19-inch 4-post or 2-post server racks without binding.
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```
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◄────────────────────────── 482.6 mm [19.00"] Front Flange ────────────────────────►
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◄─── 23.3 mm ───►◄────────────── 436.0 mm [17.17"] Chassis Width ──────────────►◄─── 23.3 mm ───►
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┌────────────────┬──────────────────────────────────────────────────────────────┬────────────────┐
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▲ │ [O] 6U Ear │ [ Modular 3D-Printed Facade with Interlocking Dovetails ] │ 6U Ear [O] │
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│ │ ├──────────────────────────────────────────────────────────────┤ │
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│ │ [O] │ 8x Toolless Vertical U.3 (NVMe/SAS/SATA) Hot-Swap Bays │ [O] │
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260.0 │ │ (Pitch: 49.5 mm, Channel Width: 23.4 mm) │ │
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mm │ [O] │ │ [O] │
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[10.24│ ├──────────────────────────────────────────────────────────────┤ │
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in] │ [O] │ Front Air Intake Mesh (50% Open Aerodynamic Hexagonal Grid) │ [O] │
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▼ └────────────────┴──────────────────────────────────────────────────────────────┴────────────────┘
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◄───────────────────── 500.0 mm [19.69"] Depth ────────────────►
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```
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### Critical Envelope Dimensions:
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- **Total Height (Skeleton + Sheets):** $260.0\,\text{mm} + 2 \times 1.2\,\text{mm (Skin)} = \mathbf{262.4\,\text{mm}}$ (EIA-310-D 6U max: $266.70\,\text{mm}$, giving $4.3\,\text{mm}$ safety clearance).
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- **Total Width (Skeleton Body):** $\mathbf{436.0\,\text{mm}}$ (EIA-310-D rack post clearance min: $450.85\,\text{mm}$, giving $14.85\,\text{mm}$ total side clearance).
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- **Total Depth:** $\mathbf{500.0\,\text{mm}}$ (Chassis front lip to rear exhaust plane).
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- **Front Faceplate Width:** $\mathbf{482.6\,\text{mm}}$ (19.00 inches).
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- **Rack Ear Mounting Hole Centers:** $\mathbf{465.1\,\text{mm}}$ horizontal pitch; EIA standard alternating vertical hole spacing ($15.875\,\text{mm} - 15.875\,\text{mm} - 12.700\,\text{mm}$ per 1U).
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---
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## 2. Structural Extrusion Cut-List
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All frame members are cut from standard **20mm x 20mm T-slot (or V-slot) aluminum extrusions**. Precision cutting tolerance: $\pm 0.2\,\text{mm}$, square cut ends $< 0.1^\circ$.
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| Part ID | Description / Position | Quantity | Cut Length (mm) | Total Linear (mm) | Sourcing / Stock Item (80/20 / Faztek / Misumi) |
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| :--- | :--- | :---: | :---: | :---: | :--- |
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| **EXT-01** | Vertical Corner Uprights (Z-axis) | 4 | **260.0 mm** | 1,040.0 mm | 20-2020 / HFS5-2020-260 |
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| **EXT-02** | Width Crossbars (X-axis, Top/Bottom Front/Rear) | 4 | **396.0 mm** | 1,584.0 mm | 20-2020 / HFS5-2020-396 |
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| **EXT-03** | Depth Side Rails (Y-axis, Top/Bottom Left/Right) | 4 | **460.0 mm** | 1,840.0 mm | 20-2020 / HFS5-2020-460 |
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| **EXT-04** | Mid Fan-Wall Vertical Stretchers (Z-axis) | 2 | **220.0 mm** | 440.0 mm | 20-2020 / HFS5-2020-220 |
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| **EXT-05** | Mid Fan-Wall & Drive Backplane Rails (X-axis) | 2 | **396.0 mm** | 792.0 mm | 20-2020 / HFS5-2020-396 |
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| **EXT-06** | Rear Mezzanine Floor Braces (Y-axis) | 2 | **300.0 mm** | 600.0 mm | 20-2020 / HFS5-2020-300 |
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| **TOTAL** | **Linear 2020 Extrusion Requirement** | **18 pcs** | — | **6,296.0 mm** | **~6.3 Meters (~3x 2.5m or 7x 1m standard bars)** |
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---
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## 3. Structural Joinery & Fastener Schedule
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To prevent vibration loosening under 24/7 server fan operation and mechanical hard drive harmonic vibration, all connections utilize hardened steel fasteners and cast zinc/aluminum corner gussets.
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```
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CORNER GUSSET ASSEMBLY EXPLOSION
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[EXT-01 Vertical Upright]
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│
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┌──────┴──────┐
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│ ( | ) │ ◄── 2020 Corner Gusset (Cast Zinc)
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│ ┌─────────┐ │
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[M5x10mm BHSCS]─┼─┤ (O) (O) ├─┼─► [M5 Drop-In T-Nut (Spring Loaded)]
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│ └─────────┘ │
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└──────┬──────┘
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│
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[EXT-02 Crossbar / EXT-03 Side Rail]
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```
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### Fastener Schedule Matrix:
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| Fastener Item | Specification | Quantity | Application | Est. Cost (1k Vol) |
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| :--- | :--- | :---: | :--- | :--- |
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| **FAST-01** | M5 x 10mm Button Head Socket Cap Screws (ISO 7380, Class 10.9) | 48 pcs | Corner gussets to 2020 extrusion | $2.40 |
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| **FAST-02** | M5 Roll-in T-Nuts with Spring Ball (6mm slot) | 48 pcs | Corner gusset anchor channels | $3.60 |
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| **FAST-03** | 2020 90-Degree Cast Aluminum Corner Gusset Brackets (20x20mm) | 24 pcs | 8 primary frame corners + 4 internal joints | $4.80 |
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| **FAST-04** | M4 x 8mm Button Head Screws + M4 Drop-in T-Nuts | 32 pcs | Securing laser-cut sheet metal panels | $2.20 |
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| **FAST-05** | M3 Heat-Set Brass Threaded Inserts (Ø4.2mm OD, 4.0mm L) | 40 pcs | Pressed into 3D-printed facade and fan wall | $1.80 |
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| **FAST-06** | M4 Heat-Set Brass Threaded Inserts (Ø5.6mm OD, 5.0mm L) | 16 pcs | Facade-to-extrusion mounting interfaces | $1.20 |
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| **TOTAL** | **Hardware Fasteners Package** | — | Complete structural fastening kit | **~$16.00** |
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---
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## 4. Mechanical Subsystem Spatial Zones
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```
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TOP VIEW SKELETON LAYOUT (Z=0 Plane)
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┌─────────────────────────────────────────────────────────────────────────────┐
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│ ◄───────────────────────── 436.0 mm Skeleton Width ───────────────────────► │
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│ │
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│ ┌───────────┐ ◄────────── 396.0 mm Front Crossbar (EXT-02) ───────► ┌───────────┐
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│ │ EXT-01(L) │ │ EXT-01(R) │
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│ └─────┬─────┘ └─────┬─────┘
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│ │ │
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│ ▲ │ [ZONE 1: STORAGE ARRAY - 0 to 125 mm Depth] │
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│ │ │ - 8x Vertical U.3 Toolless Caddies (Width 49.5mm pitch) │
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│ 125mm │ - SFF-TA-1001 Passive Backplane PCB (Mounted at Y=115mm) │
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│ │ │ │
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│ ▼ ├───────────────────────────────────────────────────────────────────┤
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│ │ [ZONE 2: PRESSURE WALL & FAN BARRIER - 125 to 195 mm Depth] │
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│ ▲ │ - Mid Crossbar (EXT-05) + Vertical Stretchers (EXT-04) │
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│ 70mm │ - 3x 120mm Enterprise PWM Fans (Noctua/Sanyo/Delta) │
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│ │ │ - 3D-Printed Acoustic Shroud with 5mm Filleted Baffles │
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│ ▼ ├───────────────────────────────────────────────────────────────────┤
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│ │ [ZONE 3: COMPUTE & GPU MEZZANINE - 195 to 500 mm Depth] │
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│ ▲ │ - Radxa CM3 + Broadcom SAS3408 Carrier Baseboard (Y=205 to 330mm)│
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│ │ - Unobstructed Mezzanine Space (300mm length) │
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│ 305mm │ - Vertical GPU Compute Bay with Rear Exhaust Venting │
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│ │ │ - External 12V High-Current Input Panel │
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│ ▼ │ │
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│ ┌─────┴─────┐ ◄────────── 396.0 mm Rear Crossbar (EXT-02) ────────► ┌─────┴─────┐
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│ │ EXT-01(RL)│ │ EXT-01(RR)│
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│ └───────────┘ └───────────┘
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└─────────────────────────────────────────────────────────────────────────────┘
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```
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---
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## 5. Structural Squaring & Assembly Protocol
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1. **Sub-Assembly 1 (Left & Right Side Ladders):**
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- Lay two EXT-01 vertical uprights (260mm) parallel on a flat reference table.
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- Join using two EXT-03 side rails (460mm) at the top and bottom with 4x corner gussets (FAST-03).
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- Use a precision machinist's square ($90^\circ \pm 0.05^\circ$) across diagonal corners ($L_{\text{diag}} = \sqrt{260^2 + 460^2} = 528.4\,\text{mm}$). Torque M5 screws to $4.5\,\text{N}\cdot\text{m}$.
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- Repeat for the opposite side ladder.
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2. **Sub-Assembly 2 (3D Box Integration):**
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- Stand both side ladders vertically.
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- Bridge the ladders using the four EXT-02 width crossbars (396mm) at the front-top, front-bottom, rear-top, and rear-bottom.
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- Measure 3D spatial diagonals ($L_{\text{3D}} = \sqrt{260^2 + 460^2 + 396^2} = 660.3\,\text{mm}$). Verify that all four 3D diagonals match within $\pm 0.5\,\text{mm}$.
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3. **Sub-Assembly 3 (Mid Fan Wall & Mezzanine Rails):**
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- Drop 4x M5 roll-in T-nuts into the top and bottom inner slots of EXT-03 at position $Y = 135\,\text{mm}$.
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- Bolt in the lower and upper EXT-05 mid-crossbars (396mm) and EXT-04 vertical stretchers (220mm).
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- Bolt the two EXT-06 mezzanine rails (300mm) to the bottom rear frame.
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