Vehicular LED Display Case

in Product Design held by DealerSync
Contest Ended, Winner(s) have been selected.
Description:
I am prototyping a display for a startup that will be mounted on the tops of vehicles. It will eventually be either CNC milled or 3D printed, depending on the material decided on. For this display I am looking for a sleek case design that also meets the specifications below.
The display panel itself is 81.75625 cm x 15.24 cm and needs to be able to slide into and out of the case when a side panel is removed. The electronics are mounted on the back of the display panel and require a clearance of 5.08 cm. There needs to be a source of ventilation for the electronics except on the top as it will be outdoors, as well as one usb port and space for the power cable on the bottom of the display case. For the feet, they will be made of magnets with quite a strong pull force that have been dipped in rubber to prevent scratching. This also needs to be accounted for in the design with there being 3 to 4 feet supporting the case.
There are other cases for various products that need to be designed/redesigned, so we would like to find somebody to work with through this contest.
Wants:
(in order of importance)
1. Function: The case needs to be structurally sound and durable while meeting the requirements of the ports, holes, and feet.
2. Aesthetics: The more attractive and successful in directing attention to the display panel, the better. Sleek and minimalistic is preferred.
3. Cost: As this will potentially become a product sold, cost of manufacturing is important.
Don't Wants:
Ideally, the case will not be blocky in shape, however if that is the most structurally sound design it will still be considered. The interior of the case must be accessible to a technician in case of repairs or maintenance.
Software:
  1. AutoCAD (latest)
  2. SolidWorks (latest)
Additional Information
To answer the questions from comments (1/4/2016):
1) This project is housing for a display that will mount on top of vehicles. The design specs were recently edited to include a method of mounting in the interior of the vehicle if at all possible.
2) While mounted, the case will be exposed to open air conditions.
3) The attached photos are what we currently have, but it is purely functional and not very aesthetic. I will attempt some designs, but the general idea is for the case to be sleek and to avoid a bulky look.

Also the production by using sheet metal was a good suggestion for durability and cost.

To answer the questions from comments (1/5/2016):
1. The pitch is roughly 15mm in all directions. The viewing angle is either 120 or 160 degrees depending on the supplier.
2. The width of each LED hole in the faceplate is 7.5mm currently.
3. This is for a one-sided display.
4. All LEDs are mounted on a back panel, currently as the electronics are still being prototyped they are not all on a single board although we hope to move that direction in later stages of development.

To answer the questions from comments (2/11/2016):
1. The vehicle will be stationary while the display is mounted. The display will go on vehicles that are parked in lots for extended periods.
2. Regarding water resistance IP67 is preferred although as long as the original requirements are satisfied.
3. The depth of the current faceplate being used is roughly 3mm, although this is flexible in the overall design.
4. The direction of the display on the vehicle will be left to the end user.
5. The electronics shouldn't be more than 5 lbs. If you need more specifics please leave a note in the comments and I will try to answer quickly.
6. The pitch is roughly 15 mm in all directions.
7. 'Rounded' and 'organic' edges are preferred.
8. The current target for units built is unknown but I will clarify this with Sam. - Eli Blain (Software Developer)
8(cont.): The production goal is in the 10's of thousands annually.
9. The device is not completely programmable by the end user and it does device overall generates some heat, hence the need for some sort of ventilation, but it doesn't fail in ambient temperatures during normal operation for extended periods. (Longest test so far has been 42 hours of continuous operation.)

Project Update (3/5/2016):
Hello All,
Due to unforseen circumstances on our end regarding team availability, the contest will be extended another month so we can meet and decide on a winning design.
Thank you,
Eli Blain

Entries

1st Winner
#37 Display Panel Casing by PJCAD by PJCAD
- Main body of the casing is made of sheet metal, therefore it presents good strength and stiffness with preservation of low manufacturing costs;
- Plastic parts are designed to allow manufacturing by either: 3D printing, CNC milling or injection molding;
- The display panel can be taken out from the casing after removal of a side panel;
- Natural ventilation – simple and reliable;
Inside the casing there is a clearance for electronics and for flow of ventilating air;
- Adjustable height of legs – enables leveling / angle adjustment of the display panel if needed;
- Swivel mount of legs enables perfect match to curvature of vehicle’s roof and therefore gives steady base for the panel;
- 3 legs – to get reliable and not wobbly (as with 4 legs) mounting;
- Each leg comprise a socket for substantial magnet;
- All legs are equipped in easy to manufacture rubber bottoms;
- Legs can be easily replaced with other mounting suitable for vehicle's interior (I can design this mounting, after you tell me where exactly in the interior you want the panel to be located)
- The casing is resistant to any weather conditions (except for natural disasters);
- Ventilation holes, power cable and USB port are located under hoods to give protection from rain or snow;
- The display panel is located in the casing recess to improve visibility in strong sunlight and to give protection from rain or snow;
- Required viewing angle is assured despite the recess in the casing.
more
Feb 26, 2016 12:55
#53 led display case by RBLdesign
3d printed or molded plastic case. For the front must be a transparent, black tinted 3mm acrilic sheet. I think the front cover is important for protection against the nasty weather :) and hide the unused led modules, only the lighted ones are visible.
more
Mar 5, 2016 23:27
#52 Plastic housing by Paul Druta
Mar 5, 2016 23:06
#51 Bullet Light Sign - Update by Decker
I added an example of what I envisioned the extrusion may look like as well, an exploded view of what the assembly may look like taken apart.
more
Mar 5, 2016 18:40
#50 LED display case by Rene Kruger
Hi,
Herewith my design for the display case. This design is easy to manufacture (see image 5), and structural very sound.
Strong magnetic feet, sleek and simple design.
Kind regards.
more
Mar 4, 2016 11:12
#49 Vehicular LED Display Case by MRM1
Mar 4, 2016 1:52
#48 Dealersync LED CASE FINAL VERSION by Mouathel
Hope you liked my design
you can visit
mouathel.com or contact me on mouathel@gmail.com
more
Mar 3, 2016 9:59
#44 LED Enclosure Sheet Metal + Plastic by Adam
Conceptual
more
Feb 29, 2016 5:04
#43 LED Enclosure Plastic by Adam
Plastic enclosure concept. Thermals may prohibit an ABS enclosure. Ultem could be utilized but is expensive. Internal sheet metal plates heat staked to plastic for board and LED panel retention.
more
Feb 29, 2016 3:42
#42 Vehicular LED Display Case by REDA
:)
more
Feb 28, 2016 17:09
#41 Vehicular LED Display Case by REDA
;)
more
Feb 28, 2016 16:56
#40 Vehicular display 2 by Kristian
It's a much complicated design the side panels are made from plastic but the rest may produce by sheet metal.Rubber gaskets are providing the waterproofing.The vent orifices let the fresh air to come if the water comes too it won't reach the led panel because of the height of the inside walls.I provide files in .step format(my other design too).
more
Feb 27, 2016 15:06
#39 Vehicular display 1 by Kristian
This is simple design made from stainless steel(or aluminium) sheets.The case is sealed by rubber gaskets between the covers
more
Feb 27, 2016 14:49
#38 Display Panel Casing by PJCAD by PJCAD
Feb 26, 2016 12:57
#63 Car LED Display Enclosure by Mahbub
Sheet Metal enclosure for mass production and low manufacturing cost. 3d file and more images are attached.
more
Apr 4, 2016 17:29
#71 led display by priyanshu pandey
a conceptual one
more
Apr 5, 2016 7:55
#70 LED Display Case - Indoor/Outdoor/Hang/Stand by benito
Hi DealerSync:
Last minute entry,...I'm running out of time to submit the pretty renderings for this project. The case and hardware chassis is sheet metal (extruded) and the end caps/chassis-hatch are plastic. Adhesives can be used to fasten all the parts together. Magnetic base stand w/ adjustable ball-joint for vertical stand and, suction cup type hangar w/ dual adjustable ball-joint for glass mount. This can be mass produce relatively cheap.
more
Apr 5, 2016 7:42
#68 Vehicular LED by MRM1
Apr 5, 2016 2:14
#67 Vehicular LED Display Case by Joel Lozano
Apr 5, 2016 0:37
#66 Vehicle_LED Display Case_plastic housing by Paul Druta
Apr 4, 2016 18:33
#64 amarok-tepeflorosan-montaj by slim mougou
Vehicular LED Display Case
more
Apr 4, 2016 17:38
#36 LDC-2 by vinya
Feb 25, 2016 7:04
#62 LED Display With Foot Magnetic Base by Edi Suhendi
Foot Magnetic Base is standard part, available in a market.
more
Apr 4, 2016 16:13
#61 Sleek and Minimal, Functionally Durable and Optimized for Manufacturing Cost by DesignLab
Would like to have a discussion on dimensional adjustments. The working prototype will be given once the discussion is over.
more
Apr 3, 2016 5:10
#58 VEHICULAR LED DISPLAY CASE V2.0 by BRAVO
VEHICULAR LED DISPLAY CASE V2.0
more
Mar 16, 2016 8:13
#57 LED Display LC by Edi Suhendi
Mininamlis Design and Low cost production case
more
Mar 15, 2016 22:19
#56 LED Car Display by Chris Rozycki - ENS Design Group
IP67 Molded Plastic Case, Front clear acrylic plate, red aluminum plate, PCB with LED lights, red aluminum back plate with USB port and power cable hole.
more
Mar 15, 2016 2:26
#55 VEHICULAR LED DISPLAY CASE V1.0 by BRAVO
VEHICULAR LED DISPLAY CASE V1.0
more
Mar 14, 2016 19:34
#10 led display box revision1 by yitian
correct the flat pattern error in sheet metal models "led box"
more
Feb 7, 2016 16:35
#18 Vehicular LED Display Case by Flaviano Crespi
Dear Sirs,
I submit for your consideration my proposal for the construction of the Vehicular LED Display Case.
First clear that about 90% of the components are available from the market.
The main feature is the type of support realized with three magnetic feet arranged on the vertex of a triangle.
This arrangement allows the adaptation to the convex surfaces of the car roof and also the feet have a ball joint for greater adaptability, while the rear foot allows the tilt of control panel.
The main box is available from the market by "Hammond Manufacturing" ;
this is the link to the page where I could download the 3D model:
http://www.hammondmfg.com/1455.htm
The modeli is: 1455T2201 size mm 200 x 51.5
As you can see the box is already full of seals and complete with end plugs.
Hammond provides boxes of length 165 mm, is obviously necessary to request the pieces of extruded aluminum cut to the size of 830 mm.
The piece shaped as a "C" will be drilled with the laser to create the holes matrix.
With a CNC machine will be drilled the other holes for the feet fixings and the ventilation openings. After the surfaces is cleaned by removing the burrs, and finally the front face will be painted with flat black paint.
The adjustable feet are the FATH company; 3D models are available on the site
tracepartonline.net.
The model I chose is suitable for fixing the magnets, that will be encapsulated by a soft rubber cover glued in position.
For future development of the model I can provide constructive two-dimensional tables.
Best regards
Flaviano Crespi
more
Feb 11, 2016 10:59
#17 Assembly LED CASE by Waks
Unconventional and modern design of LED case. Very easy access to technician and effective airflow to reject electronic heat.
more
Feb 10, 2016 13:34
#16 LED BOX by yitian
NEW DESIGN
more
Feb 10, 2016 5:58
#15 Veh LED Panel by ProtoTech Workbench
Hello,
I've sent you some renderings of my work and I would like you to tell me if I'm on the right direction with the outline shape of the item.
COMPONENTS:
There are 4 main components:
1. Back case
2. LED and LED panel
3. Plexiglass panel
4. Front frame
The package of components are fixed together with screws
There are also secondary components:
5. Rubber and magnets
6. Back hatch (to access the electronics)
7. Electronics and main PCB
MATERIAL:
-For PROTOTYPE it may be use:
1. Wood for Front Frame and Back Case
2. Wood for LED Panel
3. Acrylic plexiglass
4. M5 and M6 screws
For MASS PRODUCTION
1. Sheet of metal
2. Acrylic
OUTDOOR PROTECTION:
-The acrylic panel and assembly between front frame and back case will protect the interior components from moisture.
ELECTRONICS PLACEMENT:
-as seen in the pictures
Please guide me so I will design the item in consistent with your vision and requirements.
Looking forward,
Liviu Barbu
ProtoTech Team
more
Feb 9, 2016 20:23
#14 Concept2Assy.step by Chris Trummer
Product description details features of the design.
more
Feb 9, 2016 4:58
#13 Vehicular LED Display Case by REDA
;)
more
Feb 8, 2016 19:13
#12 Transparent by Jeshwanth
The box is made out of plastic, so is the lid. The LED plate instead of having holes can be transparent which allows for far more dissipation of light. The USB port and the power port have also been included in the design. The transparent case is placed in a groove which will help in the easy sliding. The lid is a simple and easy snap-on mechanism using ridges and slots.
more
Feb 7, 2016 20:29
#11 Vehicular LED Display Case - plastic ver. - Rev. 0.1 by Vincenzo Ricci
Feb 7, 2016 16:36
#19 Vehicular LED Display Case powerful and moder design by Mouathel
Hello
you contact me on private and i will sen the description file because here is not private
or on mail mouathel@gmail.com
Hope you liked
more
Feb 12, 2016 0:20
#9 Vehicular LED Display Case by markol
You can see the panel from both sides.
more
Feb 7, 2016 16:28
#8 Vehicular LED Display Case by markol
Feb 7, 2016 14:51
#7 LED DISPLAY BOX by yitian
This box will be processed by punching,lazer cut,bending, welding. finish treatment and painting will be applied after
more
Feb 7, 2016 7:38
#6 Led Panel by arunkumar0514
Sheet Metal frame for paneling.
Acrylic/glass to cover LEDs.
Rubber coated magnet at bottom for placement.
More details can be added.
This was just a preview of the project.
more
Feb 6, 2016 7:35

Discussion

Showing last 20 comments - View All

PJCAD

Designer

Fri, 29 Apr 2016 07:37:22 +0000
Thank you benito :) And thank you DealerSync for awarding my project :)

benito

Designer

Thu, 28 Apr 2016 23:40:28 +0000
Congrats PJCad!

benito

Designer

Wed, 20 Apr 2016 17:30:55 +0000
70+ entries to consider and weed through the design scope. That's a lot....

Lucian

Administrator

Wed, 20 Apr 2016 09:20:41 +0000
Hi everyone,

A winner will be selected over the next days/week.

Regards,
Lucian
Wed, 20 Apr 2016 04:26:40 +0000
NO WINNER??? Great job CADCROWD... another unsuccessful contest. I feel there needs to be a penalty or something when this happens. Also, the client should not be allowed to hold another contest on this site. Lots of work and time go into designing these products.

Adam

Designer

Tue, 19 Apr 2016 02:15:54 +0000
Who won this contest ?

vinya

Designer

Wed, 13 Apr 2016 03:36:24 +0000
who is winner ?
Tue, 05 Apr 2016 08:44:00 +0000
Because I have only PTC creo file
Tue, 05 Apr 2016 08:40:56 +0000
I have uploaded in my portfolio
Thu, 31 Mar 2016 09:28:50 +0000
can i use PTC Creo Parametric

MRM1

Designer

Mon, 21 Mar 2016 13:47:54 +0000
HI
I'd like to ask some questions.
What is the width of the vehicle 81 L X 15 H X ? w
Fri, 19 Feb 2016 22:08:49 +0000
Hey guys, how large quantities are you planning to produce?
Fri, 19 Feb 2016 06:17:50 +0000
Hey, hi! I'm just wondering since you mentioned only the height and width of the LCD panel, can I have the freedom of design the case with a long tear drop rear? I'm a professional car designing student and trust me, I can make a cool looking streamlined case if you can accept having a case with a lengthy extension in its rear.
Wed, 17 Feb 2016 17:01:24 +0000
Hi,
I'd like to ask some questions.
The picture shows a grid of 37x8 LEDs. Is this your current grid or the picture is a general example. Secondly, do you need the 5.08cm clearance over the entire depth of the display panel or the case may curve around the top and bottom of the display panel.
Thanks

PJCAD

Designer

Mon, 15 Feb 2016 08:08:29 +0000
If you want casing with ventilation holes, then IP43 is the max you can get. For IP67 the whole casing should be sealed and ready to be immersed under water, so there should be no holes at all. Moreover lower IP number means lower costs. Please consider IP43 instead of IP67 and let us know if you want entirely sealed casing or just the casing resistant for all weather conditions.
Please specify what is the quantity you want to produce, as it affects technology and hence the design.

Regards,

PJCAD
Thu, 11 Feb 2016 00:06:27 +0000
That's an awful lot of high-output SMT LEDs. My first concern of many is thermal dissipation, is this device completely programmable by the end-user? If so then there is the possibility that the end user would turn it into a full-ON light bar for any amount of time. Have you noticed the device generating a considerable amount of heat during your testing? This will let me know whether the back can be enclosed or whether it needs to have heat exchanging fins. Thanks!
Wed, 10 Feb 2016 23:38:03 +0000
This seems like an interesting project. I have a couple questions about your requirements.

What is the max speed of the vehicle? This will determine how much force the sign will see from wind, and how much G-force it will see during emergency stops.

What is the pitch and diameter of the LEDs?

Regarding aesthetics, do you have a preference for sharper more "boxy" edges, or do you prefer a more "rounded" or "organic" design?

What is the quantity that you plan on manufacturing? This is really important. It will dictate production methods and some design features, as well as material selection.

Thank you,
--Art R.
Wed, 10 Feb 2016 16:13:40 +0000
if you could tell an estimated weight of the electric components, it would help in making a sturdy structure.

Regards
hammad

Decker

Designer

Wed, 10 Feb 2016 13:41:31 +0000
Message:
Have a look at a product called a Roku it is a case that is simple and cheap in manufacturing cost minus the ends. In particular take note of the housing. A simple aluminium extrusion with caps where the electronics slide into place. (Just a real durable design that would work for your application.
Regards, Decker
Tue, 09 Feb 2016 20:44:53 +0000
Which direction of vehicle you want the panel to face?

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