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This project involved designing a case for a human presence detection radar for in-vehicle data collection systems, printed circuit boards (PCBs) and an accelerometer with a light sensor for installation in commercial delivery vehicles. This project evolved significantly over time. Initially designed for a specific radar board, the case was subsequently adapted for use with two radar models and eventually was deployed in more than 25
commercial delivery vehicles. The initial version of the case, designed for the radar board shown below, served as the basis of design for subsequent improvements.

 

 

 

 

 

 

 

 

 

 

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​​​​​​​​​After completing the initial design of the case for a specific radar board, I refined the design to accommodate a new radar variant. Unlike the original design, the radar in this iteration was positioned more centrally on the PCB and without protruding as prominently. I also incorporated mounting locations to secure the case to a sheet metal bracket featuring PEM fasteners as shown below.

 

 

 

 

 

 

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In the final iteration, I included countersinks in both mounting holes to ensure that the screws sit flush with the top surface of the mounting flange. I also redesigned the case to securely fasten the top to the bottom using screws, instead of the prior iterations using no screws, a single screw, adhesive, or tape for securing the case. This modification resulted in a robust and reliable assembly. I oversaw the manufacturing of 28 cases of which 25 were assembled and installed in new in-vehicle data collection systems.

 

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