Brakeman

Fork project on GitHub

An electronic DCC-track-driven figurine with a red or blue LED

Unlit
Unlit
Mockup
Mockup
Fabricated
Fabricated
Packaged
Packaged
Assembled
Assembled
Lit
Lit
Fabricated-backside
Fabricated-backside

 

 

Brakeman Version 2.3

First built: 2016-11

Designed for fabrication and ease of assembly For best results when fabing, choose

  • ENIG (gold) rather than a Hot Air Solder Layer (HASL) for the pads
  • White or Blue soldermask
  • Panalize = 1

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Download Brakeman.gerbers.zip - Gerber Fabrication files
Download Brakeman.parts - Parts List (spreadsheet data)
Download Brakeman_array.gerbers.zip - Gerber Fabrication files
Download Brakeman_array.parts - Parts List (spreadsheet data)

 

Brakeman.bom

Parts Value Package Quantity Library Type/Feeder
R1 1k0 0204/5 1x resistor PTH
PADL1, PADL2, PADNA, PADNA2, PADNF, PADNF2, PADSF, PADSF2 pad SMD1.27-2.54 8x wirepad NONE

Brakeman_array.bom

Parts Value Package Quantity Library Type/Feeder
R1, R2, R3, R4, R5, R6, R7, R8 1k0 0204/5 8x resistor PTH
PADL1, PADL2, PADL3, PADL4, PADL5, PADL6, PADL7, PADL8, PADL9, PADL10, PADL11, PADL12, PADL13, PADL14, PADL15, PADL16, PADNA, PADNA1, PADNA2, PADNA3, PADNA4, PADNA5, PADNA6, PADNA7, PADNA8, PADNA9, PADNA10, PADNA11, PADNA12, PADNA13, PADNA14, PADNA15, PADNF, PADNF1, PADNF2, PADNF3, PADNF4, PADNF5, PADNF6, PADNF7, PADNF8, PADNF9, PADNF10, PADNF11, PADNF12, PADNF13, PADNF14, PADNF15, PADSF, PADSF1, PADSF2, PADSF3, PADSF4, PADSF5, PADSF6, PADSF7, PADSF8, PADSF9, PADSF10, PADSF11, PADSF12, PADSF13, PADSF14, PADSF15 pad SMD1.27-2.54 64x wirepad NONE

Brakeman Version 2.2

First built: 2016-10

The 2.1 panel was fragile - this attempts to improve things

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Download Brakeman - CHMT Component and feeder definitions
Download Brakeman.gerbers.zip - Gerber Fabrication files
Download Brakeman.parts - Parts List (spreadsheet data)
Download Brakeman_array - CHMT Component and feeder definitions
Download Brakeman_array.gerbers.zip - Gerber Fabrication files
Download Brakeman_array.parts - Parts List (spreadsheet data)

 

Brakeman.bom

Parts Value Package Quantity Library Type/Feeder
R1 1k0 0204/5 1x resistor PTH
PADL1, PADL2, PADNA, PADNA2, PADNF, PADNF2, PADSF, PADSF2   SMD1.27-2.54 8x wirepad NONE

Brakeman_array.bom

Parts Value Package Quantity Library Type/Feeder
R1, R2, R3, R4, R5, R6, R7, R8 1k0 0204/5 8x resistor PTH
PADL1, PADL2, PADL3, PADL4, PADL5, PADL6, PADL7, PADL8, PADL9, PADL10, PADL11, PADL12, PADL13, PADL14, PADL15, PADL16, PADNA, PADNA1, PADNA2, PADNA3, PADNA4, PADNA5, PADNA6, PADNA7, PADNA8, PADNA9, PADNA10, PADNA11, PADNA12, PADNA13, PADNA14, PADNA15, PADNF, PADNF1, PADNF2, PADNF3, PADNF4, PADNF5, PADNF6, PADNF7, PADNF8, PADNF9, PADNF10, PADNF11, PADNF12, PADNF13, PADNF14, PADNF15, PADSF, PADSF1, PADSF2, PADSF3, PADSF4, PADSF5, PADSF6, PADSF7, PADSF8, PADSF9, PADSF10, PADSF11, PADSF12, PADSF13, PADSF14, PADSF15   SMD1.27-2.54 64x wirepad NONE

Brakeman Version 2.1

First built: 2016-10

The circuit / layout from 2.0, manually panelized into an 8x 10cmx10cm size.

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Brakeman Version 2.0

First built: 2016-06

V2.0 is effectively the same as v1.3, but it has better documentation in the gerber files for panelization and adds a couple of traces between the base and the figure to allow full panel prebuilds and easy testing - the 2 traces are intended to be cut during the final assembly process. This version adds back the vias on the feet to allow for adding support wires to reinforce the solder joint that is prone to snapping off when Brakie is taken out of service and stuck in a pocket - and then sat upon… Finally, the figure is now wearing a belt :-)

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Brakeman Version 1.3

First built: 2016-04

Panelized

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Brakeman Version 1.2

First built: 2012-03

First volume production run

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Download Brakeman - CHMT Component and feeder definitions
Download Brakeman.gerbers.zip - Gerber Fabrication files
Download Brakeman.parts - Parts List (spreadsheet data)

 

Brakeman.bom

Parts Value Package Quantity Library Type/Feeder
R1   R0805 1x resistor NONE
PAD1, PAD2, PAD10, PAD11, PAD12, PAD14, PAD20, PAD21, PAD23, PAD24   SMD1.27-2.54 10x wirepad NONE

Brakeman Version 1.1

First built: 2012-01

Sizes and orientation

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Brakeman Version 1.0

Not built

Playing with different outlines

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Brakeman Version 0.0

Not built

Initial experimentation

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GCOR

GCOR Rule 6.19 D (paraphrased)

When a train stops on a main track, flag protection must be provided

On a layout, torpedoes and fusees are a bit over the top, but a brakeman/flagman with a red lantern can add a twist to your next operating session. Adopt prototype practices and have your crews protect their trains when switching a town or otherwise fouling the main. Just don’t forget to recall the flagman before leaving town!

Designed in the NMRA/PCR for DCC layouts

Assembly required

  1. V1.0-1.3: Use a track nipper to detach the base from the hand holding the LED.
  2. V2.x: Snap the base from the feet and remove any extra PCB frame from around the figure.
  3. Solder the two feet to the two small gold pads on the top of the base
  4. You can solder a wire (the clipped off resistor leads work well) to strengthen and align this connection
  5. Attach the weight to the top of the base next to (but not touching) his feet with double sided foam tape
  6. Place the large gold pads across the rails to light the red lantern.

Variation:

  • Make a “Safety Sam” to indicate track or rolling stock that must not be used/moved. Use 2 BLUE LEDs instead of one RED one - solder them “back to back, opposite” so that one LED’s long lead is soldered to the “front” on the raised hand, while the other’s long lead is soldered to the figure’s “back” on the lowered hand. Using 2x Blue LEDS is necessary because the Blue LED’s have a reverse breakdown voltage close to 5v, while the common Red ones seem to be able to handle 20v+. (DCC track voltage is ~15v…)

Clean track works best. Use violates UP Safety Rule 81.2.1, Step Over Rail

John Plocher, SPCoast.com

WARNING: This product may contain chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.

TestPlan

Brakeman Testplan and Assembly:

  • SMT 1K0 0805 or PTH resistor on body top surface
  • Cut the LED leads to between 3mm and 4mm long
  • Edge mount the Red LED to the raised arm, polarity does not matter
    • Colors other than red: must use 2x LEDS, one on each arm, with opposite polarity

Testing:

  • Red LED:
    • Touch 9-12vAC to one "foot" and Gnd to the other,
    • observe RED LED on hand light up.
  • Other Colors:
    • Touch 9-12vDC to one foot and GND the other,
    • Observe ONE LED light up
    • Reverse the foot connections
    • Observe the OTHER LED light up

The end user will snap apart the base and body, solder the feet to the base and attach a lead weight to the base, making a figure with a LED lantern in its hand that lights up when placed on a HO model railroad track.

This technical documentation is licensed under the CERN Open Hardware Licence v1.2