PS2游戏手柄面板固定架/护壳

Joystick panel mount / bezel for "PS2" joystick modules

2023-09-08 03:25:02

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Summary

These are panel mounting adapters for a common type of small joystick PCB module, generally sold as PS/2 or PS2 joysticks or thumbsticks.

As bought, those modules are not simple to attach to a panel, as the only mountings are four holes in the PCB at the back - which is also offset from the joystick centre.
(The ones I got came in a bag branded "DollaTek").

This mount adapter is designed to fit a 30mm hole, and be used with four 3mm screws to attach it to the panel.

The joystick module attaches separately to the rear of the adapter using ~2mm screws.

There are three versions included, to suit different size thumb stick levers that can be used with these modules:

The _2p one is sized to fit the black plastic stick they come with.

The _2m version has a smaller inner radius, to suit a nicer looking replacement aluminium stick section you can use on these, that's available on ebay etc.

The _2a is an intermediate radius, in case there are other stick replacements in between those two!

Print Settings

Printer:
Kossel XL
Rafts:
No
Supports:
Yes
Resolution:
0.2mm
Infill:
I used 50%
Filament brand:
Generic
Filament color:
black
Filament material:
PETG
Notes:
I printed these with the panel side upwards, so the panel fitting surface and visible bezel area did not have any support removal marks.

It means a lot of support material, but looks good!

Post-Printing

Assembly

The support material needs removing carefully as the corner pillars have recesses to clear the stick "dome", so the are somewhat fragile and the support can snag in the recesses.

The clearance around the stick dome is deliberately very tight, for appearance and to keep dust out.

I had to file the back edges of the opening to remove slight smears and traces of support material, for the sticks to move freely.

The holes in the rear pillars should be cleaned out with a 1.5mm drill, if they are clogged.

The front mounting holes should be cleaned out to 2.5mm or a fraction over (eg. wobble the drill slightly).

I used some tiny self-tapping screws that came with MG90S servos to attach the PCBs to the adapters; M2 screws should also work, or M2.5 if you enlarge the rear holes appropriately.

Viewed from the rear, with the dimpled edge of the adapter upwards, the module fits with the pins to the right; so connector pins to the left when viewed from the front and dimpled edge upwards.

The adapter itself can be fitted to a panel with the stick in any orientation needed.

The main mounting hole to the panel is 30mm. I used a small step drill to open a pilot holes up to around 12mm, then a 32mm cone cut bit (tapered bit) to widen them to the full 30mm, working from the rear of the panel, When it got near the correct size, I alternated between trying an adapter in place and cutting a fraction more, until the adapter flange just fitted flush to the rear of the panel with any force.

The mounting hole centres are arranged symmetrically on a 31mm square; +/- 15.5mm vertically and horizontally each way from the joystick and main mounting home centre, so the stick mechanism can be oriented in any direction, as appropriate.

I aligned them in the panel I made them for by cutting the 30mm holes, then holding tow adapters in place with a straight edge across underneath them & piloting through the upper holes with a 2.5mm bit. After those were opened to 3mm I could fix the adapters top down temporarily and pilot through for the lower holes.

It's easier to use the "top" holes (near the edge with the dimple) as one of the lower ones overlaps a pillar, making it difficult to get a drill dead straight through from the back.

Due to the close clearances, centering the joystick in the adapter can be tricky to about it binding.

If you have problems, make sure the thumbstick is fully seated on the mechanism and that the rear edge of the opening is fully deburred.

You can use strips of plastic or paper as shims around the stick as you fit it to the adapter, to ensure there is equal space at all sides, then pull those out once the screws are tightened.

If it's still too tight, you could sand the inside of the adapter, or use small pieces of thick paper or thin card, or small washers, to space the stick PCB back slightly from the mounting pillars. I did not need that with the ones I made, but there may well be different ones with different stick mouldings or tolerances!

How I Designed This

I bought some of these modules for a robot controller panel I'm working on, for testing the mechanics of robots before they have the final "brains" installed (Jetson nano plus ROS based systems).

I could not figure out any sensible way of mounting them to the controller front panel and nothing relating to them on any 3D model site seemed suitable - so I created these!

The CAD system I used for 3D modelling is "Designspark Mechanical" which is free from RS Components.
(Free, as long as you are only creating your own items and do not need to import from other programs; it then needs a subscription).