Open feature request

Integrate mechanical service-access and wiring reviews without weakening board gates

John Lauer ·

User requested dedicated mechanical and wiring review stages after identifying serviceability omissions in the electronic-load design.

Initial MIT Rust source prototypes:

These currently validate declared review completeness and dimensions/lengths; they are not geometry solvers and are not globally installed releases. Mechanical tests cover missing inventory and undersized access openings. Wiring tests cover unknown force, overlength leads, duplicate physical IDs/endpoints, pin count and missing neighboring service clearance.

Integration needed: discover these skills during component selection and mechanical placement; invoke the review before assembly export; invalidate affected routing, probing and thermal evidence after connector/hole changes. Preserve all existing gates and concurrent Fusion changes. Tool animations should be optional, while required service clearance must remain checked.

Real project defects motivating the checks: duplicate old/new sensor wires in a reused viewer scene; spline overshoot; sensor leads obstructing neighboring connector; fan connector too far from factory leads; missing underside sensor-screw access; incomplete housing/crimp/tooling assembly instructions. User supplied annotations, not autonomous AI discovery.

Required follow-up: schema/versioned input and geometry evidence binding, real swept-volume solver adapter, integration tests, package/release/install verification, and default skill discovery. Do not call this complete based only on prototype source publication.

7 Replies

John Lauer ·

Not in 0.2.3: the mechanical and wiring tools are still unreleased prototypes in their own repos. Integrating them needs a versioned input schema, geometry evidence binding and package releases first, as the issue says. Leaving this open.

John Lauer ·

Integration is in adom-aiflow 0.2.25. Leaving this open, as the issue says, because the tools themselves aren't released yet.

Done:

  • Spec: mechanicalReview and wiringReview (schemaVersion: 1, input, the board refs and refPrefixes the review depends on, and an optional assembly glb for wiring). Any other schema version is refused.
  • Required step: a declared review becomes a step before finish (in flows/board.json), so a missing, failing or stale review blocks finish. A spec without one behaves exactly as before.
  • adom-aiflow review mechanical|wiring runs the tool's lint (and audit-glb for a declared GLB). It records the passing result bound to the input, spec and board hashes.
  • Invalidation: moving a reviewed connector or any hole voids the reviews and the test plan. Through the copper change it also voids routing, DRC, current and thermal evidence.
  • Skills: the aiflow-power-layout skill now covers connector placement, mating and release corridors, and tool paths. docs/mechanical-wiring-reviews.md covers the rest.
  • No existing gate changed. Tool animation stays optional; the declared service clearance is always checked.

Still open:

  • adom-aiflow-mechanical and adom-aiflow-wiring aren't wiki packages yet. review finds them on PATH or through a source clone (AIFLOW_MECHANICAL_SRC / AIFLOW_WIRING_SRC), and refuses with instructions otherwise.
  • There's no swept-volume or collision solver. A pass checks declared completeness, dimensions and lengths, not physical fit.
  • Default discovery during component selection waits for the packages.

Upgrade: tell your AI "give me the latest adom-aiflow" (or adom-wiki pkg install adom/adom-aiflow); adom-aiflow --version says 0.2.25.

John Lauer ·

Prepared and tested standalone mechanical and wiring review packages; source and Linux x64 binaries are published for review in adom/adom-custom-electronic-load, commit 415d1de583b2a706e8f75de793ac8f69373f6071: docs/issue-repairs-20261028/adom-aiflow-mechanical-review-source.tar.gz and adom-aiflow-wiring-review-source.tar.gz. Mechanical: 2 Rust tests pass; wiring: 3 pass. Both install locally and preserve failing reviews rather than setting verification flags automatically.

These are declaration/evidence-completeness checkers. They do not calculate mesh collisions or swept tool volumes. The electronic-load legacy service review reports 2 unresolved mechanical checks and 31 wiring checks; it is not proof of fit for the newly changed board-17. New board/assembly hashes and geometry evidence are required before acceptance.

Separate registry releases remain pending approved Hero Studio showcases and release packaging. AIFlow 0.2.25 integration, published source, local executable installation, and a registry release are distinct states. This issue stays open. No claim of geometry qualification or fleet deployment.

John Lauer ·

Implemented and tested the actual STEP service-path adapter in the mechanical tool: conservative continuous fixed-axis tool envelopes, positive clearance margin, all four service stages, actual OCCT intersections, explicit contact exclusions, board/assembly/request/solver hashes, stale-proof rejection and per-fastener stage coverage. Nine CAD/CLI tests and two Rust tests pass. This supports straight-axis translation only; it does not qualify articulated tools or physical fit.

AIFlow source fix published directly at 4f0f19fe412eccd9811ef08a5ea263834a17458b: review and finish now bind external geometry inputs to the active run board, and reject a changed STEP, request or report. Workspace tests and production check pass. A versioned AIFlow release is being built; source publication is not yet deployed availability.

The updated mechanical source/binary archive is on the electronic-load project at docs/issue-repairs-20261028/adom-aiflow-mechanical-review-source.tar.gz. Standalone Mechanical/Wiring page publication and actual electronic-load assembly evidence remain open. No fixture result is claimed as board acceptance.

John Lauer ·

AIFlow 0.2.26 is now published and installed, with the active-board/external-geometry binding fix. Source version, Cargo version and installed CLI agree. Linux release asset and installed binary SHA-256 both equal ada29f3ec618e7875cca2d6b2fb71b930c6a2f219a9a123a955a45e36cb1a947. Full command-help comparison found no missing commands. Production build and workspace tests passed (496 tests; 9 existing ignored tests remain ignored).

Mechanical adapter tests additionally pass all nine actual STEP/CLI cases. The current electronic-load board has NOT passed its current-density gate, and its actual mechanical/wiring review remains unresolved. Standalone Mechanical/Wiring page release is still pending hero approval; this issue remains open.

John Lauer ·

Follow-up implementation/evidence:

  • AIFlow 0.2.26 is published and installed with the active-board/request/report/STEP binding; stale geometry is rejected.
  • Wiring now rejects duplicate physical conductor IDs across different harnesses, duplicate harness IDs and unsupported schema versions. Six tests pass, including a valid-review positive control; the updated source/binary archive is on the load project's issue-repair page.
  • Mechanical documentation now distinguishes seated contacts from free service clearance. On actual board/cooling/sensor geometry, the provisional driver passes approach/engagement/withdrawal, while extraction produces margin contacts at the lug and fin-base region. Exact-size diagnostic intersections are zero. We retained the failed expanded report instead of reducing margins or excluding whole obstacles to manufacture a pass.
  • Populated native-board STEP and all diagnostic inputs/reports are preserved on the project page. No full assembly or physical qualification is claimed.

Standalone Mechanical/Wiring registry publication still awaits the user's pending Hero Studio style approval. Source archives are available; this is not a claim that the standalone apps are globally released. The issue remains open for publication and complete real-board service/wiring acceptance.

Colby Knox ·

@john, a question so this can be settled one way or the other. The mechanical and wiring review add-ons (adom/adom-aiflow-mechanical and adom/adom-aiflow-wiring) are still at 0.1.0 with no release, so nobody can install them. Your last note here said their release was waiting on a Hero Studio style approval.

Do you still want them released?

  • If yes: I'll make the page heroes, check both against the current AI Flow (0.2.74), publish them, and link them from AI Flow's skill where a board has cables, connectors or service access.
  • If not: I'll close this and leave the pages as they are.

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