project
Adom Custom Electronic Load
Public Made by Adomby adom
Two-layer digitally controlled electronic-load prototype. Compact R11 is under active electrical, cooling and probe-access review; not a manufacturing release.
← Commit history
Add drawing-led alternative AlN and PEEK stack with explicit grease gaps
5 files changed
+1728
mechanical/aln-stack-study/README.mdadded+11@@ -0,0 +1,11 @@+# Alternative AlN interface stack++This separate candidate combines an Innovacera drawing-led AlN pad with the NBK PEEK screw/nut study. The pad is 20 × 14 × 0.635 mm, with a 3.2 mm hole centered across its width and 5 mm from one end. It is an alternative supplier configuration, not a claimed drawing for Wakefield 178-25-220.++The nominal model clears the fitted Q1 solid, other 90 component bounds, the incomplete sink model and the sensor candidate. Two assumed 20 µm grease films raise the proposed sink bottom from 5.09 to 5.13 mm above top copper. Grease occupies specified gaps rather than separate rendered solids. The existing carrier and main assembly GLB have not adopted this change. Nut protrusion is 2.8798 mm nominal; the screw-head clearance remains 1.185 mm.++[Nominal STEP](aln-stack-candidate.step) · [Nominal GLB](aln-stack-candidate.glb) · [Review](review.json) · [Generator](../../tools/aln_stack_study.py).++Source: [Innovacera brochure](https://files.2innova.com/innovacera-v2/2024/01/Aluminum-Nitride-Ceramic-Thermal-Pads.pdf), PDF page 4 drawing and page 3 material table. Its TO-220 drawing does not give all manufacturing tolerances. The brochure's 170 W/mK value is stated at 30 C, not verified over this assembly's complete operating range. The archived $0.45-per-pad table is for 1000 pieces EXW; it is not a current quotation or a one-unit purchase price and is excluded from the prototype subtotal.++Order-specific tolerances, sample availability, grease application, clamp preload, creep, electrical isolation and installed airflow remain unqualified. No formal BOM, thermal gate, board geometry or production release changes. The old unresolved AlN source remains recorded separately.
mechanical/aln-stack-study/aln-stack-candidate.glbadded⋯ 1 unchanged line ⋯
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REPRESENTATION_ITEM('') );+#1211 = CARTESIAN_POINT('',(-1.5,0.));+#1212 = CARTESIAN_POINT('',(-1.5,2.598076211353));+#1213 = CARTESIAN_POINT('',(0.75,1.299038105677));+#1214 = CARTESIAN_POINT('',(3.,3.673940397442E-16));+#1215 = CARTESIAN_POINT('',(0.75,-1.299038105677));+#1216 = CARTESIAN_POINT('',(-1.5,-2.598076211353));+#1217 = CARTESIAN_POINT('',(-1.5,0.));+#1218 = ( GEOMETRIC_REPRESENTATION_CONTEXT(2) +PARAMETRIC_REPRESENTATION_CONTEXT() REPRESENTATION_CONTEXT('2D SPACE',''+ ) );+#1219 = PCURVE('',#1112,#1220);+#1220 = DEFINITIONAL_REPRESENTATION('',(#1221),#1225);+#1221 = LINE('',#1222,#1223);+#1222 = CARTESIAN_POINT('',(-0.,2.5));+#1223 = VECTOR('',#1224,1.);+#1224 = DIRECTION('',(-1.,0.));+#1225 = ( GEOMETRIC_REPRESENTATION_CONTEXT(2) +PARAMETRIC_REPRESENTATION_CONTEXT() REPRESENTATION_CONTEXT('2D SPACE',''+ ) );+#1226 = ADVANCED_FACE('',(#1227),#880,.F.);+#1227 = FACE_BOUND('',#1228,.T.);+#1228 = EDGE_LOOP('',(#1229,#1250,#1251,#1252));+#1229 = ORIENTED_EDGE('',*,*,#1230,.T.);+#1230 = EDGE_CURVE('',#1040,#1153,#1231,.T.);+#1231 = SURFACE_CURVE('',#1232,(#1236,#1243),.PCURVE_S1.);+#1232 = LINE('',#1233,#1234);+#1233 = CARTESIAN_POINT('',(25.872286759729,37.41,15.8852));+#1234 = VECTOR('',#1235,1.);+#1235 = DIRECTION('',(-0.,-0.,1.));+#1236 = PCURVE('',#880,#1237);+#1237 = DEFINITIONAL_REPRESENTATION('',(#1238),#1242);+#1238 = LINE('',#1239,#1240);+#1239 = CARTESIAN_POINT('',(-0.,0.));+#1240 = VECTOR('',#1241,1.);+#1241 = DIRECTION('',(-0.,-1.));+#1242 = ( GEOMETRIC_REPRESENTATION_CONTEXT(2) +PARAMETRIC_REPRESENTATION_CONTEXT() REPRESENTATION_CONTEXT('2D SPACE',''+ ) );+#1243 = PCURVE('',#1055,#1244);+#1244 = DEFINITIONAL_REPRESENTATION('',(#1245),#1249);+#1245 = LINE('',#1246,#1247);+#1246 = CARTESIAN_POINT('',(-3.175426480543,0.));+#1247 = VECTOR('',#1248,1.);+#1248 = DIRECTION('',(-0.,-1.));+#1249 = ( GEOMETRIC_REPRESENTATION_CONTEXT(2) +PARAMETRIC_REPRESENTATION_CONTEXT() REPRESENTATION_CONTEXT('2D SPACE',''+ ) );+#1250 = ORIENTED_EDGE('',*,*,#1175,.T.);+#1251 = ORIENTED_EDGE('',*,*,#862,.F.);+#1252 = ORIENTED_EDGE('',*,*,#1067,.F.);+#1253 = ADVANCED_FACE('',(#1254),#978,.F.);+#1254 = FACE_BOUND('',#1255,.T.);+#1255 = EDGE_LOOP('',(#1256,#1257,#1258,#1279));+#1256 = ORIENTED_EDGE('',*,*,#962,.T.);+#1257 = ORIENTED_EDGE('',*,*,#1129,.T.);+#1258 = ORIENTED_EDGE('',*,*,#1259,.F.);+#1259 = EDGE_CURVE('',#1017,#1130,#1260,.T.);+#1260 = SURFACE_CURVE('',#1261,(#1265,#1272),.PCURVE_S1.);+#1261 = LINE('',#1262,#1263);+#1262 = CARTESIAN_POINT('',(24.284573519457,34.66,15.8852));+#1263 = VECTOR('',#1264,1.);+#1264 = DIRECTION('',(-0.,-0.,1.));+#1265 = PCURVE('',#978,#1266);+#1266 = DEFINITIONAL_REPRESENTATION('',(#1267),#1271);+#1267 = LINE('',#1268,#1269);+#1268 = CARTESIAN_POINT('',(-3.175426480543,-0.));+#1269 = VECTOR('',#1270,1.);+#1270 = DIRECTION('',(-0.,-1.));+#1271 = ( GEOMETRIC_REPRESENTATION_CONTEXT(2) +PARAMETRIC_REPRESENTATION_CONTEXT() REPRESENTATION_CONTEXT('2D SPACE',''+ ) );+#1272 = PCURVE('',#1055,#1273);+#1273 = DEFINITIONAL_REPRESENTATION('',(#1274),#1278);+#1274 = LINE('',#1275,#1276);+#1275 = CARTESIAN_POINT('',(-0.,0.));+#1276 = VECTOR('',#1277,1.);+#1277 = DIRECTION('',(-0.,-1.));+#1278 = ( GEOMETRIC_REPRESENTATION_CONTEXT(2) +PARAMETRIC_REPRESENTATION_CONTEXT() REPRESENTATION_CONTEXT('2D SPACE',''+ ) );+#1279 = ORIENTED_EDGE('',*,*,#1016,.F.);+#1280 = ADVANCED_FACE('',(#1281),#1055,.F.);+#1281 = FACE_BOUND('',#1282,.T.);+#1282 = EDGE_LOOP('',(#1283,#1284,#1285,#1286));+#1283 = ORIENTED_EDGE('',*,*,#1259,.T.);+#1284 = ORIENTED_EDGE('',*,*,#1152,.T.);+#1285 = ORIENTED_EDGE('',*,*,#1230,.F.);+#1286 = ORIENTED_EDGE('',*,*,#1039,.F.);+#1287 = ADVANCED_FACE('',(#1288),#1112,.F.);+#1288 = FACE_BOUND('',#1289,.T.);+#1289 = EDGE_LOOP('',(#1290,#1291,#1312,#1313));+#1290 = ORIENTED_EDGE('',*,*,#1199,.F.);+#1291 = ORIENTED_EDGE('',*,*,#1292,.F.);+#1292 = EDGE_CURVE('',#1092,#1200,#1293,.T.);+#1293 = SEAM_CURVE('',#1294,(#1298,#1305),.PCURVE_S1.);+#1294 = LINE('',#1295,#1296);+#1295 = CARTESIAN_POINT('',(28.96,34.66,15.7852));+#1296 = VECTOR('',#1297,1.);+#1297 = DIRECTION('',(-0.,-0.,1.));+#1298 = PCURVE('',#1112,#1299);+#1299 = DEFINITIONAL_REPRESENTATION('',(#1300),#1304);+#1300 = LINE('',#1301,#1302);+#1301 = CARTESIAN_POINT('',(-6.28318530718,-0.));+#1302 = VECTOR('',#1303,1.);+#1303 = DIRECTION('',(-0.,1.));+#1304 = ( GEOMETRIC_REPRESENTATION_CONTEXT(2) +PARAMETRIC_REPRESENTATION_CONTEXT() REPRESENTATION_CONTEXT('2D SPACE',''+ ) );+#1305 = PCURVE('',#1112,#1306);+#1306 = DEFINITIONAL_REPRESENTATION('',(#1307),#1311);+#1307 = LINE('',#1308,#1309);+#1308 = CARTESIAN_POINT('',(-0.,-0.));+#1309 = VECTOR('',#1310,1.);+#1310 = DIRECTION('',(-0.,1.));+#1311 = ( GEOMETRIC_REPRESENTATION_CONTEXT(2) +PARAMETRIC_REPRESENTATION_CONTEXT() REPRESENTATION_CONTEXT('2D SPACE',''+ ) );+#1312 = ORIENTED_EDGE('',*,*,#1091,.T.);+#1313 = ORIENTED_EDGE('',*,*,#1292,.T.);+#1314 = ( GEOMETRIC_REPRESENTATION_CONTEXT(3) +GLOBAL_UNCERTAINTY_ASSIGNED_CONTEXT((#1318)) +GLOBAL_UNIT_ASSIGNED_CONTEXT((#1315,#1316,#1317)) REPRESENTATION_CONTEXT+('Context #1','3D Context with UNIT and UNCERTAINTY') );+#1315 = ( LENGTH_UNIT() NAMED_UNIT(*) SI_UNIT(.MILLI.,.METRE.) );+#1316 = ( NAMED_UNIT(*) PLANE_ANGLE_UNIT() SI_UNIT($,.RADIAN.) );+#1317 = ( NAMED_UNIT(*) SI_UNIT($,.STERADIAN.) SOLID_ANGLE_UNIT() );+#1318 = UNCERTAINTY_MEASURE_WITH_UNIT(LENGTH_MEASURE(1.E-07),#1315,+ 'distance_accuracy_value','confusion accuracy');+#1319 = CONTEXT_DEPENDENT_SHAPE_REPRESENTATION(#1320,#1322);+#1320 = ( REPRESENTATION_RELATIONSHIP('','',#735,#10) +REPRESENTATION_RELATIONSHIP_WITH_TRANSFORMATION(#1321) +SHAPE_REPRESENTATION_RELATIONSHIP() );+#1321 = ITEM_DEFINED_TRANSFORMATION('','',#11,#27);+#1322 = PRODUCT_DEFINITION_SHAPE('Placement','Placement of an item',+ #1323);+#1323 = NEXT_ASSEMBLY_USAGE_OCCURRENCE('4',+ 'Fastener_SPE-M3-N_NutEnvelope','',#5,#730,$);+#1324 = PRODUCT_RELATED_PRODUCT_CATEGORY('part',$,(#732));+#1325 = MECHANICAL_DESIGN_GEOMETRIC_PRESENTATION_REPRESENTATION('',(+ #1326),#592);+#1326 = STYLED_ITEM('color',(#1327),#486);+#1327 = PRESENTATION_STYLE_ASSIGNMENT((#1328));+#1328 = SURFACE_STYLE_USAGE(.BOTH.,#1329);+#1329 = SURFACE_SIDE_STYLE('',(#1330));+#1330 = SURFACE_STYLE_FILL_AREA(#1331);+#1331 = FILL_AREA_STYLE('',(#1332));+#1332 = FILL_AREA_STYLE_COLOUR('',#1333);+#1333 = COLOUR_RGB('',0.530000000233,0.369999997777,0.199999998682);+#1334 = MECHANICAL_DESIGN_GEOMETRIC_PRESENTATION_REPRESENTATION('',(+ #1335),#717);+#1335 = STYLED_ITEM('color',(#1336),#611);+#1336 = PRESENTATION_STYLE_ASSIGNMENT((#1337));+#1337 = SURFACE_STYLE_USAGE(.BOTH.,#1338);+#1338 = SURFACE_SIDE_STYLE('',(#1339));+#1339 = SURFACE_STYLE_FILL_AREA(#1340);+#1340 = FILL_AREA_STYLE('',(#1341));+#1341 = FILL_AREA_STYLE_COLOUR('',#1333);+#1342 = MECHANICAL_DESIGN_GEOMETRIC_PRESENTATION_REPRESENTATION('',(+ #1343),#1314);+#1343 = STYLED_ITEM('color',(#1344),#736);+#1344 = PRESENTATION_STYLE_ASSIGNMENT((#1345));+#1345 = SURFACE_STYLE_USAGE(.BOTH.,#1346);+#1346 = SURFACE_SIDE_STYLE('',(#1347));+#1347 = SURFACE_STYLE_FILL_AREA(#1348);+#1348 = FILL_AREA_STYLE('',(#1349));+#1349 = FILL_AREA_STYLE_COLOUR('',#1333);+#1350 = MECHANICAL_DESIGN_GEOMETRIC_PRESENTATION_REPRESENTATION('',(+ #1351),#467);+#1351 = STYLED_ITEM('color',(#1352),#45);+#1352 = PRESENTATION_STYLE_ASSIGNMENT((#1353));+#1353 = SURFACE_STYLE_USAGE(.BOTH.,#1354);+#1354 = SURFACE_SIDE_STYLE('',(#1355));+#1355 = SURFACE_STYLE_FILL_AREA(#1356);+#1356 = FILL_AREA_STYLE('',(#1357));+#1357 = FILL_AREA_STYLE_COLOUR('',#1358);+#1358 = COLOUR_RGB('',0.819999987296,0.830000008529,0.800000010877);+ENDSEC;+END-ISO-10303-21;
mechanical/aln-stack-study/review.jsonadded+48@@ -0,0 +1,48 @@+{+ "status": "alternative-AlN-stack-not-adopted",+ "padSource": "https://files.2innova.com/innovacera-v2/2024/01/Aluminum-Nitride-Ceramic-Thermal-Pads.pdf",+ "padDrawingPage": 4,+ "bulkPriceContext": "Brochure lists USD 0.45 each at 1000 pieces for this configuration; historical EXW figure, not a current quote or one-unit price.",+ "boardSha256": "1681eb90e49f4f229afe89bb75ff1738b7503907a52cd174e8b3d64b120082f4",+ "screw": "NBK SPE-M3-12-P",+ "nut": "NBK SPE-M3-N",+ "sourceScrew": "https://www.nbk1560.com/images/en-US/product/chemicalscrew/SPE-P/SPE-P_1.pdf",+ "sourceNut": "https://www.nbk1560.com/images/en/product/chemicalscrew/SPE-N/SPE-N_1.pdf",+ "dimensionsMm": {+ "center": [+ 127.46,+ 65.34+ ],+ "tabTop": 4.455,+ "assumedNominalTabThickness": 1.27,+ "headHeight": 2,+ "headDiameter": 5.5,+ "underHeadLength": 12,+ "nutAcrossFlats": 5.5,+ "nutHeight": 2.4,+ "sinkBaseReference": 4.7752,+ "AlNThickness": 0.635,+ "assumedGreaseFilmEach": 0.02,+ "totalInterfaceStack": 0.6749999999999998+ },+ "nominalHeadBottomAbovePcbMm": 1.185,+ "tabThicknessOnlyWorstHeadClearanceMm": 1.0550000000000002,+ "nominalProtrusionBeyondNutMm": 2.8797999999999995,+ "nominalQ1ModelConflicts": [],+ "otherFittedBodyConflicts": [],+ "incompleteSinkModelConflicts": [],+ "sensorCandidateConflicts": [],+ "manufacturerRecommendedScrewTorqueNm": 0.105,+ "assemblyTorqueApproved": false,+ "limits": [+ "No tolerances for head, sink base, TIM or board warp are included.",+ "Nominal fitted Q1 solid checked; actual MPN tolerances and contact pressure remain unqualified.",+ "Threads, screw recess and nut chamfers omitted; this is independently generated nominal geometry.",+ "Alternative Innovacera TO-220 drawing: 20 x 14 x 0.635 mm, hole 3.2 mm, centered widthwise 5 mm from end. No overall/hole tolerance supplied for this variant; obtain order-specific drawing.",+ "Preload, PEEK creep, vibration retention, tool access and thermal cycling remain unqualified.",+ "Assemble fastener before soldering; head cannot pass through 3.5 mm PCB hole.",+ "Sink rises 0.04 mm to include two assumed 20 micrometre grease films; existing carrier/assembly model not updated.",+ "Grease film thickness is an assembly assumption, not a demonstrated process or manufacturer tolerance.",+ "No formal board, BOM, thermal evidence or firmware change."+ ]+}
tools/aln_stack_study.pyadded+45@@ -0,0 +1,45 @@+#!/usr/bin/env python3+"""Alternative AlN pad and PEEK fastening stack; not adopted or qualified."""+from pathlib import Path+import json,math,hashlib+import cadquery as cq+from glb_shape_helpers import add_shape,write_glb+R=Path(__file__).resolve().parents[1];O=R/'mechanical/aln-stack-study';O.mkdir(exist_ok=True)+a=json.loads((R/'mechanical/cooling-680-body-audit.json').read_text())+assert a['boardSha256']==hashlib.sha256((R/'kicad/adom-custom-electronic-load.kicad_pcb').read_bytes()).hexdigest()+x,y=127.46,65.34;tab_top=4.455;tab_thickness=1.27;head_top=tab_top-tab_thickness;sink_bottom=5.13;sink_base=4.7752+head=cq.Solid.makeCylinder(2.75,2,cq.Vector(x,y,head_top-2))+shank=cq.Solid.makeCylinder(1.5,12,cq.Vector(x,y,head_top))+nut_z=sink_bottom+sink_base+nut=cq.Workplane('XY').polygon(6,5.5/math.cos(math.pi/6)).extrude(2.4).val().translate((x,y,nut_z)).cut(cq.Solid.makeCylinder(1.5,2.6,cq.Vector(x,y,nut_z-.1)))+pad=cq.Workplane('XY').box(14,20,.635,centered=(True,False,False)).translate((x,y-5,tab_top+.02)).val().cut(cq.Solid.makeCylinder(1.6,.8,cq.Vector(x,y,tab_top)))+parts=[('Interface.Innovacera.TO220.AlN.Nominal',pad),('Fastener.SPE-M3-12-P.HeadEnvelope',head),('Fastener.SPE-M3-12-P.ShankEnvelope',shank),('Fastener.SPE-M3-N.NutEnvelope',nut)]+g={'asset':{'version':'2.0','generator':'Adom drawing-led AlN and PEEK stack study'},'scene':0,'scenes':[{'nodes':[0]}],'nodes':[{'name':'Fastener.CANDIDATE_NOT_ADOPTED','children':[]}],'buffers':[{'byteLength':0}],'accessors':[]};blob=bytearray();assy=cq.Assembly(name='Fastener_candidate_mm')+def box(b):+ x,y,z,X,Y,Z=b;return cq.Workplane('XY').box(X-x,Y-y,Z-z,centered=(False,False,False)).translate((x,y,z)).val()+conflicts=[]+for name,s in parts:+ assert s.isValid()+ q=s.mirror('XZ').translate((-100,100,5.98));color=(.82,.83,.80) if name.startswith('Interface.') else (.53,.37,.20);add_shape(g,blob,q,name,color,0,'Independent nominal AlN/PEEK study; unqualified');assy.add(q,name=name.replace('.','_'),color=cq.Color(*color))+ for row in a['rows']:+ if row['ref']=='Q1':continue+ v=s.intersect(box(row['boundsMm'])).Volume()+ if v>1e-6:conflicts.append({'part':name,'reference':row['ref'],'volumeMm3':v})+sink=cq.importers.importStep(str(R/'mechanical/heatsink-study/680-125220-nominal.step')).val().translate((138.636,67.118,sink_bottom))+q1=cq.importers.importStep(str(R/'kicad/3d/TO-220-3_Horizontal_TabUp.step')).val().mirror('XZ').rotate((0,0,0),(0,0,1),-180).translate((130,82,0))+q1_conflicts=[]+for name,shape in parts:+ v=shape.intersect(q1).Volume()+ if v>1e-6:q1_conflicts.append({'part':name,'volumeMm3':v})+exact_sink=[]+for name,s in parts:+ v=s.intersect(sink).Volume()+ if v>1e-6:exact_sink.append({'part':name,'volumeMm3':v})+sensor=cq.importers.importStep(str(R/'mechanical/sensor-study/sensor-candidate.step')).val()+sensor_conflicts=[]+for name,s in parts:+ v=s.mirror('XZ').translate((-100,100,5.98)).intersect(sensor).Volume()+ if v>1e-6:sensor_conflicts.append({'part':name,'volumeMm3':v})+assy.save(str(O/'aln-stack-candidate.step'));write_glb(O/'aln-stack-candidate.glb',g,blob)+r={'status':'alternative-AlN-stack-not-adopted','padSource':'https://files.2innova.com/innovacera-v2/2024/01/Aluminum-Nitride-Ceramic-Thermal-Pads.pdf','padDrawingPage':4,'bulkPriceContext':'Brochure lists USD 0.45 each at 1000 pieces for this configuration; historical EXW figure, not a current quote or one-unit price.','boardSha256':a['boardSha256'],'screw':'NBK SPE-M3-12-P','nut':'NBK SPE-M3-N','sourceScrew':'https://www.nbk1560.com/images/en-US/product/chemicalscrew/SPE-P/SPE-P_1.pdf','sourceNut':'https://www.nbk1560.com/images/en/product/chemicalscrew/SPE-N/SPE-N_1.pdf','dimensionsMm':{'center':[x,y],'tabTop':tab_top,'assumedNominalTabThickness':tab_thickness,'headHeight':2,'headDiameter':5.5,'underHeadLength':12,'nutAcrossFlats':5.5,'nutHeight':2.4,'sinkBaseReference':sink_base,'AlNThickness':.635,'assumedGreaseFilmEach':.02,'totalInterfaceStack':sink_bottom-tab_top},'nominalHeadBottomAbovePcbMm':head_top-2,'tabThicknessOnlyWorstHeadClearanceMm':tab_top-1.4-2,'nominalProtrusionBeyondNutMm':head_top+12-(nut_z+2.4),'nominalQ1ModelConflicts':q1_conflicts,'otherFittedBodyConflicts':conflicts,'incompleteSinkModelConflicts':exact_sink,'sensorCandidateConflicts':sensor_conflicts,'manufacturerRecommendedScrewTorqueNm':.105,'assemblyTorqueApproved':False,'limits':['No tolerances for head, sink base, TIM or board warp are included.','Nominal fitted Q1 solid checked; actual MPN tolerances and contact pressure remain unqualified.','Threads, screw recess and nut chamfers omitted; this is independently generated nominal geometry.','Alternative Innovacera TO-220 drawing: 20 x 14 x 0.635 mm, hole 3.2 mm, centered widthwise 5 mm from end. No overall/hole tolerance supplied for this variant; obtain order-specific drawing.','Preload, PEEK creep, vibration retention, tool access and thermal cycling remain unqualified.','Assemble fastener before soldering; head cannot pass through 3.5 mm PCB hole.','Sink rises 0.04 mm to include two assumed 20 micrometre grease films; existing carrier/assembly model not updated.','Grease film thickness is an assembly assumption, not a demonstrated process or manufacturer tolerance.','No formal board, BOM, thermal evidence or firmware change.']}+(O/'review.json').write_text(json.dumps(r,indent=2)+'\n');print(json.dumps(r,indent=2))