project

Adom Custom Electronic Load

Public Made by Adom

by adom

Two-layer digitally controlled electronic-load prototype. Compact R11 is under active electrical, cooling and probe-access review; not a manufacturing release.

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Review insulated temperature sensor, route its harness and record clearance study

John Lauer ·bbcae78335 ·16d ago ·parent 6dae9c2
23 files changed +5242−9
README.md+1−1aiflow/run/timeline/presentation.json+1−1design/ps_ntcle428.json+72design/ps_ntcle428_long.json+71design/sensor-candidate.json+1docs/build-clips.md+6−2docs/clips/sensor-harness-review.jpgdocs/clips/sensor-harness-review.mp4docs/completion-plan.md+1−1docs/cost/README.md+4docs/status.md+2−2mechanical/sensor-candidate-screen.json+90mechanical/sensor-study/README.md+19mechanical/sensor-study/first-clear-route.json+49mechanical/sensor-study/rejected-short-route.json+52mechanical/sensor-study/review.json+49mechanical/sensor-study/sensor-candidate.glbmechanical/sensor-study/sensor-candidate.step+4704tools/sensor_candidate_screen.py+23tools/sensor_mount_study.py+61videos/build-storyboard.json+6videos/inventory.json+14−2videos/shotlog.json+16
README.md+1−1
@@ -18,7 +18,7 @@ The [current board model review](docs/board-model-review.md) includes the export - D1 now uses [SBR10U45SP5-13](https://wiki.adom.inc/adom/sbr10u45sp5-13), with published symbol, footprint and drawing-derived nominal STEP/GLB assets. Its local thermal study excludes Q1 and is not complete assembly acceptance. - The fan has a [component page with GLB motion states](https://wiki.adom.inc/adom/mf40200v1-1000u-g99). Its preview is simulated; shared viewer integration remains proposed. - The [thermal budget](docs/thermal-budget.md) now matches the 55 °C firmware trip ceiling. The earlier 25 W assumption is retained as an unqualified future option; R0 targets 5 W and still requires cooling validation.-- There are 87 unique raw takes, 32 reviewed excerpts and 28 storyboard clips. Failed/static captures remain identified in the shot log; the final narrated 4–5 minute film is unfinished.+- There are 89 unique raw takes, 33 reviewed excerpts and 29 storyboard clips. Failed/static captures remain identified in the shot log; the final narrated 4–5 minute film is unfinished.  Read the [engineering status](docs/status.md), [placement review](docs/placement-review.md), [library review](docs/library-review.md), [cost breakdown](docs/cost/README.md), [firmware/control-panel contract](docs/firmware-contract.md), and [raw clip log](videos/shotlog.json). The [AI Flow report](docs/runs/board-codex-20261007-1749/README.md) records the run.
aiflow/run/timeline/presentation.json+1−1
@@ -1,6 +1,6 @@ {   "image": "assembly-v85.png",   "alt": "Actual v85 board with nominal fan carrier and installed harness",-  "caption": "Control panel now links fresh measured fan RPM to the assembly model; disconnected feedback stays unknown. Thermal clamp, sensor attachment and installed airflow remain open. 87 raw takes / 32 reviewed excerpts.",+  "caption": "Insulated sensor candidate now has routed leads, J10 mating housing and nominal clearance checks. Mounting tolerances, case coupling and installed airflow remain open. 89 raw takes / 33 reviewed excerpts.",   "projectTitle": "Adom electronic load" }
design/ps_ntcle428.jsonadded+72
@@ -0,0 +1,72 @@+{+  "query": "NTCLE428E3103H400",+  "mouser": {+    "ok": true,+    "error": null,+    "total": 4,+    "hits": [+      {+        "vendor": "Mouser",+        "vendor_pn": "594-NTL428E3103H400A",+        "mpn": "NTCLE428E3103H400A",+        "manufacturer": "Vishay / BC Components",+        "description": "NTC Thermistors 10Kohms 3% 3984K/0.5% 40mm",+        "stock": 0,+        "unit_price": "$1.10",+        "price_100": "$0.857",+        "lead_time": "70 Days",+        "image_url": "https://www.mouser.com/images/vishay/images/NTCLE428-series_SPL.jpg",+        "datasheet_url": null,+        "product_url": "https://www.mouser.com/en/ProductDetail/Vishay-BC-Components/NTCLE428E3103H400A?qs=vLWxofP3U2xDCAt7O3LLwA%3D%3D",+        "flags": [+          "RoHS Compliant"+        ]+      }+    ],+    "backend_url": "https://mouser-xr8t4f5d01bt.adom.cloud",+    "elapsed_ms": 852+  },+  "digikey": {+    "ok": true,+    "error": null,+    "total": 1,+    "hits": [+      {+        "vendor": "DigiKey",+        "vendor_pn": "56-NTCLE428E3103H400A-ND",+        "mpn": "NTCLE428E3103H400A",+        "manufacturer": "Vishay Beyschlag/Draloric/BC Components",+        "description": "NTC EPOXY 3MM, PVC INSULATED AWG",+        "stock": 1025,+        "unit_price": "$1.3200",+        "price_100": "$0.9900",+        "lead_time": "",+        "image_url": "https://mm.digikey.com/Volume0/opasdata/d220001/medias/images/2642/MFG_NTCLE428.jpg",+        "datasheet_url": "https://www.vishay.com/docs/29186/ntcle428.pdf",+        "product_url": "https://www.digikey.com/en/products/detail/vishay-beyschlag-draloric-bc-components/NTCLE428E3103H400A/16530190",+        "flags": [+          "ROHS3 Compliant",+          "Active"+        ]+      }+    ],+    "backend_url": "https://digikey-gjuu8l5t69uh.adom.cloud",+    "elapsed_ms": 972+  },+  "jlcpcb": {+    "ok": true,+    "error": null,+    "total": 0,+    "hits": [],+    "backend_url": "https://jlcpcb-wela51osctvp.adom.cloud",+    "elapsed_ms": 2262+  },+  "recommendation": {+    "winner": "DigiKey",+    "reason": "Mouser is out of stock or long-lead; DigiKey has immediate stock.",+    "mpn": "NTCLE428E3103H400A",+    "unit_price": "$1.3200",+    "stock": 1025,+    "exact_match": false+  }+}
design/ps_ntcle428_long.jsonadded+71
@@ -0,0 +1,71 @@+{+  "query": "NTCLE428E3103H301A",+  "mouser": {+    "ok": true,+    "error": null,+    "total": 1,+    "hits": [+      {+        "vendor": "Mouser",+        "vendor_pn": "594-NTL428E3103H301A",+        "mpn": "NTCLE428E3103H301A",+        "manufacturer": "Vishay",+        "description": "NTC Thermistors NTCEpoxyPVCG30105C10k3%A",+        "stock": 702,+        "unit_price": "$1.82",+        "price_100": "$1.05",+        "lead_time": "70 Days",+        "image_url": null,+        "datasheet_url": null,+        "product_url": "https://www.mouser.com/en/ProductDetail/Vishay/NTCLE428E3103H301A?qs=Z%252BL2brAPG1KyWrdd8YknJA%3D%3D",+        "flags": []+      }+    ],+    "backend_url": "https://mouser-xr8t4f5d01bt.adom.cloud",+    "elapsed_ms": 514+  },+  "digikey": {+    "ok": true,+    "error": null,+    "total": 1,+    "hits": [+      {+        "vendor": "DigiKey",+        "vendor_pn": "56-NTCLE428E3103H301A-ND",+        "mpn": "NTCLE428E3103H301A",+        "manufacturer": "Vishay Beyschlag/Draloric/BC Components",+        "description": "NTC EPOXY PVC G30 105C 10K 3% A",+        "stock": 0,+        "unit_price": "$0.8331",+        "price_100": null,+        "lead_time": "",+        "image_url": "https://mm.digikey.com/Volume0/opasdata/d220001/medias/images/8885/MFG_NTCLE428E3103H301A.jpg",+        "datasheet_url": "https://www.vishay.com/doc?29186",+        "product_url": "https://www.digikey.com/en/products/detail/vishay-beyschlag-draloric-bc-components/NTCLE428E3103H301A/26637532",+        "flags": [+          "ROHS3 Compliant",+          "Active"+        ]+      }+    ],+    "backend_url": "https://digikey-gjuu8l5t69uh.adom.cloud",+    "elapsed_ms": 901+  },+  "jlcpcb": {+    "ok": true,+    "error": null,+    "total": 0,+    "hits": [],+    "backend_url": "https://jlcpcb-wela51osctvp.adom.cloud",+    "elapsed_ms": 2229+  },+  "recommendation": {+    "winner": "Mouser",+    "reason": "Mouser has the exact part in stock and is the preferred vendor: fastest, lowest-cost fulfillment.",+    "mpn": "NTCLE428E3103H301A",+    "unit_price": "$1.82",+    "stock": 702,+    "requested_mpn": "NTCLE428E3103H301A",+    "exact_match": true+  }+}
design/sensor-candidate.jsonadded+1
@@ -0,0 +1 @@+{"candidate":"NTCLE428E3103H400A","status":"candidate-not-adopted","source":"https://www.vishay.com/docs/29186/ntcle428.pdf","table":5,"columns":["temperatureC","nominalOhms","minOhms","maxOhms"],"rows":[[0,32624,31440,33809],[25,10000,9700,10300],[40,5323.9,5146.6,5501.1],[50,3598.7,3471.6,3725.8],[55,2982.3,2874,3090.5],[60,2483.8,2391.3,2576.3],[65,2078.7,1999.4,2157.9],[85,1066.1,1021.8,1110.4]],"bodyMaxDiameterMm":3,"bodyMaxLengthMm":10,"leadLengthMm":{"nominal":40,"tolerance":5},"wireGaugeAwg":30,"wireNominalODMm":0.85,"dielectricWithstandingVrms":500,"temperatureRangeC":[-40,105],"minimumWireBendFromBodyMm":4,"minimumInsulatedWireBendRadii":5}
docs/build-clips.md+6−2
@@ -180,7 +180,7 @@ The raw inventory is now 70 takes, including rejected and static footage; that i - [Live cooling preview](clips/live-cooling-dashboard.mp4): no-navigation image/caption update and scroll, 2×. Cooling estimates remain unqualified. - [Board GLB review](clips/board-glb-review.mp4): actual top, side and underside inspection, 2×. Cooling assembly absent; metadata/export warnings remain open. -Inventory: 87 raw takes (including rejected/static takes), 32 reviewed excerpts, 28 storyboard clips. The final narrated film is not assembled.+Inventory: 89 raw takes (including rejected/static takes), 33 reviewed excerpts, 29 storyboard clips. The final narrated film is not assembled.  [Package cooling sensitivity](clips/package-cooling-review.mp4): seven seconds, normal speed. Actual fine-grid still-to-moving comparison; assumed installed cooling, no thermal acceptance. @@ -188,7 +188,7 @@ Inventory: 87 raw takes (including rejected/static takes), 32 reviewed excerpts,  [Two copper layers in Gerber Viewer](clips/gerber-review.mp4): 6.5 seconds at 2× playback. Actual native export inspection. The two-layer package is review-only; cooling and stackup reconciliation remain open. -The inventory now contains **87 raw takes and 32 reviewed excerpts**. Raw takes include rejected recordings; the final narrated film is still pending. The carrier excerpt shows the historical unrotated iteration, superseded by the 45-degree fan layout.+The inventory now contains **89 raw takes and 33 reviewed excerpts**. Raw takes include rejected recordings; the final narrated film is still pending. The carrier excerpt shows the historical unrotated iteration, superseded by the 45-degree fan layout.  [Rotated fan carrier](clips/carrier-rotated-review.mp4): five seconds at 2×, current nominal geometry. Shows the separated mounting holes and PCB clearance. The installed harness and retention remain unfinished. @@ -197,3 +197,7 @@ The inventory now contains **87 raw takes and 32 reviewed excerpts**. Raw takes ## Measured fan model in the control panel  [Six-second reviewed clip, 2x](clips/control-panel-twin.mp4) · [Poster](clips/control-panel-twin.jpg). Actual disconnected UI: camera orbit, fan paused and feedback unknown. No hardware telemetry.++## Insulated sensor harness++[Six-second close review, 2x](clips/sensor-harness-review.mp4) · [Poster](clips/sensor-harness-review.jpg). First clear candidate route, before the sensor was lowered 0.65 mm for additional sink clearance. No physical fit or thermal qualification. Wide take 88 is excluded because the sensor is obscured.
docs/clips/sensor-harness-review.jpgadded
⋯ 1 unchanged line ⋯
docs/clips/sensor-harness-review.mp4added
⋯ 1 unchanged line ⋯
docs/completion-plan.md+1−1
@@ -6,7 +6,7 @@ The schematic/netlist/BOM and native models now include SBR10U45SP5-13. The v85  Thermal acceptance is still failed. The board-only model injects 5.5 W through Q1’s PCB terminal region and lacks its external case-to-heatsink path; its extreme temperatures are not a prediction of an assembled cooled unit. The actual interface, supported sink/fan mounting, duct pressure/flow and fault behavior require completion. The stock sink envelope clears all 91 fitted models and probe approaches, but this excludes mating connectors and hardware. [Package sensitivity](package-cooling-review.md) · [Fan airflow review](fan-airflow-review.md). -AIFlow 0.1.86 is published and installed with 147 tests passing, verified live presentation refresh and read-only existing-pour verification. Fields PR10 remains a separate owner-review change, and the shared runtime is not replaced. There are 87 raw takes, including static/rejected footage, 32 reviewed excerpts and 28 storyboard clips. The latest excerpt records the actual current-to-thermal dashboard transition. The final narrated 4–5 minute film remains unfinished.+AIFlow 0.1.86 is published and installed with 147 tests passing, verified live presentation refresh and read-only existing-pour verification. Fields PR10 remains a separate owner-review change, and the shared runtime is not replaced. There are 89 raw takes, including static/rejected footage, 33 reviewed excerpts and 29 storyboard clips. The latest excerpt records the actual current-to-thermal dashboard transition. The final narrated 4–5 minute film remains unfinished.  Next: complete the package/interface/duct cooling design and represent its supported operating/fault cases; then same-input thermal acceptance, Fields/pour walkthroughs, current-board silkscreen/3D review, prototype manufacturing outputs and final video. Physical calibration, safety tests and industrial qualification remain separate from digital design acceptance. No fabrication release, order or flash has occurred.
docs/cost/README.md+4
@@ -1,3 +1,7 @@+## Sensor attachment candidate, 10 October++The insulated 300 mm NTCLE428E3103H301A is listed at $1.82 in the saved Mouser API snapshot. It is being evaluated in place of the earlier $0.53 bare thermistor, which is not approved for direct live-tab attachment or potting. This candidate adds $1.29 to that earlier sensor allowance, before its housing, contacts and attachment. It is not yet adopted. [Fit and curve review](../../mechanical/sensor-study/README.md).+ ## 10 October diode revision  The SBR10U45SP5-13 is $1.61 in the new distributor snapshot, $0.67 above the former B540C listing. The priced electrical subtotal is now **$43.44**, with 63 references still unpriced. Other rows retain their older sourcing dates; this is not a complete build quote. The later Wakefield sink candidate is $17.17, superseding the $4.50 sink research option below if selected. Cooling hardware, assembly, calibration, fabrication, shipping and tax remain outside the partial electrical subtotal.
docs/status.md+2−2
@@ -10,7 +10,7 @@ The schematic/netlist/BOM and native models now include SBR10U45SP5-13. The v85  Thermal acceptance is still failed. The board-only model injects 5.5 W through Q1’s PCB terminal region and lacks its external case-to-heatsink path; its extreme temperatures are not a prediction of an assembled cooled unit. The actual interface, supported sink/fan mounting, duct pressure/flow and fault behavior require completion. The stock sink envelope clears all 91 fitted models and probe approaches, but this excludes mating connectors and hardware. [Package sensitivity](package-cooling-review.md) · [Fan airflow review](fan-airflow-review.md). -AIFlow 0.1.86 is published and installed with 147 tests passing, verified live presentation refresh and read-only existing-pour verification. Fields PR10 remains a separate owner-review change, and the shared runtime is not replaced. There are 87 raw takes, including static/rejected footage, 32 reviewed excerpts and 28 storyboard clips. The latest excerpt records the actual current-to-thermal dashboard transition. The final narrated 4–5 minute film remains unfinished.+AIFlow 0.1.86 is published and installed with 147 tests passing, verified live presentation refresh and read-only existing-pour verification. Fields PR10 remains a separate owner-review change, and the shared runtime is not replaced. There are 89 raw takes, including static/rejected footage, 33 reviewed excerpts and 29 storyboard clips. The latest excerpt records the actual current-to-thermal dashboard transition. The final narrated 4–5 minute film remains unfinished.  Next: complete the package/interface/duct cooling design and represent its supported operating/fault cases; then same-input thermal acceptance, Fields/pour walkthroughs, current-board silkscreen/3D review, prototype manufacturing outputs and final video. Physical calibration, safety tests and industrial qualification remain separate from digital design acceptance. No fabrication release, order or flash has occurred. @@ -177,7 +177,7 @@ The video inventory is 63 raw takes, including rejected material. The newest sta  ## Coupled package study -[Fine-grid package cooling study](package-cooling-study.md) completed. Full 5.5 W retained; 75.6/51.1 C case at 40 C ambient under supplied still/forced parameters. Thermal remains open. Fields PR #11 submitted for owner review. Clip inventory: 87 raw takes, 32 reviewed excerpts, 28 storyboard candidates.+[Fine-grid package cooling study](package-cooling-study.md) completed. Full 5.5 W retained; 75.6/51.1 C case at 40 C ambient under supplied still/forced parameters. Thermal remains open. Fields PR #11 submitted for owner review. Clip inventory: 89 raw takes, 33 reviewed excerpts, 29 storyboard candidates.  ### Review exports and cooling carrier
mechanical/sensor-candidate-screen.jsonadded+90
@@ -0,0 +1,90 @@+{+  "status": "candidate-screen-not-adopted",+  "candidate": "NTCLE428E3103H400A",+  "inputSha256": "75ee0242ca0188176e46e01addf9251435edc5accd6f144aa011b8fd3a26f975",+  "comparison": [+    {+      "actualC": 0,+      "nominalOhms": 32624,+      "legacyCurveC": -0.04984648930053481,+      "nominalErrorC": -0.04984648930053481,+      "legacyReadingAtMinOhmsC": 0.6781690229374817,+      "legacyReadingAtMaxOhmsC": -0.7493742379309651+    },+    {+      "actualC": 25,+      "nominalOhms": 10000,+      "legacyCurveC": 25.00003864024501,+      "nominalErrorC": 3.864024500899177e-05,+      "legacyReadingAtMinOhmsC": 25.697268121590696,+      "legacyReadingAtMaxOhmsC": 24.32611214346508+    },+    {+      "actualC": 40,+      "nominalOhms": 5323.9,+      "legacyCurveC": 40.03085018308985,+      "nominalErrorC": 0.030850183089853545,+      "legacyReadingAtMinOhmsC": 40.87583308806995,+      "legacyReadingAtMaxOhmsC": 39.21778475017487+    },+    {+      "actualC": 50,+      "nominalOhms": 3598.7,+      "legacyCurveC": 50.051739953440006,+      "nominalErrorC": 0.05173995344000559,+      "legacyReadingAtMinOhmsC": 51.00007220262688,+      "legacyReadingAtMaxOhmsC": 49.14095754221222+    },+    {+      "actualC": 55,+      "nominalOhms": 2982.3,+      "legacyCurveC": 55.06161995152189,+      "nominalErrorC": 0.061619951521890926,+      "legacyReadingAtMinOhmsC": 56.06417579809181,+      "legacyReadingAtMaxOhmsC": 54.10080316580883+    },+    {+      "actualC": 60,+      "nominalOhms": 2483.8,+      "legacyCurveC": 60.07239942030753,+      "nominalErrorC": 0.07239942030753355,+      "legacyReadingAtMinOhmsC": 61.12914224426294,+      "legacyReadingAtMaxOhmsC": 59.05989286189987+    },+    {+      "actualC": 65,+      "nominalOhms": 2078.7,+      "legacyCurveC": 65.0819530340055,+      "nominalErrorC": 0.08195303400549392,+      "legacyReadingAtMinOhmsC": 66.1941742838772,+      "legacyReadingAtMaxOhmsC": 64.01880253982682+    },+    {+      "actualC": 85,+      "nominalOhms": 1066.1,+      "legacyCurveC": 85.12538258721753,+      "nominalErrorC": 0.12538258721752982,+      "legacyReadingAtMinOhmsC": 86.4712434480266,+      "legacyReadingAtMaxOhmsC": 83.84281122481303+    }+  ],+  "maxAbsoluteNominalErrorC": 0.12538258721752982,+  "nominalHardwareComparator": {+    "referenceV": 0.6203007518796992,+    "tripResistanceOhms": 2314.814814814815,+    "interpolatedNominalTripC": 61.9786903369278,+    "interpolatedLowResistanceTripC": 60.9080802713632,+    "interpolatedHighResistanceTripC": 63.01956140909146+  },+  "nominalSelfHeatingAt55C": {+    "dissipatedMilliwatts": 0.1926974318814996,+    "assumedDissipationMilliwattsPerK": 3,+    "estimatedRiseC": 0.0642324772938332+  },+  "limits": [+    "Sparse nominal table comparison does not validate using legacy firmware with the new sensor.",+    "Comparator values exclude resistor/reference/supply/comparator tolerances; trip range is sensor resistance tolerance only.",+    "Bond-line resistance, thermal lag, case-to-sensor gradient and self-heating need assembly calibration.",+    "Candidate has not changed the formal board, spec, BOM or firmware. No physical measurement."+  ]+}
mechanical/sensor-study/README.mdadded+19
@@ -0,0 +1,19 @@+# Insulated case-sensor harness study++This isolated candidate uses **NTCLE428E3103H301A**, not the earlier bare NTCLE100 or the short-lead NTCLE428E3103H400A. The board, formal specification, BOM and firmware remain unchanged.++Vishay's NTCLE100 coating has no specified insulation and that family must not be potted. It is unsuitable for the previously unspecified bare attachment to the live MOSFET tab. The NTCLE428 permits taped or glued mounting; its 3 mm maximum body, 300 ±5 mm leads and 500 Vrms body withstand make it worth testing here. Hard potting remains excluded. Its 10 kΩ / B3984 curve differs from the existing B3977 firmware. [NTCLE100 sheet](https://www.vishay.com/docs/29049/ntcle100.pdf) · [Mounting guidance](https://www.vishay.com/docs/29222/handlmount-ntcletherm.pdf) · [NTCLE428 sheet, table 5](https://www.vishay.com/docs/29186/ntcle428.pdf).++The maximum cylindrical sensor envelope sits beside Q1's nominal metal tab with a 0.11 mm gap for a future attachment. The top clears the assumed sink envelope by 0.79 mm after lowering the sensor 0.65 mm: this is **not a toleranced fit or a selected bond line**. Exact case shape, adhesive compatibility, retention, strain relief and thermal lag remain unresolved. Do not compress the sensor body or credit its coating as the complete assembly insulation system.++The short-lead route was rejected for reach, bends and probe obstruction. The revised two-wire route uses 4.3 mm circular bends and 7.0/8.2 mm straight roots. Path lengths are 81.05/80.45 mm, with provisional 90 mm cut lengths including termination and slack allowances. It clears the 91 fitted component bounds, 13 probe approaches, nominal carrier/sink envelope and fan harness, with no wire-to-wire overlap. These are nominal CAD checks only; the 0.85 mm wire diameter is informational, so physical bend/fit validation is still required.++The added **M20-1060200** housing and two **M20-1180046** contacts mate with J10. The housing is unpolarized. Contacts are simplified envelopes. Factory solder-dipped wire ends need a reviewed crimp preparation; conductor gauge alone does not establish an acceptable crimp. [Housing](https://www.harwin.com/products/M20-1060200) · [Contacts](https://www.harwin.com/products/M20-1180046).++[Curve screen](../sensor-candidate-screen.json) compares eight nominal points: the old polynomial differs by up to 0.126 °C at those points, excluding calibration, ADC and thermal error. The unchanged analog comparator's nominal crossing is about 62.0 °C; sensor tolerance alone gives approximately 60.9–63.0 °C. It is a backup, not evidence that the physical case stays below the 55 °C software ceiling. No conversion or threshold was changed.++Mouser's 10 October API snapshot lists the exact 300 mm part at $1.82, stock 702. This is not a quote and excludes termination, attachment, tax and shipping. [Saved sourcing](../../design/ps_ntcle428_long.json).++Reproduce with `python3 tools/sensor_candidate_screen.py`, then run `tools/sensor_mount_study.py` in the existing CadQuery environment. [CAD checks](review.json) · [STEP](sensor-candidate.step) · [GLB](sensor-candidate.glb). The separate viewer at `checkpoints/board-review-v85/sensor.html` loads this candidate alongside the saved assembly; the control-panel twin still uses the earlier accepted study.++The recorded close-up shows the first clear route before the 0.65 mm downward refinement. `first-clear-route.json` retains those checks; current STEP/GLB and `review.json` describe the refinement.
mechanical/sensor-study/first-clear-route.jsonadded+49
@@ -0,0 +1,49 @@+{+  "status": "candidate-not-adopted",+  "sensor": "NTCLE428E3103H301A",+  "housing": "M20-1060200",+  "contacts": "2 x M20-1180046 (simplified contact envelopes)",+  "boardSha256": "1681eb90e49f4f229afe89bb75ff1738b7503907a52cd174e8b3d64b120082f4",+  "routes": [+    {+      "circuit": 1,+      "pathLengthMm": 80.40057971344629,+      "exactArcRadiusMm": 4.3,+      "requiredMinimumRadiusMm": 4.25,+      "rootStraightMm": 7.0,+      "minimumFactoryLeadMm": 295,+      "terminationAllowanceMm": 4,+      "minimumSlackMm": 5,+      "shortLeadFits": false,+      "longLeadFits": true,+      "provisionalCutLengthMm": 90+    },+    {+      "circuit": 2,+      "pathLengthMm": 79.79810708712711,+      "exactArcRadiusMm": 4.3,+      "requiredMinimumRadiusMm": 4.25,+      "rootStraightMm": 8.200000000000003,+      "minimumFactoryLeadMm": 295,+      "terminationAllowanceMm": 4,+      "minimumSlackMm": 5,+      "shortLeadFits": false,+      "longLeadFits": true,+      "provisionalCutLengthMm": 90+    }+  ],+  "bodyConflicts": [],+  "probeConflicts": [],+  "wireOverlapMm3": 0.0,+  "carrierSinkEnvelopeAndFanHarnessConflicts": [],+  "sensorMetalTabNominalSideGapMm": 0.11,+  "sensorTopToSinkEnvelopeGapMm": 0.14,+  "limits": [+    "Maximum cylindrical body envelope is not exact manufacturer CAD.",+    "Case edge contact and adhesive are unqualified; sensor must track metal case rather than airflow or plastic temperature.",+    "Sensor coating must not be compressed; compatibility/strain relief remain unresolved.",+    "40 +/-5 mm version is rejected for reach; the 300 +/-5 mm variant is evaluated with provisional trim lengths.",+    "Checks include carrier, sink envelope and nominal fan harness; detailed heatsink relief, clamp, mating tools and tolerances remain excluded.",+    "No change to formal board, BOM, firmware, calibration or acceptance."+  ]+}
mechanical/sensor-study/rejected-short-route.jsonadded+52
@@ -0,0 +1,52 @@+{+  "status": "candidate-not-adopted",+  "sensor": "NTCLE428E3103H400A",+  "housing": "M20-1060200",+  "contacts": "2 x M20-1180046 (not modeled)",+  "boardSha256": "1681eb90e49f4f229afe89bb75ff1738b7503907a52cd174e8b3d64b120082f4",+  "routes": [+    {+      "circuit": 1,+      "pathLengthMm": 48.72671365390632,+      "minimumSampledRadiusMm": 0.5483013883766715,+      "requiredMinimumRadiusMm": 4.25,+      "rootStraightMm": 4.5,+      "minimumFactoryLeadMm": 35,+      "terminationAllowanceMm": 4,+      "minimumSlackMm": 5,+      "shortLeadFits": false+    },+    {+      "circuit": 2,+      "pathLengthMm": 47.93678550572911,+      "minimumSampledRadiusMm": 0.7427120206056765,+      "requiredMinimumRadiusMm": 4.25,+      "rootStraightMm": 4.5,+      "minimumFactoryLeadMm": 35,+      "terminationAllowanceMm": 4,+      "minimumSlackMm": 5,+      "shortLeadFits": false+    }+  ],+  "bodyConflicts": [],+  "probeConflicts": [+    {+      "part": "Sensor.Lead.1",+      "reference": "TP12"+    },+    {+      "part": "Sensor.Lead.2",+      "reference": "TP13"+    }+  ],+  "sensorCaseNominalSideGapMm": 0.1,+  "sensorTopToSinkEnvelopeGapMm": 0.14,+  "limits": [+    "Maximum cylindrical body envelope is not exact manufacturer CAD.",+    "Case edge contact and adhesive are unqualified; sensor must track metal case rather than airflow or plastic temperature.",+    "Sensor coating must not be compressed; compatibility/strain relief remain unresolved.",+    "Short 40 +/-5 mm leads may fail required route plus slack; do not splice or trim without a reviewed harness design.",+    "No checks against detailed heatsink relief, clamp, mating tool or existing fan wires.",+    "No change to formal board, BOM, firmware, calibration or acceptance."+  ]+}
mechanical/sensor-study/review.jsonadded+49
@@ -0,0 +1,49 @@+{+  "status": "candidate-not-adopted",+  "sensor": "NTCLE428E3103H301A",+  "housing": "M20-1060200",+  "contacts": "2 x M20-1180046 (simplified contact envelopes)",+  "boardSha256": "1681eb90e49f4f229afe89bb75ff1738b7503907a52cd174e8b3d64b120082f4",+  "routes": [+    {+      "circuit": 1,+      "pathLengthMm": 81.0505797134463,+      "exactArcRadiusMm": 4.3,+      "requiredMinimumRadiusMm": 4.25,+      "rootStraightMm": 7.0,+      "minimumFactoryLeadMm": 295,+      "terminationAllowanceMm": 4,+      "minimumSlackMm": 5,+      "shortLeadFits": false,+      "longLeadFits": true,+      "provisionalCutLengthMm": 95+    },+    {+      "circuit": 2,+      "pathLengthMm": 80.44810708712711,+      "exactArcRadiusMm": 4.3,+      "requiredMinimumRadiusMm": 4.25,+      "rootStraightMm": 8.200000000000003,+      "minimumFactoryLeadMm": 295,+      "terminationAllowanceMm": 4,+      "minimumSlackMm": 5,+      "shortLeadFits": false,+      "longLeadFits": true,+      "provisionalCutLengthMm": 90+    }+  ],+  "bodyConflicts": [],+  "probeConflicts": [],+  "wireOverlapMm3": 0.0,+  "carrierSinkEnvelopeAndFanHarnessConflicts": [],+  "sensorMetalTabNominalSideGapMm": 0.11,+  "sensorTopToSinkEnvelopeGapMm": 0.79,+  "limits": [+    "Maximum cylindrical body envelope is not exact manufacturer CAD.",+    "Case edge contact and adhesive are unqualified; sensor must track metal case rather than airflow or plastic temperature.",+    "Sensor coating must not be compressed; compatibility/strain relief remain unresolved.",+    "40 +/-5 mm version is rejected for reach; the 300 +/-5 mm variant is evaluated with provisional trim lengths.",+    "Checks include carrier, sink envelope and nominal fan harness; detailed heatsink relief, clamp, mating tools and tolerances remain excluded.",+    "No change to formal board, BOM, firmware, calibration or acceptance."+  ]+}
mechanical/sensor-study/sensor-candidate.glbadded
⋯ 1 unchanged line ⋯
mechanical/sensor-study/sensor-candidate.stepadded+4704
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SOLID_ANGLE_UNIT() );+#3945 = UNCERTAINTY_MEASURE_WITH_UNIT(LENGTH_MEASURE(1.E-07),#3942,+  'distance_accuracy_value','confusion accuracy');+#3946 = CONTEXT_DEPENDENT_SHAPE_REPRESENTATION(#3947,#3949);+#3947 = ( REPRESENTATION_RELATIONSHIP('','',#3294,#10) +REPRESENTATION_RELATIONSHIP_WITH_TRANSFORMATION(#3948) +SHAPE_REPRESENTATION_RELATIONSHIP() );+#3948 = ITEM_DEFINED_TRANSFORMATION('','',#11,#35);+#3949 = PRODUCT_DEFINITION_SHAPE('Placement','Placement of an item',+  #3950);+#3950 = NEXT_ASSEMBLY_USAGE_OCCURRENCE('6','Connector_Contact_2','',#5,+  #3289,$);+#3951 = PRODUCT_RELATED_PRODUCT_CATEGORY('part',$,(#3291));+#3952 = MECHANICAL_DESIGN_GEOMETRIC_PRESENTATION_REPRESENTATION('',(+    #3953),#3941);+#3953 = STYLED_ITEM('color',(#3954),#3295);+#3954 = PRESENTATION_STYLE_ASSIGNMENT((#3955));+#3955 = SURFACE_STYLE_USAGE(.BOTH.,#3956);+#3956 = SURFACE_SIDE_STYLE('',(#3957));+#3957 = SURFACE_STYLE_FILL_AREA(#3958);+#3958 = FILL_AREA_STYLE('',(#3959));+#3959 = FILL_AREA_STYLE_COLOUR('',#3960);+#3960 = COLOUR_RGB('',0.700000005816,0.720000003324,0.740000011925);+#3961 = MECHANICAL_DESIGN_GEOMETRIC_PRESENTATION_REPRESENTATION('',(+    #3962),#159);+#3962 = STYLED_ITEM('color',(#3963),#53);+#3963 = PRESENTATION_STYLE_ASSIGNMENT((#3964));+#3964 = SURFACE_STYLE_USAGE(.BOTH.,#3965);+#3965 = SURFACE_SIDE_STYLE('',(#3966));+#3966 = SURFACE_STYLE_FILL_AREA(#3967);+#3967 = FILL_AREA_STYLE('',(#3968));+#3968 = FILL_AREA_STYLE_COLOUR('',#3969);+#3969 = COLOUR_RGB('',0.120000001395,0.120000001395,0.130000001093);+#3970 = MECHANICAL_DESIGN_GEOMETRIC_PRESENTATION_REPRESENTATION('',(+    #3971),#3276);+#3971 = STYLED_ITEM('color',(#3972),#2630);+#3972 = PRESENTATION_STYLE_ASSIGNMENT((#3973));+#3973 = SURFACE_STYLE_USAGE(.BOTH.,#3974);+#3974 = SURFACE_SIDE_STYLE('',(#3975));+#3975 = SURFACE_STYLE_FILL_AREA(#3976);+#3976 = FILL_AREA_STYLE('',(#3977));+#3977 = FILL_AREA_STYLE_COLOUR('',#3960);+#3978 = MECHANICAL_DESIGN_GEOMETRIC_PRESENTATION_REPRESENTATION('',(+    #3979),#2611);+#3979 = STYLED_ITEM('color',(#3980),#1649);+#3980 = PRESENTATION_STYLE_ASSIGNMENT((#3981));+#3981 = SURFACE_STYLE_USAGE(.BOTH.,#3982);+#3982 = SURFACE_SIDE_STYLE('',(#3983));+#3983 = SURFACE_STYLE_FILL_AREA(#3984);+#3984 = FILL_AREA_STYLE('',(#3985));+#3985 = FILL_AREA_STYLE_COLOUR('',#3986);+#3986 = COLOUR_RGB('',5.500000063064E-02,6.000000074816E-02,+  6.500000082754E-02);+#3987 = MECHANICAL_DESIGN_GEOMETRIC_PRESENTATION_REPRESENTATION('',(+    #3988),#950);+#3988 = STYLED_ITEM('color',(#3989),#178);+#3989 = PRESENTATION_STYLE_ASSIGNMENT((#3990));+#3990 = SURFACE_STYLE_USAGE(.BOTH.,#3991);+#3991 = SURFACE_SIDE_STYLE('',(#3992));+#3992 = SURFACE_STYLE_FILL_AREA(#3993);+#3993 = FILL_AREA_STYLE('',(#3994));+#3994 = FILL_AREA_STYLE_COLOUR('',#3995);+#3995 = COLOUR_RGB('',0.139999997847,0.139999997847,0.1599999992);+#3996 = MECHANICAL_DESIGN_GEOMETRIC_PRESENTATION_REPRESENTATION('',(+    #3997),#1630);+#3997 = STYLED_ITEM('color',(#3998),#969);+#3998 = PRESENTATION_STYLE_ASSIGNMENT((#3999));+#3999 = SURFACE_STYLE_USAGE(.BOTH.,#4000);+#4000 = SURFACE_SIDE_STYLE('',(#4001));+#4001 = SURFACE_STYLE_FILL_AREA(#4002);+#4002 = FILL_AREA_STYLE('',(#4003));+#4003 = FILL_AREA_STYLE_COLOUR('',#3995);+ENDSEC;+END-ISO-10303-21;
tools/sensor_candidate_screen.pyadded+23
@@ -0,0 +1,23 @@+#!/usr/bin/env python3+"""Nominal curve compatibility only; never a sensor/assembly qualification."""+import json,math,hashlib+from pathlib import Path+R=Path(__file__).resolve().parents[1]+def old_curve(r):+ l=math.log(r/10000);return 1/(.003354016+.000256985*l+.000002620131*l*l+.00000006383091*l*l*l)-273.15+def interp_temp(rows,r,col=1):+ for a,b in zip(rows,rows[1:]):+  if a[col]>=r>=b[col]:+   return a[0]+(b[0]-a[0])*(math.log(a[col])-math.log(r))/(math.log(a[col])-math.log(b[col]))+ raise ValueError('Resistance outside supplied table segment')+def main():+ source=R/'design/sensor-candidate.json';d=json.loads(source.read_text());rows=d['rows']+ comparison=[dict(actualC=t,nominalOhms=r,legacyCurveC=old_curve(r),nominalErrorC=old_curve(r)-t,legacyReadingAtMinOhmsC=old_curve(lo),legacyReadingAtMaxOhmsC=old_curve(hi))for t,r,lo,hi in rows]+ v=2.5*3300/(10000+3300);threshold=10000*v/(3.3-v)+ out=dict(status='candidate-screen-not-adopted',candidate=d['candidate'],inputSha256=hashlib.sha256(source.read_bytes()).hexdigest(),comparison=comparison,maxAbsoluteNominalErrorC=max(abs(v['nominalErrorC']) for v in comparison),+ nominalHardwareComparator=dict(referenceV=v,tripResistanceOhms=threshold,interpolatedNominalTripC=interp_temp(rows,threshold),interpolatedLowResistanceTripC=interp_temp(rows,threshold,2),interpolatedHighResistanceTripC=interp_temp(rows,threshold,3)),+ nominalSelfHeatingAt55C=dict(dissipatedMilliwatts=1000*3.3**2*2982.3/(10000+2982.3)**2,assumedDissipationMilliwattsPerK=3),+ limits=['Sparse nominal table comparison does not validate using legacy firmware with the new sensor.','Comparator values exclude resistor/reference/supply/comparator tolerances; trip range is sensor resistance tolerance only.','Bond-line resistance, thermal lag, case-to-sensor gradient and self-heating need assembly calibration.','Candidate has not changed the formal board, spec, BOM or firmware. No physical measurement.'])+ out['nominalSelfHeatingAt55C']['estimatedRiseC']=out['nominalSelfHeatingAt55C']['dissipatedMilliwatts']/3+ p=R/'mechanical/sensor-candidate-screen.json';p.write_text(json.dumps(out,indent=2)+'\n');print(json.dumps(out,indent=2))+if __name__=='__main__':main()
tools/sensor_mount_study.pyadded+61
@@ -0,0 +1,61 @@+#!/usr/bin/env python3+"""Isolated insulated NTC mounting/lead reach study. Not an adopted assembly."""+from pathlib import Path+import json,hashlib,math+import cadquery as cq+from glb_shape_helpers import add_shape,write_glb+R=Path(__file__).resolve().parents[1];O=R/'mechanical/sensor-study';O.mkdir(exist_ok=True)+audit=json.loads((R/'mechanical/cooling-680-body-audit.json').read_text());screen=json.loads((R/'mechanical/cooling-680-screen.json').read_text())+assert audit['boardSha256']==hashlib.sha256((R/'kicad/adom-custom-electronic-load.kicad_pcb').read_bytes()).hexdigest()+g={'asset':{'version':'2.0','generator':'Adom insulated NTC fit study'},'scene':0,'scenes':[{'nodes':[0]}],'nodes':[{'name':'Sensor.CANDIDATE_NOT_ADOPTED','children':[]}],'buffers':[{'byteLength':0}],'accessors':[]};blob=bytearray();assy=cq.Assembly(name='Sensor_candidate_mm');parts=[]+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()+def add(name,s,color):+ q=s.mirror('XZ').translate((-100,100,5.98));add_shape(g,blob,q,name,color,0,'Nominal NTCLE428 envelope; not adopted or assembly-qualified');assy.add(q,name=name.replace('.','_'),color=cq.Color(*color));parts.append((name,s))+# Maximum body cylinder beside Q1. 0.10 mm candidate adhesive gap, not a controlled bond line.+sensor=cq.Solid.makeCylinder(1.5,10,cq.Vector(120.735,62.8,2.8),cq.Vector(0,1,0));add('Sensor.NTCLE428.MaxEnvelope',sensor,(.12,.12,.13))+# Leads leave toward -Y, preserve a straight 4.5 mm root before bending.+route=[]+for i in range(2):+ x=120.735+(i-.5)*.85;endx=104+2.54*i+ pts=[cq.Vector(x,62.8,2.8),cq.Vector(x,51.5-i*1.2,2.8),cq.Vector(111.5+i*.9,51.5-i*1.2,2.8),cq.Vector(111.5+i*.9,51.5-i*1.2,29+i*1.5),cq.Vector(111.5+i*.9,73,29+i*1.5),cq.Vector(endx,73,23+i*1.5),cq.Vector(endx,73,16.54)]+ if i==0:pts=pts[:4]+[cq.Vector(113,75,29),cq.Vector(104,75,27),cq.Vector(104,73,20.54),cq.Vector(104,73,16.54)]+ radius=4.3;corners=[]+ for a,b,c in zip(pts,pts[1:],pts[2:]):+  u=(b-a).normalized();v=(c-b).normalized();theta=math.acos(max(-1,min(1,u.dot(v))));d=radius*math.tan(theta/2)+  ta=b-u*d;tb=b+v*d;center=ta+(v-u*u.dot(v)).normalized()*radius+  mid=center+((ta-center).normalized()+(tb-center).normalized()).normalized()*radius+  corners.append((ta,tb,mid,d))+ for j in range(len(pts)-1):+  used=(corners[j-1][3]if j else 0)+(corners[j][3]if j<len(corners)else 0)+  assert (pts[j+1]-pts[j]).Length>used,f'Overlapping fillets: lead {i+1}, segment {j}'+ edges=[];cursor=pts[0]+ for ta,tb,mid,d in corners:+  edges.append(cq.Edge.makeLine(cursor,ta));edges.append(cq.Edge.makeThreePointArc(ta,mid,tb));cursor=tb+ edges.append(cq.Edge.makeLine(cursor,pts[-1]));path=cq.Wire.assembleEdges(edges)+ shape=cq.Workplane(cq.Plane(origin=pts[0],normal=(0,-1,0))).circle(.425).sweep(path,isFrenet=True).val();add(f'Sensor.Lead.{i+1}',shape,(.14,.14,.16))+ route.append(dict(circuit=i+1,pathLengthMm=path.Length(),exactArcRadiusMm=radius,requiredMinimumRadiusMm=4.25,rootStraightMm=(corners[0][0]-pts[0]).Length,minimumFactoryLeadMm=295,terminationAllowanceMm=4,minimumSlackMm=5,shortLeadFits=path.Length()+9<=35,longLeadFits=path.Length()+9<=295,provisionalCutLengthMm=math.ceil((path.Length()+9)/5)*5))++housing=box([102.63,71.75,2.54,107.91,74.25,16.54])+for x in [104,106.54]:housing=housing.cut(box([x-.5,72.5,2.4,x+.5,73.5,16.7]))+add('Connector.M20-1060200.Housing',housing,(.055,.06,.065))+for i,x in enumerate([104,106.54]):+ contact=box([x-.425,72.575,6.54,x+.425,73.425,15.54]).cut(box([x-.325,72.675,6.4,x+.325,73.325,15.7]));add(f'Connector.Contact.{i+1}',contact,(.7,.72,.74))+conflicts=[];probes=[]+for name,s in parts:+ for row in audit['rows']:+  if row['ref']=='J10' and name.startswith('Connector.'):continue+  v=s.intersect(box(row['boundsMm'])).Volume()+  if v>1e-6:conflicts.append(dict(part=name,reference=row['ref'],volumeMm3=v))+ for p in screen['probeChecks']:+  if s.intersect(cq.Solid.makeCylinder(2,75,cq.Vector(p['x'],p['y'],0))).Volume()>1e-6:probes.append(dict(part=name,reference=p['ref']))+assembly_conflicts=[]+for fn in ['mechanical/carrier-study/carrier-layout.step','mechanical/installed-fan-study/installed-connection.step']:+ target=cq.importers.importStep(str(R/fn)).val()+ for name,shape in parts:+  rendered=shape.mirror('XZ').translate((-100,100,5.98));v=rendered.intersect(target).Volume()+  if v>1e-6:assembly_conflicts.append(dict(part=name,assembly=fn,volumeMm3=v))+assert all(s.isValid()for _,s in parts)+assy.save(str(O/'sensor-candidate.step'));write_glb(O/'sensor-candidate.glb',g,blob)+r=dict(status='candidate-not-adopted',sensor='NTCLE428E3103H301A',housing='M20-1060200',contacts='2 x M20-1180046 (simplified contact envelopes)',boardSha256=audit['boardSha256'],routes=route,bodyConflicts=conflicts,probeConflicts=probes,wireOverlapMm3=parts[1][1].intersect(parts[2][1]).Volume(),carrierSinkEnvelopeAndFanHarnessConflicts=assembly_conflicts,sensorMetalTabNominalSideGapMm=.11,sensorTopToSinkEnvelopeGapMm=.79,limits=['Maximum cylindrical body envelope is not exact manufacturer CAD.','Case edge contact and adhesive are unqualified; sensor must track metal case rather than airflow or plastic temperature.','Sensor coating must not be compressed; compatibility/strain relief remain unresolved.','40 +/-5 mm version is rejected for reach; the 300 +/-5 mm variant is evaluated with provisional trim lengths.','Checks include carrier, sink envelope and nominal fan harness; detailed heatsink relief, clamp, mating tools and tolerances remain excluded.','No change to formal board, BOM, firmware, calibration or acceptance.'])+(O/'review.json').write_text(json.dumps(r,indent=2)+'\n');print(json.dumps(r,indent=2))
videos/build-storyboard.json+6
@@ -168,6 +168,12 @@       "title": "Connect real fan telemetry to the digital model",       "description": "Actual disconnected control panel at 2x. Unknown telemetry pauses the rotor; the camera moves. No hardware RPM was synthesized.",       "raw_path": "/home/adom/project/adom-custom-electronic-load/docs/clips/control-panel-twin.mp4"+    },+    {+      "id": "sensor-harness-review",+      "title": "Make room for an insulated temperature-sensor harness",+      "description": "Actual close-up at 2x. First clear candidate route before 0.65 mm downward refinement. Nominal CAD, not thermal or mounting qualification.",+      "raw_path": "/home/adom/project/adom-custom-electronic-load/docs/clips/sensor-harness-review.mp4"     }   ] }
videos/inventory.json+14−2
@@ -1,6 +1,6 @@ {-  "rawTakeCount": 87,-  "reviewedExcerptCount": 32,+  "rawTakeCount": 89,+  "reviewedExcerptCount": 33,   "countingRule": "Unique raw window recording filenames in this project; excludes derivative action/speed exports and reference projects. Raw count includes rejected takes.",   "takes": [     {@@ -524,6 +524,18 @@       "durationSeconds": 18.066667,       "topic": "Measured-only control panel digital twin remains unknown without telemetry",       "review": "Full decode, raw contact sheet and captioned excerpt poster reviewed. Actual disconnected control panel, camera orbit only; rotor paused and feedback unknown. Six-second 2x excerpt."+    },+    {+      "file": "videos/raw/window-10291968-20261010-174958.mp4",+      "durationSeconds": 20.066667,+      "topic": "Add insulated sensor candidate, wide view",+      "review": "Decoded/contact sheet reviewed; sensor is hidden behind assembly from this angle. Excluded from action edit."+    },+    {+      "file": "videos/raw/window-10291968-20261010-175136.mp4",+      "durationSeconds": 16.033333,+      "topic": "Insulated sensor harness close review",+      "review": "Full decode, contact sheet and captioned poster reviewed. Six-second 2x excerpt; first clear nominal route before 0.65 mm downward sensor refinement. No thermal qualification."     }   ] }
videos/shotlog.json+16
@@ -401,6 +401,22 @@       "status": "Full decode, raw contact sheet and captioned excerpt poster reviewed. Actual disconnected control panel, camera orbit only; rotor paused and feedback unknown. Six-second 2x excerpt.",       "excerpt": "../docs/clips/control-panel-twin.mp4",       "playbackSpeed": 2+    },+    {+      "id": "sensor-wide-review-88",+      "file": "videos/raw/window-10291968-20261010-174958.mp4",+      "duration_s": 20.066667,+      "recordingId": "rec-869e81d0d1214af3b9e242781b31997b",+      "status": "Decoded; sensor obscured; exclude from action edit"+    },+    {+      "id": "sensor-harness-review-89",+      "file": "videos/raw/window-10291968-20261010-175136.mp4",+      "duration_s": 16.033333,+      "recordingId": "rec-6ecb04bb033f494c90ddd8f118952094",+      "status": "Decoded/contact sheet/poster reviewed; first clear candidate before 0.65 mm downward refinement",+      "excerpt": "../docs/clips/sensor-harness-review.mp4",+      "playbackSpeed": 2     }   ],   "failed_captures": [