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 nominal insulating fastener study and reviewed process clip 90
10 files changed
+1203−2
docs/build-clips.md+4docs/clips/peek-fastener-review.jpgdocs/clips/peek-fastener-review.mp4mechanical/peek-fastener-study/README.md+11mechanical/peek-fastener-study/fastener-candidate.glbmechanical/peek-fastener-study/fastener-candidate.step+1089mechanical/peek-fastener-study/review.json+41tools/peek_fastener_study.py+44videos/build-storyboard.json+6videos/inventory.json+8−2docs/build-clips.md+4@@ -201,3 +201,7 @@ The inventory now contains **89 raw takes and 33 reviewed excerpts**. Raw takes ## 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.++## PEEK fastener inspection++[Watch the 3.5-second 2× excerpt](clips/peek-fastener-review.mp4). Actual nominal-model inspection with the heatsink hidden explicitly. The excerpt excludes later frames obscured by a carrier pillar; it does not establish insulation, preload or thermal performance. Raw take 90; full decode, contact sheet and poster reviewed. Current inventory: 90 raw takes, 34 reviewed excerpts and 30 storyboard candidates. Three scenes have draft narration; final film remains unassembled.
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docs/clips/peek-fastener-review.mp4added⋯ 1 unchanged line ⋯
mechanical/peek-fastener-study/README.mdadded+11@@ -0,0 +1,11 @@+# PEEK fastener candidate++A nominal NBK SPE-M3-12-P pan-head screw and SPE-M3-N nut fit the existing Q1 hole in the saved board model. No PCB drill or circuit is changed. These independently generated envelopes omit threads, recesses and chamfers; they are not manufacturer CAD or a qualified fastening assembly.++The 2 mm head leaves 1.185 mm nominal clearance above the PCB. Varying only tab thickness to its 1.40 mm maximum leaves 1.055 mm; this is not a full tolerance stack. The 12 mm screw extends 2.9198 mm beyond the nominal nut. Checks find no intersections with the nominal Q1 solid, other 90 fitted component bounds, incomplete heatsink model, or candidate sensor harness.++The manufacturer recommends 0.105 N·m for this screw based on half its reference torsional value. That is not an approved torque for the ceramic/TIM assembly. Head and nut dimensional tolerances, interface drawing, washer need, pressure distribution, creep, vibration retention and thermal-cycle performance remain open. Assemble before soldering Q1: the head does not pass through the 3.5 mm PCB hole. Support the sink separately from transistor leads.++[Review data](review.json) · [Nominal STEP](fastener-candidate.step) · [Nominal GLB](fastener-candidate.glb) · [Generator](../../tools/peek_fastener_study.py).++Sources: [NBK screw drawing](https://www.nbk1560.com/images/en-US/product/chemicalscrew/SPE-P/SPE-P_1.pdf), [NBK nut drawing](https://www.nbk1560.com/images/en/product/chemicalscrew/SPE-N/SPE-N_1.pdf). The sink base is a reference dimension, and the 0.635 mm interface remains an unresolved candidate. No BOM or acceptance gate adopts this stack.
mechanical/peek-fastener-study/fastener-candidate.glbadded⋯ 1 unchanged line ⋯
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SOLID_ANGLE_UNIT() );+#873 = UNCERTAINTY_MEASURE_WITH_UNIT(LENGTH_MEASURE(1.E-07),#870,+ 'distance_accuracy_value','confusion accuracy');+#874 = CONTEXT_DEPENDENT_SHAPE_REPRESENTATION(#875,#877);+#875 = ( REPRESENTATION_RELATIONSHIP('','',#290,#10) +REPRESENTATION_RELATIONSHIP_WITH_TRANSFORMATION(#876) +SHAPE_REPRESENTATION_RELATIONSHIP() );+#876 = ITEM_DEFINED_TRANSFORMATION('','',#11,#23);+#877 = PRODUCT_DEFINITION_SHAPE('Placement','Placement of an item',#878+ );+#878 = NEXT_ASSEMBLY_USAGE_OCCURRENCE('3',+ 'Fastener_SPE-M3-N_NutEnvelope','',#5,#285,$);+#879 = PRODUCT_RELATED_PRODUCT_CATEGORY('part',$,(#287));+#880 = MECHANICAL_DESIGN_GEOMETRIC_PRESENTATION_REPRESENTATION('',(#881)+ ,#147);+#881 = STYLED_ITEM('color',(#882),#41);+#882 = PRESENTATION_STYLE_ASSIGNMENT((#883));+#883 = SURFACE_STYLE_USAGE(.BOTH.,#884);+#884 = SURFACE_SIDE_STYLE('',(#885));+#885 = SURFACE_STYLE_FILL_AREA(#886);+#886 = FILL_AREA_STYLE('',(#887));+#887 = FILL_AREA_STYLE_COLOUR('',#888);+#888 = COLOUR_RGB('',0.530000000233,0.369999997777,0.199999998682);+#889 = MECHANICAL_DESIGN_GEOMETRIC_PRESENTATION_REPRESENTATION('',(#890)+ ,#869);+#890 = STYLED_ITEM('color',(#891),#291);+#891 = PRESENTATION_STYLE_ASSIGNMENT((#892));+#892 = SURFACE_STYLE_USAGE(.BOTH.,#893);+#893 = SURFACE_SIDE_STYLE('',(#894));+#894 = SURFACE_STYLE_FILL_AREA(#895);+#895 = FILL_AREA_STYLE('',(#896));+#896 = FILL_AREA_STYLE_COLOUR('',#888);+#897 = MECHANICAL_DESIGN_GEOMETRIC_PRESENTATION_REPRESENTATION('',(#898)+ ,#272);+#898 = STYLED_ITEM('color',(#899),#166);+#899 = PRESENTATION_STYLE_ASSIGNMENT((#900));+#900 = SURFACE_STYLE_USAGE(.BOTH.,#901);+#901 = SURFACE_SIDE_STYLE('',(#902));+#902 = SURFACE_STYLE_FILL_AREA(#903);+#903 = FILL_AREA_STYLE('',(#904));+#904 = FILL_AREA_STYLE_COLOUR('',#888);+ENDSEC;+END-ISO-10303-21;
mechanical/peek-fastener-study/review.jsonadded+41@@ -0,0 +1,41 @@+{+ "status": "nominal-candidate-not-adopted",+ "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,+ "assumedTIMThickness": 0.6349999999999998+ },+ "nominalHeadBottomAbovePcbMm": 1.185,+ "tabThicknessOnlyWorstHeadClearanceMm": 1.0550000000000002,+ "nominalProtrusionBeyondNutMm": 2.9198000000000004,+ "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.",+ "TIM outline and hole remain unresolved; no interface insulation qualification.",+ "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.",+ "No formal board, BOM, thermal evidence or firmware change."+ ]+}
tools/peek_fastener_study.pyadded+44@@ -0,0 +1,44 @@+#!/usr/bin/env python3+"""Nominal PEEK fastening stack; no preload, insulation or thermal qualification."""+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/peek-fastener-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=5.09;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)))+parts=[('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 nominal PEEK fastener 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));add_shape(g,blob,q,name,(.53,.37,.20),0,'Nominal PEEK envelope; threads and recess omitted; unqualified');assy.add(q,name=name.replace('.','_'),color=cq.Color(.53,.37,.20))+ 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((138.636,67.118,5.09))+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/'fastener-candidate.step'));write_glb(O/'fastener-candidate.glb',g,blob)+r={'status':'nominal-candidate-not-adopted','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,'assumedTIMThickness':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.','TIM outline and hole remain unresolved; no interface insulation qualification.','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.','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))
videos/build-storyboard.json+6@@ -186,6 +186,12 @@ "warnings": [ "Draft voiceover; human clip review pending." ]+ },+ {+ "id": "peek-fastener-review",+ "title": "Check space for the insulating fastener",+ "description": "Nominal screw and nut review at 2x. Sink hidden for inspection; threads omitted. Fit does not qualify preload, insulation or cooling. Later obscured frames excluded.",+ "raw_path": "/home/adom/project/adom-custom-electronic-load/docs/clips/peek-fastener-review.mp4" } ] }
videos/inventory.json+8−2@@ -1,6 +1,6 @@ {- "rawTakeCount": 89,- "reviewedExcerptCount": 33,+ "rawTakeCount": 90,+ "reviewedExcerptCount": 34, "countingRule": "Unique raw window recording filenames in this project; excludes derivative action/speed exports and reference projects. Raw count includes rejected takes.", "takes": [ {@@ -536,6 +536,12 @@ "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."+ },+ {+ "file": "videos/raw/window-10291968-20261010-181001.mp4",+ "durationSeconds": 12.233333,+ "topic": "Nominal PEEK screw and nut clearance inspection",+ "review": "Full raw and excerpt decode; contact sheet and poster reviewed. 3.5-second 2x excerpt excludes later carrier occlusion; browser chrome cropped. Sink hidden explicitly; threads omitted. No thermal, insulation or preload qualification." } ] }