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
Land and record reviewed diode vias; reject colliding heatsink mounting pattern
16 files changed
+1592−126
checkpoints/diode-thermal-saved/native-drc.json+262design/diode-thermal-live/rounding-review.json+84design/diode-thermal-live/saved-comparison.json+174docs/build-clips.md+6docs/clips/diode-thermal-landing-2x.mp4docs/clips/diode-thermal-landing-poster.jpgdocs/completion-plan.md+1−1docs/status.md+8kicad/adom-custom-electronic-load.kicad_pcb+205−124mechanical/cooling-40mm-search.json+433mechanical/cooling-drill-screen.json+263mechanical/q1-nominal-contact-faces.json+37tools/review_diode_rounding.py+32tools/screen_cooling_drills.py+57tools/search_cooling_envelope.py+23videos/inventory.json+7−1checkpoints/diode-thermal-saved/native-drc.jsonadded+262@@ -0,0 +1,262 @@+{ + "$schema": "https://schemas.kicad.org/drc.v1.json", + "coordinate_units": "mm", + "date": "2026-10-09T13:17:14", + "ignored_checks": [ + { + "description": "Footprint has no courtyard defined", + "key": "missing_courtyard" + }, + { + "description": "Track endpoint not centered on via", + "key": "track_not_centered_on_via" + }, + { + "description": "Tuning profile track geometries", + "key": "tuning_profile_track_geometries" + }, + { + "description": "Footprint doesn't match symbol's footprint filters", + "key": "footprint_filters_mismatch" + }, + { + "description": "Footprint component type doesn't match footprint pads", + "key": "footprint_type_mismatch" + } + ], + "included_severities": [ + "error", + "warning" + ], + "kicad_version": "10.0.5", + "schematic_parity": [], + "source": "adom-custom-electronic-load.kicad_pcb", + "unconnected_items": [], + "violations": [ + { + "description": "The current configuration does not include the footprint library 'Molecule'", + "items": [ + { + "description": "Footprint MP2", + "pos": { + "x": 160.0, + "y": 100.0 + }, + "uuid": "08489986-63c7-4cfe-ba45-67384ef79934" + } + ], + "severity": "warning", + "type": "lib_footprint_issues" + }, + { + "description": "The current configuration does not include the footprint library 'Molecule'", + "items": [ + { + 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"warning", + "type": "lib_footprint_issues" + }, + { + "description": "The current configuration does not include the footprint library 'Load'", + "items": [ + { + "description": "Footprint U4", + "pos": { + "x": 141.0, + "y": 77.0 + }, + "uuid": "b585e065-e8ac-43c3-9bea-a846c5f7a747" + } + ], + "severity": "warning", + "type": "lib_footprint_issues" + }, + { + "description": "The current configuration does not include the footprint library 'Molecule'", + "items": [ + { + "description": "Footprint J7", + "pos": { + "x": 144.0, + "y": 100.0 + }, + "uuid": "e8f5ce02-a259-45e9-a4f1-ef182fb58bb6" + } + ], + "severity": "warning", + "type": "lib_footprint_issues" + }, + { + "description": "The current configuration does not include the footprint library 'Load'", + "items": [ + { + "description": "Footprint L1", + "pos": { + "x": 144.0, + "y": 95.6 + }, + "uuid": "f710bbae-8af4-4faf-8c03-b1959083aa62" + } + ], + "severity": "warning", + "type": "lib_footprint_issues" + }, + { + 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design/diode-thermal-live/rounding-review.jsonadded+84@@ -0,0 +1,84 @@+{+ "status": "documented-native-rounding-only",+ "candidateSha256": "3094fcf70404fa4d2874b543c54b4826f8297cfafc9c17a8836e386a849644a3",+ "savedSha256": "8d6cd24149f7de061f125bf45a26b50ca5b70a6b01c62b96dc3cf92187a531f1",+ "exactEquality": false,+ "otherTrackViaMultisetDifferences": 0,+ "pairs": [+ {+ "candidateMm": [+ 115.579711,+ 89.677483+ ],+ "savedMm": [+ 115.579712,+ 89.677483+ ],+ "distanceNm": 0.9999999974752427+ },+ {+ "candidateMm": [+ 115.199167,+ 91.467801+ ],+ "savedMm": [+ 115.199168,+ 91.467801+ ],+ "distanceNm": 0.9999999974752427+ },+ {+ "candidateMm": [+ 117.16481,+ 93.237674+ ],+ "savedMm": [+ 117.164811,+ 93.237674+ ],+ "distanceNm": 0.9999999974752427+ },+ {+ "candidateMm": [+ 116.275,+ 89.051442+ ],+ "savedMm": [+ 116.275,+ 89.051443+ ],+ "distanceNm": 1.0000000116860974+ },+ {+ "candidateMm": [+ 117.16481,+ 88.762325+ ],+ "savedMm": [+ 117.164811,+ 88.762326+ ],+ "distanceNm": 1.414213558802549+ },+ {+ "candidateMm": [+ 115.199167,+ 90.532198+ ],+ "savedMm": [+ 115.199168,+ 90.532199+ ],+ "distanceNm": 1.4142135688511408+ }+ ],+ "zoneSymmetricDifferenceMm2": {+ "('GND', 'F.Cu')": 9.00763032259291e-08,+ "('LOAD_POS', 'F.Cu')": 0.0,+ "('SHUNT_P', 'F.Cu')": 0.0,+ "('SHUNT_P', 'B.Cu')": 0.0,+ "('GND', 'B.Cu')": 1.356057240303816e-07,+ "('LOAD_POS', 'B.Cu')": 0.0+ },+ "qualification": "Geometric audit only. Actual saved-board native DRC required; no thermal or hardware qualification."+}
design/diode-thermal-live/saved-comparison.jsonadded+174@@ -0,0 +1,174 @@+{+ "candidateSha256": "3094fcf70404fa4d2874b543c54b4826f8297cfafc9c17a8836e386a849644a3",+ "savedSha256": "8d6cd24149f7de061f125bf45a26b50ca5b70a6b01c62b96dc3cf92187a531f1",+ "copperMultisetEqual": false,+ "missing": [+ [+ [+ "via",+ "LOAD_POS",+ [+ 115.579711,+ 89.677483+ ],+ 0.6,+ 0.3+ ],+ 1+ ],+ [+ [+ "via",+ "LOAD_POS",+ [+ 115.199167,+ 91.467801+ ],+ 0.6,+ 0.3+ ],+ 1+ ],+ [+ [+ "via",+ "LOAD_POS",+ [+ 117.16481,+ 93.237674+ ],+ 0.6,+ 0.3+ ],+ 1+ ],+ [+ [+ "via",+ "LOAD_POS",+ [+ 116.275,+ 89.051442+ ],+ 0.6,+ 0.3+ ],+ 1+ ],+ [+ [+ "via",+ "LOAD_POS",+ [+ 117.16481,+ 88.762325+ ],+ 0.6,+ 0.3+ ],+ 1+ ],+ [+ [+ "via",+ "LOAD_POS",+ [+ 115.199167,+ 90.532198+ ],+ 0.6,+ 0.3+ ],+ 1+ ]+ ],+ "extra": [+ [+ [+ "via",+ "LOAD_POS",+ [+ 117.164811,+ 88.762326+ ],+ 0.6,+ 0.3+ ],+ 1+ ],+ [+ [+ "via",+ "LOAD_POS",+ [+ 116.275,+ 89.051443+ ],+ 0.6,+ 0.3+ ],+ 1+ ],+ [+ [+ "via",+ "LOAD_POS",+ [+ 115.199168,+ 90.532199+ ],+ 0.6,+ 0.3+ ],+ 1+ ],+ [+ [+ "via",+ "LOAD_POS",+ [+ 115.199168,+ 91.467801+ ],+ 0.6,+ 0.3+ ],+ 1+ ],+ [+ [+ "via",+ "LOAD_POS",+ [+ 117.164811,+ 93.237674+ ],+ 0.6,+ 0.3+ ],+ 1+ ],+ [+ [+ "via",+ "LOAD_POS",+ [+ 115.579712,+ 89.677483+ ],+ 0.6,+ 0.3+ ],+ 1+ ]+ ],+ "zoneSymmetricDifferenceMm2": {+ "('GND', 'F.Cu')": 9.00763032259291e-08,+ "('LOAD_POS', 'F.Cu')": 0.0,+ "('SHUNT_P', 'F.Cu')": 0.0,+ "('SHUNT_P', 'B.Cu')": 0.0,+ "('GND', 'B.Cu')": 1.356057240303816e-07,+ "('LOAD_POS', 'B.Cu')": 0.0+ },+ "zoneKeysEqual": true+}
docs/build-clips.md+6@@ -128,3 +128,9 @@ Two new raw recordings capture the actual ESD/link relocation and copper landing [Watch the labeled fan-state demonstration](../videos/fan-hero/window-5969372-20261009-163213.mp4). The actual canonical viewer shows a stopped rotor, smooth spin-up, steady rotation, smooth spin-down and rest. Wires and the added Adom connector stay still. This is simulated, deliberately slowed rotation, not hardware feedback. The Sunon factory variant has bare-ended wires; the Harwin termination is an added assembly. The clip passed a full decode and contact-sheet review. The published wiki hero was separately checked through its full 20-second loop and animation-off mode. Native KiCad accepted the connector symbols and footprint. This does not establish physical mating, crimp strength, airflow or cooling qualification.++## Diode thermal vias, 9 October++<video width="100%" playsinline controls preload="metadata" poster="docs/clips/diode-thermal-landing-poster.jpg" src="docs/clips/diode-thermal-landing-2x.mp4"></video>++Nine preflighted vias appear around D1 in the native editor. Playback is 2x; the raw take is 22.77 seconds encoded. Full decode and contact-sheet review passed. Values clutter the view, so use a short action excerpt in the final film. Recorder sample-timeline warnings are retained, and encoded duration is not wall-clock proof. The saved board subsequently passed native DRC with zero errors and zero opens; this footage does not establish cooling performance.
docs/clips/diode-thermal-landing-2x.mp4added⋯ 1 unchanged line ⋯
docs/clips/diode-thermal-landing-poster.jpgadded⋯ 1 unchanged line ⋯
docs/completion-plan.md+1−1@@ -8,7 +8,7 @@ Native-saved board 17 SHA-256 `653e54e711552eb2f16b6d01cd144fd82645a52c30ff11e39 ## Resume here -1. Inspect the live AdomLapper board and AIFlow run; current required step is thermal-vias. Preserve other threads and project rules. The shunt experiment is adopted and routing proof recorded. Declared pour regions now match board 17; nine proposed D1 vias are under isolated native DRC and electrical review.+1. Inspect the live AdomLapper board and AIFlow run; current required step is thermal-vias. Preserve other threads and project rules. The shunt experiment is adopted and routing proof recorded. Declared pour regions now match board 17; nine D1 vias are now landed, native-saved and adopted, with zero errors/opens. Read design/diode-thermal-live/rounding-review.json for the explicit nanometre coordinate differences. Rebuild downstream routing and Fields proofs against the new saved board. 2. Continue the compact 5 W prototype basis announced on 9 October. It follows the original size/cost priority and 5 V/1 A DUT. The prior 25 W assistant assumption is documented as a future option, not a blocker. Keep the 55 C trip and all validation requirements. 3. Solve the actual MOSFET case/interface/sink/fan assembly and probe clearance. The shunt-via candidate now passes only with the verified GND stitch at (133.018,77.818). Earlier candidates without that stitch disconnected ground; do not replay them. Via-count acknowledgements require actual engineering justification, not a desire to advance the timeline. 4. Complete and revalidate pours, outline, same-board current/thermal Fields screens, net tour, full fitted-model/silkscreen review, native 3D, finish and fabrication exports in the enforced sequence. Record significant real actions. Never mark these passed to bypass an unresolved gate.
docs/status.md+8@@ -1,3 +1,11 @@+# Current checkpoint - 2026-10-09, 18:19 UTC++The nine reviewed D1 thermal vias are now landed, native-saved and adopted by AIFlow. The actual saved board has zero native DRC errors and zero opens, with 15 existing library warnings. Six via coordinates differ from the offline generator by at most one nanometre per axis; this is explicitly audited, not called exact equality. Other track/via geometry matches, and filled-zone differences are below 0.000001 mm2. Both native 2D and 3D views were inspected. Formal Fields/current/thermal and finish gates remain incomplete.++A new recording shows the vias appearing around D1. It decoded and its contact sheet was reviewed; a 2x edit is in the build-clips page. The inventory now contains 58 raw takes, including rejected/static takes, not 58 finished clips.++The 40 mm heatsink's four-hole arrangement does not fit the existing layout: even its smaller hardware envelope intersects routed signals at all four proposed drills. No holes were added. Q1 already includes a 3.5 mm mounting hole at (127.46, 65.34); a package-mounted cooling assembly is being investigated, with interface, support, fan duct, electrical isolation and physical qualification unresolved.+ # Current checkpoint - 2026-10-09, 16:59 UTC Fan component 0.2.3 is published and installed with the gentle 20-second hero cycle, factory flying leads, explicit added Harwin harness, grid-aligned connector symbols, mating-header footprint and static complete STEP/GLB variants. Wiki Skill Pack 0.8.42 and Component Widgets 1.1.17 teach this authoring pattern. Native symbol/footprint and published animation/static checks passed; physical crimp and fit remain unverified. Three raw fan recordings were added, bringing the inventory to 57; the short take is not a complete state cycle.
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mechanical/cooling-40mm-search.jsonadded+433@@ -0,0 +1,433 @@+{+ "boardSha256": "653e54e711552eb2f16b6d01cd144fd82645a52c30ff11e39699b760402af51a",+ "mpn": "ATS-CPX040040020-115-C1-R0",+ "method": "0.5 mm XY grid, 1 mm nominal case-face margin, 2 mm probe radius, 3 mm hardware radius plus 0.25 mm body clearance",+ "survivingProbeClearCandidates": 942,+ "bestCandidates": [+ {+ "sinkXY": [+ 110.0,+ 37.5,+ 150.0,+ 77.5+ ],+ "holeCenters": [+ [+ 113.5,+ 41.0+ ],+ [+ 146.5,+ 41.0+ ],+ [+ 113.5,+ 74.0+ ],+ [+ 146.5,+ 74.0+ ]+ ],+ "minimumBodyClearanceMm": -1.5,+ "bodyConflicts": [+ {+ "hole": [+ 146.5,+ 41.0+ ],+ "ref": "U1",+ "clearanceMm": -1.5+ }+ ]+ },+ {+ "sinkXY": [+ 121.0,+ 54.5,+ 161.0,+ 94.5+ ],+ "holeCenters": [+ [+ 124.5,+ 58.0+ ],+ [+ 157.5,+ 58.0+ ],+ [+ 124.5,+ 91.0+ ],+ [+ 157.5,+ 91.0+ ]+ ],+ "minimumBodyClearanceMm": -1.505,+ "bodyConflicts": [+ {+ "hole": [+ 157.5,+ 58.0+ ],+ "ref": "J11",+ "clearanceMm": -1.505+ }+ ]+ },+ {+ "sinkXY": [+ 121.0,+ 55.0,+ 161.0,+ 95.0+ ],+ "holeCenters": [+ [+ 124.5,+ 58.5+ ],+ [+ 157.5,+ 58.5+ ],+ [+ 124.5,+ 91.5+ ],+ [+ 157.5,+ 91.5+ ]+ ],+ "minimumBodyClearanceMm": -1.55,+ "bodyConflicts": [+ {+ "hole": [+ 157.5,+ 58.5+ ],+ "ref": "J11",+ "clearanceMm": -1.55+ }+ ]+ },+ {+ "sinkXY": [+ 120.5,+ 54.5,+ 160.5,+ 94.5+ ],+ "holeCenters": [+ [+ 124.0,+ 58.0+ ],+ [+ 157.0,+ 58.0+ ],+ [+ 124.0,+ 91.0+ ],+ [+ 157.0,+ 91.0+ ]+ ],+ "minimumBodyClearanceMm": -1.982,+ "bodyConflicts": [+ {+ "hole": [+ 157.0,+ 58.0+ ],+ "ref": "J11",+ "clearanceMm": -1.982+ }+ ]+ },+ {+ "sinkXY": [+ 117.5,+ 49.0,+ 157.5,+ 89.0+ ],+ "holeCenters": [+ [+ 121.0,+ 52.5+ ],+ [+ 154.0,+ 52.5+ ],+ [+ 121.0,+ 85.5+ ],+ [+ 154.0,+ 85.5+ ]+ ],+ "minimumBodyClearanceMm": -1.25,+ "bodyConflicts": [+ {+ "hole": [+ 121.0,+ 85.5+ ],+ "ref": "Q2",+ "clearanceMm": -1.25+ },+ {+ "hole": [+ 121.0,+ 85.5+ ],+ "ref": "Q3",+ "clearanceMm": -0.5+ }+ ]+ },+ {+ "sinkXY": [+ 117.5,+ 49.5,+ 157.5,+ 89.5+ ],+ "holeCenters": [+ [+ 121.0,+ 53.0+ ],+ [+ 154.0,+ 53.0+ ],+ [+ 121.0,+ 86.0+ ],+ [+ 154.0,+ 86.0+ ]+ ],+ "minimumBodyClearanceMm": -1.25,+ "bodyConflicts": [+ {+ "hole": [+ 121.0,+ 86.0+ ],+ "ref": "Q2",+ "clearanceMm": -1.25+ },+ {+ "hole": [+ 121.0,+ 86.0+ ],+ "ref": "Q3",+ "clearanceMm": -0.0+ }+ ]+ },+ {+ "sinkXY": [+ 121.0,+ 54.0,+ 161.0,+ 94.0+ ],+ "holeCenters": [+ [+ 124.5,+ 57.5+ ],+ [+ 157.5,+ 57.5+ ],+ [+ 124.5,+ 90.5+ ],+ [+ 157.5,+ 90.5+ ]+ ],+ "minimumBodyClearanceMm": -1.312,+ "bodyConflicts": [+ {+ "hole": [+ 157.5,+ 57.5+ ],+ "ref": "J11",+ "clearanceMm": -1.312+ },+ {+ "hole": [+ 157.5,+ 90.5+ ],+ "ref": "C6",+ "clearanceMm": -0.125+ }+ ]+ },+ {+ "sinkXY": [+ 121.0,+ 55.5,+ 161.0,+ 95.5+ ],+ "holeCenters": [+ [+ 124.5,+ 59.0+ ],+ [+ 157.5,+ 59.0+ ],+ [+ 124.5,+ 92.0+ ],+ [+ 157.5,+ 92.0+ ]+ ],+ "minimumBodyClearanceMm": -1.55,+ "bodyConflicts": [+ {+ "hole": [+ 124.5,+ 59.0+ ],+ "ref": "R22",+ "clearanceMm": 0.096+ },+ {+ "hole": [+ 157.5,+ 59.0+ ],+ "ref": "J11",+ "clearanceMm": -1.55+ }+ ]+ },+ {+ "sinkXY": [+ 120.5,+ 54.0,+ 160.5,+ 94.0+ ],+ "holeCenters": [+ [+ 124.0,+ 57.5+ ],+ [+ 157.0,+ 57.5+ ],+ [+ 124.0,+ 90.5+ ],+ [+ 157.0,+ 90.5+ ]+ ],+ "minimumBodyClearanceMm": -1.715,+ "bodyConflicts": [+ {+ "hole": [+ 157.0,+ 57.5+ ],+ "ref": "J11",+ "clearanceMm": -1.715+ },+ {+ "hole": [+ 157.0,+ 90.5+ ],+ "ref": "C6",+ "clearanceMm": -0.097+ }+ ]+ },+ {+ "sinkXY": [+ 118.5,+ 50.0,+ 158.5,+ 90.0+ ],+ "holeCenters": [+ [+ 122.0,+ 53.5+ ],+ [+ 155.0,+ 53.5+ ],+ [+ 122.0,+ 86.5+ ],+ [+ 155.0,+ 86.5+ ]+ ],+ "minimumBodyClearanceMm": -2.25,+ "bodyConflicts": [+ {+ "hole": [+ 122.0,+ 86.5+ ],+ "ref": "Q2",+ "clearanceMm": -2.25+ },+ {+ "hole": [+ 155.0,+ 86.5+ ],+ "ref": "C6",+ "clearanceMm": -0.6+ }+ ]+ }+ ],+ "limitations": [+ "No PCB holes added",+ "Copper and drill clearance not yet checked",+ "Generic Q1 contact face, not exact manufacturer CAD",+ "Actual hardware and TIM unselected",+ "Mating plugs, airflow and physical qualification pending"+ ]+}
mechanical/cooling-drill-screen.jsonadded+263@@ -0,0 +1,263 @@+{+ "boardSha256": "653e54e711552eb2f16b6d01cd144fd82645a52c30ff11e39699b760402af51a",+ "sinkXY": [+ 116.5,+ 49.5,+ 156.5,+ 89.5+ ],+ "assumedHardwareDiameterMm": 5,+ "assumedDrillDiameterMm": 2.7,+ "assumedCopperClearanceMm": 0.25,+ "status": "rejected",+ "holes": [+ {+ "centerMm": [+ 120,+ 53+ ],+ "conflicts": [+ {+ "kind": "track",+ "label": "3V3",+ "clearanceMm": -0.275+ },+ {+ "kind": "track",+ "label": "ARM_CLK",+ "clearanceMm": 0.0099+ },+ {+ "kind": "track",+ "label": "I_HARD_LIMIT",+ "clearanceMm": -1.3336+ },+ {+ "kind": "track",+ "label": "I_HARD_LIMIT",+ "clearanceMm": -0.8918+ },+ {+ "kind": "track",+ "label": "I_HARD_LIMIT",+ "clearanceMm": -0.3348+ },+ {+ "kind": "track",+ "label": "CLAMP_BASE",+ "clearanceMm": -0.9+ },+ {+ "kind": "track",+ "label": "CLAMP_BASE",+ "clearanceMm": -0.8929+ },+ {+ "kind": "track",+ "label": "CLAMP_BASE",+ "clearanceMm": -0.2657+ },+ {+ "kind": "track",+ "label": "DUT_ADC",+ "clearanceMm": -0.4851+ },+ {+ "kind": "track",+ "label": "DUT_ADC",+ "clearanceMm": -0.3348+ },+ {+ "kind": "track",+ "label": "DUT_ADC",+ "clearanceMm": -0.4454+ },+ {+ "kind": "via",+ "label": "CLAMP_BASE",+ "clearanceMm": -0.9884+ },+ {+ "kind": "via",+ "label": "DUT_ADC",+ "clearanceMm": -0.6204+ }+ ]+ },+ {+ "centerMm": [+ 153,+ 53+ ],+ "conflicts": [+ {+ "kind": "track",+ "label": "3V3",+ "clearanceMm": -0.075+ },+ {+ "kind": "track",+ "label": "3V3",+ "clearanceMm": 0.0118+ },+ {+ "kind": "track",+ "label": "USB_VBUS",+ "clearanceMm": -0.019+ },+ {+ "kind": "track",+ "label": "USB_VBUS",+ "clearanceMm": -0.1408+ },+ {+ "kind": "track",+ "label": "USB_VBUS",+ "clearanceMm": -0.4143+ },+ {+ "kind": "track",+ "label": "FAN_TACH",+ "clearanceMm": -1.35+ },+ {+ "kind": "track",+ "label": "FAN_TACH",+ "clearanceMm": -0.8918+ },+ {+ "kind": "track",+ "label": "SWDIO",+ "clearanceMm": -0.4851+ },+ {+ "kind": "via",+ "label": "GND",+ "clearanceMm": 0.1694+ },+ {+ "kind": "via",+ "label": "FAN_TACH",+ "clearanceMm": 0.1195+ },+ {+ "kind": "via",+ "label": "FAN_TACH",+ "clearanceMm": -1.0665+ }+ ]+ },+ {+ "centerMm": [+ 120,+ 86+ ],+ "conflicts": [+ {+ "kind": "track",+ "label": "3V3",+ "clearanceMm": 0.0482+ },+ {+ "kind": "track",+ "label": "3V3",+ "clearanceMm": -0.0432+ },+ {+ "kind": "track",+ "label": "3V3",+ "clearanceMm": -0.0432+ },+ {+ "kind": "track",+ "label": "SHUNT_P_SENSE",+ "clearanceMm": -0.694+ },+ {+ "kind": "track",+ "label": "SHUNT_P_SENSE",+ "clearanceMm": -0.6972+ },+ {+ "kind": "track",+ "label": "SHUNT_P_SENSE",+ "clearanceMm": -0.1596+ },+ {+ "kind": "track",+ "label": "I_SET",+ "clearanceMm": 0.0871+ },+ {+ "kind": "track",+ "label": "I_SET",+ "clearanceMm": -0.475+ },+ {+ "kind": "track",+ "label": "I_SET",+ "clearanceMm": -0.47+ },+ {+ "kind": "track",+ "label": "GATE",+ "clearanceMm": -0.85+ },+ {+ "kind": "track",+ "label": "GATE",+ "clearanceMm": -0.1292+ },+ {+ "kind": "track",+ "label": "LOAD_POS",+ "clearanceMm": -1.35+ },+ {+ "kind": "via",+ "label": "3V3",+ "clearanceMm": -0.1268+ },+ {+ "kind": "via",+ "label": "I_SET",+ "clearanceMm": -0.0879+ }+ ]+ },+ {+ "centerMm": [+ 153,+ 86+ ],+ "conflicts": [+ {+ "kind": "track",+ "label": "5V_AUX",+ "clearanceMm": -0.4+ },+ {+ "kind": "track",+ "label": "V_GATE",+ "clearanceMm": -1.3+ },+ {+ "kind": "track",+ "label": "V_GATE",+ "clearanceMm": -1.0527+ },+ {+ "kind": "via",+ "label": "V_GATE",+ "clearanceMm": -1.2025+ }+ ]+ }+ ],+ "limitations": [+ "Candidate hardware not selected",+ "Pad circles are conservative",+ "Pours, copper graphics, slots and arcs not included; native DRC still required",+ "No board geometry changed; no thermal or mechanical qualification"+ ]+}
mechanical/q1-nominal-contact-faces.jsonadded+37@@ -0,0 +1,37 @@+{+ "boardRef": "Q1",+ "model": "KiCad generic TO-220-3 Horizontal TabUp, not exact manufacturer CAD",+ "faces": [+ {+ "areaMm2": 12.603250000000031,+ "zMm": 4.445000000000001,+ "boundsXY": [+ 122.335,+ 68.825,+ 132.585,+ 77.515+ ]+ },+ {+ "areaMm2": 53.49251890601886,+ "zMm": 3.1850000000000014,+ "boundsXY": [+ 122.345,+ 62.525,+ 132.575,+ 68.825+ ]+ },+ {+ "areaMm2": 129.96176890601888,+ "zMm": 4.455000000000001,+ "boundsXY": [+ 122.345,+ 62.525,+ 132.575,+ 76.3+ ]+ }+ ],+ "qualification": "Geometric candidates only; confirm exact metal tab face/dimensions from IXYS drawing"+}
tools/review_diode_rounding.pyadded+32@@ -0,0 +1,32 @@+"""Audit the exact six documented native nanometre rounding differences, not a general tolerance bypass."""+import json+import math+from pathlib import Path++root = Path(__file__).resolve().parents[1]+source = root / 'design/diode-thermal-live/saved-comparison.json'+report = json.loads(source.read_text())+assert not report['copperMultisetEqual']+assert len(report['missing']) == len(report['extra']) == 6+remaining = list(report['extra'])+pairs = []+for old, count in report['missing']:+ assert count == 1 and old[0:2] == ['via', 'LOAD_POS'] and old[3:] == [.6, .3]+ match = min(remaining, key=lambda row: math.dist(old[2], row[0][2]))+ new, new_count = match+ assert new_count == 1 and old[:2] == new[:2] and old[3:] == new[3:]+ delta = math.dist(old[2], new[2])+ assert delta <= 1.415e-6 # at most one native nanometre on each axis+ pairs.append({'candidateMm': old[2], 'savedMm': new[2], 'distanceNm': delta * 1e6})+ remaining.remove(match)+assert not remaining and report['zoneKeysEqual']+assert max(report['zoneSymmetricDifferenceMm2'].values()) < 1e-6+result = {+ 'status': 'documented-native-rounding-only',+ 'candidateSha256': report['candidateSha256'], 'savedSha256': report['savedSha256'],+ 'exactEquality': False, 'otherTrackViaMultisetDifferences': 0, 'pairs': pairs,+ 'zoneSymmetricDifferenceMm2': report['zoneSymmetricDifferenceMm2'],+ 'qualification': 'Geometric audit only. Actual saved-board native DRC required; no thermal or hardware qualification.',+}+(source.parent / 'rounding-review.json').write_text(json.dumps(result, indent=2) + '\n')+print(json.dumps(result, indent=2))
tools/screen_cooling_drills.pyadded+57@@ -0,0 +1,57 @@+"""Reject proposed mount drills against existing tracks/vias and conservative pad envelopes.++This read-only screen excludes pours (which require native refill) and is not DRC.+"""+import hashlib+import json+import math+from pathlib import Path++from shapely.geometry import LineString, Point+import sexp++root = Path(__file__).resolve().parents[1]+board = root / 'kicad/adom-custom-electronic-load.kicad_pcb'+tree = sexp.parse(board.read_text())+holes = [(120, 53), (153, 53), (120, 86), (153, 86)]+obstacles = []+for segment in sexp.find(tree, 'segment'):+ points = [tuple(map(float, sexp.first(segment, key)[1:3])) for key in ('start', 'end')]+ shape = LineString(points).buffer(float(sexp.first(segment, 'width')[1]) / 2)+ obstacles.append(('track', str(sexp.first(segment, 'net')[1]), shape))+for via in sexp.find(tree, 'via'):+ shape = Point(*map(float, sexp.first(via, 'at')[1:3])).buffer(float(sexp.first(via, 'size')[1]) / 2)+ obstacles.append(('via', str(sexp.first(via, 'net')[1]), shape))+for fp in sexp.find(tree, 'footprint'):+ ref = next(p[2] for p in sexp.find(fp, 'property') if p[1] == 'Reference')+ at = list(map(float, sexp.first(fp, 'at')[1:]))+ angle = math.radians(at[2] if len(at) > 2 else 0)+ for pad in sexp.find(fp, 'pad'):+ x, y = map(float, sexp.first(pad, 'at')[1:3])+ px = at[0] + x * math.cos(angle) + y * math.sin(angle)+ py = at[1] - x * math.sin(angle) + y * math.cos(angle)+ width, height = map(float, sexp.first(pad, 'size')[1:3])+ # Circumscribed circle deliberately over-rejects rectangular/oval pads.+ shape = Point(px, py).buffer(math.hypot(width, height) / 2)+ obstacles.append(('pad-envelope', f'{ref}.{pad[1]}', shape))+rows = []+for x, y in holes:+ conflicts = []+ for kind, label, shape in obstacles:+ clearance = Point(x, y).distance(shape) - 1.35+ if clearance < .25:+ conflicts.append({'kind': kind, 'label': label, 'clearanceMm': round(clearance, 4)})+ rows.append({'centerMm': [x, y], 'conflicts': conflicts})+report = {+ 'boardSha256': hashlib.sha256(board.read_bytes()).hexdigest(),+ 'sinkXY': [116.5, 49.5, 156.5, 89.5],+ 'assumedHardwareDiameterMm': 5, 'assumedDrillDiameterMm': 2.7,+ 'assumedCopperClearanceMm': .25,+ 'status': 'rejected' if any(r['conflicts'] for r in rows) else 'requires-native-review',+ 'holes': rows,+ 'limitations': ['Candidate hardware not selected', 'Pad circles are conservative',+ 'Pours, copper graphics, slots and arcs not included; native DRC still required',+ 'No board geometry changed; no thermal or mechanical qualification'],+}+(root / 'mechanical/cooling-drill-screen.json').write_text(json.dumps(report, indent=2) + '\n')+print(json.dumps(report, indent=2))
tools/search_cooling_envelope.pyadded+23@@ -0,0 +1,23 @@+"""Screen commercial 40 mm sink placement against nominal contact, bodies and probes."""+import json,math+from pathlib import Path+P=Path(__file__).resolve().parents[1];a=json.loads((P/'mechanical/cooling-body-audit.json').read_text());old=json.loads((P/'mechanical/cooling-mount-screen.json').read_text());bodies=[r for r in a['rows']if r.get('boundsMm') and r['boundsMm'][5]>=0];probes=old['probeChecks'];solutions=[]+def distance(pt,b):return math.hypot(max(b[0]-pt[0],0,pt[0]-b[2]),max(b[1]-pt[1],0,pt[1]-b[3]))+for i in range(47):+ x=98+i*.5+ for k in range(51):+ y=37+k*.5;box=[x,y,x+40,y+40]+ if not(x<=121.345 and x+40>=133.575 and y<=61.525 and y+40>=77.3):continue+ if y+40>102:continue+ conflicts=[r['ref']for r in probes if distance((r['x'],r['y']),box)<2]+ if conflicts:continue+ holes=[(x+3.5,y+3.5),(x+36.5,y+3.5),(x+3.5,y+36.5),(x+36.5,y+36.5)]+ collisions=[];minimum=1e9+ for pt in holes:+ for r in bodies:+ b=r['boundsMm'];d=distance(pt,[b[0],b[1],b[3],b[4]])-3+ minimum=min(minimum,d)+ if d<.25:collisions.append({'hole':pt,'ref':r['ref'],'clearanceMm':round(d,3)})+ solutions.append({'sinkXY':box,'holeCenters':holes,'minimumBodyClearanceMm':round(minimum,3),'bodyConflicts':collisions})+solutions.sort(key=lambda r:(len(r['bodyConflicts']),-r['minimumBodyClearanceMm']))+r={'boardSha256':a['boardSha256'],'mpn':'ATS-CPX040040020-115-C1-R0','method':'0.5 mm XY grid, 1 mm nominal case-face margin, 2 mm probe radius, 3 mm hardware radius plus 0.25 mm body clearance','survivingProbeClearCandidates':len(solutions),'bestCandidates':solutions[:10],'limitations':['No PCB holes added','Copper and drill clearance not yet checked','Generic Q1 contact face, not exact manufacturer CAD','Actual hardware and TIM unselected','Mating plugs, airflow and physical qualification pending']};(P/'mechanical/cooling-40mm-search.json').write_text(json.dumps(r,indent=2)+'\n');print(json.dumps({**r,'bestCandidates':solutions[:3]},indent=2))
videos/inventory.json+7−1@@ -1,5 +1,5 @@ {- "rawTakeCount": 57,+ "rawTakeCount": 58, "reviewedExcerptCount": 16, "countingRule": "Unique raw window recording filenames in this project; excludes derivative action/speed exports and reference projects. Raw count includes rejected takes.", "takes": [@@ -344,6 +344,12 @@ "durationSeconds": 20.533333, "topic": "Gentle fan state cycle and added Adom connector harness", "review": "published wiki viewer recording; editorial review pending"+ },+ {+ "file": "videos/diode-thermal/window-4654168-20261009-181525.mp4",+ "durationSeconds": 22.766667,+ "topic": "Nine D1 thermal vias landed through native KiCad IPC",+ "review": "Full decode and contact sheet reviewed: vias visibly added around D1; 2x excerpt prepared. Native recorder sample-timeline warning retained; encoded duration is not an engineering stopwatch." } ] }