Base Scaffold Control Panel

@@ -1,31 +1,166 @@ # Base Scaffold Control Panel -> **Status: DRAFT.** Owned by **Caleb**. Items marked `🔶 FILL-IN` need details before this page is considered complete. This page is a dependency of the [Base Scaffold System](https://wiki.adom.inc/adom/base-scaffold-system) main page.+> **Status: DRAFT.** Owned by **Caleb**. Specifications below are drawn from the two board+> designs that implement the panel. Items still marked `🔶 FILL-IN` are values not yet+> published. This page is a dependency of the+> [Base Scaffold System](https://wiki.adom.inc/adom/base-scaffold-system) main page.  The control panel is the electrical front door of the Base Scaffold System: it carries the scaffold's power and signal interface and provides the connector/disconnect that mates the scaffold to a workcell each time it docks. +It is a **two-board pair** that mate at a blade dock — one half stays with the workcell, the other rides on the base scaffold with the customer's project.++## The Pair++| Half | Role |+|---|---|+| **Workcell side** (system) | Power-distribution hub and workcell controller. Bench supplies land here, every rail is metered, and power + debug are delivered across the dock. |+| **Scaffold side** (user) | Power and I/O dock board. Lands the supply rails, USB and user I/O on the scaffold's machine-contact field, where the project is built. |++### Workcell side++![Control panel — workcell side](docs/workcell-render.png)++### Scaffold side++![Control panel — scaffold side](docs/scaffold-render.png)++### Mated — how the pair comes together++The two halves mate coplanar at the blade dock, with the project's molecules, jumpers and wires dropping into place:++![Mated control panel assembly](docs/mated-assembly.gif)+ ## Specifications -🔶 **FILL-IN (Caleb):**+### Input power++Four independent bench-supply inputs land on the workcell side at a WAGO terminal block+(dual contacts per pole). **Every rail is individually metered at 20-bit precision+(±0.05 %)**, so consumption is visible live throughout a project's life.++| Rail | Rating | Notes |+|---|---|---|+| **PS1** | 0–60 V / 12 A | User-variable — behaves like a bench supply the customer can set |+| **PS2** | 5 V / 10 A | **Switchable** — can be commanded on/off without touching the bench supply |+| **PS3** | spare | Passed straight through to the scaffold |+| **PS4** | 5 V | Powers the panel itself, behind a 6.3 A fuse. Not a project rail. |++PS1–PS3 cross the dock to the scaffold on power blades. Each rail's return arrives at the+scaffold **isolated**, and a switched rail's isolated return may float up to **±2.5 V**+from common ground.++**Ground scheme.** Large machine-pin jumper fields bond a **single return-to-ground per+rail** (default: bridged), so each rail's grounding is an explicit, per-project choice+rather than a fixed assumption.++🔶 **FILL-IN (Caleb):** aggregate power budget for the panel as a whole — the board designs+specify per-rail ratings only, not a combined ceiling or simultaneous-load derating.++### I/O available to the project++Everything the project touches lands on the scaffold side, at a **65-contact machine field+(62 medium + 3 large)** — the same contact system used across the base scaffold, so project+wires and panel wires terminate identically.++| Resource | Provision |+|---|---|+| **Supply rails** | PS1 (sense-tapped), PS2 and PS3, each on its own group of contacts |+| **User MCU I/O** | **26 user I/O lines** from a user-programmable MCU module hosted on the board |+| **USB** | USB-C 2.0 **dual-role**, PD 3.0 A |+| **Grounds / spares** | Rail returns, grounds and spare contacts alongside the above |++**USB behavior.** In **host** role the board sources VBUS from the switched 5 V rail through+a protected path; in **device** role (for example, plugged into a PC) VBUS sourcing is off+and back-feed into the supply is blocked. VBUS can be brought out to the machine contacts+for the project when wanted.++### Debug and control across the dock -- Input power: voltage(s), max current, total power budget.-- Signal/comms interface: protocol(s), channel count, data rates.-- I/O available to the project on the scaffold side.-- Physical: dimensions, mass, mounting location on the scaffold.-- Protection: fusing/breakers, overcurrent/overvoltage behavior, ingress rating if any.-- Environmental/operating range.+The dock also carries the facilities needed to program and control the project's MCU+without opening anything up: **SWD and UART debug**, plus **boot-strap and reset control**+of the user MCU, and low-voltage service rails. A **companion dashboard application**+provides live control and telemetry — meter all four rails, set PS1 like a bench supply,+switch rails, drive the scaffold I/O, and program the user MCU.++> **Note for integrators:** the user MCU's boot and reset lines are **active-low** — both+> must be released (driven high) for the MCU to run the program in its flash.++### Workcell-side infrastructure++The workcell half also carries the cell's own connectivity and sensing. These serve the+workcell, not the project directly:++Gigabit Ethernet · Wi-Fi and Bluetooth module slot · CAN FD on daisy-chainable contacts ·+USB-C and USB-A (both protected) · environmental and motion sensing · an indicator LED ring+used for camera-feed verification.++### Physical++| Item | Value |+|---|---|+| Workcell board | **172 × 72 mm**, 6-layer |+| Scaffold board | **160 × 45 mm** |+| Scaffold mounting | 6 × M3 (3.2 mm) |++🔶 **FILL-IN (Caleb + James/Luke):** mass of each half, and the mounting location and+orientation of the panel on the base scaffold frame.++### Protection++- **Panel supply** behind a 6.3 A fuse.+- **Switched rail** delivered through a 10 A load switch, galvanically isolated from the controller that commands it.+- **USB VBUS** behind an eFuse providing current limiting and **back-feed blocking** into the supply rail.+- **USB data lines** ESD-protected.++🔶 **FILL-IN (Caleb):** published overcurrent/overvoltage trip and recovery thresholds per+rail, and any ingress rating. (Design targets for the USB eFuse exist in the Control Panel+Test Procedure, but those are test-acceptance values rather than published panel specs —+promote them here once confirmed.)++### Environmental++🔶 **FILL-IN (Caleb):** operating temperature and humidity range. Note the panel carries+environmental sensing, so the stated envelope should be reconciled with that sensor's range.  ## Connector / Disconnect -🔶 **FILL-IN (Caleb):**+The scaffold mates to the workcell through a **Samtec ET60 blade dock** — the connector that+makes and breaks on every docking cycle.++| Side | Part |+|---|---|+| **Workcell (system)** | Samtec **ET60S-S03** |+| **Scaffold (user)** | Samtec **ET60T-S03** |++**Contact set** — three power blades plus a signal field:++| Blade | Rail |+|---|---|+| P1 | PS1 — 0–60 V / 12 A |+| P2 | PS2 — 5 V / 10 A, switchable |+| P3 | PS3 — spare | -- Connector family and part numbers (scaffold side and workcell side), pinout.-- Rated mating cycles and blind-mate/misalignment tolerance (this connector mates on every workcell docking, so cycle life matters).-- Connect/disconnect sequence: is it hot-pluggable, or sequenced (e.g. ground-first pins, power-off before extraction)?-- Safety: lockout/tagout, interlock with the workcell, E-stop behavior across the connector.-- How disconnect interacts with the mechanical slide — can the scaffold physically leave a workcell while still connected?+Each blade carries **five contacts per polarity, with separate returns**. The signal field+carries debug, MCU boot/reset control, spare control lines and low-voltage service rails.++> ⚠️ **To reconcile:** the scaffold design describes the dock as *3 power blades + 60 signal+> pins*, while the workcell design's summary says *3 blades + 25 signals*. These are most+> likely **60 physical positions vs. 25 currently assigned** — the two should be made to+> agree before this page is final. 🔶 **FILL-IN (Caleb).**++🔶 **FILL-IN (Caleb)** — not yet published, and important because this connector mates on+every docking cycle:++- **Rated mating cycles** and blind-mate / misalignment tolerance.+- **Connect/disconnect sequencing** — whether the dock is hot-pluggable or must be sequenced. The panel already has the means for a safe sequence, since PS2 is switchable and can be de-energized before extraction; confirm what is required of PS1/PS3, and whether the blade geometry provides first-make/last-break ordering.+- **Safety** — lockout/tagout, interlock with the workcell, and E-stop behavior across the connector.+- **Mechanical interaction** — whether a scaffold can physically slide out of a workcell while still electrically connected, and what prevents it if not.  ## Relationship to the Rest of the System +- The **electrical boundary** sits at the dock: everything upstream — bench inputs, metering, the workcell controller and the cell's own connectivity — is the workcell half. Everything the project touches — rails at the machine contacts, user I/O, USB and ground bonding — is the scaffold half. - Wiring from the panels to the control panel is bent automatically; gauges and termination are documented in the [Base Scaffold System — Wiring](https://wiki.adom.inc/adom/base-scaffold-system) section (James/Luke).-- 🔶 **FILL-IN (Caleb + James/Luke):** where the electrical boundary sits — which specs live on this page vs the Panels section of the main page.+- The project's connections land on the **65-contact machine field**, terminating exactly like every other contact on the scaffold.++🔶 **FILL-IN (Caleb + James/Luke):** confirm which specs are authoritative here versus the+Panels section of the main page — contact ratings in particular appear in both places.