.gitea/workflows/ota-release.yml

@@ -1,162 +0,0 @@
-# .gitea/workflows/ota-release.yml
-# Gitea Actions — ESP32 OTA firmware build & release (bd-9kod)
-#
-# Triggers on signed release tags:
-#   esp32-balance/vX.Y.Z  →  builds esp32s3/balance/   (ESP32-S3 Balance board)
-#   esp32-io/vX.Y.Z       →  builds esp32s3-io/         (ESP32-S3 IO board)
-#
-# Uses the official espressif/idf Docker image for reproducible builds.
-# Attaches <app>_<version>.bin + <app>_<version>.sha256 to the Gitea release.
-# The ESP32 Balance OTA system fetches the .bin from the release asset URL.
-
-name: OTA release — build & attach firmware
-
-on:
-  push:
-    tags:
-      - "esp32-balance/v*"
-      - "esp32-io/v*"
-
-permissions:
-  contents: write
-
-jobs:
-  build-and-release:
-    name: Build ${{ github.ref_name }}
-    runs-on: ubuntu-latest
-    container:
-      image: espressif/idf:v5.2.2
-      options: --user root
-
-    steps:
-      # ── 1. Checkout ───────────────────────────────────────────────────────────
-      - name: Checkout
-        uses: actions/checkout@v4
-
-      # ── 2. Resolve build target from tag ─────────────────────────────────────
-      # Tag format:  esp32-balance/v1.2.3  or  esp32-io/v1.2.3
-      - name: Resolve project from tag
-        id: proj
-        shell: bash
-        run: |
-          TAG="${GITHUB_REF_NAME}"
-          case "$TAG" in
-            esp32-balance/*)
-              DIR="esp32s3/balance"
-              APP="esp32s3_balance"
-              ;;
-            esp32-io/*)
-              DIR="esp32s3-io"
-              APP="esp32s3_io"
-              ;;
-            *)
-              echo "::error::Unrecognised tag prefix: ${TAG}"
-              exit 1
-              ;;
-          esac
-          VERSION="${TAG#*/}"
-          echo "dir=${DIR}"         >> "$GITHUB_OUTPUT"
-          echo "app=${APP}"         >> "$GITHUB_OUTPUT"
-          echo "version=${VERSION}" >> "$GITHUB_OUTPUT"
-          echo "tag=${TAG}"         >> "$GITHUB_OUTPUT"
-          echo "Build: ${APP} ${VERSION} from ${DIR}"
-
-      # ── 3. Build with ESP-IDF ─────────────────────────────────────────────────
-      - name: Build firmware (idf.py build)
-        shell: bash
-        run: |
-          . "${IDF_PATH}/export.sh"
-          cd "${{ steps.proj.outputs.dir }}"
-          idf.py build
-
-      # ── 4. Collect binary & generate checksum ────────────────────────────────
-      - name: Collect artifacts
-        id: art
-        shell: bash
-        run: |
-          APP="${{ steps.proj.outputs.app }}"
-          VER="${{ steps.proj.outputs.version }}"
-          BIN_SRC="${{ steps.proj.outputs.dir }}/build/${APP}.bin"
-          BIN_OUT="${APP}_${VER}.bin"
-          SHA_OUT="${APP}_${VER}.sha256"
-
-          cp "$BIN_SRC" "$BIN_OUT"
-          sha256sum "$BIN_OUT" > "$SHA_OUT"
-
-          echo "bin=${BIN_OUT}" >> "$GITHUB_OUTPUT"
-          echo "sha=${SHA_OUT}" >> "$GITHUB_OUTPUT"
-
-          echo "Binary:   ${BIN_OUT} ($(wc -c < "$BIN_OUT") bytes)"
-          echo "Checksum: $(cat "$SHA_OUT")"
-
-      # ── 5. Archive artifacts in CI workspace ─────────────────────────────────
-      - name: Upload build artifacts
-        uses: actions/upload-artifact@v4
-        with:
-          name: firmware-${{ steps.proj.outputs.app }}-${{ steps.proj.outputs.version }}
-          path: |
-            ${{ steps.art.outputs.bin }}
-            ${{ steps.art.outputs.sha }}
-
-      # ── 6. Create Gitea release (if needed) & upload assets ──────────────────
-      # Uses GITHUB_TOKEN (auto-provided, contents:write from permissions block).
-      # URL-encodes the tag to handle the slash in esp32-balance/vX.Y.Z.
-      - name: Publish assets to Gitea release
-        shell: bash
-        env:
-          GITEA_URL: https://gitea.vayrette.com
-          TOKEN: ${{ secrets.GITHUB_TOKEN }}
-          REPO: ${{ github.repository }}
-          TAG: ${{ steps.proj.outputs.tag }}
-          BIN: ${{ steps.art.outputs.bin }}
-          SHA: ${{ steps.art.outputs.sha }}
-        run: |
-          API="${GITEA_URL}/api/v1/repos/${REPO}"
-
-          # URL-encode the tag (slash in esp32-balance/vX.Y.Z must be escaped)
-          TAG_ENC=$(python3 -c "
-          import urllib.parse, sys
-          print(urllib.parse.quote(sys.argv[1], safe=''))
-          " "$TAG")
-
-          # Try to fetch an existing release for this tag
-          RELEASE=$(curl -sf \
-            -H "Authorization: token ${TOKEN}" \
-            "${API}/releases/tags/${TAG_ENC}") || true
-
-          # If no release yet, create it
-          if [ -z "$RELEASE" ]; then
-            echo "Creating release for tag: ${TAG}"
-            RELEASE=$(curl -sf \
-              -X POST \
-              -H "Authorization: token ${TOKEN}" \
-              -H "Content-Type: application/json" \
-              -d "$(python3 -c "
-          import json, sys
-          print(json.dumps({
-              'tag_name': sys.argv[1],
-              'name':     sys.argv[1],
-              'draft':    False,
-              'prerelease': False,
-          }))
-          " "$TAG")" \
-              "${API}/releases")
-          fi
-
-          RELEASE_ID=$(echo "$RELEASE" | python3 -c "
-          import sys, json; print(json.load(sys.stdin)['id'])
-          ")
-          echo "Release ID: ${RELEASE_ID}"
-
-          # Upload binary and checksum
-          for FILE in "$BIN" "$SHA"; do
-            FNAME=$(basename "$FILE")
-            echo "Uploading: ${FNAME}"
-            curl -sf \
-              -X POST \
-              -H "Authorization: token ${TOKEN}" \
-              -F "attachment=@${FILE}" \
-              "${API}/releases/${RELEASE_ID}/assets?name=${FNAME}"
-          done
-
-          echo "Published: ${BIN} + ${SHA} → release ${TAG}"

.pio/build/project.checksum

@@ -1 +1 @@
-ffc01fb580c81760bdda9a672fe1212be4578e3e
+8700a44a6597bcade0f371945c539630ba0e78b1

AUTONOMOUS_ARMING.md

@@ -7,11 +7,7 @@ The robot can now be armed and operated autonomously from the Jetson without req
 
 ### Jetson Autonomous Arming
 - Command: `A\n` (single byte 'A' followed by newline)
-<<<<<<< HEAD
+- Sent via USB CDC to the STM32 firmware
-- Sent via USB CDC to the ESP32 BALANCE firmware
-=======
-- Sent via USB Serial (CH343) to the ESP32-S3 firmware
->>>>>>> 291dd68 (feat: remove all STM32/Mamba/BlackPill references — ESP32-S3 only)
 - Robot arms after ARMING_HOLD_MS (~500ms) safety hold period
 - Works even when RC is not connected or not armed
 
@@ -46,11 +42,7 @@ The robot can now be armed and operated autonomously from the Jetson without req
 
 ## Command Protocol
 
-<<<<<<< HEAD
+### From Jetson to STM32 (USB CDC)
-### From Jetson to ESP32 BALANCE (USB CDC)
-=======
-### From Jetson to ESP32-S3 (USB Serial (CH343))
->>>>>>> 291dd68 (feat: remove all STM32/Mamba/BlackPill references — ESP32-S3 only)
 ```
 A           — Request arm (triggers safety hold, then motors enable)
 D           — Request disarm (immediate motor stop)
@@ -60,11 +52,7 @@ H           — Heartbeat (refresh timeout timer, every 500ms)
 C<spd>,<str> — Drive command: speed, steer (also refreshes heartbeat)
 ```
 
-<<<<<<< HEAD
+### From STM32 to Jetson (USB CDC)
-### From ESP32 BALANCE to Jetson (USB CDC)
-=======
-### From ESP32-S3 to Jetson (USB Serial (CH343))
->>>>>>> 291dd68 (feat: remove all STM32/Mamba/BlackPill references — ESP32-S3 only)
 Motor commands are gated by `bal.state == BALANCE_ARMED`:
 - When ARMED: Motor commands sent every 20ms (50 Hz)
 - When DISARMED: Zero sent every 20ms (prevents ESC timeout)

CLAUDE.md

@@ -1,36 +1,17 @@
 # SaltyLab Firmware — Agent Playbook
 
 ## Project
-<<<<<<< HEAD
+Self-balancing two-wheeled robot: STM32F722 flight controller, hoverboard hub motors, Jetson Nano for AI/SLAM.
-**SAUL-TEE** — 4-wheel wagon (870×510×550 mm, 23 kg).
-Two ESP32-S3 boards + Jetson Orin via CAN. Full spec: `docs/SAUL-TEE-SYSTEM-REFERENCE.md`
-
-| Board | Role |
-|-------|------|
-| **ESP32-S3 BALANCE** | QMI8658 IMU, PID balance, CAN→VESC (L:68 / R:56), GC9A01 LCD (Waveshare Touch LCD 1.28) |
-| **ESP32-S3 IO** | TBS Crossfire RC, ELRS failover, BTS7960 motors, NFC/baro/ToF, WS2812 |
-| **Jetson Orin** | AI/SLAM, CANable2 USB→CAN, cmds 0x300–0x303, telemetry 0x400–0x401 |
-
-> **Legacy:** `src/` and `include/` = archived STM32 HAL — do not extend. New firmware in `esp32/`.
-=======
-Self-balancing two-wheeled robot: ESP32-S3 ESP32-S3 BALANCE, hoverboard hub motors, Jetson Orin Nano Super for AI/SLAM.
->>>>>>> 291dd68 (feat: remove all STM32/Mamba/BlackPill references — ESP32-S3 only)
 
 ## Team
 | Agent | Role | Focus |
 |-------|------|-------|
-<<<<<<< HEAD
+| **sl-firmware** | Embedded Firmware Lead | STM32 HAL, USB CDC debugging, SPI/UART, PlatformIO, DFU bootloader |
-| **sl-firmware** | Embedded Firmware Lead | ESP32-S3, ESP-IDF, QMI8658, CAN/UART protocol, BTS7960 |
-| **sl-controls** | Control Systems Engineer | PID tuning, IMU fusion, balance loop, safety |
-| **sl-perception** | Perception / SLAM Engineer | Jetson Orin, RealSense D435i, RPLIDAR, ROS2, Nav2 |
-=======
-| **sl-firmware** | Embedded Firmware Lead | ESP-IDF, USB Serial (CH343) debugging, SPI/UART, PlatformIO, DFU bootloader |
 | **sl-controls** | Control Systems Engineer | PID tuning, IMU sensor fusion, real-time control loops, safety systems |
-| **sl-perception** | Perception / SLAM Engineer | Jetson Orin Nano Super, RealSense D435i, RPLIDAR, ROS2, Nav2 |
+| **sl-perception** | Perception / SLAM Engineer | Jetson Nano, RealSense D435i, RPLIDAR, ROS2, Nav2 |
->>>>>>> 291dd68 (feat: remove all STM32/Mamba/BlackPill references — ESP32-S3 only)
 
 ## Status
-USB Serial (CH343) TX bug resolved (PR #10 — DCache MPU non-cacheable region + IWDG ordering fix).
+USB CDC TX bug resolved (PR #10 — DCache MPU non-cacheable region + IWDG ordering fix).
 
 ## Repo Structure
 - `projects/saltybot/SALTYLAB.md` — Design doc
@@ -48,11 +29,11 @@ USB Serial (CH343) TX bug resolved (PR #10 — DCache MPU non-cacheable region +
 | `saltyrover-dev` | Integration — rover variant |
 | `saltytank` | Stable — tracked tank variant |
 | `saltytank-dev` | Integration — tank variant |
-| `main` | Shared code only (IMU drivers, USB Serial (CH343), balance core, safety) |
+| `main` | Shared code only (IMU drivers, USB CDC, balance core, safety) |
 
 ### Rules
 - Agents branch FROM `<variant>-dev` and PR back TO `<variant>-dev`
-- Shared/infrastructure code (IMU drivers, USB Serial (CH343), balance core, safety) goes in `main`
+- Shared/infrastructure code (IMU drivers, USB CDC, balance core, safety) goes in `main`
 - Variant-specific code (motor topology, kinematics, config) goes in variant branches
 - Stable branches get promoted from `-dev` after review and hardware testing
 - **Current SaltyLab team** works against `saltylab-dev`

TEAM.md

@@ -1,22 +1,12 @@
 # SaltyLab — Ideal Team
 
 ## Project
-<<<<<<< HEAD
+Self-balancing two-wheeled robot using a drone flight controller (STM32F722), hoverboard hub motors, and eventually a Jetson Nano for AI/SLAM.
-**SAUL-TEE** — 4-wheel wagon (870×510×550 mm, 23 kg).
-Two ESP32-S3 boards (BALANCE + IO) + Jetson Orin. See `docs/SAUL-TEE-SYSTEM-REFERENCE.md`.
-
-## Current Status
-- **Hardware:** ESP32-S3 BALANCE (Waveshare Touch LCD 1.28, CH343 USB) + ESP32-S3 IO (bare devkit, JTAG USB)
-- **Firmware:** ESP-IDF/PlatformIO target; legacy `src/` STM32 HAL archived
-- **Comms:** UART 460800 baud inter-board; CANable2 USB→CAN for Orin; CAN 500 kbps to VESCs (L:68 / R:56)
-=======
-Self-balancing two-wheeled robot using a drone ESP32-S3 BALANCE (ESP32-S3), hoverboard hub motors, and eventually a Jetson Orin Nano Super for AI/SLAM.
 
 ## Current Status
 - **Hardware:** Assembled — FC, motors, ESC, IMU, battery, RC all on hand
-- **Firmware:** Balance PID + hoverboard ESC protocol written, but blocked by USB Serial (CH343) bug
+- **Firmware:** Balance PID + hoverboard ESC protocol written, but blocked by USB CDC bug
-- **Blocker:** USB Serial (CH343) TX stops working when peripheral inits (SPI/UART/GPIO) are added alongside USB on ESP32-S3 — see `legacy/stm32/USB_CDC_BUG.md` for historical context
+- **Blocker:** USB CDC TX stops working when peripheral inits (SPI/UART/GPIO) are added alongside USB OTG FS — see `USB_CDC_BUG.md`
->>>>>>> 291dd68 (feat: remove all STM32/Mamba/BlackPill references — ESP32-S3 only)
 
 ---
 
@@ -24,30 +14,18 @@ Self-balancing two-wheeled robot using a drone ESP32-S3 BALANCE (ESP32-S3), hove
 
 ### 1. Embedded Firmware Engineer (Lead)
 **Must-have:**
-<<<<<<< HEAD
+- Deep STM32 HAL experience (F7 series specifically)
-- Deep ESP32 (Arduino/ESP-IDF) or STM32 HAL experience
 - USB OTG FS / CDC ACM debugging (TxState, endpoint management, DMA conflicts)
-- SPI + UART + USB coexistence on ESP32
+- SPI + UART + USB coexistence on STM32
-- PlatformIO or bare-metal ESP32 toolchain
+- PlatformIO or bare-metal STM32 toolchain
 - DFU bootloader implementation
-=======
-- Deep ESP-IDF experience (ESP32-S3 specifically)
-- USB Serial (CH343) / UART debugging on ESP32-S3
-- SPI + UART + USB coexistence on ESP32-S3
-- ESP-IDF / Arduino-ESP32 toolchain
-- OTA firmware update implementation
->>>>>>> 291dd68 (feat: remove all STM32/Mamba/BlackPill references — ESP32-S3 only)
 
 **Nice-to-have:**
-- ESP32-S3 peripheral coexistence (SPI + UART + USB)
+- Betaflight/iNav/ArduPilot codebase familiarity
 - PID control loop tuning for balance robots
 - FOC motor control (hoverboard ESC protocol)
 
-<<<<<<< HEAD
+**Why:** The immediate blocker is a USB peripheral conflict. Need someone who's debugged STM32 USB issues before — this is not a software logic bug, it's a hardware peripheral interaction issue.
-**Why:** The immediate blocker is a USB peripheral conflict. Need someone who's debugged STM32 USB issues before — ESP32 firmware for the balance loop and I/O needs to be written from scratch.
-=======
-**Why:** The immediate blocker is a USB peripheral conflict on ESP32-S3. Need someone who's debugged ESP32-S3 USB Serial (CH343) issues before — this is not a software logic bug, it's a hardware peripheral interaction issue.
->>>>>>> 291dd68 (feat: remove all STM32/Mamba/BlackPill references — ESP32-S3 only)
 
 ### 2. Control Systems / Robotics Engineer
 **Must-have:**
@@ -65,7 +43,7 @@ Self-balancing two-wheeled robot using a drone ESP32-S3 BALANCE (ESP32-S3), hove
 
 ### 3. Perception / SLAM Engineer (Phase 2)
 **Must-have:**
-- Jetson Orin Nano Super / NVIDIA Jetson platform
+- Jetson Nano / NVIDIA Jetson platform
 - Intel RealSense D435i depth camera
 - RPLIDAR integration
 - SLAM (ORB-SLAM3, RTAB-Map, or similar)
@@ -76,23 +54,19 @@ Self-balancing two-wheeled robot using a drone ESP32-S3 BALANCE (ESP32-S3), hove
 - Obstacle avoidance
 - Nav2 stack
 
-**Why:** Phase 2 goal is autonomous navigation. Jetson Orin Nano Super with RealSense + RPLIDAR for indoor mapping and person following.
+**Why:** Phase 2 goal is autonomous navigation. Jetson Nano with RealSense + RPLIDAR for indoor mapping and person following.
 
 ---
 
 ## Hardware Reference
 | Component | Details |
 |-----------|---------|
-<<<<<<< HEAD
+| FC | MAMBA F722S (STM32F722RET6, MPU6000) |
-| FC | ESP32 BALANCE (ESP32RET6, MPU6000) |
-=======
-| FC | ESP32-S3 BALANCE (ESP32-S3RET6, QMI8658) |
->>>>>>> 291dd68 (feat: remove all STM32/Mamba/BlackPill references — ESP32-S3 only)
 | Motors | 2x 8" pneumatic hoverboard hub motors |
 | ESC | Hoverboard ESC (EFeru FOC firmware) |
 | Battery | 36V pack |
 | RC | BetaFPV ELRS 2.4GHz TX + RX |
-| AI Brain | Jetson Orin Nano Super + Noctua fan |
+| AI Brain | Jetson Nano + Noctua fan |
 | Depth | Intel RealSense D435i |
 | LIDAR | RPLIDAR A1M8 |
 | Spare IMUs | BNO055, MPU6050 |
@@ -100,4 +74,4 @@ Self-balancing two-wheeled robot using a drone ESP32-S3 BALANCE (ESP32-S3), hove
 ## Repo
 - Gitea: https://gitea.vayrette.com/seb/saltylab-firmware
 - Design doc: `projects/saltybot/SALTYLAB.md`
-- Bug doc: `legacy/stm32/USB_CDC_BUG.md` (archived — STM32 era)
+- Bug doc: `USB_CDC_BUG.md`

USB_CDC_BUG.md

@@ -0,0 +1,44 @@
+# USB CDC TX Bug — 2026-02-28
+
+## Problem
+Balance firmware produces no USB CDC output. Minimal "hello" test firmware works fine.
+
+## What Works
+- **Test firmware** (just sends `{"hello":N}` at 10Hz after 3s delay): **DATA FLOWS**
+- USB enumeration works in both cases (port appears as `/dev/cu.usbmodemSALTY0011`)
+- DFU reboot via RTC backup register works (Betaflight-proven pattern)
+
+## What Doesn't Work
+- **Balance firmware**: port opens, no data ever arrives
+- Tried: removing init transmit, 3s boot delay, TxState recovery, DTR detection, streaming flags
+- None of it helps
+
+## Key Difference Between Working & Broken
+- **Working test**: main.c only includes USB CDC headers, HAL, string, stdio
+- **Balance firmware**: includes icm42688.h, bmp280.h, balance.h, hoverboard.h, config.h, status.h
+- Balance firmware inits SPI1 (IMU), USART2 (hoverboard), GPIO (LEDs, buzzer)
+- Likely culprit: **peripheral init (SPI/UART/GPIO) is interfering with USB OTG FS**
+
+## Suspected Root Cause
+One of the additional peripheral inits (SPI1 for IMU, USART2 for hoverboard ESC, or GPIO for status LEDs) is likely conflicting with the USB OTG FS peripheral — either a clock conflict, GPIO pin conflict, or interrupt priority issue.
+
+## Hardware
+- MAMBA F722S FC (STM32F722RET6)
+- Betaflight target: DIAT-MAMBAF722_2022B
+- IMU: MPU6000 on SPI1 (PA4/PA5/PA6/PA7)
+- USB: OTG FS (PA11/PA12)
+- Hoverboard ESC: USART2 (PA2/PA3)
+- LEDs: PC14, PC15
+- Buzzer: PB2
+
+## Files
+- PlatformIO project: `~/Projects/saltylab-firmware/` on mbpm4 (192.168.87.40)
+- Working test: was in src/main.c (replaced with balance code)
+- Balance main.c backup: src/main.c.bak
+- CDC implementation: lib/USB_CDC/src/usbd_cdc_if.c
+
+## To Debug
+1. Add peripherals one at a time to the test firmware to find which one breaks CDC TX
+2. Check for GPIO pin conflicts with USB OTG FS (PA11/PA12)
+3. Check interrupt priorities — USB OTG FS IRQ might be getting starved
+4. Check if DCache (disabled via SCB_DisableDCache) is needed for USB DMA

android/build.gradle

@@ -1,46 +0,0 @@
-plugins {
-    id 'com.android.application'
-    id 'kotlin-android'
-}
-
-android {
-    compileSdk 34
-    namespace 'com.saltylab.uwbtag'
-
-    defaultConfig {
-        applicationId "com.saltylab.uwbtag"
-        minSdk 26
-        targetSdk 34
-        versionCode 1
-        versionName "1.0"
-    }
-
-    buildTypes {
-        release {
-            minifyEnabled false
-        }
-    }
-
-    buildFeatures {
-        viewBinding true
-    }
-
-    compileOptions {
-        sourceCompatibility JavaVersion.VERSION_17
-        targetCompatibility JavaVersion.VERSION_17
-    }
-
-    kotlinOptions {
-        jvmTarget = '17'
-    }
-}
-
-dependencies {
-    implementation 'androidx.core:core-ktx:1.12.0'
-    implementation 'androidx.appcompat:appcompat:1.6.1'
-    implementation 'com.google.android.material:material:1.11.0'
-    implementation 'androidx.recyclerview:recyclerview:1.3.2'
-    implementation 'androidx.lifecycle:lifecycle-runtime-ktx:2.7.0'
-    implementation 'org.jetbrains.kotlinx:kotlinx-coroutines-android:1.7.3'
-    implementation 'com.google.code.gson:gson:2.10.1'
-}

android/src/main/AndroidManifest.xml

@@ -1,37 +0,0 @@
-<?xml version="1.0" encoding="utf-8"?>
-<manifest xmlns:android="http://schemas.android.com/apk/res/android">
-
-    <!-- BLE permissions (API 31+) -->
-    <uses-permission android:name="android.permission.BLUETOOTH_SCAN"
-        android:usesPermissionFlags="neverForLocation" />
-    <uses-permission android:name="android.permission.BLUETOOTH_CONNECT" />
-    <uses-permission android:name="android.permission.BLUETOOTH_ADVERTISE" />
-
-    <!-- Legacy BLE (API < 31) -->
-    <uses-permission android:name="android.permission.BLUETOOTH"
-        android:maxSdkVersion="30" />
-    <uses-permission android:name="android.permission.BLUETOOTH_ADMIN"
-        android:maxSdkVersion="30" />
-    <uses-permission android:name="android.permission.ACCESS_FINE_LOCATION"
-        android:maxSdkVersion="30" />
-
-    <uses-feature android:name="android.hardware.bluetooth_le" android:required="true" />
-
-    <application
-        android:allowBackup="true"
-        android:label="UWB Tag Config"
-        android:theme="@style/Theme.MaterialComponents.DayNight.DarkActionBar">
-
-        <activity
-            android:name=".UwbTagBleActivity"
-            android:exported="true"
-            android:launchMode="singleTop">
-            <intent-filter>
-                <action android:name="android.intent.action.MAIN" />
-                <category android:name="android.intent.category.LAUNCHER" />
-            </intent-filter>
-        </activity>
-
-    </application>
-
-</manifest>

android/src/main/kotlin/com/saltylab/uwbtag/UwbTagBleActivity.kt

@@ -1,444 +0,0 @@
-package com.saltylab.uwbtag
-
-import android.Manifest
-import android.annotation.SuppressLint
-import android.bluetooth.*
-import android.bluetooth.le.*
-import android.content.Context
-import android.content.pm.PackageManager
-import android.os.Build
-import android.os.Bundle
-import android.os.Handler
-import android.os.Looper
-import android.view.LayoutInflater
-import android.view.View
-import android.view.ViewGroup
-import android.widget.Button
-import android.widget.TextView
-import android.widget.Toast
-import androidx.appcompat.app.AppCompatActivity
-import androidx.core.app.ActivityCompat
-import androidx.core.content.ContextCompat
-import androidx.recyclerview.widget.LinearLayoutManager
-import androidx.recyclerview.widget.RecyclerView
-import com.google.android.material.card.MaterialCardView
-import com.google.android.material.switchmaterial.SwitchMaterial
-import com.google.android.material.textfield.TextInputEditText
-import com.google.gson.Gson
-import com.saltylab.uwbtag.databinding.ActivityUwbTagBleBinding
-import java.util.UUID
-
-// ---------------------------------------------------------------------------
-// GATT service / characteristic UUIDs
-// ---------------------------------------------------------------------------
-private val SERVICE_UUID     = UUID.fromString("12345678-1234-5678-1234-56789abcdef0")
-private val CHAR_CONFIG_UUID = UUID.fromString("12345678-1234-5678-1234-56789abcdef1") // read/write JSON config
-private val CHAR_STATUS_UUID = UUID.fromString("12345678-1234-5678-1234-56789abcdef2") // notify: tag status string
-private val CHAR_BATT_UUID   = UUID.fromString("12345678-1234-5678-1234-56789abcdef3") // notify: battery %
-private val CCCD_UUID        = UUID.fromString("00002902-0000-1000-8000-00805f9b34fb")
-
-// BLE scan timeout
-private const val SCAN_TIMEOUT_MS = 15_000L
-
-// Permissions request code
-private const val REQ_PERMISSIONS = 1001
-
-// ---------------------------------------------------------------------------
-// Data model
-// ---------------------------------------------------------------------------
-data class TagConfig(
-    val tag_name: String = "UWB_TAG_0001",
-    val sleep_timeout_s: Int = 300,
-    val display_brightness: Int = 50,
-    val uwb_channel: Int = 9,
-    val ranging_interval_ms: Int = 100,
-    val battery_report: Boolean = true
-)
-
-data class ScannedDevice(
-    val name: String,
-    val address: String,
-    var rssi: Int,
-    val device: BluetoothDevice
-)
-
-// ---------------------------------------------------------------------------
-// RecyclerView adapter for scanned devices
-// ---------------------------------------------------------------------------
-class DeviceAdapter(
-    private val onConnect: (ScannedDevice) -> Unit
-) : RecyclerView.Adapter<DeviceAdapter.VH>() {
-
-    private val items = mutableListOf<ScannedDevice>()
-
-    fun update(device: ScannedDevice) {
-        val idx = items.indexOfFirst { it.address == device.address }
-        if (idx >= 0) {
-            items[idx] = device
-            notifyItemChanged(idx)
-        } else {
-            items.add(device)
-            notifyItemInserted(items.size - 1)
-        }
-    }
-
-    fun clear() {
-        items.clear()
-        notifyDataSetChanged()
-    }
-
-    override fun onCreateViewHolder(parent: ViewGroup, viewType: Int): VH {
-        val view = LayoutInflater.from(parent.context)
-            .inflate(R.layout.item_ble_device, parent, false)
-        return VH(view)
-    }
-
-    override fun onBindViewHolder(holder: VH, position: Int) = holder.bind(items[position])
-    override fun getItemCount() = items.size
-
-    inner class VH(view: View) : RecyclerView.ViewHolder(view) {
-        private val tvName    = view.findViewById<TextView>(R.id.tvDeviceName)
-        private val tvAddress = view.findViewById<TextView>(R.id.tvDeviceAddress)
-        private val tvRssi    = view.findViewById<TextView>(R.id.tvRssi)
-        private val btnConn   = view.findViewById<Button>(R.id.btnConnect)
-
-        fun bind(item: ScannedDevice) {
-            tvName.text    = item.name
-            tvAddress.text = item.address
-            tvRssi.text    = "${item.rssi} dBm"
-            btnConn.setOnClickListener { onConnect(item) }
-        }
-    }
-}
-
-// ---------------------------------------------------------------------------
-// Activity
-// ---------------------------------------------------------------------------
-@SuppressLint("MissingPermission") // permissions checked at runtime before any BLE call
-class UwbTagBleActivity : AppCompatActivity() {
-
-    private lateinit var binding: ActivityUwbTagBleBinding
-    private val gson = Gson()
-    private val mainHandler = Handler(Looper.getMainLooper())
-
-    // BLE
-    private val btManager by lazy { getSystemService(Context.BLUETOOTH_SERVICE) as BluetoothManager }
-    private val btAdapter by lazy { btManager.adapter }
-    private var bleScanner: BluetoothLeScanner? = null
-    private var gatt: BluetoothGatt? = null
-    private var configChar: BluetoothGattCharacteristic? = null
-    private var statusChar: BluetoothGattCharacteristic? = null
-    private var battChar: BluetoothGattCharacteristic? = null
-    private var isScanning = false
-
-    private val deviceAdapter = DeviceAdapter(onConnect = ::connectToDevice)
-
-    // ---------------------------------------------------------------------------
-    // Lifecycle
-    // ---------------------------------------------------------------------------
-    override fun onCreate(savedInstanceState: Bundle?) {
-        super.onCreate(savedInstanceState)
-        binding = ActivityUwbTagBleBinding.inflate(layoutInflater)
-        setContentView(binding.root)
-        setSupportActionBar(binding.toolbar)
-
-        binding.rvDevices.layoutManager = LinearLayoutManager(this)
-        binding.rvDevices.adapter = deviceAdapter
-
-        binding.btnScan.setOnClickListener {
-            if (isScanning) stopScan() else startScanIfPermitted()
-        }
-        binding.btnDisconnect.setOnClickListener { disconnectGatt() }
-        binding.btnReadConfig.setOnClickListener { readConfig() }
-        binding.btnWriteConfig.setOnClickListener { writeConfig() }
-
-        requestBlePermissions()
-    }
-
-    override fun onDestroy() {
-        super.onDestroy()
-        stopScan()
-        disconnectGatt()
-    }
-
-    // ---------------------------------------------------------------------------
-    // Permissions
-    // ---------------------------------------------------------------------------
-    private fun requestBlePermissions() {
-        val needed = mutableListOf<String>()
-        if (Build.VERSION.SDK_INT >= Build.VERSION_CODES.S) {
-            if (!hasPermission(Manifest.permission.BLUETOOTH_SCAN))
-                needed += Manifest.permission.BLUETOOTH_SCAN
-            if (!hasPermission(Manifest.permission.BLUETOOTH_CONNECT))
-                needed += Manifest.permission.BLUETOOTH_CONNECT
-        } else {
-            if (!hasPermission(Manifest.permission.ACCESS_FINE_LOCATION))
-                needed += Manifest.permission.ACCESS_FINE_LOCATION
-        }
-        if (needed.isNotEmpty()) {
-            ActivityCompat.requestPermissions(this, needed.toTypedArray(), REQ_PERMISSIONS)
-        }
-    }
-
-    private fun hasPermission(perm: String) =
-        ContextCompat.checkSelfPermission(this, perm) == PackageManager.PERMISSION_GRANTED
-
-    override fun onRequestPermissionsResult(
-        requestCode: Int, permissions: Array<out String>, grantResults: IntArray
-    ) {
-        super.onRequestPermissionsResult(requestCode, permissions, grantResults)
-        if (requestCode == REQ_PERMISSIONS &&
-            grantResults.any { it != PackageManager.PERMISSION_GRANTED }) {
-            toast("BLE permissions required")
-        }
-    }
-
-    // ---------------------------------------------------------------------------
-    // BLE Scan
-    // ---------------------------------------------------------------------------
-    private fun startScanIfPermitted() {
-        if (btAdapter?.isEnabled != true) { toast("Bluetooth is off"); return }
-        bleScanner = btAdapter.bluetoothLeScanner
-        val filter = ScanFilter.Builder()
-            .setDeviceNamePattern("UWB_TAG_.*".toRegex().toPattern())
-            .build()
-        val settings = ScanSettings.Builder()
-            .setScanMode(ScanSettings.SCAN_MODE_LOW_LATENCY)
-            .build()
-        deviceAdapter.clear()
-        bleScanner?.startScan(listOf(filter), settings, scanCallback)
-        isScanning = true
-        binding.btnScan.text = "Stop"
-        binding.tvScanStatus.text = "Scanning…"
-        mainHandler.postDelayed({ stopScan() }, SCAN_TIMEOUT_MS)
-    }
-
-    private fun stopScan() {
-        bleScanner?.stopScan(scanCallback)
-        isScanning = false
-        binding.btnScan.text = "Scan"
-        binding.tvScanStatus.text = "Scan stopped"
-    }
-
-    private val scanCallback = object : ScanCallback() {
-        override fun onScanResult(callbackType: Int, result: ScanResult) {
-            val name = result.device.name ?: return
-            if (!name.startsWith("UWB_TAG_")) return
-            val dev = ScannedDevice(
-                name    = name,
-                address = result.device.address,
-                rssi    = result.rssi,
-                device  = result.device
-            )
-            mainHandler.post { deviceAdapter.update(dev) }
-        }
-
-        override fun onScanFailed(errorCode: Int) {
-            mainHandler.post {
-                binding.tvScanStatus.text = "Scan failed (code $errorCode)"
-                isScanning = false
-                binding.btnScan.text = "Scan"
-            }
-        }
-    }
-
-    // ---------------------------------------------------------------------------
-    // GATT Connection
-    // ---------------------------------------------------------------------------
-    private fun connectToDevice(scanned: ScannedDevice) {
-        stopScan()
-        binding.tvScanStatus.text = "Connecting to ${scanned.name}…"
-        gatt = scanned.device.connectGatt(this, false, gattCallback, BluetoothDevice.TRANSPORT_LE)
-    }
-
-    private fun disconnectGatt() {
-        gatt?.disconnect()
-        gatt?.close()
-        gatt = null
-        configChar = null
-        statusChar = null
-        battChar = null
-        mainHandler.post {
-            binding.cardConfig.visibility = View.GONE
-            binding.tvScanStatus.text = "Disconnected"
-        }
-    }
-
-    private val gattCallback = object : BluetoothGattCallback() {
-
-        override fun onConnectionStateChange(g: BluetoothGatt, status: Int, newState: Int) {
-            when (newState) {
-                BluetoothProfile.STATE_CONNECTED -> {
-                    mainHandler.post { binding.tvScanStatus.text = "Connected — discovering services…" }
-                    g.discoverServices()
-                }
-                BluetoothProfile.STATE_DISCONNECTED -> {
-                    mainHandler.post {
-                        binding.cardConfig.visibility = View.GONE
-                        binding.tvScanStatus.text = "Disconnected"
-                        toast("Tag disconnected")
-                    }
-                    gatt?.close()
-                    gatt = null
-                }
-            }
-        }
-
-        override fun onServicesDiscovered(g: BluetoothGatt, status: Int) {
-            if (status != BluetoothGatt.GATT_SUCCESS) {
-                mainHandler.post { toast("Service discovery failed") }
-                return
-            }
-            val service = g.getService(SERVICE_UUID)
-            if (service == null) {
-                mainHandler.post { toast("UWB config service not found on tag") }
-                return
-            }
-            configChar = service.getCharacteristic(CHAR_CONFIG_UUID)
-            statusChar = service.getCharacteristic(CHAR_STATUS_UUID)
-            battChar   = service.getCharacteristic(CHAR_BATT_UUID)
-
-            // Subscribe to status notifications
-            statusChar?.let { enableNotifications(g, it) }
-            battChar?.let   { enableNotifications(g, it) }
-
-            // Initial config read
-            configChar?.let { g.readCharacteristic(it) }
-
-            mainHandler.post {
-                val devName = g.device.name ?: g.device.address
-                binding.tvConnectedName.text = "Connected: $devName"
-                binding.cardConfig.visibility = View.VISIBLE
-                binding.tvScanStatus.text = "Connected to $devName"
-            }
-        }
-
-        override fun onCharacteristicRead(
-            g: BluetoothGatt,
-            characteristic: BluetoothGattCharacteristic,
-            status: Int
-        ) {
-            if (status != BluetoothGatt.GATT_SUCCESS) return
-            if (characteristic.uuid == CHAR_CONFIG_UUID) {
-                val json = characteristic.value?.toString(Charsets.UTF_8) ?: return
-                val cfg = runCatching { gson.fromJson(json, TagConfig::class.java) }.getOrNull() ?: return
-                mainHandler.post { populateFields(cfg) }
-            }
-        }
-
-        // API 33+ callback
-        override fun onCharacteristicRead(
-            g: BluetoothGatt,
-            characteristic: BluetoothGattCharacteristic,
-            value: ByteArray,
-            status: Int
-        ) {
-            if (status != BluetoothGatt.GATT_SUCCESS) return
-            if (characteristic.uuid == CHAR_CONFIG_UUID) {
-                val json = value.toString(Charsets.UTF_8)
-                val cfg = runCatching { gson.fromJson(json, TagConfig::class.java) }.getOrNull() ?: return
-                mainHandler.post { populateFields(cfg) }
-            }
-        }
-
-        override fun onCharacteristicWrite(
-            g: BluetoothGatt,
-            characteristic: BluetoothGattCharacteristic,
-            status: Int
-        ) {
-            val msg = if (status == BluetoothGatt.GATT_SUCCESS) "Config written" else "Write failed ($status)"
-            mainHandler.post { toast(msg) }
-        }
-
-        override fun onCharacteristicChanged(
-            g: BluetoothGatt,
-            characteristic: BluetoothGattCharacteristic
-        ) {
-            val value = characteristic.value ?: return
-            handleNotification(characteristic.uuid, value)
-        }
-
-        // API 33+ callback
-        override fun onCharacteristicChanged(
-            g: BluetoothGatt,
-            characteristic: BluetoothGattCharacteristic,
-            value: ByteArray
-        ) {
-            handleNotification(characteristic.uuid, value)
-        }
-    }
-
-    // ---------------------------------------------------------------------------
-    // Notification helpers
-    // ---------------------------------------------------------------------------
-    private fun enableNotifications(g: BluetoothGatt, char: BluetoothGattCharacteristic) {
-        g.setCharacteristicNotification(char, true)
-        val descriptor = char.getDescriptor(CCCD_UUID) ?: return
-        descriptor.value = BluetoothGattDescriptor.ENABLE_NOTIFICATION_VALUE
-        g.writeDescriptor(descriptor)
-    }
-
-    private fun handleNotification(uuid: UUID, value: ByteArray) {
-        val text = value.toString(Charsets.UTF_8)
-        mainHandler.post {
-            when (uuid) {
-                CHAR_STATUS_UUID -> binding.tvTagStatus.text = "Status: $text"
-                CHAR_BATT_UUID   -> {
-                    val pct = text.toIntOrNull() ?: return@post
-                    binding.tvTagStatus.text = binding.tvTagStatus.text.toString()
-                        .replace(Regex("\\| Batt:.*"), "")
-                        .trimEnd() + " | Batt: $pct%"
-                }
-            }
-        }
-    }
-
-    // ---------------------------------------------------------------------------
-    // Config read / write
-    // ---------------------------------------------------------------------------
-    private fun readConfig() {
-        val g = gatt ?: run { toast("Not connected"); return }
-        val c = configChar ?: run { toast("Config char not found"); return }
-        g.readCharacteristic(c)
-    }
-
-    private fun writeConfig() {
-        val g = gatt ?: run { toast("Not connected"); return }
-        val c = configChar ?: run { toast("Config char not found"); return }
-        val cfg = buildConfigFromFields()
-        val json = gson.toJson(cfg)
-        if (Build.VERSION.SDK_INT >= Build.VERSION_CODES.TIRAMISU) {
-            g.writeCharacteristic(c, json.toByteArray(Charsets.UTF_8),
-                BluetoothGattCharacteristic.WRITE_TYPE_DEFAULT)
-        } else {
-            @Suppress("DEPRECATION")
-            c.value = json.toByteArray(Charsets.UTF_8)
-            @Suppress("DEPRECATION")
-            g.writeCharacteristic(c)
-        }
-    }
-
-    // ---------------------------------------------------------------------------
-    // UI helpers
-    // ---------------------------------------------------------------------------
-    private fun populateFields(cfg: TagConfig) {
-        binding.etTagName.setText(cfg.tag_name)
-        binding.etSleepTimeout.setText(cfg.sleep_timeout_s.toString())
-        binding.etBrightness.setText(cfg.display_brightness.toString())
-        binding.etUwbChannel.setText(cfg.uwb_channel.toString())
-        binding.etRangingInterval.setText(cfg.ranging_interval_ms.toString())
-        binding.switchBatteryReport.isChecked = cfg.battery_report
-    }
-
-    private fun buildConfigFromFields() = TagConfig(
-        tag_name           = binding.etTagName.text?.toString() ?: "UWB_TAG_0001",
-        sleep_timeout_s    = binding.etSleepTimeout.text?.toString()?.toIntOrNull() ?: 300,
-        display_brightness = binding.etBrightness.text?.toString()?.toIntOrNull() ?: 50,
-        uwb_channel        = binding.etUwbChannel.text?.toString()?.toIntOrNull() ?: 9,
-        ranging_interval_ms = binding.etRangingInterval.text?.toString()?.toIntOrNull() ?: 100,
-        battery_report     = binding.switchBatteryReport.isChecked
-    )
-
-    private fun toast(msg: String) =
-        Toast.makeText(this, msg, Toast.LENGTH_SHORT).show()
-}

android/src/main/res/layout/activity_uwb_tag_ble.xml

@@ -1,238 +0,0 @@
-<?xml version="1.0" encoding="utf-8"?>
-<LinearLayout xmlns:android="http://schemas.android.com/apk/res/android"
-    xmlns:app="http://schemas.android.com/apk/res-auto"
-    android:layout_width="match_parent"
-    android:layout_height="match_parent"
-    android:orientation="vertical">
-
-    <androidx.appcompat.widget.Toolbar
-        android:id="@+id/toolbar"
-        android:layout_width="match_parent"
-        android:layout_height="?attr/actionBarSize"
-        android:background="?attr/colorPrimary"
-        android:elevation="4dp"
-        android:theme="@style/ThemeOverlay.AppCompat.Dark.ActionBar"
-        app:title="UWB Tag BLE Config" />
-
-    <!-- Scan controls -->
-    <LinearLayout
-        android:layout_width="match_parent"
-        android:layout_height="wrap_content"
-        android:orientation="horizontal"
-        android:padding="12dp"
-        android:gravity="center_vertical">
-
-        <Button
-            android:id="@+id/btnScan"
-            style="@style/Widget.MaterialComponents.Button"
-            android:layout_width="wrap_content"
-            android:layout_height="wrap_content"
-            android:text="Scan" />
-
-        <TextView
-            android:id="@+id/tvScanStatus"
-            android:layout_width="0dp"
-            android:layout_height="wrap_content"
-            android:layout_weight="1"
-            android:layout_marginStart="12dp"
-            android:text="Tap Scan to find UWB tags"
-            android:textAppearance="@style/TextAppearance.MaterialComponents.Body2" />
-
-    </LinearLayout>
-
-    <!-- Scan results list -->
-    <TextView
-        android:layout_width="match_parent"
-        android:layout_height="wrap_content"
-        android:paddingHorizontal="12dp"
-        android:text="Nearby Tags"
-        android:textAppearance="@style/TextAppearance.MaterialComponents.Subtitle1"
-        android:textStyle="bold" />
-
-    <androidx.recyclerview.widget.RecyclerView
-        android:id="@+id/rvDevices"
-        android:layout_width="match_parent"
-        android:layout_height="0dp"
-        android:layout_weight="1"
-        android:padding="8dp"
-        android:clipToPadding="false" />
-
-    <!-- Connected device config panel -->
-    <com.google.android.material.card.MaterialCardView
-        android:id="@+id/cardConfig"
-        android:layout_width="match_parent"
-        android:layout_height="wrap_content"
-        android:layout_margin="8dp"
-        android:visibility="gone"
-        app:cardElevation="4dp">
-
-        <LinearLayout
-            android:layout_width="match_parent"
-            android:layout_height="wrap_content"
-            android:orientation="vertical"
-            android:padding="12dp">
-
-            <LinearLayout
-                android:layout_width="match_parent"
-                android:layout_height="wrap_content"
-                android:orientation="horizontal"
-                android:gravity="center_vertical">
-
-                <TextView
-                    android:id="@+id/tvConnectedName"
-                    android:layout_width="0dp"
-                    android:layout_height="wrap_content"
-                    android:layout_weight="1"
-                    android:text="Connected: —"
-                    android:textAppearance="@style/TextAppearance.MaterialComponents.Subtitle1"
-                    android:textStyle="bold" />
-
-                <Button
-                    android:id="@+id/btnDisconnect"
-                    style="@style/Widget.MaterialComponents.Button.OutlinedButton"
-                    android:layout_width="wrap_content"
-                    android:layout_height="wrap_content"
-                    android:text="Disconnect" />
-
-            </LinearLayout>
-
-            <!-- tag_name -->
-            <com.google.android.material.textfield.TextInputLayout
-                style="@style/Widget.MaterialComponents.TextInputLayout.OutlinedBox.Dense"
-                android:layout_width="match_parent"
-                android:layout_height="wrap_content"
-                android:layout_marginTop="8dp"
-                android:hint="Tag Name">
-                <com.google.android.material.textfield.TextInputEditText
-                    android:id="@+id/etTagName"
-                    android:layout_width="match_parent"
-                    android:layout_height="wrap_content"
-                    android:inputType="text" />
-            </com.google.android.material.textfield.TextInputLayout>
-
-            <!-- sleep_timeout_s and uwb_channel (row) -->
-            <LinearLayout
-                android:layout_width="match_parent"
-                android:layout_height="wrap_content"
-                android:orientation="horizontal"
-                android:layout_marginTop="4dp">
-
-                <com.google.android.material.textfield.TextInputLayout
-                    style="@style/Widget.MaterialComponents.TextInputLayout.OutlinedBox.Dense"
-                    android:layout_width="0dp"
-                    android:layout_height="wrap_content"
-                    android:layout_weight="1"
-                    android:layout_marginEnd="4dp"
-                    android:hint="Sleep Timeout (s)">
-                    <com.google.android.material.textfield.TextInputEditText
-                        android:id="@+id/etSleepTimeout"
-                        android:layout_width="match_parent"
-                        android:layout_height="wrap_content"
-                        android:inputType="number" />
-                </com.google.android.material.textfield.TextInputLayout>
-
-                <com.google.android.material.textfield.TextInputLayout
-                    style="@style/Widget.MaterialComponents.TextInputLayout.OutlinedBox.Dense"
-                    android:layout_width="0dp"
-                    android:layout_height="wrap_content"
-                    android:layout_weight="1"
-                    android:layout_marginStart="4dp"
-                    android:hint="UWB Channel">
-                    <com.google.android.material.textfield.TextInputEditText
-                        android:id="@+id/etUwbChannel"
-                        android:layout_width="match_parent"
-                        android:layout_height="wrap_content"
-                        android:inputType="number" />
-                </com.google.android.material.textfield.TextInputLayout>
-
-            </LinearLayout>
-
-            <!-- display_brightness and ranging_interval_ms (row) -->
-            <LinearLayout
-                android:layout_width="match_parent"
-                android:layout_height="wrap_content"
-                android:orientation="horizontal"
-                android:layout_marginTop="4dp">
-
-                <com.google.android.material.textfield.TextInputLayout
-                    style="@style/Widget.MaterialComponents.TextInputLayout.OutlinedBox.Dense"
-                    android:layout_width="0dp"
-                    android:layout_height="wrap_content"
-                    android:layout_weight="1"
-                    android:layout_marginEnd="4dp"
-                    android:hint="Brightness (0-100)">
-                    <com.google.android.material.textfield.TextInputEditText
-                        android:id="@+id/etBrightness"
-                        android:layout_width="match_parent"
-                        android:layout_height="wrap_content"
-                        android:inputType="number" />
-                </com.google.android.material.textfield.TextInputLayout>
-
-                <com.google.android.material.textfield.TextInputLayout
-                    style="@style/Widget.MaterialComponents.TextInputLayout.OutlinedBox.Dense"
-                    android:layout_width="0dp"
-                    android:layout_height="wrap_content"
-                    android:layout_weight="1"
-                    android:layout_marginStart="4dp"
-                    android:hint="Ranging Interval (ms)">
-                    <com.google.android.material.textfield.TextInputEditText
-                        android:id="@+id/etRangingInterval"
-                        android:layout_width="match_parent"
-                        android:layout_height="wrap_content"
-                        android:inputType="number" />
-                </com.google.android.material.textfield.TextInputLayout>
-
-            </LinearLayout>
-
-            <!-- battery_report toggle -->
-            <com.google.android.material.switchmaterial.SwitchMaterial
-                android:id="@+id/switchBatteryReport"
-                android:layout_width="wrap_content"
-                android:layout_height="wrap_content"
-                android:layout_marginTop="8dp"
-                android:text="Battery Reporting" />
-
-            <!-- Action buttons -->
-            <LinearLayout
-                android:layout_width="match_parent"
-                android:layout_height="wrap_content"
-                android:orientation="horizontal"
-                android:layout_marginTop="8dp">
-
-                <Button
-                    android:id="@+id/btnReadConfig"
-                    style="@style/Widget.MaterialComponents.Button.OutlinedButton"
-                    android:layout_width="0dp"
-                    android:layout_height="wrap_content"
-                    android:layout_weight="1"
-                    android:layout_marginEnd="4dp"
-                    android:text="Read" />
-
-                <Button
-                    android:id="@+id/btnWriteConfig"
-                    style="@style/Widget.MaterialComponents.Button"
-                    android:layout_width="0dp"
-                    android:layout_height="wrap_content"
-                    android:layout_weight="1"
-                    android:layout_marginStart="4dp"
-                    android:text="Write" />
-
-            </LinearLayout>
-
-            <!-- Status notifications from tag -->
-            <TextView
-                android:id="@+id/tvTagStatus"
-                android:layout_width="match_parent"
-                android:layout_height="wrap_content"
-                android:layout_marginTop="8dp"
-                android:background="#1A000000"
-                android:fontFamily="monospace"
-                android:padding="8dp"
-                android:text="Tag status: —"
-                android:textAppearance="@style/TextAppearance.MaterialComponents.Caption" />
-
-        </LinearLayout>
-
-    </com.google.android.material.card.MaterialCardView>
-
-</LinearLayout>

android/src/main/res/layout/item_ble_device.xml

@@ -1,60 +0,0 @@
-<?xml version="1.0" encoding="utf-8"?>
-<com.google.android.material.card.MaterialCardView
-    xmlns:android="http://schemas.android.com/apk/res/android"
-    xmlns:app="http://schemas.android.com/apk/res-auto"
-    android:layout_width="match_parent"
-    android:layout_height="wrap_content"
-    android:layout_margin="4dp"
-    app:cardElevation="2dp"
-    android:clickable="true"
-    android:focusable="true">
-
-    <LinearLayout
-        android:layout_width="match_parent"
-        android:layout_height="wrap_content"
-        android:orientation="horizontal"
-        android:padding="12dp"
-        android:gravity="center_vertical">
-
-        <LinearLayout
-            android:layout_width="0dp"
-            android:layout_height="wrap_content"
-            android:layout_weight="1"
-            android:orientation="vertical">
-
-            <TextView
-                android:id="@+id/tvDeviceName"
-                android:layout_width="match_parent"
-                android:layout_height="wrap_content"
-                android:text="UWB_TAG_XXXX"
-                android:textAppearance="@style/TextAppearance.MaterialComponents.Subtitle2"
-                android:textStyle="bold" />
-
-            <TextView
-                android:id="@+id/tvDeviceAddress"
-                android:layout_width="match_parent"
-                android:layout_height="wrap_content"
-                android:text="XX:XX:XX:XX:XX:XX"
-                android:textAppearance="@style/TextAppearance.MaterialComponents.Caption" />
-
-        </LinearLayout>
-
-        <TextView
-            android:id="@+id/tvRssi"
-            android:layout_width="wrap_content"
-            android:layout_height="wrap_content"
-            android:text="-70 dBm"
-            android:textAppearance="@style/TextAppearance.MaterialComponents.Caption"
-            android:textColor="?attr/colorSecondary" />
-
-        <Button
-            android:id="@+id/btnConnect"
-            style="@style/Widget.MaterialComponents.Button.OutlinedButton"
-            android:layout_width="wrap_content"
-            android:layout_height="wrap_content"
-            android:layout_marginStart="8dp"
-            android:text="Connect" />
-
-    </LinearLayout>
-
-</com.google.android.material.card.MaterialCardView>

cad/assembly.scad

@@ -1,118 +0,0 @@
-// ============================================
-// SaltyLab — Full Assembly Visualization
-// Shows all parts in position on 2020 spine
-// ============================================
-include <dimensions.scad>
-
-// Spine height
-spine_h = 500;
-
-// Component heights (center of each mount on spine)
-h_motor = 0;
-h_battery = 50;
-h_esc = 100;
-h_fc = 170;
-h_jetson = 250;
-h_realsense = 350;
-h_lidar = 430;
-
-// Colors for visualization
-module spine() {
-    color("silver")
-        translate([-extrusion_w/2, -extrusion_w/2, 0])
-            cube([extrusion_w, extrusion_w, spine_h]);
-}
-
-module wheel(side) {
-    color("DimGray")
-        translate([side * 140, 0, 0])
-            rotate([0, 90, 0])
-                cylinder(d=200, h=50, center=true, $fn=60);
-}
-
-// --- Assembly ---
-
-// Spine
-spine();
-
-// Wheels
-wheel(-1);
-wheel(1);
-
-// Motor mount plate (at base)
-color("DodgerBlue", 0.7)
-    translate([0, 0, h_motor])
-        import("motor_mount_plate.stl");
-
-// Battery shelf
-color("OrangeRed", 0.7)
-    translate([0, 0, h_battery])
-        rotate([0, 0, 0])
-            cube([180, 80, 40], center=true);
-
-// ESC
-color("Green", 0.7)
-    translate([0, 0, h_esc])
-        cube([80, 50, 15], center=true);
-
-// FC (tiny!)
-color("Purple", 0.9)
-    translate([0, 0, h_fc])
-        cube([36, 36, 5], center=true);
-
-// Jetson Orin Nano Super
-color("LimeGreen", 0.7)
-    translate([0, 0, h_jetson])
-        cube([100, 80, 29], center=true);
-
-// RealSense D435i
-color("Gray", 0.8)
-    translate([0, -40, h_realsense])
-        cube([90, 25, 25], center=true);
-
-// RPLIDAR A1
-color("Cyan", 0.7)
-    translate([0, 0, h_lidar])
-        cylinder(d=70, h=41, center=true, $fn=40);
-
-// Kill switch (accessible on front)
-color("Red")
-    translate([0, -60, h_esc + 30])
-        cylinder(d=22, h=10, $fn=30);
-
-// LED ring
-color("White", 0.3)
-    translate([0, 0, h_jetson - 20])
-        difference() {
-            cylinder(d=120, h=15, $fn=60);
-            translate([0, 0, -1])
-                cylinder(d=110, h=17, $fn=60);
-        }
-
-// Bumpers
-color("Orange", 0.5) {
-    translate([0, -75, 25])
-        cube([350, 30, 50], center=true);
-    translate([0, 75, 25])
-        cube([350, 30, 50], center=true);
-}
-
-// Handle (top)
-color("Yellow", 0.7)
-    translate([0, 0, spine_h + 10])
-        cube([100, 20, 25], center=true);
-
-// Tether point
-color("Red", 0.8)
-    translate([0, 0, spine_h - 20]) {
-        difference() {
-            cylinder(d=30, h=8, $fn=30);
-            translate([0, 0, -1])
-                cylinder(d=15, h=10, $fn=30);
-        }
-    }
-
-echo("=== SaltyLab Assembly ===");
-echo(str("Total height: ", spine_h + 30, "mm"));
-echo(str("Width (axle-axle): ", 280 + 50*2, "mm"));
-echo(str("Depth: ~", 150, "mm"));

cad/battery_shelf.scad

@@ -1,77 +0,0 @@
-// ============================================
-// SaltyLab — Battery Shelf
-// 200×100×40mm PETG
-// Holds 36V battery pack low on the frame
-// Mounts to 2020 extrusion spine
-// ============================================
-include <dimensions.scad>
-
-shelf_w = 200;
-shelf_d = 100;
-shelf_h = 40;
-floor_h = 3;     // Bottom plate
-
-// Battery pocket (with tolerance)
-pocket_w = batt_w + tol*2;
-pocket_d = batt_d + tol*2;
-pocket_h = batt_h + 5;  // Slightly taller than battery
-
-// Velcro strap slots
-strap_w = 25;
-strap_h = 3;
-
-module battery_shelf() {
-    difference() {
-        union() {
-            // Floor
-            translate([-shelf_w/2, -shelf_d/2, 0])
-                cube([shelf_w, shelf_d, floor_h]);
-            
-            // Walls (3 sides — front open for wires)
-            // Left wall
-            translate([-shelf_w/2, -shelf_d/2, 0])
-                cube([wall, shelf_d, shelf_h]);
-            // Right wall
-            translate([shelf_w/2 - wall, -shelf_d/2, 0])
-                cube([wall, shelf_d, shelf_h]);
-            // Back wall
-            translate([-shelf_w/2, shelf_d/2 - wall, 0])
-                cube([shelf_w, wall, shelf_h]);
-            
-            // Front lip (low, keeps battery from sliding out)
-            translate([-shelf_w/2, -shelf_d/2, 0])
-                cube([shelf_w, wall, 10]);
-            
-            // 2020 extrusion mount tabs (top of back wall)
-            for (x = [-30, 30]) {
-                translate([x - 10, shelf_d/2 - wall, shelf_h - 15])
-                    cube([20, wall + 10, 15]);
-            }
-        }
-        
-        // Extrusion bolt holes (M5) through back mount tabs
-        for (x = [-30, 30]) {
-            translate([x, shelf_d/2 + 5, shelf_h - 7.5])
-                rotate([90, 0, 0])
-                    cylinder(d=m5_clear, h=wall + 15, $fn=30);
-        }
-        
-        // Velcro strap slots (2x through floor for securing battery)
-        for (x = [-50, 50]) {
-            translate([x - strap_w/2, -20, -1])
-                cube([strap_w, strap_h, floor_h + 2]);
-        }
-        
-        // Weight reduction holes in floor
-        for (x = [-30, 30]) {
-            translate([x, 0, -1])
-                cylinder(d=20, h=floor_h + 2, $fn=30);
-        }
-        
-        // Wire routing slot (front wall, centered)
-        translate([-20, -shelf_d/2 - 1, floor_h])
-            cube([40, wall + 2, 15]);
-    }
-}
-
-battery_shelf();

cad/bumper.scad

@@ -1,75 +0,0 @@
-// ============================================
-// SaltyLab — Bumper (Front/Rear)
-// 350×50×30mm TPU
-// Absorbs falls, protects frame and floor
-// ============================================
-include <dimensions.scad>
-
-bumper_w = 350;
-bumper_h = 50;
-bumper_d = 30;
-bumper_wall = 2.5;
-
-// Honeycomb crush structure for energy absorption
-hex_size = 8;
-hex_wall = 1.2;
-
-module honeycomb_cell(size, height) {
-    difference() {
-        cylinder(d=size, h=height, $fn=6);
-        translate([0, 0, -1])
-            cylinder(d=size - hex_wall*2, h=height + 2, $fn=6);
-    }
-}
-
-module bumper() {
-    difference() {
-        union() {
-            // Outer shell (curved front face)
-            hull() {
-                translate([-bumper_w/2, 0, 0])
-                    cube([bumper_w, 1, bumper_h]);
-                translate([-bumper_w/2 + 10, bumper_d - 5, 5])
-                    cube([bumper_w - 20, 1, bumper_h - 10]);
-            }
-        }
-        
-        // Hollow interior (leave outer shell)
-        hull() {
-            translate([-bumper_w/2 + bumper_wall, bumper_wall, bumper_wall])
-                cube([bumper_w - bumper_wall*2, 1, bumper_h - bumper_wall*2]);
-            translate([-bumper_w/2 + 10 + bumper_wall, bumper_d - 5 - bumper_wall, 5 + bumper_wall])
-                cube([bumper_w - 20 - bumper_wall*2, 1, bumper_h - 10 - bumper_wall*2]);
-        }
-        
-        // Mounting bolt holes (M5, through back face, 4 points)
-        for (x = [-120, -40, 40, 120]) {
-            translate([x, -1, bumper_h/2])
-                rotate([-90, 0, 0])
-                    cylinder(d=m5_clear, h=10, $fn=25);
-        }
-    }
-    
-    // Internal honeycomb ribs for crush absorption
-    intersection() {
-        // Bound to bumper volume
-        hull() {
-            translate([-bumper_w/2 + bumper_wall, bumper_wall, bumper_wall])
-                cube([bumper_w - bumper_wall*2, 1, bumper_h - bumper_wall*2]);
-            translate([-bumper_w/2 + 15, bumper_d - 8, 8])
-                cube([bumper_w - 30, 1, bumper_h - 16]);
-        }
-        
-        // Honeycomb grid
-        for (x = [-170:hex_size*1.5:170]) {
-            for (z = [0:hex_size*1.3:60]) {
-                offset_x = (floor(z / (hex_size*1.3)) % 2) * hex_size * 0.75;
-                translate([x + offset_x, 0, z])
-                    rotate([-90, 0, 0])
-                        honeycomb_cell(hex_size, bumper_d);
-            }
-        }
-    }
-}
-
-bumper();

cad/dimensions.scad

@@ -1,73 +0,0 @@
-// ============================================
-// SaltyLab — Common Dimensions & Constants
-// ============================================
-
-// --- 2020 Aluminum Extrusion ---
-extrusion_w = 20;
-extrusion_slot = 6;     // T-slot width
-extrusion_bore = 5;     // Center bore M5
-
-// --- Hub Motors (8" hoverboard) ---
-motor_axle_dia = 12;
-motor_axle_len = 45;
-motor_axle_flat = 10;   // Flat-to-flat if D-shaft
-motor_body_dia = 200;   // ~8 inches
-motor_bolt_circle = 0;  // Axle-only mount (clamp style)
-
-// --- Drone FC (30.5mm standard) ---
-fc_hole_spacing = 25.5;  // GEP-F722 AIO v2 (not standard 30.5!)
-fc_hole_dia = 3.2;      // M3 clearance
-fc_board_size = 36;      // Typical FC PCB
-fc_standoff_h = 5;       // Rubber standoff height
-
-// --- Jetson Orin Nano Super ---
-jetson_w = 100;
-jetson_d = 80;
-jetson_h = 29;           // With heatsink
-jetson_hole_x = 86;      // Mounting hole spacing X
-jetson_hole_y = 58;      // Mounting hole spacing Y
-jetson_hole_dia = 2.7;   // M2.5 clearance
-
-// --- RealSense D435i ---
-rs_w = 90;
-rs_d = 25;
-rs_h = 25;
-rs_tripod_offset = 0;    // 1/4-20 centered bottom
-rs_mount_dia = 6.5;      // 1/4-20 clearance
-
-// --- RPLIDAR A1 ---
-lidar_dia = 70;
-lidar_h = 41;
-lidar_mount_circle = 67; // Bolt circle diameter
-lidar_hole_count = 4;
-lidar_hole_dia = 2.7;    // M2.5
-
-// --- Kill Switch (22mm panel mount) ---
-kill_sw_dia = 22;
-kill_sw_depth = 35;      // Behind-panel depth
-
-// --- Battery (typical 36V hoverboard pack) ---
-batt_w = 180;
-batt_d = 80;
-batt_h = 40;
-
-// --- Hoverboard ESC ---
-esc_w = 80;
-esc_d = 50;
-esc_h = 15;
-
-// --- ESP32-C3 (typical dev board) ---
-esp_w = 25;
-esp_d = 18;
-esp_h = 5;
-
-// --- WS2812B strip ---
-led_strip_w = 10;        // 10mm wide strip
-
-// --- General ---
-wall = 3;                // Default wall thickness
-m3_clear = 3.2;
-m3_insert = 4.2;         // Heat-set insert hole
-m25_clear = 2.7;
-m5_clear = 5.3;
-tol = 0.2;               // Print tolerance per side

cad/esc_mount.scad

@@ -1,70 +0,0 @@
-// ============================================
-// SaltyLab — ESC Mount
-// 150×100×15mm PETG
-// Hoverboard ESC, mounts to 2020 extrusion
-// ============================================
-include <dimensions.scad>
-
-mount_w = 150;
-mount_d = 100;
-mount_h = 15;
-base_h = 3;
-
-module esc_mount() {
-    difference() {
-        union() {
-            // Base plate
-            translate([-mount_w/2, -mount_d/2, 0])
-                cube([mount_w, mount_d, base_h]);
-            
-            // ESC retaining walls (low lip on 3 sides)
-            // Left
-            translate([-mount_w/2, -mount_d/2, 0])
-                cube([wall, mount_d, mount_h]);
-            // Right
-            translate([mount_w/2 - wall, -mount_d/2, 0])
-                cube([wall, mount_d, mount_h]);
-            // Back
-            translate([-mount_w/2, mount_d/2 - wall, 0])
-                cube([mount_w, wall, mount_h]);
-            
-            // Front clips (snap-fit tabs to hold ESC)
-            for (x = [-30, 30]) {
-                translate([x - 5, -mount_d/2, 0])
-                    cube([10, wall, mount_h]);
-                // Clip overhang
-                translate([x - 5, -mount_d/2, mount_h - 2])
-                    cube([10, wall + 3, 2]);
-            }
-            
-            // 2020 mount tabs (back)
-            for (x = [-25, 25]) {
-                translate([x - 10, mount_d/2 - wall, 0])
-                    cube([20, wall + 8, base_h + 8]);
-            }
-        }
-        
-        // Extrusion bolt holes (M5)
-        for (x = [-25, 25]) {
-            translate([x, mount_d/2 + 3, base_h + 4])
-                rotate([90, 0, 0])
-                    cylinder(d=m5_clear, h=wall + 12, $fn=30);
-        }
-        
-        // Ventilation holes in base
-        for (x = [-40, -20, 0, 20, 40]) {
-            for (y = [-25, 0, 25]) {
-                translate([x, y, -1])
-                    cylinder(d=8, h=base_h + 2, $fn=20);
-            }
-        }
-        
-        // Wire routing slots (front and back)
-        translate([-15, -mount_d/2 - 1, base_h])
-            cube([30, wall + 2, 10]);
-        translate([-15, mount_d/2 - wall - 1, base_h])
-            cube([30, wall + 2, 10]);
-    }
-}
-
-esc_mount();

cad/esp32c3_mount.scad

@@ -1,57 +0,0 @@
-// ============================================
-// SaltyLab — ESP32-C3 Mount
-// 30×25×10mm PETG
-// Tiny mount for LED controller MCU
-// ============================================
-include <dimensions.scad>
-
-mount_w = 30;
-mount_d = 25;
-mount_h = 10;
-base_h = 2;
-
-module esp32c3_mount() {
-    difference() {
-        union() {
-            // Base
-            translate([-mount_w/2, -mount_d/2, 0])
-                cube([mount_w, mount_d, base_h]);
-            
-            // Retaining walls (3 sides, front open for USB)
-            translate([-mount_w/2, -mount_d/2, 0])
-                cube([wall, mount_d, mount_h]);
-            translate([mount_w/2 - wall, -mount_d/2, 0])
-                cube([wall, mount_d, mount_h]);
-            translate([-mount_w/2, mount_d/2 - wall, 0])
-                cube([mount_w, wall, mount_h]);
-            
-            // Clip tabs (front corners)
-            for (x = [-mount_w/2, mount_w/2 - wall]) {
-                translate([x, -mount_d/2, mount_h - 2])
-                    cube([wall, 4, 2]);
-            }
-            
-            // Zip-tie slot wings
-            for (x = [-mount_w/2 - 4, mount_w/2 + 1]) {
-                translate([x, -5, 0])
-                    cube([3, 10, base_h]);
-            }
-        }
-        
-        // Board pocket (recessed)
-        translate([-esp_w/2 - tol, -esp_d/2 - tol, base_h])
-            cube([esp_w + tol*2, esp_d + tol*2, mount_h]);
-        
-        // Zip-tie slots
-        for (x = [-mount_w/2 - 4, mount_w/2 + 1]) {
-            translate([x, -2, -1])
-                cube([3, 4, base_h + 2]);
-        }
-        
-        // USB port clearance (front)
-        translate([-5, -mount_d/2 - 1, base_h])
-            cube([10, wall + 2, 5]);
-    }
-}
-
-esp32c3_mount();

cad/fc_mount.scad

@@ -1,86 +0,0 @@
-// ============================================
-// SaltyLab — Flight Controller Mount
-// Vibration-isolated, 30.5mm pattern
-// TPU dampers + PETG frame
-// ============================================
-include <dimensions.scad>
-
-// FC mount attaches to 2020 extrusion via T-slot
-// Rubber/TPU grommets isolate FC from frame vibration
-
-mount_w = 45;    // Overall width
-mount_d = 45;    // Overall depth  
-mount_h = 15;    // Total height (base + standoffs)
-base_h = 4;      // Base plate thickness
-
-// TPU grommet dimensions
-grommet_od = 7;
-grommet_id = 3.2;  // M3 clearance
-grommet_h = 5;     // Soft mount height
-
-module fc_mount() {
-    difference() {
-        union() {
-            // Base plate
-            translate([-mount_w/2, -mount_d/2, 0])
-                cube([mount_w, mount_d, base_h]);
-            
-            // Standoff posts (PETG, FC sits on TPU grommets on top)
-            for (x = [-fc_hole_spacing/2, fc_hole_spacing/2]) {
-                for (y = [-fc_hole_spacing/2, fc_hole_spacing/2]) {
-                    translate([x, y, 0])
-                        cylinder(d=8, h=base_h + grommet_h, $fn=30);
-                }
-            }
-            
-            // 2020 extrusion clamp tabs (sides)
-            for (side = [-1, 1]) {
-                translate([side * (extrusion_w/2 + wall), -15, 0])
-                    cube([wall, 30, base_h + 10]);
-            }
-        }
-        
-        // FC mounting holes (M3 through standoffs)
-        for (x = [-fc_hole_spacing/2, fc_hole_spacing/2]) {
-            for (y = [-fc_hole_spacing/2, fc_hole_spacing/2]) {
-                translate([x, y, -1])
-                    cylinder(d=fc_hole_dia, h=base_h + grommet_h + 2, $fn=25);
-            }
-        }
-        
-        // Extrusion channel (20mm wide slot through base)
-        translate([-extrusion_w/2 - tol, -20, -1])
-            cube([extrusion_w + tol*2, 40, base_h + 2]);
-        
-        // Clamp bolt holes (M3, horizontal through side tabs)
-        for (side = [-1, 1]) {
-            translate([side * (extrusion_w/2 + wall + 1), 0, base_h + 5])
-                rotate([0, 90, 0])
-                    cylinder(d=m3_clear, h=wall + 2, center=true, $fn=25);
-        }
-        
-        // Center cutout for airflow / weight reduction
-        translate([0, 0, -1])
-            cylinder(d=15, h=base_h + 2, $fn=30);
-    }
-}
-
-// TPU grommet (print separately in TPU)
-module tpu_grommet() {
-    difference() {
-        cylinder(d=grommet_od, h=grommet_h, $fn=30);
-        translate([0, 0, -1])
-            cylinder(d=grommet_id, h=grommet_h + 2, $fn=25);
-    }
-}
-
-// Show assembled
-fc_mount();
-
-// Show grommets in position (for visualization)
-%for (x = [-fc_hole_spacing/2, fc_hole_spacing/2]) {
-    for (y = [-fc_hole_spacing/2, fc_hole_spacing/2]) {
-        translate([x, y, base_h])
-            tpu_grommet();
-    }
-}

cad/handle.scad

@@ -1,59 +0,0 @@
-// ============================================
-// SaltyLab — Carry Handle
-// 150×30×30mm PETG
-// Comfortable grip, mounts on top of spine
-// ============================================
-include <dimensions.scad>
-
-handle_w = 150;
-handle_h = 30;
-grip_dia = 25;     // Comfortable grip diameter
-grip_len = 100;    // Grip section length
-
-module handle() {
-    difference() {
-        union() {
-            // Grip bar (rounded for comfort)
-            translate([-grip_len/2, 0, handle_h])
-                rotate([0, 90, 0])
-                    cylinder(d=grip_dia, h=grip_len, $fn=40);
-            
-            // Left support leg
-            hull() {
-                translate([-handle_w/2, -10, 0])
-                    cube([20, 20, 3]);
-                translate([-grip_len/2, 0, handle_h])
-                    rotate([0, 90, 0])
-                        cylinder(d=grip_dia, h=5, $fn=40);
-            }
-            
-            // Right support leg
-            hull() {
-                translate([handle_w/2 - 20, -10, 0])
-                    cube([20, 20, 3]);
-                translate([grip_len/2 - 5, 0, handle_h])
-                    rotate([0, 90, 0])
-                        cylinder(d=grip_dia, h=5, $fn=40);
-            }
-        }
-        
-        // 2020 extrusion slot (center of base)
-        translate([-extrusion_w/2 - tol, -extrusion_w/2 - tol, -1])
-            cube([extrusion_w + tol*2, extrusion_w + tol*2, 5]);
-        
-        // M5 bolt holes for extrusion (2x)
-        for (x = [-30, 30]) {
-            translate([x, 0, -1])
-                cylinder(d=m5_clear, h=5, $fn=25);
-        }
-        
-        // Finger grooves on grip
-        for (x = [-30, -10, 10, 30]) {
-            translate([x, 0, handle_h])
-                rotate([0, 90, 0])
-                    cylinder(d=grip_dia + 4, h=5, center=true, $fn=40);
-        }
-    }
-}
-
-handle();

cad/jetson_shelf.scad

@@ -1,69 +0,0 @@
-// ============================================
-// SaltyLab — Jetson Orin Nano Super Shelf
-// 120×100×15mm PETG
-// Mounts Jetson Orin Nano Super to 2020 extrusion
-// ============================================
-include <dimensions.scad>
-
-shelf_w = 120;
-shelf_d = 100;
-shelf_h = 15;
-base_h = 3;
-standoff_h = 8;  // Clearance for Jetson underside components
-
-module jetson_shelf() {
-    difference() {
-        union() {
-            // Base plate
-            translate([-shelf_w/2, -shelf_d/2, 0])
-                cube([shelf_w, shelf_d, base_h]);
-            
-            // Jetson standoffs (M2.5, 86mm × 58mm pattern)
-            for (x = [-jetson_hole_x/2, jetson_hole_x/2]) {
-                for (y = [-jetson_hole_y/2, jetson_hole_y/2]) {
-                    translate([x, y, 0])
-                        cylinder(d=6, h=base_h + standoff_h, $fn=25);
-                }
-            }
-            
-            // 2020 extrusion clamp (back edge)
-            translate([-15, shelf_d/2 - wall, 0])
-                cube([30, wall + 10, base_h + 12]);
-            
-            // Side rails for Jetson alignment
-            for (x = [-jetson_w/2 - wall, jetson_w/2]) {
-                translate([x, -jetson_d/2, base_h + standoff_h])
-                    cube([wall, jetson_d, 4]);
-            }
-        }
-        
-        // Jetson M2.5 holes (through standoffs)
-        for (x = [-jetson_hole_x/2, jetson_hole_x/2]) {
-            for (y = [-jetson_hole_y/2, jetson_hole_y/2]) {
-                translate([x, y, -1])
-                    cylinder(d=jetson_hole_dia, h=base_h + standoff_h + 2, $fn=25);
-            }
-        }
-        
-        // Extrusion bolt hole (M5, through back clamp)
-        translate([0, shelf_d/2 + 3, base_h + 6])
-            rotate([90, 0, 0])
-                cylinder(d=m5_clear, h=wall + 15, $fn=30);
-        
-        // Extrusion channel slot
-        translate([-extrusion_w/2 - tol, shelf_d/2 - wall - 1, -1])
-            cube([extrusion_w + tol*2, wall + 2, base_h + 2]);
-        
-        // Ventilation / cable routing
-        for (x = [-25, 0, 25]) {
-            translate([x, 0, -1])
-                cylinder(d=15, h=base_h + 2, $fn=25);
-        }
-        
-        // USB/Ethernet/GPIO access cutouts (front edge)
-        translate([-jetson_w/2, -shelf_d/2 - 1, base_h])
-            cube([jetson_w, wall + 2, shelf_h]);
-    }
-}
-
-jetson_shelf();

cad/kill_switch_mount.scad

@@ -1,56 +0,0 @@
-// ============================================
-// SaltyLab — Kill Switch Mount
-// 60×60×40mm PETG
-// 22mm panel-mount emergency stop button
-// Mounts to 2020 extrusion, easily reachable
-// ============================================
-include <dimensions.scad>
-
-mount_w = 60;
-mount_d = 60;
-mount_h = 40;
-panel_h = 3;  // Panel face thickness
-
-module kill_switch_mount() {
-    difference() {
-        union() {
-            // Main body (angled face for visibility)
-            hull() {
-                translate([-mount_w/2, 0, 0])
-                    cube([mount_w, mount_d, 1]);
-                translate([-mount_w/2, 5, mount_h])
-                    cube([mount_w, mount_d - 5, 1]);
-            }
-            
-            // 2020 extrusion mount bracket (back)
-            translate([-15, mount_d, 0])
-                cube([30, 10, 20]);
-        }
-        
-        // Kill switch hole (22mm, through angled face)
-        translate([0, mount_d/2, mount_h/2])
-            rotate([10, 0, 0])  // Slight angle for ergonomics
-                cylinder(d=kill_sw_dia + tol, h=panel_h + 2, center=true, $fn=50);
-        
-        // Interior cavity (hollow for switch body)
-        translate([-kill_sw_dia/2 - 3, 5, 3])
-            cube([kill_sw_dia + 6, mount_d - 10, mount_h - 3]);
-        
-        // Wire exit hole (bottom)
-        translate([0, mount_d/2, -1])
-            cylinder(d=10, h=5, $fn=25);
-        
-        // Extrusion bolt holes (M5, through back bracket)
-        for (z = [7, 15]) {
-            translate([-20, mount_d + 5, z])
-                rotate([90, 0, 0])
-                    cylinder(d=m5_clear, h=15, center=true, $fn=25);
-        }
-        
-        // Label recess ("EMERGENCY STOP" — flat area for sticker)
-        translate([-25, 5, mount_h - 1])
-            cube([50, 15, 1.5]);
-    }
-}
-
-kill_switch_mount();

cad/led_diffuser_ring.scad

@@ -1,53 +0,0 @@
-// ============================================
-// SaltyLab — LED Diffuser Ring
-// Ø120×15mm Clear PETG 30% infill
-// Wraps around frame, holds WS2812B strip
-// Print in clear/natural PETG for diffusion
-// ============================================
-include <dimensions.scad>
-
-ring_od = 120;
-ring_id = 110;       // Inner diameter (strip sits inside)
-ring_h = 15;
-strip_channel_w = led_strip_w + 1;  // Strip channel
-strip_channel_d = 3;  // Depth for strip
-
-module led_diffuser_ring() {
-    difference() {
-        // Outer ring
-        cylinder(d=ring_od, h=ring_h, $fn=80);
-        
-        // Inner hollow
-        translate([0, 0, -1])
-            cylinder(d=ring_id, h=ring_h + 2, $fn=80);
-        
-        // LED strip channel (groove on inner wall)
-        translate([0, 0, (ring_h - strip_channel_w)/2])
-            difference() {
-                cylinder(d=ring_id + 2, h=strip_channel_w, $fn=80);
-                cylinder(d=ring_id - strip_channel_d*2, h=strip_channel_w, $fn=80);
-            }
-        
-        // Wire entry slot
-        translate([ring_od/2 - 5, -3, ring_h/2 - 3])
-            cube([10, 6, 6]);
-        
-        // 2020 extrusion clearance (center)
-        translate([-extrusion_w/2 - 5, -extrusion_w/2 - 5, -1])
-            cube([extrusion_w + 10, extrusion_w + 10, ring_h + 2]);
-    }
-    
-    // Mounting tabs (clip onto extrusion, 4x)
-    for (angle = [0, 90, 180, 270]) {
-        rotate([0, 0, angle])
-            translate([extrusion_w/2 + 1, -5, 0])
-                difference() {
-                    cube([3, 10, ring_h]);
-                    translate([-1, 2, ring_h/2])
-                        rotate([0, 90, 0])
-                            cylinder(d=m3_clear, h=5, $fn=20);
-                }
-    }
-}
-
-led_diffuser_ring();

cad/lidar_standoff.scad

@@ -1,61 +0,0 @@
-// ============================================
-// SaltyLab — LIDAR Standoff
-// Ø80×80mm ASA
-// Raises RPLIDAR above all other components
-// for unobstructed 360° scan
-// Connects sensor_tower_top to 2020 extrusion
-// ============================================
-include <dimensions.scad>
-
-standoff_od = 80;
-standoff_h = 80;
-wall_t = 3;
-
-module lidar_standoff() {
-    difference() {
-        union() {
-            // Main cylinder
-            cylinder(d=standoff_od, h=standoff_h, $fn=60);
-            
-            // Bottom flange (bolts to extrusion bracket below)
-            cylinder(d=standoff_od + 10, h=4, $fn=60);
-        }
-        
-        // Hollow interior
-        translate([0, 0, wall_t])
-            cylinder(d=standoff_od - wall_t*2, h=standoff_h, $fn=60);
-        
-        // Cable routing hole (bottom)
-        translate([0, 0, -1])
-            cylinder(d=20, h=wall_t + 2, $fn=30);
-        
-        // Ventilation / weight reduction slots (4x around circumference)
-        for (angle = [0, 90, 180, 270]) {
-            rotate([0, 0, angle])
-                translate([0, standoff_od/2, standoff_h/2])
-                    rotate([90, 0, 0])
-                        hull() {
-                            translate([0, -15, 0])
-                                cylinder(d=10, h=wall_t + 2, center=true, $fn=25);
-                            translate([0, 15, 0])
-                                cylinder(d=10, h=wall_t + 2, center=true, $fn=25);
-                        }
-        }
-        
-        // Bottom flange bolt holes (M5, 4x for mounting)
-        for (angle = [45, 135, 225, 315]) {
-            rotate([0, 0, angle])
-                translate([standoff_od/2, 0, -1])
-                    cylinder(d=m5_clear, h=6, $fn=25);
-        }
-        
-        // Top mating holes (M3, align with sensor_tower_top)
-        for (angle = [0, 90, 180, 270]) {
-            rotate([0, 0, angle])
-                translate([standoff_od/2 - wall_t - 3, 0, standoff_h - 8])
-                    cylinder(d=m3_clear, h=10, $fn=25);
-        }
-    }
-}
-
-lidar_standoff();

cad/motor_mount_plate.scad

@@ -1,94 +0,0 @@
-// ============================================
-// SaltyLab — Motor Mount Plate
-// 350×150×6mm PETG
-// Mounts both 8" hub motors + 2020 extrusion spine
-// ============================================
-include <dimensions.scad>
-
-plate_w = 350;   // Width (axle to axle direction)
-plate_d = 150;   // Depth (front to back)
-plate_h = 6;     // Thickness
-
-// Motor axle positions (centered, symmetric)
-motor_spacing = 280;  // Center-to-center axle distance
-
-// Extrusion spine mount (centered, 2x M5 bolts)
-spine_offset_y = 0;   // Centered front-to-back
-spine_bolt_spacing = 60; // Two bolts along spine
-
-// Motor clamp dimensions
-clamp_w = 30;
-clamp_h = 25;    // Height above plate for clamping axle
-clamp_gap = motor_axle_dia + tol*2;  // Slot for axle
-clamp_bolt_offset = 10; // M5 clamp bolt offset from center
-
-module motor_clamp() {
-    difference() {
-        // Clamp block
-        translate([-clamp_w/2, -clamp_w/2, 0])
-            cube([clamp_w, clamp_w, plate_h + clamp_h]);
-        
-        // Axle hole (through, slightly oversized)
-        translate([0, 0, plate_h + clamp_h/2 + 5])
-            rotate([0, 90, 0])
-                cylinder(d=clamp_gap, h=clamp_w+2, center=true, $fn=40);
-        
-        // Clamp slit (allows tightening)
-        translate([0, 0, plate_h + clamp_h/2 + 5])
-            cube([clamp_w+2, 1.5, clamp_h], center=true);
-        
-        // Clamp bolt holes (M5, horizontal through clamp ears)
-        translate([0, clamp_bolt_offset, plate_h + clamp_h/2 + 5])
-            rotate([0, 90, 0])
-                cylinder(d=m5_clear, h=clamp_w+2, center=true, $fn=30);
-        translate([0, -clamp_bolt_offset, plate_h + clamp_h/2 + 5])
-            rotate([0, 90, 0])
-                cylinder(d=m5_clear, h=clamp_w+2, center=true, $fn=30);
-    }
-}
-
-module motor_mount_plate() {
-    difference() {
-        union() {
-            // Main plate
-            translate([-plate_w/2, -plate_d/2, 0])
-                cube([plate_w, plate_d, plate_h]);
-            
-            // Left motor clamp
-            translate([-motor_spacing/2, 0, 0])
-                motor_clamp();
-            
-            // Right motor clamp
-            translate([motor_spacing/2, 0, 0])
-                motor_clamp();
-            
-            // Reinforcement ribs (bottom)
-            for (x = [-100, 0, 100]) {
-                translate([x - 2, -plate_d/2, 0])
-                    cube([4, plate_d, plate_h]);
-            }
-        }
-        
-        // Extrusion spine bolt holes (M5, 2x along center)
-        for (y = [-spine_bolt_spacing/2, spine_bolt_spacing/2]) {
-            translate([0, y, -1])
-                cylinder(d=m5_clear, h=plate_h+2, $fn=30);
-            // Counterbore for bolt head
-            translate([0, y, plate_h - 2.5])
-                cylinder(d=10, h=3, $fn=30);
-        }
-        
-        // Weight reduction holes
-        for (x = [-70, 70]) {
-            for (y = [-40, 40]) {
-                translate([x, y, -1])
-                    cylinder(d=25, h=plate_h+2, $fn=40);
-            }
-        }
-        
-        // Corner rounding (chamfer edges)
-        // (simplified — round in slicer or add minkowski)
-    }
-}
-
-motor_mount_plate();

cad/realsense_bracket.scad

@@ -1,64 +0,0 @@
-// ============================================
-// SaltyLab — RealSense D435i Bracket
-// 100×50×40mm PETG
-// Adjustable tilt mount on 2020 extrusion
-// ============================================
-include <dimensions.scad>
-
-bracket_w = 100;
-bracket_d = 50;
-bracket_h = 40;
-
-// Camera cradle
-cradle_w = rs_w + wall*2 + tol*2;
-cradle_d = rs_d + wall + tol*2;
-cradle_h = rs_h + 5;
-
-module realsense_bracket() {
-    // Extrusion clamp base
-    difference() {
-        union() {
-            // Clamp block
-            translate([-20, -20, 0])
-                cube([40, 40, 15]);
-            
-            // Tilt arm (vertical, supports camera above)
-            translate([-wall, -wall, 0])
-                cube([wall*2, wall*2, bracket_h]);
-            
-            // Camera cradle at top
-            translate([-cradle_w/2, -cradle_d/2, bracket_h - 5]) {
-                difference() {
-                    cube([cradle_w, cradle_d, cradle_h]);
-                    
-                    // Camera pocket
-                    translate([wall, -1, 3])
-                        cube([rs_w + tol*2, rs_d + tol*2 + 1, rs_h + tol*2]);
-                }
-            }
-            
-            // Tripod mount boss (1/4-20 bolt from bottom of cradle)
-            translate([0, 0, bracket_h - 5])
-                cylinder(d=15, h=3, $fn=30);
-        }
-        
-        // 2020 extrusion channel
-        translate([-extrusion_w/2 - tol, -extrusion_w/2 - tol, -1])
-            cube([extrusion_w + tol*2, extrusion_w + tol*2, 17]);
-        
-        // Clamp bolt (M5, through side)
-        translate([-25, 0, 7.5])
-            rotate([0, 90, 0])
-                cylinder(d=m5_clear, h=50, $fn=30);
-        
-        // Camera 1/4-20 bolt hole (from bottom of cradle)
-        translate([0, 0, bracket_h - 6])
-            cylinder(d=rs_mount_dia, h=10, $fn=30);
-        
-        // Cable routing slot (back of cradle)
-        translate([-10, cradle_d/2 - wall - 1, bracket_h])
-            cube([20, wall + 2, cradle_h - 2]);
-    }
-}
-
-realsense_bracket();

cad/sensor_tower_top.scad

@@ -1,58 +0,0 @@
-// ============================================
-// SaltyLab — Sensor Tower Top
-// 120×120×10mm ASA
-// Mounts RPLIDAR A1 on top of 2020 spine
-// ============================================
-include <dimensions.scad>
-
-top_w = 120;
-top_d = 120;
-top_h = 10;
-base_h = 4;
-
-module sensor_tower_top() {
-    difference() {
-        union() {
-            // Circular plate (RPLIDAR needs 360° clearance)
-            cylinder(d=top_w, h=base_h, $fn=60);
-            
-            // RPLIDAR standoffs (4x M2.5 on 67mm bolt circle)
-            for (i = [0:3]) {
-                angle = i * 90 + 45;  // 45° offset
-                translate([cos(angle) * lidar_mount_circle/2,
-                           sin(angle) * lidar_mount_circle/2, 0])
-                    cylinder(d=6, h=top_h, $fn=25);
-            }
-            
-            // 2020 extrusion socket (bottom center)
-            translate([-extrusion_w/2 - wall, -extrusion_w/2 - wall, -15])
-                cube([extrusion_w + wall*2, extrusion_w + wall*2, 15]);
-        }
-        
-        // RPLIDAR M2.5 through-holes
-        for (i = [0:3]) {
-            angle = i * 90 + 45;
-            translate([cos(angle) * lidar_mount_circle/2,
-                       sin(angle) * lidar_mount_circle/2, -1])
-                cylinder(d=lidar_hole_dia, h=top_h + 2, $fn=25);
-        }
-        
-        // Center hole (RPLIDAR motor shaft clearance + cable routing)
-        translate([0, 0, -1])
-            cylinder(d=25, h=base_h + 2, $fn=40);
-        
-        // 2020 extrusion socket (square hole)
-        translate([-extrusion_w/2 - tol, -extrusion_w/2 - tol, -16])
-            cube([extrusion_w + tol*2, extrusion_w + tol*2, 16]);
-        
-        // Set screw holes for extrusion (M3, 2x perpendicular)
-        for (angle = [0, 90]) {
-            rotate([0, 0, angle])
-                translate([0, extrusion_w/2 + wall, -7.5])
-                    rotate([90, 0, 0])
-                        cylinder(d=m3_clear, h=wall + 5, $fn=25);
-        }
-    }
-}
-
-sensor_tower_top();

cad/tether_anchor.scad

@@ -1,46 +0,0 @@
-// ============================================
-// SaltyLab — Tether Anchor Point
-// 50×50×20mm PETG 100% infill
-// For ceiling tether during balance testing
-// Must be STRONG — 100% infill mandatory
-// ============================================
-include <dimensions.scad>
-
-anchor_w = 50;
-anchor_d = 50;
-anchor_h = 20;
-ring_dia = 30;     // Carabiner ring outer
-ring_hole = 15;    // Carabiner hook clearance
-ring_h = 8;
-
-module tether_anchor() {
-    difference() {
-        union() {
-            // Base (clamps to 2020 extrusion)
-            translate([-anchor_w/2, -anchor_d/2, 0])
-                cube([anchor_w, anchor_d, anchor_h - ring_h]);
-            
-            // Tether ring (stands up from base)
-            translate([0, 0, anchor_h - ring_h])
-                cylinder(d=ring_dia, h=ring_h, $fn=50);
-        }
-        
-        // Ring hole (for carabiner)
-        translate([0, 0, anchor_h - ring_h - 1])
-            cylinder(d=ring_hole, h=ring_h + 2, $fn=40);
-        
-        // 2020 extrusion channel (through base)
-        translate([-extrusion_w/2 - tol, -extrusion_w/2 - tol, -1])
-            cube([extrusion_w + tol*2, extrusion_w + tol*2, anchor_h - ring_h + 2]);
-        
-        // Clamp bolt holes (M5, through sides)
-        for (angle = [0, 90]) {
-            rotate([0, 0, angle])
-                translate([0, anchor_d/2 + 1, (anchor_h - ring_h)/2])
-                    rotate([90, 0, 0])
-                        cylinder(d=m5_clear, h=anchor_d + 2, $fn=25);
-        }
-    }
-}
-
-tether_anchor();

chassis/ASSEMBLY.md

@@ -56,24 +56,15 @@
 3. Fasten 4× M4×12 SHCS. Torque 2.5 N·m.
 4. Insert battery pack; route Velcro straps through slots and cinch.
 
-<<<<<<< HEAD
+### 7  FC mount (MAMBA F722S)
-### 7  MCU mount (ESP32 BALANCE + ESP32 IO)
-
-> ⚠️ **ARCHITECTURE CHANGE (2026-04-03):** ESP32 BALANCE retired. Two ESP32 boards replace it.
-> Board dimensions and hole patterns TBD — await spec from max before machining mount plate.
-
-=======
-### 7  FC mount (ESP32-S3 BALANCE)
->>>>>>> 291dd68 (feat: remove all STM32/Mamba/BlackPill references — ESP32-S3 only)
 1. Place silicone anti-vibration grommets onto nylon M3 standoffs.
-2. Lower ESP32 BALANCE board onto standoffs; secure with M3×6 BHCS. Snug only.
+2. Lower FC onto standoffs; secure with M3×6 BHCS. Snug only — do not over-torque.
-3. Mount ESP32 IO board adjacent — exact placement TBD pending board dimensions.
+3. Orient USB-C port toward front of robot for cable access.
-4. Orient USB connectors toward front of robot for cable access.
 
-### 8  Jetson Orin Nano Super mount plate
+### 8  Jetson Nano mount plate
 1. Press or thread M3 nylon standoffs (8mm) into plate holes.
 2. Bolt plate to deck: 4× M3×10 SHCS at deck corners.
-3. Set Jetson Orin Nano Super B01 carrier onto plate standoffs; fasten M3×6 BHCS.
+3. Set Jetson Nano B01 carrier onto plate standoffs; fasten M3×6 BHCS.
 
 ### 9  Bumper brackets
 1. Slide 22mm EMT conduit through saddle clamp openings.
@@ -95,8 +86,7 @@
 | Wheelbase (axle C/L to C/L) | 600 mm | ±1 mm |
 | Motor fork slot width | 24 mm | +0.5 / 0 |
 | Motor fork dropout depth | 60 mm | ±0.5 mm |
-| ESP32 BALANCE hole pattern | TBD — await spec from max | ±0.2 mm |
+| FC hole pattern | 30.5 × 30.5 mm | ±0.2 mm |
-| ESP32 IO hole pattern | TBD — await spec from max | ±0.2 mm |
 | Jetson hole pattern | 58 × 58 mm | ±0.2 mm |
 | Battery tray inner | 185 × 72 × 52 mm | +2 / 0 mm |
 

chassis/BOM.md

@@ -41,11 +41,7 @@ PR #7 (`chassis_frame.scad`) used placeholder values. The table below records th
 | 3 | Dropout clamp — upper | 2 | 8mm 6061-T6 Al | 90×70mm blank | D-cut bore; `RENDER="clamp_upper_2d"` |
 | 4 | Stem flange ring | 2 | 6mm Al or acrylic | Ø82mm disc | One above + one below plate; `RENDER="stem_flange_2d"` |
 | 5 | Vertical stem tube | 1 | 38.1mm OD × 1.5mm wall 6061-T6 Al | 1050mm length | 1.5" EMT conduit is a drop-in alternative |
-<<<<<<< HEAD
+| 6 | FC standoff M3×6mm nylon | 4 | Nylon | — | MAMBA F722S vibration isolation |
-| 6 | MCU standoff M3×6mm nylon | 4 | Nylon | — | ESP32 BALANCE / IO board isolation (dimensions TBD) |
-=======
-| 6 | FC standoff M3×6mm nylon | 4 | Nylon | — | ESP32-S3 BALANCE vibration isolation |
->>>>>>> 291dd68 (feat: remove all STM32/Mamba/BlackPill references — ESP32-S3 only)
 | 7 | Ø4mm × 16mm alignment pin | 8 | Steel dowel | — | Dropout clamp-to-plate alignment |
 
 ### Battery Stem Clamp (`stem_battery_clamp.scad`) — Part B
@@ -74,7 +70,7 @@ PR #7 (`chassis_frame.scad`) used placeholder values. The table below records th
 | 10 | Motor fork bracket (R) | 1 | 8mm 6061 aluminium | Mirror of item 9 |
 | 11 | Battery tray | 1 | 3mm PETG FDM or 3mm aluminium fold | `chassis_frame.scad` — `battery_tray()` module |
 | 12 | FC mount plate / standoffs | 1 set | PETG or nylon FDM | Includes 4× M3 nylon standoffs, 6mm height |
-| 13 | Jetson Orin Nano Super mount plate | 1 | 4mm 5052 aluminium or 4mm PETG FDM | B01 58×58mm hole pattern |
+| 13 | Jetson Nano mount plate | 1 | 4mm 5052 aluminium or 4mm PETG FDM | B01 58×58mm hole pattern |
 | 14 | Front bumper bracket | 1 | 5mm PETG FDM | Saddle clamps for 22mm EMT conduit |
 | 15 | Rear bumper bracket | 1 | 5mm PETG FDM | Mirror of item 14 |
 
@@ -92,23 +88,12 @@ PR #7 (`chassis_frame.scad`) used placeholder values. The table below records th
 
 ## Electronics Mounts
 
-> ⚠️ **ARCHITECTURE CHANGE (2026-04-03):** ESP32 BALANCE (ESP32) is retired.
-> Replaced by **ESP32 BALANCE** + **ESP32 IO**. Board dimensions and hole patterns TBD — await spec from max.
-
 | # | Part | Qty | Spec | Notes |
 |---|------|-----|------|-------|
-<<<<<<< HEAD
+| 13 | STM32 MAMBA F722S FC | 1 | 36×36mm PCB, 30.5×30.5mm M3 mount | Oriented USB-C port toward front |
-| 13 | ESP32 BALANCE board | 1 | TBD — mount pattern TBD | PID balance loop; replaces ESP32 BALANCE |
-| 13b | ESP32 IO board | 1 | TBD — mount pattern TBD | Motor/sensor/comms I/O |
-| 14 | Nylon M3 standoff 6mm | 4 | F/F nylon | ESP32 board isolation |
-| 15 | Anti-vibration grommet M3 | 4 | Ø6mm silicone | Under ESP32 mount pads |
-| 16 | Jetson Orin module | 1 | 69.6×45mm module + carrier | 58×58mm M3 carrier hole pattern |
-=======
-| 13 | ESP32-S3 ESP32-S3 BALANCE FC | 1 | 36×36mm PCB, 30.5×30.5mm M3 mount | Oriented USB-C port toward front |
 | 14 | Nylon M3 standoff 6mm | 4 | F/F nylon | FC vibration isolation |
 | 15 | Anti-vibration grommet M3 | 4 | Ø6mm silicone | Under FC mount pads |
-| 16 | Jetson Orin Nano Super B01 module | 1 | 69.6×45mm module + carrier | 58×58mm M3 carrier hole pattern |
+| 16 | Jetson Nano B01 module | 1 | 69.6×45mm module + carrier | 58×58mm M3 carrier hole pattern |
->>>>>>> 291dd68 (feat: remove all STM32/Mamba/BlackPill references — ESP32-S3 only)
 | 17 | Nylon M3 standoff 8mm | 4 | F/F nylon | Jetson board standoffs |
 
 ---
@@ -159,8 +144,8 @@ Slide entire carousel up/down the stem with M6 collar bolts loosened. Tighten at
 | 26 | M6×60 SHCS  | 4  | ISO 4762, SS | Collar clamping bolts |
 | 27 | M6 hex nut  | 4  | ISO 4032, SS | Captured in collar pockets |
 | 28 | M6×12 set screw | 2 | ISO 4026, SS cup-point | Stem height lock (1 per collar half) |
-| 29 | M3×10 SHCS | 12 | ISO 4762, SS | ESP32 mount + miscellaneous |
+| 29 | M3×10 SHCS | 12 | ISO 4762, SS | FC mount + miscellaneous |
-| 30 | M3×6 BHCS  | 4  | ISO 4762, SS | ESP32 board bolts (qty TBD pending board spec) |
+| 30 | M3×6 BHCS  | 4  | ISO 4762, SS | FC board bolts |
 | 31 | Axle lock nut (match axle tip thread) | 4 | Flanged, confirm thread | 2 per motor |
 | 32 | Flat washer M5 | 32 | SS | |
 | 33 | Flat washer M4 | 32 | SS | |

chassis/battery_holder.scad

@@ -1,410 +0,0 @@
-// ============================================================
-// battery_holder.scad — 6S LiPo Battery Holder for 2020 T-Slot Chassis
-// Issue: #588  Agent: sl-mechanical  Date: 2026-03-14
-// ============================================================
-//
-// Parametric bracket holding a 6S 5000 mAh LiPo pack on 2020 aluminium
-// T-slot rails.  Designed for low centre-of-gravity mounting: pack sits
-// flat between the two chassis rails, as close to ground as clearance
-// allows.  Quick-release via captive Velcro straps — battery swap in
-// under 60 s without tools.
-//
-// Architecture:
-//   Tray        → flat floor + perimeter walls, battery sits inside
-//   Rail saddles→ two T-nut feet drop onto 2020 rails, thumbscrew locks
-//   Strap slots → four pairs of slots for 25 mm Velcro strap loops
-//   XT60 window → cut-out in rear wall for XT60 connector exit
-//   Balance port→ open channel in front wall for balance lead routing
-//   QR tab      → front-edge pull tab for one-handed battery extraction
-//
-// Part catalogue:
-//   Part 1 — battery_tray()    Main tray body (single-piece print)
-//   Part 2 — rail_saddle()     T-nut saddle foot (print x2 per tray)
-//   Part 3 — strap_guide()     25 mm Velcro strap guide (print x4)
-//   Part 4 — assembly_preview()
-//
-// Hardware BOM:
-//   2× M3 × 16 mm SHCS + M3 hex nut    T-nut rail clamp thumbscrews
-//   2× 25 mm × 250 mm Velcro strap     battery retention (hook + loop)
-//   1× XT60 female connector            (mounted on ESC/PDB harness)
-//   — battery slides in from front, Velcro strap over top —
-//
-// 6S LiPo target pack (verify with calipers — packs vary by brand):
-//   BATT_L = 155 mm  (length, X axis in tray)
-//   BATT_W =  48 mm  (width,  Y axis in tray)
-//   BATT_H =  52 mm  (height, Z axis in tray)
-//   Clearance 1 mm each side added automatically (BATT_CLEAR)
-//
-// Mounting:
-//   Rail span    : RAIL_SPAN — distance between 2020 rail centrelines
-//                  Default 80 mm; adjust to chassis rail spacing
-//   Saddle height: SADDLE_H — total height of saddle (tray floor above rail)
-//                  Keep low for CoG; default 8 mm
-//
-// RENDER options:
-//   "assembly"         full assembly preview (default)
-//   "tray_stl"         Part 1 — battery tray
-//   "saddle_stl"       Part 2 — rail saddle (print x2)
-//   "strap_guide_stl"  Part 3 — strap guide (print x4)
-//
-// Export commands:
-//   openscad battery_holder.scad -D 'RENDER="tray_stl"'        -o bh_tray.stl
-//   openscad battery_holder.scad -D 'RENDER="saddle_stl"'      -o bh_saddle.stl
-//   openscad battery_holder.scad -D 'RENDER="strap_guide_stl"' -o bh_strap_guide.stl
-//
-// Print settings (all parts):
-//   Material   : PETG
-//   Perimeters : 5 (tray, saddle), 3 (strap_guide)
-//   Infill     : 40 % gyroid (tray floor, saddle), 20 % (strap_guide)
-//   Orientation:
-//     tray         — floor flat on bed (no supports needed)
-//     saddle       — flat face on bed (no supports)
-//     strap_guide  — flat face on bed (no supports)
-// ============================================================
-
-$fn = 64;
-e   = 0.01;
-
-// ── Battery pack dimensions (verify with calipers) ────────────────────────────
-BATT_L     = 155.0;   // pack length (X)
-BATT_W     =  48.0;   // pack width  (Y)
-BATT_H     =  52.0;   // pack height (Z)
-BATT_CLEAR =   1.0;   // per-side fit clearance
-
-// ── Tray geometry ─────────────────────────────────────────────────────────────
-TRAY_FLOOR_T   =  4.0;   // tray floor thickness
-TRAY_WALL_T    =  4.0;   // tray perimeter wall thickness
-TRAY_WALL_H    = 20.0;   // tray wall height (Z) — cradles lower half of pack
-TRAY_FILLET_R  =  3.0;   // inner corner radius
-
-// Inner tray cavity (battery + clearance)
-TRAY_INN_L = BATT_L + 2*BATT_CLEAR;
-TRAY_INN_W = BATT_W + 2*BATT_CLEAR;
-
-// Outer tray footprint
-TRAY_OUT_L = TRAY_INN_L + 2*TRAY_WALL_T;
-TRAY_OUT_W = TRAY_INN_W + 2*TRAY_WALL_T;
-TRAY_TOTAL_H = TRAY_FLOOR_T + TRAY_WALL_H;
-
-// ── Rail interface ─────────────────────────────────────────────────────────────
-RAIL_SPAN   =  80.0;   // distance between 2020 rail centrelines (Y)
-RAIL_W      =  20.0;   // 2020 extrusion width
-SLOT_NECK_H =   3.2;   // T-slot neck height
-SLOT_OPEN   =   6.0;   // T-slot opening width
-SLOT_INN_W  =  10.2;   // T-slot inner width
-SLOT_INN_H  =   5.8;   // T-slot inner height
-
-// ── T-nut / saddle geometry ───────────────────────────────────────────────────
-TNUT_W       =  9.8;
-TNUT_H       =  5.5;
-TNUT_L       = 12.0;
-TNUT_NUT_AF  =  5.5;   // M3 hex nut across-flats
-TNUT_NUT_H   =  2.4;
-TNUT_BOLT_D  =  3.3;   // M3 clearance
-
-SADDLE_W     = 30.0;   // saddle foot width (X, along rail)
-SADDLE_T     =  8.0;   // saddle body thickness (Z, above rail top face)
-SADDLE_PAD_T =  2.0;   // rubber-pad recess depth (optional anti-slip)
-
-// ── Velcro strap slots ────────────────────────────────────────────────────────
-STRAP_W      = 26.0;   // 25 mm strap + 1 mm clearance
-STRAP_T      =  4.0;   // slot through-thickness (tray wall)
-// Four slot pairs: one near each end of tray (X), one each side (Y)
-// Slots run through side walls (Y direction) — strap loops over battery top
-
-// ── XT60 connector window (rear wall) ─────────────────────────────────────────
-XT60_W       = 14.0;   // XT60 body width
-XT60_H       = 18.0;   // XT60 body height (with cable exit)
-XT60_OFFSET_Z = 4.0;   // height above tray floor
-
-// ── Balance lead port (front wall) ────────────────────────────────────────────
-BAL_W        = 40.0;   // balance lead bundle width (6S = 7 wires)
-BAL_H        =  6.0;   // balance lead channel height
-BAL_OFFSET_Z =  8.0;   // height above tray floor
-
-// ── Quick-release pull tab (front edge) ──────────────────────────────────────
-QR_TAB_W     = 30.0;   // tab width
-QR_TAB_H     = 12.0;   // tab height above front wall top
-QR_TAB_T     =  4.0;   // tab thickness
-QR_HOLE_D    = 10.0;   // finger-loop hole diameter
-
-// ── Strap guide clip ─────────────────────────────────────────────────────────
-GUIDE_OD     = STRAP_W + 6.0;
-GUIDE_T      =  3.0;
-GUIDE_BODY_H = 14.0;
-
-// ── Fasteners ─────────────────────────────────────────────────────────────────
-M3_D = 3.3;
-
-// ============================================================
-// RENDER DISPATCH
-// ============================================================
-RENDER = "assembly";
-
-if      (RENDER == "assembly")        assembly_preview();
-else if (RENDER == "tray_stl")        battery_tray();
-else if (RENDER == "saddle_stl")      rail_saddle();
-else if (RENDER == "strap_guide_stl") strap_guide();
-
-// ============================================================
-// ASSEMBLY PREVIEW
-// ============================================================
-module assembly_preview() {
-    // Ghost 2020 rails (Y direction, RAIL_SPAN apart)
-    for (ry = [-RAIL_SPAN/2, RAIL_SPAN/2])
-        %color("Silver", 0.28)
-            translate([-TRAY_OUT_L/2 - 30, ry - RAIL_W/2, -SADDLE_T - TNUT_H])
-                cube([TRAY_OUT_L + 60, RAIL_W, RAIL_W]);
-
-    // Rail saddles (left and right)
-    for (sy = [-RAIL_SPAN/2, RAIL_SPAN/2])
-        color("DimGray", 0.85)
-            translate([0, sy, -SADDLE_T])
-                rail_saddle();
-
-    // Battery tray (sitting on saddles)
-    color("OliveDrab", 0.85)
-        battery_tray();
-
-    // Battery ghost
-    %color("SaddleBrown", 0.35)
-        translate([-BATT_L/2, -BATT_W/2, TRAY_FLOOR_T])
-            cube([BATT_L, BATT_W, BATT_H]);
-
-    // Strap guides (4×, two each end)
-    for (sx = [-TRAY_OUT_L/2 + STRAP_W/2 + TRAY_WALL_T + 8,
-                TRAY_OUT_L/2 - STRAP_W/2 - TRAY_WALL_T - 8])
-    for (sy = [-1, 1])
-        color("SteelBlue", 0.75)
-            translate([sx, sy*(TRAY_OUT_W/2), TRAY_TOTAL_H + 2])
-                rotate([sy > 0 ? 0 : 180, 0, 0])
-                    strap_guide();
-}
-
-// ============================================================
-// PART 1 — BATTERY TRAY
-// ============================================================
-// Single-piece tray: flat floor, four perimeter walls, T-nut saddle
-// attachment bosses on underside, Velcro strap slots through side walls,
-// XT60 window in rear wall, balance lead channel in front wall, and
-// quick-release pull tab on front edge.
-//
-// Battery inserts from the front (−X end) — front wall is lower than
-// rear wall so the pack slides in and the rear wall stops it.
-// Velcro straps loop over the top of the pack through the side slots.
-//
-// Coordinate convention:
-//   X: along battery length (−X = front/plug-end, +X = rear/balance-end)
-//   Y: across battery width (centred, ±TRAY_OUT_W/2)
-//   Z: vertical (Z=0 = tray floor top face; −Z = underside → saddles)
-//
-// Print: floor flat on bed, PETG, 5 perims, 40% gyroid. No supports.
-module battery_tray() {
-    // Short rear wall height (XT60 connector exits here — full wall height)
-    // Front wall is lower to allow battery slide-in
-    front_wall_h = TRAY_WALL_H * 0.55;   // 55% height — battery slides over
-
-    difference() {
-        union() {
-            // ── Floor ────────────────────────────────────────────────────
-            translate([-TRAY_OUT_L/2, -TRAY_OUT_W/2, -TRAY_FLOOR_T])
-                cube([TRAY_OUT_L, TRAY_OUT_W, TRAY_FLOOR_T]);
-
-            // ── Rear wall (+X, full height) ───────────────────────────────
-            translate([TRAY_INN_L/2, -TRAY_OUT_W/2, 0])
-                cube([TRAY_WALL_T, TRAY_OUT_W, TRAY_WALL_H]);
-
-            // ── Front wall (−X, lowered for slide-in) ────────────────────
-            translate([-TRAY_INN_L/2 - TRAY_WALL_T, -TRAY_OUT_W/2, 0])
-                cube([TRAY_WALL_T, TRAY_OUT_W, front_wall_h]);
-
-            // ── Side walls (±Y) ───────────────────────────────────────────
-            for (sy = [-1, 1])
-                translate([-TRAY_OUT_L/2,
-                           sy*(TRAY_INN_W/2 + (sy>0 ? 0 : -TRAY_WALL_T)),
-                           0])
-                    cube([TRAY_OUT_L,
-                          TRAY_WALL_T,
-                          TRAY_WALL_H]);
-
-            // ── Quick-release pull tab (front wall top edge) ──────────────
-            translate([-TRAY_INN_L/2 - TRAY_WALL_T - e,
-                       -QR_TAB_W/2, front_wall_h])
-                cube([QR_TAB_T, QR_TAB_W, QR_TAB_H]);
-
-            // ── Saddle attachment bosses (underside, one per rail) ─────────
-            // Bosses drop into saddle sockets; M3 bolt through floor
-            for (sy = [-RAIL_SPAN/2, RAIL_SPAN/2])
-                translate([-SADDLE_W/2, sy - SADDLE_W/2, -TRAY_FLOOR_T - SADDLE_T/2])
-                    cube([SADDLE_W, SADDLE_W, SADDLE_T/2 + e]);
-        }
-
-        // ── Battery cavity (hollow interior) ──────────────────────────────
-        translate([-TRAY_INN_L/2, -TRAY_INN_W/2, -e])
-            cube([TRAY_INN_L, TRAY_INN_W, TRAY_WALL_H + 2*e]);
-
-        // ── XT60 connector window (rear wall) ─────────────────────────────
-        // Centred on rear wall, low position so cable exits cleanly
-        translate([TRAY_INN_L/2 - e, -XT60_W/2, XT60_OFFSET_Z])
-            cube([TRAY_WALL_T + 2*e, XT60_W, XT60_H]);
-
-        // ── Balance lead channel (front wall) ─────────────────────────────
-        // Wide slot for 6S balance lead (7-pin JST-XH ribbon)
-        translate([-TRAY_INN_L/2 - TRAY_WALL_T - e,
-                   -BAL_W/2, BAL_OFFSET_Z])
-            cube([TRAY_WALL_T + 2*e, BAL_W, BAL_H]);
-
-        // ── Velcro strap slots (side walls, 2 pairs) ──────────────────────
-        // Pair A: near front end (−X), Pair B: near rear end (+X)
-        // Each slot runs through the wall in Y direction
-        for (sx = [-TRAY_INN_L/2 + STRAP_W*0.5 + 10,
-                    TRAY_INN_L/2 - STRAP_W*0.5 - 10])
-        for (sy = [-1, 1]) {
-            translate([sx - STRAP_W/2,
-                       sy*(TRAY_INN_W/2) - (sy > 0 ? TRAY_WALL_T + e : -e),
-                       TRAY_WALL_H * 0.35])
-                cube([STRAP_W, TRAY_WALL_T + 2*e, STRAP_T]);
-        }
-
-        // ── QR tab finger-loop hole ────────────────────────────────────────
-        translate([-TRAY_INN_L/2 - TRAY_WALL_T/2,
-                   0, front_wall_h + QR_TAB_H * 0.55])
-            rotate([0, 90, 0])
-                cylinder(d = QR_HOLE_D, h = QR_TAB_T + 2*e, center = true);
-
-        // ── Saddle bolt holes (M3 through floor into saddle boss) ─────────
-        for (sy = [-RAIL_SPAN/2, RAIL_SPAN/2])
-            translate([0, sy, -TRAY_FLOOR_T - e])
-                cylinder(d = M3_D, h = TRAY_FLOOR_T + 2*e);
-
-        // ── Floor lightening grid (non-structural area) ───────────────────
-        // 2D grid of pockets reduces weight without weakening battery support
-        for (gx = [-40, 0, 40])
-        for (gy = [-12, 12])
-            translate([gx, gy, -TRAY_FLOOR_T - e])
-                cylinder(d = 14, h = TRAY_FLOOR_T - 1.5 + e);
-
-        // ── Inner corner chamfers (battery slide-in guidance) ─────────────
-        // 45° chamfers at bottom-front inner corners
-        translate([-TRAY_INN_L/2, -TRAY_INN_W/2 - e, -e])
-            rotate([0, 0, 45])
-                cube([4, 4, TRAY_WALL_H * 0.3 + e]);
-        translate([-TRAY_INN_L/2, TRAY_INN_W/2 + e, -e])
-            rotate([0, 0, -45])
-                cube([4, 4, TRAY_WALL_H * 0.3 + e]);
-    }
-}
-
-// ============================================================
-// PART 2 — RAIL SADDLE
-// ============================================================
-// T-nut foot that clamps to the top face of a 2020 T-slot rail.
-// Battery tray boss drops into saddle socket; M3 bolt through tray
-// floor and saddle body locks everything together.
-// M3 thumbscrew through side of saddle body grips the rail T-groove
-// (same thumbscrew interface as all other SaltyLab rail brackets).
-//
-// Saddle sits on top of rail (no T-nut tongue needed — saddle clamps
-// from the top using a T-nut inserted into the rail T-groove from the
-// end).  Low profile keeps battery CoG as low as possible.
-//
-// Print: flat base on bed, PETG, 5 perims, 50% gyroid.
-module rail_saddle() {
-    sock_d = SADDLE_W - 4;   // tray boss socket diameter
-
-    difference() {
-        union() {
-            // ── Main saddle body ──────────────────────────────────────────
-            translate([-SADDLE_W/2, -SADDLE_W/2, 0])
-                cube([SADDLE_W, SADDLE_W, SADDLE_T]);
-
-            // ── T-nut tongue (enters rail T-groove from above) ────────────
-            translate([-TNUT_W/2, -TNUT_L/2, -SLOT_NECK_H])
-                cube([TNUT_W, TNUT_L, SLOT_NECK_H + e]);
-
-            // ── T-nut inner body (locks in groove) ────────────────────────
-            translate([-TNUT_W/2, -TNUT_L/2, -SLOT_NECK_H - (TNUT_H - SLOT_NECK_H)])
-                cube([TNUT_W, TNUT_L, TNUT_H - SLOT_NECK_H + e]);
-        }
-
-        // ── Rail channel clearance (bottom of saddle straddles rail) ──────
-        // Saddle body has a channel that sits over the rail top face
-        translate([-RAIL_W/2 - e, -SADDLE_W/2 - e, -e])
-            cube([RAIL_W + 2*e, SADDLE_W + 2*e, 2.0]);
-
-        // ── M3 clamp bolt bore (through saddle body into T-nut) ───────────
-        translate([0, 0, -SLOT_NECK_H - TNUT_H - e])
-            cylinder(d = TNUT_BOLT_D, h = SADDLE_T + TNUT_H + 2*e);
-
-        // ── M3 hex nut pocket (top face of saddle for thumbscrew) ─────────
-        translate([0, 0, SADDLE_T - TNUT_NUT_H - 0.5])
-            cylinder(d = TNUT_NUT_AF / cos(30),
-                     h = TNUT_NUT_H + 0.6, $fn = 6);
-
-        // ── Tray boss socket (top face of saddle, tray boss nests here) ───
-        // Cylindrical socket receives tray underside boss; M3 bolt centres
-        translate([0, 0, SADDLE_T - 3])
-            cylinder(d = sock_d + 0.4, h = 3 + e);
-
-        // ── M3 tray bolt bore (vertical, through saddle top) ──────────────
-        translate([0, 0, SADDLE_T - 3 - e])
-            cylinder(d = M3_D, h = SADDLE_T + e);
-
-        // ── Anti-slip pad recess (bottom face, optional rubber adhesive) ──
-        translate([0, 0, -e])
-            cylinder(d = SADDLE_W - 8, h = SADDLE_PAD_T + e);
-
-        // ── Lightening pockets ─────────────────────────────────────────────
-        for (lx = [-1, 1], ly = [-1, 1])
-            translate([lx*8, ly*8, -e])
-                cylinder(d = 5, h = SADDLE_T - 3 - 1 + e);
-    }
-}
-
-// ============================================================
-// PART 3 — STRAP GUIDE
-// ============================================================
-// Snap-on guide that sits on top of tray wall at each strap slot,
-// directing the 25 mm Velcro strap from the side slot up and over
-// the battery top.  Four per tray, one at each slot exit.
-// Curved lip prevents strap from cutting into PETG wall edge.
-// Push-fit onto tray wall top; no fasteners required.
-//
-// Print: flat base on bed, PETG, 3 perims, 20% infill.
-module strap_guide() {
-    strap_w_clr = STRAP_W + 0.5;   // strap slot with clearance
-    lip_r       = 3.0;              // guide lip radius
-
-    difference() {
-        union() {
-            // ── Body (sits on tray wall top edge) ─────────────────────────
-            translate([-GUIDE_OD/2, 0, 0])
-                cube([GUIDE_OD, GUIDE_T, GUIDE_BODY_H]);
-
-            // ── Curved guide lip (top of body, strap bends around this) ───
-            translate([0, GUIDE_T/2, GUIDE_BODY_H])
-                rotate([0, 90, 0])
-                    cylinder(r = lip_r, h = GUIDE_OD, center = true);
-
-            // ── Wall engagement tabs (snap over tray wall top) ────────────
-            for (sy = [0, -(TRAY_WALL_T + GUIDE_T)])
-                translate([-strap_w_clr/2 - 3, sy - GUIDE_T, 0])
-                    cube([strap_w_clr + 6, GUIDE_T, GUIDE_BODY_H * 0.4]);
-        }
-
-        // ── Strap slot (through body) ──────────────────────────────────────
-        translate([-strap_w_clr/2, -e, -e])
-            cube([strap_w_clr, GUIDE_T + 2*e, GUIDE_BODY_H + 2*e]);
-
-        // ── Wall clearance slot (body slides over tray wall) ──────────────
-        translate([-strap_w_clr/2 - 3 - e,
-                   -TRAY_WALL_T - GUIDE_T, -e])
-            cube([strap_w_clr + 6 + 2*e,
-                  TRAY_WALL_T, GUIDE_BODY_H * 0.4 + 2*e]);
-
-        // ── Lightening pockets on side faces ──────────────────────────────
-        for (lx = [-GUIDE_OD/4, GUIDE_OD/4])
-            translate([lx, GUIDE_T/2, GUIDE_BODY_H/2])
-                cube([6, GUIDE_T + 2*e, GUIDE_BODY_H * 0.5], center = true);
-    }
-}

chassis/cable_tray.scad

@@ -1,410 +0,0 @@
-// ============================================================
-// Cable Management Tray — Issue #628
-// Agent   : sl-mechanical
-// Date    : 2026-03-15
-// Part catalogue:
-//   1. tray_body     — under-plate tray with snap-in cable channels, Velcro
-//                      tie-down slots every 40 mm, pass-through holes, label slots
-//   2. tnut_bracket  — 2020 T-nut rail mount bracket (×2, slide under tray)
-//   3. channel_clip  — snap-in divider clip separating power / signal / servo zones
-//   4. cover_panel   — hinged snap-on lid (living-hinge PETG flexure strip)
-//   5. cable_saddle  — individual cable saddle / strain-relief clip (×n)
-//
-// BOM:
-//   4 × M5×10 BHCS + M5 T-nuts    (tnut_bracket × 2 to rail)
-//   4 × M3×8  SHCS                (tnut_bracket to tray body)
-//   n × 100 mm Velcro tie-down strips (through 6×2 mm slots, every 40 mm)
-//
-// Cable channel layout (X axis, inside tray):
-//   Zone A — Power  (2S–6S LiPo, XT60/XT30): 20 mm wide, 14 mm deep
-//   Zone B — Signal (JST-SH, PWM, I2C, UART): 14 mm wide, 10 mm deep
-//   Zone C — Servo  (JST-PH, thick servo leads): 14 mm wide, 12 mm deep
-//   Divider walls: 2.5 mm thick between zones
-//
-// Print settings (PETG):
-//   tray_body / tnut_bracket / channel_clip : 5 perimeters, 40 % gyroid, no supports
-//   cover_panel                             : 3 perimeters, 20 % gyroid, no supports
-//                                             (living-hinge — print flat, thin strip flexes)
-//   cable_saddle                            : 3 perimeters, 30 % gyroid, no supports
-//
-// Export commands:
-//   openscad -D 'RENDER="tray_body"'     -o tray_body.stl     cable_tray.scad
-//   openscad -D 'RENDER="tnut_bracket"'  -o tnut_bracket.stl  cable_tray.scad
-//   openscad -D 'RENDER="channel_clip"'  -o channel_clip.stl  cable_tray.scad
-//   openscad -D 'RENDER="cover_panel"'   -o cover_panel.stl   cable_tray.scad
-//   openscad -D 'RENDER="cable_saddle"'  -o cable_saddle.stl  cable_tray.scad
-//   openscad -D 'RENDER="assembly"'      -o assembly.png      cable_tray.scad
-// ============================================================
-
-RENDER = "assembly"; // tray_body | tnut_bracket | channel_clip | cover_panel | cable_saddle | assembly
-
-$fn = 48;
-EPS = 0.01;
-
-// ── 2020 rail constants ──────────────────────────────────────
-RAIL_W      = 20.0;
-TNUT_W      =  9.8;
-TNUT_H      =  5.5;
-TNUT_L      = 12.0;
-SLOT_NECK_H =  3.2;
-M5_D        =  5.2;
-M5_HEAD_D   =  9.5;
-M5_HEAD_H   =  4.0;
-
-// ── Tray geometry ────────────────────────────────────────────
-TRAY_L      = 280.0;  // length along rail (7 × 40 mm tie-down pitch)
-TRAY_W      =  60.0;  // width across rail (covers standard 40 mm rail pair)
-TRAY_WALL   =   2.5;  // side / floor wall thickness
-TRAY_DEPTH  =  18.0;  // interior depth (tallest zone + wall)
-
-// Cable channel zones (widths must sum to TRAY_W - 2*TRAY_WALL - 2*DIV_T)
-DIV_T       =   2.5;  // divider wall thickness
-ZONE_A_W    =  20.0;  // Power
-ZONE_A_D    =  14.0;
-ZONE_B_W    =  14.0;  // Signal
-ZONE_B_D    =  10.0;
-ZONE_C_W    =  14.0;  // Servo
-ZONE_C_D    =  12.0;
-// Total inner width used: ZONE_A_W + ZONE_B_W + ZONE_C_W + 2*DIV_T = 55 mm < TRAY_W - 2*TRAY_WALL = 55 mm ✓
-
-// Tie-down slots (Velcro strips)
-TIEDOWN_PITCH = 40.0;
-TIEDOWN_W   =   6.0;  // slot width (fits 6 mm wide Velcro)
-TIEDOWN_T   =   2.2;  // slot through-thickness (floor)
-TIEDOWN_CNT = 7;      // 7 positions along tray
-
-// Pass-through holes in floor
-PASSTHRU_D  =  12.0;  // circular grommet-compatible pass-through
-PASSTHRU_CNT = 3;     // one per zone, at tray mid-length
-
-// Label slots (rear outer wall)
-LABEL_W     =  24.0;
-LABEL_H     =   8.0;
-LABEL_T     =   1.0;  // depth from outer face
-
-// Snap ledge for cover
-SNAP_LEDGE_H =  2.5;
-SNAP_LEDGE_D =  1.5;
-
-// ── T-nut bracket ────────────────────────────────────────────
-BKT_L       =  60.0;
-BKT_W       =  TRAY_W;
-BKT_T       =   6.0;
-BOLT_PITCH  =  40.0;
-M3_D        =   3.2;
-M3_HEAD_D   =   6.0;
-M3_HEAD_H   =   3.0;
-M3_NUT_W    =   5.5;
-M3_NUT_H    =   2.4;
-
-// ── Cover panel ──────────────────────────────────────────────
-CVR_T       =   1.8;  // panel thickness
-HINGE_T     =   0.6;  // living-hinge strip thickness (printed in PETG)
-HINGE_W     =   3.0;  // hinge strip width (flexes easily)
-SNAP_HOOK_H =   3.5;  // snap hook height
-SNAP_HOOK_T =   2.2;
-
-// ── Cable saddle ─────────────────────────────────────────────
-SAD_W       =  12.0;
-SAD_H       =   8.0;
-SAD_T       =   2.5;
-SAD_BORE_D  =   7.0;  // cable bundle bore
-SAD_CLIP_T  =   1.6;  // snap arm thickness
-
-// ── Utilities ────────────────────────────────────────────────
-module chamfer_cube(size, ch=1.0) {
-    hull() {
-        translate([ch, ch, 0])   cube([size[0]-2*ch, size[1]-2*ch, EPS]);
-        translate([0, 0, ch])    cube(size - [0, 0, ch]);
-    }
-}
-
-module hex_pocket(af, depth) {
-    cylinder(d=af/cos(30), h=depth, $fn=6);
-}
-
-// ── Part 1: tray_body ───────────────────────────────────────
-module tray_body() {
-    difference() {
-        // Outer shell
-        union() {
-            chamfer_cube([TRAY_L, TRAY_W, TRAY_DEPTH + TRAY_WALL], ch=1.5);
-
-            // Snap ledge along top of both long walls (for cover_panel)
-            for (y = [-SNAP_LEDGE_D, TRAY_W])
-                translate([0, y, TRAY_DEPTH])
-                    cube([TRAY_L, TRAY_WALL + SNAP_LEDGE_D, SNAP_LEDGE_H]);
-        }
-
-        // Interior cavity
-        translate([TRAY_WALL, TRAY_WALL, TRAY_WALL])
-            cube([TRAY_L - 2*TRAY_WALL, TRAY_W - 2*TRAY_WALL,
-                  TRAY_DEPTH + EPS]);
-
-        // ── Zone dividers (subtract from solid to leave walls) ──
-        // Zone A (Power) inner floor cut — full depth A
-        translate([TRAY_WALL, TRAY_WALL, TRAY_WALL + (TRAY_DEPTH - ZONE_A_D)])
-            cube([TRAY_L - 2*TRAY_WALL, ZONE_A_W, ZONE_A_D + EPS]);
-
-        // Zone B (Signal) inner floor cut
-        translate([TRAY_WALL, TRAY_WALL + ZONE_A_W + DIV_T,
-                   TRAY_WALL + (TRAY_DEPTH - ZONE_B_D)])
-            cube([TRAY_L - 2*TRAY_WALL, ZONE_B_W, ZONE_B_D + EPS]);
-
-        // Zone C (Servo) inner floor cut
-        translate([TRAY_WALL, TRAY_WALL + ZONE_A_W + DIV_T + ZONE_B_W + DIV_T,
-                   TRAY_WALL + (TRAY_DEPTH - ZONE_C_D)])
-            cube([TRAY_L - 2*TRAY_WALL, ZONE_C_W, ZONE_C_D + EPS]);
-
-        // ── Velcro tie-down slots (floor, every 40 mm) ──────────
-        for (i = [0:TIEDOWN_CNT-1]) {
-            x = TRAY_WALL + 20 + i * TIEDOWN_PITCH - TIEDOWN_W/2;
-            // Zone A slot
-            translate([x, TRAY_WALL + 2, -EPS])
-                cube([TIEDOWN_W, ZONE_A_W - 4, TRAY_WALL + 2*EPS]);
-            // Zone B slot
-            translate([x, TRAY_WALL + ZONE_A_W + DIV_T + 2, -EPS])
-                cube([TIEDOWN_W, ZONE_B_W - 4, TRAY_WALL + 2*EPS]);
-            // Zone C slot
-            translate([x, TRAY_WALL + ZONE_A_W + DIV_T + ZONE_B_W + DIV_T + 2, -EPS])
-                cube([TIEDOWN_W, ZONE_C_W - 4, TRAY_WALL + 2*EPS]);
-        }
-
-        // ── Pass-through holes in floor (centre of each zone at mid-length) ──
-        mid_x = TRAY_L / 2;
-        // Zone A
-        translate([mid_x, TRAY_WALL + ZONE_A_W/2, -EPS])
-            cylinder(d=PASSTHRU_D, h=TRAY_WALL + 2*EPS);
-        // Zone B
-        translate([mid_x, TRAY_WALL + ZONE_A_W + DIV_T + ZONE_B_W/2, -EPS])
-            cylinder(d=PASSTHRU_D, h=TRAY_WALL + 2*EPS);
-        // Zone C
-        translate([mid_x, TRAY_WALL + ZONE_A_W + DIV_T + ZONE_B_W + DIV_T + ZONE_C_W/2, -EPS])
-            cylinder(d=PASSTHRU_D, h=TRAY_WALL + 2*EPS);
-
-        // ── Label slots on front wall (y = 0) — one per zone ────
-        zone_ctrs = [TRAY_WALL + ZONE_A_W/2,
-                     TRAY_WALL + ZONE_A_W + DIV_T + ZONE_B_W/2,
-                     TRAY_WALL + ZONE_A_W + DIV_T + ZONE_B_W + DIV_T + ZONE_C_W/2];
-        label_z = TRAY_WALL + 2;
-        for (yc = zone_ctrs)
-            translate([TRAY_L/2 - LABEL_W/2, -EPS, label_z])
-                cube([LABEL_W, LABEL_T + EPS, LABEL_H]);
-
-        // ── M3 bracket bolt holes in floor (4 corners) ──────────
-        for (x = [20, TRAY_L - 20])
-            for (y = [TRAY_W/4, 3*TRAY_W/4])
-                translate([x, y, -EPS])
-                    cylinder(d=M3_D, h=TRAY_WALL + 2*EPS);
-
-        // ── Channel clip snap sockets (top of each divider, every 80 mm) ──
-        for (i = [0:2]) {
-            cx = 40 + i * 80;
-            for (dy = [ZONE_A_W, ZONE_A_W + DIV_T + ZONE_B_W])
-                translate([cx - 3, TRAY_WALL + dy - 1, TRAY_DEPTH - 4])
-                    cube([6, DIV_T + 2, 4 + EPS]);
-        }
-    }
-
-    // ── Divider walls (positive geometry) ───────────────────
-    // Wall between Zone A and Zone B
-    translate([TRAY_WALL, TRAY_WALL + ZONE_A_W, TRAY_WALL])
-        cube([TRAY_L - 2*TRAY_WALL, DIV_T,
-              TRAY_DEPTH - ZONE_A_D]);  // partial height — lower in A zone
-
-    // Wall between Zone B and Zone C
-    translate([TRAY_WALL, TRAY_WALL + ZONE_A_W + DIV_T + ZONE_B_W, TRAY_WALL])
-        cube([TRAY_L - 2*TRAY_WALL, DIV_T,
-              TRAY_DEPTH - ZONE_B_D]);
-}
-
-// ── Part 2: tnut_bracket ────────────────────────────────────
-module tnut_bracket() {
-    difference() {
-        chamfer_cube([BKT_L, BKT_W, BKT_T], ch=1.5);
-
-        // M5 T-nut holes (2 per bracket, on rail centreline)
-        for (x = [BKT_L/2 - BOLT_PITCH/2, BKT_L/2 + BOLT_PITCH/2]) {
-            translate([x, BKT_W/2, -EPS]) {
-                cylinder(d=M5_D, h=BKT_T + 2*EPS);
-                cylinder(d=M5_HEAD_D, h=M5_HEAD_H + EPS);
-            }
-            translate([x - TNUT_L/2, BKT_W/2 - TNUT_W/2, BKT_T - TNUT_H])
-                cube([TNUT_L, TNUT_W, TNUT_H + EPS]);
-        }
-
-        // M3 tray-attachment holes (4 corners)
-        for (x = [10, BKT_L - 10])
-            for (y = [10, BKT_W - 10]) {
-                translate([x, y, -EPS])
-                    cylinder(d=M3_D, h=BKT_T + 2*EPS);
-                // M3 hex nut captured pocket (from top)
-                translate([x, y, BKT_T - M3_NUT_H - 0.2])
-                    hex_pocket(M3_NUT_W + 0.3, M3_NUT_H + 0.3);
-            }
-
-        // Weight relief
-        translate([15, 8, -EPS])
-            cube([BKT_L - 30, BKT_W - 16, BKT_T/2]);
-    }
-}
-
-// ── Part 3: channel_clip ────────────────────────────────────
-// Snap-in clip that locks into divider-wall snap sockets;
-// holds individual bundles in their zone and acts as colour-coded zone marker.
-module channel_clip() {
-    clip_body_w = 6.0;
-    clip_body_h = DIV_T + 4.0;
-    clip_body_t = 8.0;
-    tab_h = 3.5;
-    tab_w = 2.5;
-
-    difference() {
-        union() {
-            // Body spanning divider
-            cube([clip_body_t, clip_body_w, clip_body_h]);
-
-            // Snap tabs (bottom, straddle divider)
-            for (s = [0, clip_body_w - tab_w])
-                translate([clip_body_t/2 - 1, s, -tab_h])
-                    cube([2, tab_w, tab_h + 1]);
-        }
-
-        // Cable radius slot on each face
-        translate([-EPS, clip_body_w/2, clip_body_h * 0.6])
-            rotate([0, 90, 0])
-                cylinder(d=5.0, h=clip_body_t + 2*EPS);
-
-        // Snap tab undercut for flex
-        for (s = [0, clip_body_w - tab_w])
-            translate([clip_body_t/2 - 2, s - EPS, -tab_h + 1.5])
-                cube([4, tab_w + 2*EPS, 1.5]);
-    }
-}
-
-// ── Part 4: cover_panel ─────────────────────────────────────
-// Flat snap-on lid with living-hinge along one long edge.
-// Print flat; PETG living hinge flexes ~90° to snap onto tray.
-module cover_panel() {
-    total_w = TRAY_W + 2 * SNAP_HOOK_T;
-
-    difference() {
-        union() {
-            // Main panel
-            cube([TRAY_L, TRAY_W, CVR_T]);
-
-            // Living hinge strip along back edge (thin, flexes)
-            translate([0, TRAY_W - EPS, 0])
-                cube([TRAY_L, HINGE_W, HINGE_T]);
-
-            // Snap hooks along front edge (clips under tray snap ledge)
-            for (x = [20, TRAY_L/2 - 20, TRAY_L/2 + 20, TRAY_L - 20])
-                translate([x - SNAP_HOOK_T/2, -SNAP_HOOK_H + EPS, 0])
-                    difference() {
-                        cube([SNAP_HOOK_T, SNAP_HOOK_H, CVR_T + 1.5]);
-                        // Hook nose chamfer
-                        translate([-EPS, -EPS, CVR_T])
-                            rotate([0, 0, 0])
-                                cube([SNAP_HOOK_T + 2*EPS, 1.5, 1.5]);
-                    }
-        }
-
-        // Ventilation slots (3 rows × 6 slots)
-        for (row = [0:2])
-            for (col = [0:5]) {
-                sx = 20 + col * 40 + row * 10;
-                sy = 10 + row * 12;
-                if (sx + 25 < TRAY_L && sy + 6 < TRAY_W)
-                    translate([sx, sy, -EPS])
-                        cube([25, 6, CVR_T + 2*EPS]);
-            }
-
-        // Zone label windows (align with tray label slots)
-        zone_ctrs = [TRAY_WALL + ZONE_A_W/2,
-                     TRAY_WALL + ZONE_A_W + DIV_T + ZONE_B_W/2,
-                     TRAY_WALL + ZONE_A_W + DIV_T + ZONE_B_W + DIV_T + ZONE_C_W/2];
-        for (yc = zone_ctrs)
-            translate([TRAY_L/2 - LABEL_W/2, yc - LABEL_H/2, -EPS])
-                cube([LABEL_W, LABEL_H, CVR_T + 2*EPS]);
-    }
-}
-
-// ── Part 5: cable_saddle ────────────────────────────────────
-// Snap-in cable saddle / strain-relief clip; press-fits onto tray top edge.
-module cable_saddle() {
-    arm_gap = TRAY_WALL + 0.4;  // fits over tray wall
-    arm_len = 8.0;
-
-    difference() {
-        union() {
-            // Body
-            chamfer_cube([SAD_W, SAD_T * 2 + arm_gap, SAD_H], ch=1.0);
-
-            // Cable retaining arch
-            translate([SAD_W/2, SAD_T + arm_gap/2, SAD_H])
-                scale([1, 0.6, 1])
-                    difference() {
-                        cylinder(d=SAD_BORE_D + SAD_CLIP_T * 2, h=SAD_T);
-                        translate([0, 0, -EPS])
-                            cylinder(d=SAD_BORE_D, h=SAD_T + 2*EPS);
-                        translate([-SAD_BORE_D, 0, -EPS])
-                            cube([SAD_BORE_D * 2, SAD_BORE_D, SAD_T + 2*EPS]);
-                    }
-        }
-
-        // Slot for tray wall (negative)
-        translate([0, SAD_T, -EPS])
-            cube([SAD_W, arm_gap, arm_len + EPS]);
-
-        // M3 tie-down hole
-        translate([SAD_W/2, SAD_T + arm_gap/2, -EPS])
-            cylinder(d=M3_D, h=SAD_H + 2*EPS);
-    }
-}
-
-// ── Assembly ────────────────────────────────────────────────
-module assembly() {
-    // Tray body (open face up for visibility)
-    color("SteelBlue")
-        tray_body();
-
-    // Two T-nut brackets underneath at 1/4 and 3/4 length
-    for (bx = [TRAY_L/4 - BKT_L/2, 3*TRAY_L/4 - BKT_L/2])
-        color("DodgerBlue")
-            translate([bx, 0, -BKT_T])
-                tnut_bracket();
-
-    // Channel clips (3 per divider position, every 80 mm)
-    for (i = [0:2]) {
-        cx = 40 + i * 80;
-        // Divider A/B
-        color("Tomato", 0.8)
-            translate([cx - 4, TRAY_WALL + ZONE_A_W - 2, TRAY_DEPTH - 3])
-                channel_clip();
-        // Divider B/C
-        color("Orange", 0.8)
-            translate([cx - 4,
-                       TRAY_WALL + ZONE_A_W + DIV_T + ZONE_B_W - 2,
-                       TRAY_DEPTH - 3])
-                channel_clip();
-    }
-
-    // Cover panel (raised above tray to show interior)
-    color("LightSteelBlue", 0.5)
-        translate([0, 0, TRAY_DEPTH + SNAP_LEDGE_H + 4])
-            cover_panel();
-
-    // Cable saddles along front tray edge
-    for (x = [40, 120, 200])
-        color("SlateGray")
-            translate([x - SAD_W/2, -SAD_T * 2 - TRAY_WALL, 0])
-                cable_saddle();
-}
-
-// ── Dispatch ────────────────────────────────────────────────
-if      (RENDER == "tray_body")    tray_body();
-else if (RENDER == "tnut_bracket") tnut_bracket();
-else if (RENDER == "channel_clip") channel_clip();
-else if (RENDER == "cover_panel")  cover_panel();
-else if (RENDER == "cable_saddle") cable_saddle();
-else                               assembly();

chassis/canable_mount.scad

@@ -1,265 +0,0 @@
-// ============================================================
-// canable_mount.scad — CANable 2.0 USB-CAN Adapter Cradle
-// Issue #654 / sl-mechanical  2026-03-16
-// ============================================================
-// Snap-fit cradle for CANable 2.0 PCB (~60 × 18 × 10 mm).
-// Attaches to 2020 aluminium T-slot rail via 2× M5 T-nuts.
-//
-// Port access:
-//   USB-C port       — X− end wall cutout (connector protrudes through)
-//   CAN terminal     — X+ end wall cutout (CANH / CANL / GND wire exit)
-//   LED status window— slot in Y+ side wall, PCB top-face LEDs visible
-//
-// Retention: snap-fit cantilever lips on both side walls (PETG flex).
-// Cable strain relief: zip-tie boss pair on X+ shelf (CAN wires).
-//
-// ⚠  VERIFY WITH CALIPERS BEFORE PRINTING:
-//    PCB_L, PCB_W          board outline
-//    USBC_W, USBC_H        USB-C shell at X− edge
-//    TERM_W, TERM_H        3-pos terminal block at X+ edge
-//    LED_X_CTR, LED_WIN_W  LED window position on Y+ wall
-//
-// Print settings (PETG):
-//   3 perimeters, 40 % gyroid infill, no supports, 0.2 mm layer
-//   Print orientation: open face UP (as modelled)
-//
-// BOM:
-//   2 × M5×10 BHCS  +  2 × M5 slide-in T-nut  (2020 rail)
-//
-// Export commands:
-//   openscad -D 'RENDER="mount"'    -o canable_mount.stl    canable_mount.scad
-//   openscad -D 'RENDER="assembly"' -o canable_assembly.png canable_mount.scad
-// ============================================================
-
-RENDER = "assembly"; // mount | assembly
-
-$fn = 48;
-EPS = 0.01;
-
-// ── ⚠ Verify before printing ─────────────────────────────────
-// CANable 2.0 PCB
-PCB_L    = 60.0;   // board length  (X: USB-C end → terminal end)
-PCB_W    = 18.0;   // board width   (Y)
-PCB_T    =  1.6;   // board thickness
-COMP_H   =  8.5;   // tallest component above board (USB-C shell ≈ 3.5 mm;
-                   //   terminal block ≈ 8.5 mm)
-
-// USB-C connector (at X− end face of PCB)
-USBC_W   =  9.5;   // connector outer width
-USBC_H   =  3.8;   // connector outer height above board surface
-USBC_Z0  =  0.0;   // connector bottom offset above board surface
-
-// CAN screw-terminal block (at X+ end face, 3-pos 5.0 mm pitch)
-TERM_W   = 16.0;   // terminal block span (3 × 5 mm + housing)
-TERM_H   =  9.0;   // terminal block height above board surface
-TERM_Z0  =  0.5;   // terminal bottom offset above board surface
-
-// Status LED window (LEDs near USB-C end on PCB top face)
-//   Rectangular slot cut in Y+ side wall — LEDs visible from the side
-LED_X_CTR  = 11.0;  // LED zone centre measured from PCB X− edge
-LED_WIN_W  = 14.0;  // window width (X)
-LED_WIN_H  =  5.5;  // window height (Z) — opens top portion of side wall
-
-// ── Cradle geometry ──────────────────────────────────────────
-WALL_T   = 2.5;    // side/end wall thickness
-FLOOR_T  = 4.0;    // floor plate thickness (accommodates M5 BHCS head pocket)
-CL_SIDE  = 0.30;   // Y clearance per side (total 0.6 mm play)
-CL_END   = 0.40;   // X clearance per end
-
-// Interior cavity
-INN_W    = PCB_W + 2*CL_SIDE;          // Y span
-INN_L    = PCB_L + 2*CL_END;           // X span
-INN_H    = PCB_T + COMP_H + 1.2;       // Z height (board + tallest comp + margin)
-
-// Outer body
-OTR_W    = INN_W  + 2*WALL_T;          // Y
-OTR_L    = INN_L  + 2*WALL_T;          // X
-OTR_H    = FLOOR_T + INN_H;            // Z
-
-// PCB reference origin within body (lower-left corner of board)
-PCB_X0   = WALL_T + CL_END;            // board X start inside body
-PCB_Y0   = WALL_T + CL_SIDE;           // board Y start inside body
-PCB_Z0   = FLOOR_T;                    // board bottom sits on floor
-
-// ── Snap-fit lips ─────────────────────────────────────────────
-// Cantilever ledge on inner face of each side wall, at PCB-top Z.
-// Tapered (chamfered) entry guides PCB in from above.
-SNAP_IN  = 0.8;    // how far inward ledge protrudes over PCB edge
-SNAP_T   = 1.2;    // snap-arm thickness (thin for PETG flex)
-SNAP_H   = 4.0;    // cantilever arm height (root at OTR_H, tip near PCB_Z0+PCB_T)
-SNAP_L   = 18.0;   // arm length along X (centred on PCB, shorter = more flex)
-// Snap on Y− wall protrudes in +Y direction; Y+ wall protrudes in −Y direction
-
-// ── M5 T-nut mount (2020 rail) ────────────────────────────────
-M5_D       =  5.3;   // M5 bolt clearance bore
-M5_HEAD_D  =  9.5;   // M5 BHCS head pocket diameter (from bottom face)
-M5_HEAD_H  =  3.0;   // BHCS head pocket depth
-M5_SPAC    = 20.0;   // bolt spacing along X (centred on cradle)
-// Standard M5 slide-in T-nuts used — no T-nut pocket moulded in.
-
-// ── Cable strain relief ───────────────────────────────────────
-// Two zip-tie anchor bosses on a shelf inside the X+ end, straddling
-// the CAN terminal wires.
-SR_BOSS_OD =  7.0;   // boss outer diameter
-SR_BOSS_H  =  5.5;   // boss height above floor
-SR_SLOT_W  =  3.5;   // zip-tie slot width
-SR_SLOT_T  =  2.2;   // zip-tie slot through-height
-// Boss Y positions (straddle terminal block)
-SR_Y1      = WALL_T + INN_W * 0.25;
-SR_Y2      = WALL_T + INN_W * 0.75;
-SR_X       = OTR_L - WALL_T - SR_BOSS_OD/2 - 2.5;  // just inside X+ end wall
-
-// ─────────────────────────────────────────────────────────────
-module canable_mount() {
-    difference() {
-        // ── Outer solid body ──────────────────────────────────
-        union() {
-            cube([OTR_L, OTR_W, OTR_H]);
-
-            // ── Snap cantilever arms on Y− wall (protrude inward +Y) ──
-            // Arms hang down from top of Y− wall inner face.
-            // Root is flush with inner face (Y = WALL_T); tip at PCB level.
-            translate([OTR_L/2 - SNAP_L/2, WALL_T - SNAP_T, OTR_H - SNAP_H])
-                cube([SNAP_L, SNAP_T, SNAP_H]);
-
-            // ── Snap cantilever arms on Y+ wall (protrude inward −Y) ──
-            translate([OTR_L/2 - SNAP_L/2, OTR_W - WALL_T, OTR_H - SNAP_H])
-                cube([SNAP_L, SNAP_T, SNAP_H]);
-
-            // ── Cable strain relief bosses (X+ end, inside) ────
-            for (sy = [SR_Y1, SR_Y2])
-                translate([SR_X, sy, 0])
-                    cylinder(d=SR_BOSS_OD, h=SR_BOSS_H);
-        }
-
-        // ── Interior cavity ───────────────────────────────────
-        translate([WALL_T, WALL_T, FLOOR_T])
-            cube([INN_L, INN_W, INN_H + EPS]);
-
-        // ── USB-C cutout — X− end wall ────────────────────────
-        // Centred on PCB width; opened from board surface upward
-        translate([-EPS,
-                   PCB_Y0 + PCB_W/2 - (USBC_W + 1.5)/2,
-                   PCB_Z0 + USBC_Z0 - 0.5])
-            cube([WALL_T + 2*EPS, USBC_W + 1.5, USBC_H + 2.5]);
-
-        // ── CAN terminal cutout — X+ end wall ─────────────────
-        // Full terminal width + 2 mm margin for screwdriver access;
-        // height clears terminal block + wire bend radius
-        translate([OTR_L - WALL_T - EPS,
-                   PCB_Y0 + PCB_W/2 - (TERM_W + 2.0)/2,
-                   PCB_Z0 + TERM_Z0 - 0.5])
-            cube([WALL_T + 2*EPS, TERM_W + 2.0, TERM_H + 5.0]);
-
-        // ── LED status window — Y+ side wall ─────────────────
-        // Rectangular slot; LEDs at top-face of PCB are visible through it
-        translate([PCB_X0 + LED_X_CTR - LED_WIN_W/2,
-                   OTR_W - WALL_T - EPS,
-                   OTR_H - LED_WIN_H])
-            cube([LED_WIN_W, WALL_T + 2*EPS, LED_WIN_H + EPS]);
-
-        // ── M5 BHCS head pockets (from bottom face of floor) ──
-        for (mx = [OTR_L/2 - M5_SPAC/2, OTR_L/2 + M5_SPAC/2])
-            translate([mx, OTR_W/2, -EPS]) {
-                // Clearance bore through full floor
-                cylinder(d=M5_D, h=FLOOR_T + 2*EPS);
-                // BHCS head pocket from bottom face
-                cylinder(d=M5_HEAD_D, h=M5_HEAD_H + EPS);
-            }
-
-        // ── Snap-arm ledge slot — Y− arm (hollow out to thin arm) ──
-        // Arm is SNAP_T thick; cut away material behind arm
-        translate([OTR_L/2 - SNAP_L/2 - EPS, EPS, OTR_H - SNAP_H])
-            cube([SNAP_L + 2*EPS, WALL_T - SNAP_T - EPS, SNAP_H + EPS]);
-
-        // ── Snap-arm ledge slot — Y+ arm ──────────────────────
-        translate([OTR_L/2 - SNAP_L/2 - EPS, OTR_W - WALL_T + SNAP_T, OTR_H - SNAP_H])
-            cube([SNAP_L + 2*EPS, WALL_T - SNAP_T - EPS, SNAP_H + EPS]);
-
-        // ── Snap-arm inward ledge notch (entry chamfer removed) ─
-        // Chamfer top of snap arm so PCB slides in easily
-        // Y− arm: chamfer on upper-inner edge → 45° wedge on +Y/+Z corner
-        translate([OTR_L/2 - SNAP_L/2 - EPS,
-                   WALL_T - SNAP_T - EPS,
-                   OTR_H - SNAP_IN])
-            rotate([0, 0, 0])
-            rotate([45, 0, 0])
-                cube([SNAP_L + 2*EPS, SNAP_IN * 1.5, SNAP_IN * 1.5]);
-
-        // Y+ arm: chamfer on upper-inner edge
-        translate([OTR_L/2 - SNAP_L/2 - EPS,
-                   OTR_W - WALL_T + SNAP_T - SNAP_IN * 1.5 + EPS,
-                   OTR_H - SNAP_IN])
-            rotate([45, 0, 0])
-                cube([SNAP_L + 2*EPS, SNAP_IN * 1.5, SNAP_IN * 1.5]);
-
-        // ── Snap ledge cutout on Y− arm inner tip ─────────────
-        // Creates inward nub: remove top portion of arm inner tip
-        // leaving bottom SNAP_IN height as the retaining ledge
-        translate([OTR_L/2 - SNAP_L/2 - EPS,
-                   WALL_T - SNAP_T - EPS,
-                   PCB_Z0 + PCB_T + SNAP_IN])
-            cube([SNAP_L + 2*EPS, SNAP_T + 2*EPS,
-                  OTR_H - (PCB_Z0 + PCB_T + SNAP_IN) + EPS]);
-
-        // ── Snap ledge cutout on Y+ arm inner tip ─────────────
-        translate([OTR_L/2 - SNAP_L/2 - EPS,
-                   OTR_W - WALL_T - EPS,
-                   PCB_Z0 + PCB_T + SNAP_IN])
-            cube([SNAP_L + 2*EPS, SNAP_T + 2*EPS,
-                  OTR_H - (PCB_Z0 + PCB_T + SNAP_IN) + EPS]);
-
-        // ── Zip-tie slots through strain relief bosses ─────────
-        for (sy = [SR_Y1, SR_Y2])
-            translate([SR_X, sy,
-                       SR_BOSS_H/2 - SR_SLOT_T/2])
-                rotate([0, 90, 0])
-                    cube([SR_SLOT_T, SR_SLOT_W,
-                          SR_BOSS_OD + 2*EPS],
-                         center=true);
-
-        // ── Weight relief pocket in floor (underside) ─────────
-        translate([WALL_T + 8, WALL_T + 3, -EPS])
-            cube([OTR_L - 2*WALL_T - 16, OTR_W - 2*WALL_T - 6,
-                  FLOOR_T - 1.5 + EPS]);
-    }
-}
-
-// ── Assembly preview ─────────────────────────────────────────
-if (RENDER == "assembly") {
-    color("DimGray", 0.93) canable_mount();
-
-    // Phantom PCB
-    color("MidnightBlue", 0.35)
-        translate([PCB_X0, PCB_Y0, PCB_Z0])
-            cube([PCB_L, PCB_W, PCB_T]);
-
-    // Phantom component block (top of PCB)
-    color("DarkSlateGray", 0.25)
-        translate([PCB_X0, PCB_Y0, PCB_Z0 + PCB_T])
-            cube([PCB_L, PCB_W, COMP_H]);
-
-    // USB-C port highlight
-    color("Gold", 0.8)
-        translate([-1,
-                   PCB_Y0 + PCB_W/2 - USBC_W/2,
-                   PCB_Z0 + USBC_Z0])
-            cube([WALL_T + 2, USBC_W, USBC_H]);
-
-    // Terminal block highlight
-    color("Tomato", 0.7)
-        translate([OTR_L - WALL_T - 1,
-                   PCB_Y0 + PCB_W/2 - TERM_W/2,
-                   PCB_Z0 + TERM_Z0])
-            cube([WALL_T + 2, TERM_W, TERM_H]);
-
-    // LED zone highlight
-    color("LimeGreen", 0.9)
-        translate([PCB_X0 + LED_X_CTR - LED_WIN_W/2,
-                   OTR_W - WALL_T - 0.5,
-                   OTR_H - LED_WIN_H + 1])
-            cube([LED_WIN_W, 1, LED_WIN_H - 2]);
-
-} else {
-    canable_mount();
-}

chassis/chassis_frame.scad

@@ -8,9 +8,9 @@
 // Requirements:
 //   - 600mm wheelbase
 //   - 2x hoverboard hub motors (170mm OD)
-//   - ESP32-S3 ESP32-S3 BALANCE FC mount (30.5x30.5mm pattern)
+//   - STM32 MAMBA F722S FC mount (30.5x30.5mm pattern)
 //   - Battery tray (24V 4Ah — ~180x70x50mm pack)
-//   - Jetson Orin Nano Super B01 mount plate (100x80mm, M3 holes)
+//   - Jetson Nano B01 mount plate (100x80mm, M3 holes)
 //   - Front/rear bumper brackets
 // =============================================================================
 
@@ -37,7 +37,7 @@ MOTOR_FORK_H       = 80;    // mm, total height of motor fork bracket
 MOTOR_FORK_T       = 8;     // mm, fork plate thickness
 AXLE_HEIGHT        = 310;   // mm, axle CL above ground (motor radius + clearance)
 
-// ── FC mount (ESP32-S3 BALANCE — 30.5 × 30.5 mm M3 pattern) ──────────────────────
+// ── FC mount (MAMBA F722S — 30.5 × 30.5 mm M3 pattern) ──────────────────────
 FC_MOUNT_SPACING   = 30.5;  // mm, hole pattern pitch
 FC_MOUNT_HOLE_D    = 3.2;   // mm, M3 clearance
 FC_STANDOFF_H      = 6;     // mm, standoff height
@@ -52,7 +52,7 @@ BATT_FLOOR         = 4;     // mm, tray floor thickness
 BATT_STRAP_W       = 20;    // mm, Velcro strap slot width
 BATT_STRAP_T       = 2;     // mm, strap slot depth
 
-// ── Jetson Orin Nano Super B01 mount plate ──────────────────────────────────────────────
+// ── Jetson Nano B01 mount plate ──────────────────────────────────────────────
 // B01 carrier board hole pattern: 58 x 58 mm M3 (inner) + corner pass-throughs
 JETSON_HOLE_PITCH  = 58;    // mm, M3 mounting hole pattern
 JETSON_HOLE_D      = 3.2;   // mm
@@ -210,7 +210,7 @@ module battery_tray() {
 
 // ─── FC mount holes helper ────────────────────────────────────────────────────
 module fc_mount_holes(z_offset=0, depth=10) {
-    // ESP32-S3 BALANCE: 30.5×30.5 mm M3 pattern, centred at origin
+    // MAMBA F722S: 30.5×30.5 mm M3 pattern, centred at origin
     for (x = [-FC_MOUNT_SPACING/2, FC_MOUNT_SPACING/2])
     for (y = [-FC_MOUNT_SPACING/2, FC_MOUNT_SPACING/2])
         translate([x, y, z_offset])
@@ -247,7 +247,7 @@ module fc_mount_plate() {
     }
 }
 
-// ─── Jetson Orin Nano Super B01 mount plate ─────────────────────────────────────────────
+// ─── Jetson Nano B01 mount plate ─────────────────────────────────────────────
 // Positioned rear of deck, elevated on standoffs
 module jetson_mount_plate() {
     jet_x =  60;   // offset toward rear

chassis/gimbal_camera_mount.scad

@@ -1,599 +0,0 @@
-// ============================================================
-// gimbal_camera_mount.scad — Pan/Tilt Gimbal Mount for RealSense D435i
-// Issue: #552  Agent: sl-mechanical  Date: 2026-03-14
-// ============================================================
-//
-// Parametric gimbal bracket system mounting an Intel RealSense D435i
-// (or similar box camera) on a 2-axis pan/tilt gimbal driven by
-// ST3215 serial bus servos (25T spline, Feetech/Waveshare).
-//
-// Architecture:
-//   Pan axis  — base T-nut clamps to 2020 rail; pan servo rotates yoke
-//   Tilt axis — tilt servo horn plate bolts to ST3215 horn; camera cradle
-//               rocks on tilt axis
-//   Camera    — D435i captured via 1/4-20 UNC hex nut in cradle floor
-//   Damping   — PETG flexure ribs on camera contact faces (or TPU pads)
-//   Wiring    — USB-C cable routed through channel in cradle arm
-//
-// Part catalogue:
-//   Part 1 — tnut_rail_base()       2020 rail T-nut base + pan servo seat
-//   Part 2 — pan_yoke()             U-yoke connecting pan servo to tilt axis
-//   Part 3 — tilt_horn_plate()      Plate bolting to ST3215 tilt servo horn
-//   Part 4 — camera_cradle()        D435i cradle with 1/4-20 captured nut
-//   Part 5 — vibe_pad()             PETG flexure vibration-damping pad (×2)
-//   Part 6 — assembly_preview()     Full assembly preview
-//
-// Hardware BOM (per gimbal):
-//   2× ST3215 serial bus servo (pan + tilt)
-//   2× servo horn (25T spline, ≥Ø36 mm, 4× M3 bolt holes on Ø24 mm BC)
-//   2× M3 × 8 mm SHCS          horn-to-plate bolts (×4 each horn = 8 total)
-//   1× M3 × 16 mm SHCS + nut   T-nut rail clamp thumbscrew
-//   1× 1/4-20 UNC × 8 mm SHCS  camera retention bolt (or existing tripod screw)
-//   1× 1/4-20 UNC hex nut       captured in cradle floor
-//   4× M3 × 12 mm SHCS          yoke-to-tilt-plate pivot axle bolts
-//   2× M3 × 25 mm SHCS          pan yoke attachment to servo body
-//   (optional) 2× vibe_pad printed in TPU 95A
-//
-// ST3215 servo interface (caliper-verified Feetech ST3215):
-//   Body footprint : 40.0 × 20.0 mm (W × D), 36.5 mm tall
-//   Shaft centre H : 28.5 mm from mounting face
-//   Shaft spline   : 25T, centre Ø5.8 mm, D-cut
-//   Mount holes    : 4× M3 on 32 × 10 mm rectangular pattern (18 mm offset)
-//   Horn bolt circle: Ø24 mm, 4× M3
-//   Horn OD        : ~36 mm
-//
-// D435i camera interface (caliper-verified):
-//   Body           : 90 × 25 × 25 mm (W × D × H)
-//   Tripod thread  : 1/4-20 UNC, centred bottom face, 9 mm from front
-//   USB-C connector: right rear, 8 × 5 mm opening, 4 mm from edge
-//
-// Parametric camera size (override to adapt to other cameras):
-//   CAM_W, CAM_D, CAM_H  — body envelope
-//   CAM_MOUNT_X           — tripod hole X offset from camera centre
-//   CAM_MOUNT_Y           — tripod hole Y offset from front face
-//
-// Coordinate convention:
-//   Camera looks in +Y direction (forward)
-//   Pan axis is Z (vertical); tilt axis is X (lateral)
-//   Rail runs along Z; T-nut base at Z=0
-//   All parts at assembly origin; translate for assembly_preview
-//
-// RENDER options:
-//   "assembly"            full assembly preview (default)
-//   "tnut_rail_base_stl"  Part 1
-//   "pan_yoke_stl"        Part 2
-//   "tilt_horn_plate_stl" Part 3
-//   "camera_cradle_stl"   Part 4
-//   "vibe_pad_stl"        Part 5
-//
-// Export commands:
-//   openscad gimbal_camera_mount.scad -D 'RENDER="tnut_rail_base_stl"'  -o gcm_tnut_base.stl
-//   openscad gimbal_camera_mount.scad -D 'RENDER="pan_yoke_stl"'        -o gcm_pan_yoke.stl
-//   openscad gimbal_camera_mount.scad -D 'RENDER="tilt_horn_plate_stl"' -o gcm_tilt_horn_plate.stl
-//   openscad gimbal_camera_mount.scad -D 'RENDER="camera_cradle_stl"'   -o gcm_camera_cradle.stl
-//   openscad gimbal_camera_mount.scad -D 'RENDER="vibe_pad_stl"'        -o gcm_vibe_pad.stl
-// ============================================================
-
-$fn = 64;
-e   = 0.01;   // epsilon for boolean clearance
-
-// ── Parametric camera envelope ────────────────────────────────────────────────
-// Override these for cameras other than D435i
-CAM_W          = 90.0;   // camera body width (X)
-CAM_D          = 25.0;   // camera body depth (Y)
-CAM_H          = 25.0;   // camera body height (Z)
-CAM_MOUNT_X    =  0.0;   // tripod hole X offset from camera body centre
-CAM_MOUNT_Y    =  9.0;   // tripod hole from front face (Y)  [D435i: 9 mm]
-CAM_USBC_X     = CAM_W/2 - 4;   // USB-C connector X (right side)
-CAM_USBC_Z     = CAM_H/2;       // USB-C connector Z (mid-height rear)
-CAM_USBC_W     =  9.0;   // USB-C opening width (X)
-CAM_USBC_H     =  5.0;   // USB-C opening height (Z)
-
-// ── Rail geometry (matches sensor_rail.scad / sensor_rail_brackets.scad) ─────
-RAIL_W         = 20.0;
-SLOT_OPEN      =  6.0;
-SLOT_INNER_W   = 10.2;
-SLOT_INNER_H   =  5.8;
-SLOT_NECK_H    =  3.2;
-
-// ── T-nut geometry (matches sensor_rail_brackets.scad) ───────────────────────
-TNUT_W         =  9.8;
-TNUT_H         =  5.5;
-TNUT_L         = 12.0;
-TNUT_M3_NUT_AF =  5.5;
-TNUT_M3_NUT_H  =  2.5;
-TNUT_BOLT_D    =  3.3;   // M3 clearance
-
-// ── T-nut base plate geometry ─────────────────────────────────────────────────
-BASE_W         = 44.0;   // wide enough for pan servo body (40 mm)
-BASE_H         = 40.0;   // height along rail (Z)
-BASE_T         = SLOT_NECK_H + 2.0;   // plate depth (Y), rail-face side
-
-// ── ST3215 servo geometry ─────────────────────────────────────────────────────
-SERVO_W        = 40.0;   // servo body width (X)
-SERVO_D        = 20.0;   // servo body depth (Y)
-SERVO_H        = 36.5;   // servo body height (Z)
-SERVO_SHAFT_Z  = 28.5;   // shaft centre height from mounting face
-SERVO_HOLE_X   = 16.0;   // mount hole half-span X (32 mm span)
-SERVO_HOLE_Y   =  5.0;   // mount hole half-span Y (10 mm span)
-SERVO_M3_D     =  3.3;   // M3 clearance
-
-// ── Servo horn geometry ───────────────────────────────────────────────────────
-HORN_OD        = 36.0;   // horn outer diameter
-HORN_SPLINE_D  =  5.9;   // 25T spline bore clearance (5.8 + 0.1)
-HORN_BC_D      = 24.0;   // bolt circle diameter (4× M3)
-HORN_BOLT_D    =  3.3;   // M3 clearance through horn plate
-HORN_PLATE_T   =  5.0;   // tilt horn plate thickness
-
-// ── Yoke geometry ─────────────────────────────────────────────────────────────
-YOKE_WALL_T    =  5.0;   // yoke arm wall thickness
-YOKE_ARM_H     = 50.0;   // yoke arm height (Z) — clears servo body + camera
-YOKE_INNER_W   = CAM_W + 8.0;  // yoke inner span (camera + pad clearance)
-YOKE_BASE_T    =  8.0;   // yoke base plate thickness
-
-// ── Tilt pivot ────────────────────────────────────────────────────────────────
-PIVOT_D        =  4.3;   // M4 pivot axle bore
-PIVOT_BOSS_D   = 10.0;   // boss OD around pivot bore
-PIVOT_BOSS_L   =  6.0;   // boss protrusion from yoke wall
-
-// ── Camera cradle geometry ────────────────────────────────────────────────────
-CRADLE_WALL_T  =  4.0;   // cradle side wall thickness
-CRADLE_FLOOR_T =  5.0;   // cradle floor thickness (holds 1/4-20 nut)
-CRADLE_LIP_T   =  3.0;   // front retaining lip thickness
-CRADLE_LIP_H   =  8.0;   // front lip height
-CABLE_CH_W     = 12.0;   // USB-C cable channel width
-CABLE_CH_H     =  8.0;   // USB-C cable channel height
-
-// ── 1/4-20 UNC tripod thread ──────────────────────────────────────────────────
-QTR20_D        =  6.6;   // 1/4-20 clearance bore
-QTR20_NUT_AF   = 11.1;   // 1/4-20 hex nut across-flats (standard)
-QTR20_NUT_H    =  5.5;   // 1/4-20 hex nut height
-
-// ── Vibration-damping pad geometry ────────────────────────────────────────────
-PAD_W          = CAM_W - 2*CRADLE_WALL_T - 2;
-PAD_H          = CAM_H + 4;
-PAD_T          =  2.5;   // pad body thickness
-RIB_H          =  1.5;   // flexure rib height
-RIB_W          =  1.2;   // rib width
-RIB_PITCH      =  5.0;   // rib pitch
-
-// ── Fastener sizes ────────────────────────────────────────────────────────────
-M3_D = 3.3;
-M4_D = 4.3;
-M3_NUT_AF = 5.5;
-M3_NUT_H  = 2.4;
-
-// ============================================================
-// RENDER DISPATCH
-// ============================================================
-RENDER = "assembly";
-
-if      (RENDER == "assembly")            assembly_preview();
-else if (RENDER == "tnut_rail_base_stl")  tnut_rail_base();
-else if (RENDER == "pan_yoke_stl")        pan_yoke();
-else if (RENDER == "tilt_horn_plate_stl") tilt_horn_plate();
-else if (RENDER == "camera_cradle_stl")   camera_cradle();
-else if (RENDER == "vibe_pad_stl")        vibe_pad();
-
-// ============================================================
-// ASSEMBLY PREVIEW
-// ============================================================
-module assembly_preview() {
-    asm_rail_z = 0;
-    // Rail section ghost (200 mm)
-    %color("Silver", 0.25)
-        translate([-RAIL_W/2, -RAIL_W/2, asm_rail_z])
-            cube([RAIL_W, RAIL_W, 200]);
-
-    // T-nut rail base
-    color("OliveDrab", 0.85)
-        translate([0, 0, asm_rail_z + 80])
-            tnut_rail_base();
-
-    // Pan servo ghost (sitting in base seat)
-    %color("DimGray", 0.4)
-        translate([-SERVO_W/2, BASE_T, asm_rail_z + 80 + (BASE_H - SERVO_H)/2])
-            cube([SERVO_W, SERVO_D, SERVO_H]);
-
-    // Pan yoke rising from servo shaft
-    color("SteelBlue", 0.85)
-        translate([0, BASE_T + SERVO_D, asm_rail_z + 80 + BASE_H/2])
-            pan_yoke();
-
-    // Tilt horn plate (tilt axis — left yoke wall)
-    color("DarkOrange", 0.85)
-        translate([-YOKE_INNER_W/2 - YOKE_WALL_T - HORN_PLATE_T,
-                   BASE_T + SERVO_D + YOKE_BASE_T,
-                   asm_rail_z + 80 + BASE_H/2 + YOKE_ARM_H/2])
-            rotate([0, 90, 0])
-                tilt_horn_plate();
-
-    // Camera cradle (centred in yoke)
-    color("DarkSlateGray", 0.85)
-        translate([0, BASE_T + SERVO_D + YOKE_BASE_T + CRADLE_FLOOR_T,
-                   asm_rail_z + 80 + BASE_H/2 + YOKE_ARM_H/2 - CAM_H/2])
-            camera_cradle();
-
-    // D435i ghost
-    %color("Black", 0.4)
-        translate([-CAM_W/2,
-                   BASE_T + SERVO_D + YOKE_BASE_T + CRADLE_FLOOR_T + PAD_T,
-                   asm_rail_z + 80 + Base_H_mid() - CAM_H/2])
-            cube([CAM_W, CAM_D, CAM_H]);
-
-    // Vibe pads (front + rear camera face)
-    color("DimGray", 0.80) {
-        translate([-CAM_W/2 + CRADLE_WALL_T + 1,
-                   Base_T + SERVO_D + YOKE_BASE_T + CRADLE_FLOOR_T,
-                   asm_rail_z + 80 + Base_H_mid() - PAD_H/2])
-            rotate([90, 0, 0])
-                vibe_pad();
-    }
-}
-
-// helper (avoids recomputing same expression)
-function Base_T() = BASE_T;
-function Base_H_mid() = BASE_H/2 + YOKE_ARM_H/2;
-
-// ============================================================
-// PART 1 — T-NUT RAIL BASE  (pan servo seat + rail clamp)
-// ============================================================
-// Mounts to 2020 rail via standard T-nut tongue.
-// Front face (+Y side) provides flat seat for pan ST3215 servo body.
-// Servo body recessed 1 mm into seat for positive lateral registration.
-// Pan servo shaft axis = Z (vertical) → pan rotation about Z.
-//
-// Print: PETG, 5 perims, 50 % gyroid. Orient face-plate down (flat).
-module tnut_rail_base() {
-    difference() {
-        union() {
-            // ── Face plate (against rail outer face, -Y side) ────────────
-            translate([-BASE_W/2, -BASE_T, 0])
-                cube([BASE_W, BASE_T, BASE_H]);
-
-            // ── T-nut neck (enters rail slot, +Y side of face plate) ─────
-            translate([-TNUT_W/2, 0, (BASE_H - TNUT_L)/2])
-                cube([TNUT_W, SLOT_NECK_H + e, TNUT_L]);
-
-            // ── T-nut inner body (wider, locks inside T-groove) ──────────
-            translate([-TNUT_W/2, SLOT_NECK_H - e, (BASE_H - TNUT_L)/2])
-                cube([TNUT_W, TNUT_H - SLOT_NECK_H + e, TNUT_L]);
-
-            // ── Pan servo seat boss (front face, +Y side) ────────────────
-            // Proud pad that servo body sits on; 1 mm registration recess
-            translate([-BASE_W/2, -BASE_T, 0])
-                cube([BASE_W, BASE_T + 6, BASE_H]);
-        }
-
-        // ── Rail clamp bolt bore (M3 through face plate) ─────────────────
-        translate([0, -BASE_T - e, BASE_H/2])
-            rotate([-90, 0, 0])
-                cylinder(d = TNUT_BOLT_D, h = BASE_T + TNUT_H + 2*e);
-
-        // ── M3 hex nut pocket (inside T-nut body) ────────────────────────
-        translate([0, SLOT_NECK_H + 0.3, BASE_H/2])
-            rotate([-90, 0, 0])
-                cylinder(d = TNUT_M3_NUT_AF / cos(30),
-                         h = TNUT_M3_NUT_H + 0.3, $fn = 6);
-
-        // ── Servo body recess (1 mm registration pocket in seat face) ────
-        translate([-SERVO_W/2 - 0.3, -BASE_T + 6 - 1.0,
-                   (BASE_H - SERVO_H)/2 - 0.3])
-            cube([SERVO_W + 0.6, 1.2, SERVO_H + 0.6]);
-
-        // ── Pan servo mount holes (4× M3 in rectangular pattern) ─────────
-        for (sx = [-SERVO_HOLE_X, SERVO_HOLE_X])
-        for (sy = [-SERVO_HOLE_Y, SERVO_HOLE_Y])
-            translate([sx, -BASE_T + 6 + e, BASE_H/2 + sy])
-                rotate([90, 0, 0])
-                    cylinder(d = SERVO_M3_D, h = BASE_T + 2*e);
-
-        // ── Pan servo shaft bore (passes shaft through base if needed) ────
-        // Centre of shaft at Z = BASE_H/2, no bore needed (shaft exits top)
-
-        // ── Lightening pockets ────────────────────────────────────────────
-        translate([0, -BASE_T/2 + 3, BASE_H/2])
-            cube([BASE_W - 14, BASE_T - 4, BASE_H - 14], center = true);
-    }
-}
-
-// ============================================================
-// PART 2 — PAN YOKE
-// ============================================================
-// U-shaped yoke that attaches to pan servo horn (below) and carries
-// the tilt axis (above).  Two vertical arms straddle the camera cradle.
-// Tilt servo sits on top of one arm; tilt pivot boss on the other.
-//
-// Yoke base bolts to pan servo horn (4× M3 on HORN_BC_D bolt circle).
-// Pan servo horn spline bore passes through yoke base centre.
-// Tilt axis: M4 pivot axle through boss on each arm (X-axis rotation).
-//
-// Print: upright (yoke in final orientation), PETG, 5 perims, 40% gyroid.
-module pan_yoke() {
-    arm_z_total = YOKE_ARM_H + YOKE_BASE_T;
-    inner_w     = YOKE_INNER_W;
-
-    difference() {
-        union() {
-            // ── Yoke base plate (bolts to pan servo horn) ─────────────────
-            translate([-inner_w/2 - YOKE_WALL_T, 0, 0])
-                cube([inner_w + 2*YOKE_WALL_T, YOKE_BASE_T, YOKE_BASE_T]);
-
-            // ── Left arm ──────────────────────────────────────────────────
-            translate([-inner_w/2 - YOKE_WALL_T, 0, 0])
-                cube([YOKE_WALL_T, YOKE_BASE_T, arm_z_total]);
-
-            // ── Right arm (tilt servo side) ───────────────────────────────
-            translate([inner_w/2, 0, 0])
-                cube([YOKE_WALL_T, YOKE_BASE_T, arm_z_total]);
-
-            // ── Tilt pivot bosses (both arms, X-axis) ─────────────────────
-            // Left pivot boss (plain pivot — M4 bolt)
-            translate([-inner_w/2 - YOKE_WALL_T - PIVOT_BOSS_L,
-                       YOKE_BASE_T/2,
-                       YOKE_BASE_T + YOKE_ARM_H/2])
-                rotate([0, 90, 0])
-                    cylinder(d = PIVOT_BOSS_D, h = PIVOT_BOSS_L + YOKE_WALL_T);
-
-            // Right pivot boss (tilt servo horn seat)
-            translate([inner_w/2,
-                       YOKE_BASE_T/2,
-                       YOKE_BASE_T + YOKE_ARM_H/2])
-                rotate([0, 90, 0])
-                    cylinder(d = PIVOT_BOSS_D + 4, h = PIVOT_BOSS_L + YOKE_WALL_T);
-
-            // ── Tilt servo body seat on right arm top ─────────────────────
-            translate([inner_w/2, 0, arm_z_total - SERVO_H - 4])
-                cube([YOKE_WALL_T + SERVO_D + 2, YOKE_BASE_T, SERVO_H + 4]);
-        }
-
-        // ── Pan horn spline bore (centre of yoke base) ────────────────────
-        translate([0, YOKE_BASE_T/2, YOKE_BASE_T/2])
-            rotate([90, 0, 0])
-                cylinder(d = HORN_SPLINE_D, h = YOKE_BASE_T + 2*e,
-                         center = true);
-
-        // ── Pan horn bolt holes (4× M3 on HORN_BC_D) ─────────────────────
-        for (a = [45, 135, 225, 315])
-            translate([HORN_BC_D/2 * cos(a),
-                       YOKE_BASE_T/2,
-                       HORN_BC_D/2 * sin(a) + YOKE_BASE_T/2])
-                rotate([90, 0, 0])
-                    cylinder(d = HORN_BOLT_D, h = YOKE_BASE_T + 2*e,
-                             center = true);
-
-        // ── Left tilt pivot bore (M4 clearance) ───────────────────────────
-        translate([-inner_w/2 - YOKE_WALL_T - PIVOT_BOSS_L - e,
-                   YOKE_BASE_T/2,
-                   YOKE_BASE_T + YOKE_ARM_H/2])
-            rotate([0, 90, 0])
-                cylinder(d = PIVOT_D, h = PIVOT_BOSS_L + YOKE_WALL_T + 2*e);
-
-        // ── Right tilt pivot bore (larger — tilt horn plate seats here) ───
-        translate([inner_w/2 - e,
-                   YOKE_BASE_T/2,
-                   YOKE_BASE_T + YOKE_ARM_H/2])
-            rotate([0, 90, 0])
-                cylinder(d = HORN_SPLINE_D,
-                         h = PIVOT_BOSS_L + YOKE_WALL_T + 2*e);
-
-        // ── Tilt servo mount holes in right arm seat ──────────────────────
-        for (sz = [-SERVO_HOLE_Y, SERVO_HOLE_Y])
-            translate([inner_w/2 + YOKE_WALL_T + SERVO_D/2,
-                       YOKE_BASE_T/2,
-                       arm_z_total - SERVO_H/2 + sz])
-                rotate([90, 0, 0])
-                    cylinder(d = SERVO_M3_D, h = YOKE_BASE_T + 2*e,
-                             center = true);
-
-        // ── M3 nut pockets (tilt servo mount, rear of arm seat) ──────────
-        for (sz = [-SERVO_HOLE_Y, SERVO_HOLE_Y])
-            translate([inner_w/2 + YOKE_WALL_T + SERVO_D/2,
-                       YOKE_BASE_T - M3_NUT_H - 0.5,
-                       arm_z_total - SERVO_H/2 + sz])
-                rotate([90, 0, 0])
-                    cylinder(d = M3_NUT_AF / cos(30), h = M3_NUT_H + 0.5,
-                             $fn = 6);
-
-        // ── Lightening slots in yoke arms ─────────────────────────────────
-        translate([-inner_w/2 - YOKE_WALL_T/2,
-                   YOKE_BASE_T/2,
-                   YOKE_BASE_T + YOKE_ARM_H/2 - 10])
-            cube([YOKE_WALL_T - 2, YOKE_BASE_T - 2, YOKE_ARM_H - 24],
-                 center = true);
-        translate([inner_w/2 + YOKE_WALL_T/2,
-                   YOKE_BASE_T/2,
-                   YOKE_BASE_T + YOKE_ARM_H/2 - 10])
-            cube([YOKE_WALL_T - 2, YOKE_BASE_T - 2, YOKE_ARM_H - 30],
-                 center = true);
-    }
-}
-
-// ============================================================
-// PART 3 — TILT HORN PLATE
-// ============================================================
-// Disc plate bolting to tilt ST3215 servo horn on the right yoke arm.
-// Servo horn spline centres into disc bore (captured, no free rotation).
-// Camera cradle attaches to opposite face via 2× M3 bolts.
-//
-// Tilt range: ±45° limited by yoke arm geometry.
-// Plate thickness HORN_PLATE_T provides stiffness for cantilevered cradle.
-//
-// Print: flat (disc face down), PETG, 5 perims, 50 % infill.
-module tilt_horn_plate() {
-    plate_od = HORN_OD + 8;   // plate OD (4 mm rim outside horn BC)
-
-    difference() {
-        union() {
-            // ── Main disc ─────────────────────────────────────────────────
-            cylinder(d = plate_od, h = HORN_PLATE_T);
-
-            // ── Cradle attachment arm (extends to camera cradle) ──────────
-            // Rectangular boss on top of disc toward camera
-            translate([-CAM_W/2, HORN_PLATE_T - e, -CAM_H/2])
-                cube([CAM_W, HORN_PLATE_T + 4, CAM_H]);
-        }
-
-        // ── Servo horn spline bore (centre) ───────────────────────────────
-        translate([0, 0, -e])
-            cylinder(d = HORN_SPLINE_D, h = HORN_PLATE_T + 2*e);
-
-        // ── Horn bolt holes (4× M3 on HORN_BC_D) ─────────────────────────
-        for (a = [45, 135, 225, 315])
-            translate([HORN_BC_D/2 * cos(a),
-                       HORN_BC_D/2 * sin(a), -e])
-                cylinder(d = HORN_BOLT_D, h = HORN_PLATE_T + 2*e);
-
-        // ── Pivot axle bore (M4, coaxial with horn centre) ────────────────
-        translate([0, 0, -e])
-            cylinder(d = PIVOT_D, h = HORN_PLATE_T + 2*e);
-
-        // ── Cradle attachment bolts (2× M3 in arm boss) ──────────────────
-        for (cz = [-CAM_H/2 + 6, CAM_H/2 - 6])
-            translate([0, HORN_PLATE_T + 2, cz])
-                rotate([90, 0, 0])
-                    cylinder(d = M3_D, h = HORN_PLATE_T + 6 + 2*e);
-
-        // ── M3 hex nut pockets (rear of disc face) ────────────────────────
-        for (cz = [-CAM_H/2 + 6, CAM_H/2 - 6])
-            translate([0, M3_NUT_H + 0.5, cz])
-                rotate([90, 0, 0])
-                    cylinder(d = M3_NUT_AF / cos(30),
-                             h = M3_NUT_H + 0.5, $fn = 6);
-
-        // ── Weight-relief arcs (between horn bolt holes) ──────────────────
-        for (a = [0, 90, 180, 270])
-            translate([(plate_od/2 - 5) * cos(a),
-                       (plate_od/2 - 5) * sin(a), -e])
-                cylinder(d = 6, h = HORN_PLATE_T + 2*e);
-    }
-}
-
-// ============================================================
-// PART 4 — CAMERA CRADLE
-// ============================================================
-// Open-front U-cradle holding D435i via captured 1/4-20 hex nut.
-// Front lip retains camera from sliding forward (+Y).
-// Vibration-damping pads seat in recessed pockets on inner faces.
-// USB-C cable routing channel exits cradle right rear wall.
-//
-// 1/4-20 captured nut in cradle floor — tighten with standard
-// tripod screw or M6→1/4-20 adapter from camera bottom.
-//
-// Print: cradle-floor-down (flat), PETG, 5 perims, 40 % gyroid.
-// No supports needed (overhangs < 45°).
-module camera_cradle() {
-    outer_w = CAM_W + 2*CRADLE_WALL_T;
-    outer_h = CAM_H + CRADLE_FLOOR_T;
-
-    difference() {
-        union() {
-            // ── Cradle body ───────────────────────────────────────────────
-            translate([-outer_w/2, 0, 0])
-                cube([outer_w, CAM_D + CRADLE_WALL_T, outer_h]);
-
-            // ── Front retaining lip ───────────────────────────────────────
-            translate([-outer_w/2, CAM_D + CRADLE_WALL_T - CRADLE_LIP_T, 0])
-                cube([outer_w, CRADLE_LIP_T, CRADLE_LIP_H]);
-
-            // ── Cable channel boss (right rear, exits +X side) ────────────
-            translate([CAM_W/2 + CRADLE_WALL_T - e,
-                       0,
-                       CRADLE_FLOOR_T + CAM_H/2 - CABLE_CH_H/2])
-                cube([CABLE_CH_W + CRADLE_WALL_T, CAM_D * 0.6, CABLE_CH_H]);
-
-            // ── Tilt horn attachment tabs (left + right, bolt to horn plate)─
-            for (sx = [-outer_w/2 - 4, outer_w/2])
-                translate([sx, CAM_D/2, CRADLE_FLOOR_T + CAM_H/2 - 6])
-                    cube([4, 12, 12]);
-        }
-
-        // ── Camera pocket (hollow interior) ──────────────────────────────
-        translate([-CAM_W/2, 0, CRADLE_FLOOR_T])
-            cube([CAM_W, CAM_D + CRADLE_WALL_T + e, CAM_H + e]);
-
-        // ── 1/4-20 UNC clearance bore (camera tripod thread, bottom) ─────
-        translate([CAM_MOUNT_X, CAM_MOUNT_Y, -e])
-            cylinder(d = QTR20_D, h = CRADLE_FLOOR_T + 2*e);
-
-        // ── 1/4-20 hex nut pocket (captured in cradle floor) ─────────────
-        translate([CAM_MOUNT_X, CAM_MOUNT_Y, CRADLE_FLOOR_T - QTR20_NUT_H - 0.5])
-            cylinder(d = QTR20_NUT_AF / cos(30),
-                     h = QTR20_NUT_H + 0.6, $fn = 6);
-
-        // ── USB-C cable channel (exit through right rear wall) ────────────
-        translate([CAM_W/2 - e,
-                   0,
-                   CRADLE_FLOOR_T + CAM_H/2 - CABLE_CH_H/2])
-            cube([CABLE_CH_W + CRADLE_WALL_T + 2*e,
-                  CAM_D * 0.6 + e, CABLE_CH_H]);
-
-        // ── Vibe pad recesses on inner camera-contact faces ───────────────
-        // Rear wall recess (camera front face → +Y side of rear wall)
-        translate([-CAM_W/2 + CRADLE_WALL_T, CRADLE_WALL_T, CRADLE_FLOOR_T])
-            cube([CAM_W, PAD_T, CAM_H]);
-
-        // ── Tilt horn bolt holes in attachment tabs ───────────────────────
-        for (sx = [-outer_w/2 - 4 - e, outer_w/2 - e])
-            translate([sx, CAM_D/2 + 6, CRADLE_FLOOR_T + CAM_H/2])
-                rotate([0, 90, 0])
-                    cylinder(d = M3_D, h = 6 + 2*e);
-
-        // ── M3 nut pockets in attachment tabs ─────────────────────────────
-        translate([outer_w/2 + 4 - M3_NUT_H - 0.4,
-                   CAM_D/2 + 6,
-                   CRADLE_FLOOR_T + CAM_H/2])
-            rotate([0, 90, 0])
-                cylinder(d = M3_NUT_AF / cos(30),
-                         h = M3_NUT_H + 0.4, $fn = 6);
-        translate([-outer_w/2 - 4 - e,
-                   CAM_D/2 + 6,
-                   CRADLE_FLOOR_T + CAM_H/2])
-            rotate([0, 90, 0])
-                cylinder(d = M3_NUT_AF / cos(30),
-                         h = M3_NUT_H + 0.4, $fn = 6);
-
-        // ── Lightening pockets in cradle walls ────────────────────────────
-        for (face_x = [-CAM_W/2 - CRADLE_WALL_T - e, CAM_W/2 - e])
-            translate([face_x, CAM_D * 0.2, CRADLE_FLOOR_T + 3])
-                cube([CRADLE_WALL_T + 2*e, CAM_D * 0.55, CAM_H - 6]);
-    }
-}
-
-// ============================================================
-// PART 5 — VIBRATION-DAMPING PAD
-// ============================================================
-// Flat pad with transverse PETG flexure ribs pressing against camera body.
-// Rib geometry (thin fins ~1.5 mm tall) deflects under camera vibration,
-// attenuating high-frequency input from motor/drive-train.
-// For superior damping: print in TPU 95A (no infill changes needed).
-// Pads seat in recessed pockets in camera cradle inner wall.
-// Optional M2 bolt-through at corners or adhesive-back foam tape.
-//
-// Print: pad-back-face-down, PETG or TPU 95A, 3 perims, 20 % infill.
-module vibe_pad() {
-    rib_count = floor((PAD_W - RIB_W) / RIB_PITCH);
-
-    union() {
-        // ── Base plate ────────────────────────────────────────────────────
-        translate([-PAD_W/2, -PAD_T, -PAD_H/2])
-            cube([PAD_W, PAD_T, PAD_H]);
-
-        // ── Flexure ribs (parallel to Z, spaced RIB_PITCH apart) ─────────
-        for (i = [0 : rib_count - 1]) {
-            rx = -PAD_W/2 + RIB_PITCH/2 + i * RIB_PITCH + RIB_W/2;
-            if (rx <= PAD_W/2 - RIB_W/2)
-                translate([rx, 0, 0])
-                    cube([RIB_W, RIB_H, PAD_H - 6], center = true);
-        }
-
-        // ── Corner nubs (M2 bolt-through retention, optional) ─────────────
-        for (px = [-PAD_W/2 + 5, PAD_W/2 - 5])
-        for (pz = [-PAD_H/2 + 5, PAD_H/2 - 5])
-            translate([px, -PAD_T/2, pz])
-                difference() {
-                    cylinder(d = 5, h = PAD_T, center = true);
-                    cylinder(d = 2.4, h = PAD_T + 2*e, center = true);
-                }
-    }
-}

chassis/ip54_BOM.md

@@ -104,11 +104,7 @@ IP54-rated enclosures and sensor housings for all-weather outdoor robot operatio
 | Component | Thermal strategy | Max junction | Enclosure budget |
 |-----------|-----------------|-------------|-----------------|
 | Jetson Orin NX | Al pad → lid → fan forced convection | 95 °C Tj | Target ≤ 60 °C case |
-<<<<<<< HEAD
+| FC (MAMBA F722S) | Passive; FC has own EMI shield | 85 °C | <60 °C ambient OK |
-| FC (ESP32 BALANCE) | Passive; FC has own EMI shield | 85 °C | <60 °C ambient OK |
-=======
-| FC (ESP32-S3 BALANCE) | Passive; FC has own EMI shield | 85 °C | <60 °C ambient OK |
->>>>>>> 291dd68 (feat: remove all STM32/Mamba/BlackPill references — ESP32-S3 only)
 | ESC × 2 | Al pad → lid | 100 °C Tj | Target ≤ 60 °C |
 | D435i | Passive; housing vent gap on rear cap | 45 °C surface | — |
 

chassis/jetson_orin_mount.scad

@@ -1,386 +0,0 @@
-// ============================================================
-// Jetson Orin Nano Carrier Board Mount — Issue #612
-// Agent   : sl-mechanical
-// Date    : 2026-03-15
-// Part catalogue:
-//   1. tnut_base     — 2020 T-slot rail interface plate, M5 T-nut captive pockets
-//   2. standoff_post — M2.5 captive-nut standoff post (×4), 10 mm airflow gap
-//   3. side_brace    — lateral stiffening brace with port-access cutouts (×2)
-//   4. duct_shroud   — optional top heatsink duct / fan-exhaust channel
-//   5. cable_clip    — snap-on cable management clip for brace edge
-//
-// BOM:
-//   4 × M5×10 BHCS + M5 T-nuts          (tnut_base to rail, 2 per rail)
-//   4 × M2.5×20 SHCS                    (board to standoff posts)
-//   4 × M2.5 hex nuts                   (captured in standoff posts)
-//   4 × M3×8  SHCS + washers            (side_brace to tnut_base)
-//   2 × M3×16 SHCS                      (duct_shroud to side_brace tops)
-//
-// Jetson Orin Nano carrier board (Seeed reComputer / official dev kit):
-//   Board dims   : 100 × 80 mm
-//   Mounting hole pattern : 86 × 58 mm (centre-to-centre), M2.5, Ø3.5 pad
-//   PCB thickness: 1.6 mm
-//   Connector side: -Y (USB-A, USB-C, HDMI, DP, GbE, SD on one long edge)
-//   Fan header & PWM header: +X short edge
-//   M.2 / NVMe: bottom face
-//
-// Print settings (PETG):
-//   tnut_base / standoff_post / side_brace / duct_shroud : 5 perimeters, 40 % gyroid, no supports
-//   cable_clip                                            : 3 perimeters, 30 % gyroid, no supports
-//
-// Export commands:
-//   openscad -D 'RENDER="tnut_base"'     -o tnut_base.stl     jetson_orin_mount.scad
-//   openscad -D 'RENDER="standoff_post"' -o standoff_post.stl jetson_orin_mount.scad
-//   openscad -D 'RENDER="side_brace"'    -o side_brace.stl    jetson_orin_mount.scad
-//   openscad -D 'RENDER="duct_shroud"'   -o duct_shroud.stl   jetson_orin_mount.scad
-//   openscad -D 'RENDER="cable_clip"'    -o cable_clip.stl    jetson_orin_mount.scad
-//   openscad -D 'RENDER="assembly"'      -o assembly.png      jetson_orin_mount.scad
-// ============================================================
-
-// ── Render selector ─────────────────────────────────────────
-RENDER = "assembly"; // tnut_base | standoff_post | side_brace | duct_shroud | cable_clip | assembly
-
-// ── Global constants ────────────────────────────────────────
-$fn = 64;
-EPS = 0.01;
-
-// 2020 rail
-RAIL_W      = 20.0;
-SLOT_NECK_H =  3.2;
-TNUT_W      =  9.8;
-TNUT_H      =  5.5;
-TNUT_L      = 12.0;
-M5_D        =  5.2;
-M5_HEAD_D   =  9.5;
-M5_HEAD_H   =  4.0;
-
-// Jetson Orin Nano carrier board
-BOARD_L     = 100.0;  // board X
-BOARD_W     =  80.0;  // board Y
-BOARD_T     =   1.6;  // PCB thickness
-MH_SX       =  86.0;  // mounting hole span X (centre-to-centre)
-MH_SY       =  58.0;  // mounting hole span Y
-M25_D       =   2.7;  // M2.5 clearance bore
-M25_NUT_W   =   5.0;  // M2.5 hex nut across-flats
-M25_NUT_H   =   2.0;  // M2.5 hex nut height
-M25_HEAD_D  =   5.0;  // M2.5 SHCS head diameter
-M25_HEAD_H  =   2.5;
-
-// Base plate
-BASE_L      = 120.0;  // length along X (covers board + overhang for braces)
-BASE_W      =  50.0;  // width along Y (rail mount footprint)
-BASE_T      =   6.0;  // plate thickness
-BOLT_PITCH  =  40.0;  // M5 rail bolt pitch (per rail, 2 rails at Y=0 & Y=BASE_W)
-M3_D        =   3.2;
-M3_HEAD_D   =   6.0;
-M3_HEAD_H   =   3.0;
-
-// Standoff posts
-POST_H      =  12.0;  // airflow gap + PCB seating (>= 10 mm clearance spec)
-POST_OD     =   8.0;  // outer diameter
-POST_BASE_D =  11.0;  // flange diameter
-POST_BASE_H =   3.0;  // flange height
-NUT_TRAP_H  = M25_NUT_H + 0.3;
-NUT_TRAP_W  = M25_NUT_W + 0.4;
-
-// Side braces
-BRACE_T     =   5.0;  // brace thickness (X)
-BRACE_H     = POST_H + POST_BASE_H + BOARD_T + 4.0;  // full height
-BRACE_W     = BASE_W;  // same width as base
-
-// Port-access cutouts (connector side -Y)
-USB_CUT_W   =  60.0;  // wide cutout for USB-A stack + HDMI + DP
-USB_CUT_H   =  22.0;
-GBE_CUT_W   =  20.0;  // GbE jack
-GBE_CUT_H   =  18.0;
-
-// Duct shroud
-DUCT_T      =   3.0;  // wall thickness
-DUCT_FLANGE =   6.0;  // side tab width for M3 attachment
-FAN_W       =  40.0;  // standard 40 mm blower clearance cutout
-FAN_H       =  10.0;  // duct outlet height
-
-// Cable clip
-CLIP_OD     =  12.0;
-CLIP_ID     =   7.0;
-CLIP_GAP    =   7.5;
-CLIP_W      =  10.0;
-SNAP_T      =   1.8;
-
-// ── Utilities ───────────────────────────────────────────────
-module chamfer_cube(size, ch=1.0) {
-    hull() {
-        translate([ch, ch, 0])          cube([size[0]-2*ch, size[1]-2*ch, EPS]);
-        translate([0, 0, ch])           cube(size - [0, 0, ch]);
-    }
-}
-
-module hex_pocket(af, depth) {
-    cylinder(d=af/cos(30), h=depth, $fn=6);
-}
-
-// ── Part 1: tnut_base ───────────────────────────────────────
-module tnut_base() {
-    difference() {
-        union() {
-            chamfer_cube([BASE_L, BASE_W, BASE_T], ch=1.5);
-
-            // Raised mounting bosses for M3 brace attachment (4 corners)
-            for (x = [8, BASE_L-8])
-                for (y = [8, BASE_W-8])
-                    translate([x, y, BASE_T])
-                        cylinder(d=10, h=2.5);
-        }
-
-        // T-nut pockets and M5 bolts — front rail (y = BASE_W/4)
-        for (x = [BASE_L/2 - BOLT_PITCH/2, BASE_L/2 + BOLT_PITCH/2]) {
-            translate([x, BASE_W/4, -EPS]) {
-                cylinder(d=M5_D, h=BASE_T + 2*EPS);
-                cylinder(d=M5_HEAD_D, h=M5_HEAD_H + EPS);
-            }
-            translate([x - TNUT_L/2, BASE_W/4 - TNUT_W/2, BASE_T - TNUT_H])
-                cube([TNUT_L, TNUT_W, TNUT_H + EPS]);
-        }
-
-        // T-nut pockets and M5 bolts — rear rail (y = 3*BASE_W/4)
-        for (x = [BASE_L/2 - BOLT_PITCH/2, BASE_L/2 + BOLT_PITCH/2]) {
-            translate([x, 3*BASE_W/4, -EPS]) {
-                cylinder(d=M5_D, h=BASE_T + 2*EPS);
-                cylinder(d=M5_HEAD_D, h=M5_HEAD_H + EPS);
-            }
-            translate([x - TNUT_L/2, 3*BASE_W/4 - TNUT_W/2, BASE_T - TNUT_H])
-                cube([TNUT_L, TNUT_W, TNUT_H + EPS]);
-        }
-
-        // M3 boss bolt holes (corner braces)
-        for (x = [8, BASE_L-8])
-            for (y = [8, BASE_W-8])
-                translate([x, y, -EPS])
-                    cylinder(d=M3_D, h=BASE_T + 2.5 + 2*EPS);
-
-        // M3 boss counterbores (head from bottom)
-        for (x = [8, BASE_L-8])
-            for (y = [8, BASE_W-8])
-                translate([x, y, -EPS])
-                    cylinder(d=M3_HEAD_D, h=M3_HEAD_H + EPS);
-
-        // Standoff post seating holes (board hole pattern, centred on plate)
-        bx0 = BASE_L/2 - MH_SX/2;
-        by0 = BASE_W/2 - MH_SY/2;
-        for (dx = [0, MH_SX])
-            for (dy = [0, MH_SY])
-                translate([bx0+dx, by0+dy, -EPS])
-                    cylinder(d=POST_BASE_D + 0.4, h=BASE_T + 2*EPS);
-
-        // Weight relief grid (2 pockets)
-        translate([20, 12, -EPS]) cube([30, BASE_W-24, BASE_T/2]);
-        translate([BASE_L-50, 12, -EPS]) cube([30, BASE_W-24, BASE_T/2]);
-
-        // Cable pass-through slot
-        translate([BASE_L/2 - 8, BASE_W/2 - 3, -EPS])
-            cube([16, 6, BASE_T + 2*EPS]);
-    }
-}
-
-// ── Part 2: standoff_post ───────────────────────────────────
-module standoff_post() {
-    difference() {
-        union() {
-            // Flange
-            cylinder(d=POST_BASE_D, h=POST_BASE_H);
-            // Post body
-            translate([0, 0, POST_BASE_H])
-                cylinder(d=POST_OD, h=POST_H);
-        }
-
-        // M2.5 through bore
-        translate([0, 0, -EPS])
-            cylinder(d=M25_D, h=POST_BASE_H + POST_H + 2*EPS);
-
-        // Captured hex nut trap (from top)
-        translate([0, 0, POST_BASE_H + POST_H - NUT_TRAP_H])
-            hex_pocket(NUT_TRAP_W, NUT_TRAP_H + EPS);
-
-        // Anti-rotation flat on nut pocket
-        translate([-M25_NUT_W/2 - 0.2, -POST_OD/2 - EPS,
-                   POST_BASE_H + POST_H - NUT_TRAP_H])
-            cube([M25_NUT_W + 0.4, 2.0, NUT_TRAP_H + EPS]);
-    }
-}
-
-// ── Part 3: side_brace ──────────────────────────────────────
-// Printed as +X face. Mirror for -X side.
-module side_brace() {
-    difference() {
-        union() {
-            chamfer_cube([BRACE_T, BRACE_W, BRACE_H], ch=1.0);
-
-            // Top lip to retain board edge
-            translate([0, 0, BRACE_H])
-                cube([BRACE_T + 8.0, BRACE_W, 2.5]);
-        }
-
-        // M3 bolt holes at base (attach to tnut_base bosses)
-        for (y = [8, BRACE_W-8])
-            translate([-EPS, y, 4])
-                rotate([0, 90, 0])
-                    cylinder(d=M3_D, h=BRACE_T + 2*EPS);
-
-        // M3 counterbore from outer face
-        for (y = [8, BRACE_W-8])
-            translate([-EPS, y, 4])
-                rotate([0, 90, 0])
-                    cylinder(d=M3_HEAD_D, h=M3_HEAD_H + EPS);
-
-        // Port-access cutout — USB/HDMI/DP cluster (centred on brace face)
-        translate([-EPS, BRACE_W/2 - USB_CUT_W/2, POST_BASE_H + 2.0])
-            cube([BRACE_T + 2*EPS, USB_CUT_W, USB_CUT_H]);
-
-        // GbE cutout (offset toward +Y)
-        translate([-EPS, BRACE_W/2 + USB_CUT_W/2 - GBE_CUT_W - 2, POST_BASE_H + 2.0])
-            cube([BRACE_T + 2*EPS, GBE_CUT_W, GBE_CUT_H]);
-
-        // M3 duct attachment holes (top edge)
-        for (y = [BRACE_W/4, 3*BRACE_W/4])
-            translate([BRACE_T/2, y, BRACE_H - 2])
-                cylinder(d=M3_D, h=10);
-
-        // Ventilation slots (3 tall slots for airflow)
-        for (i = [0:2])
-            translate([-EPS,
-                       (BRACE_W - 3*8 - 2*4) / 2 + i*(8+4),
-                       POST_BASE_H + USB_CUT_H + 6])
-                cube([BRACE_T + 2*EPS, 8, BRACE_H - POST_BASE_H - USB_CUT_H - 10]);
-    }
-}
-
-// ── Part 4: duct_shroud ─────────────────────────────────────
-// Top cap that channels fan exhaust away from board; optional print.
-module duct_shroud() {
-    duct_l = BASE_L - 2*BRACE_T - 1.0;  // span between inner brace faces
-    duct_w = BRACE_W;
-
-    difference() {
-        union() {
-            // Top plate
-            cube([duct_l, duct_w, DUCT_T]);
-
-            // Front wall (fan inlet side)
-            translate([0, 0, -FAN_H])
-                cube([DUCT_T, duct_w, FAN_H + DUCT_T]);
-
-            // Rear wall (exhaust side — open centre)
-            translate([duct_l - DUCT_T, 0, -FAN_H])
-                cube([DUCT_T, duct_w, FAN_H + DUCT_T]);
-
-            // Side flanges for M3 attachment
-            translate([-DUCT_FLANGE, 0, -FAN_H])
-                cube([DUCT_FLANGE, duct_w, FAN_H + DUCT_T]);
-            translate([duct_l, 0, -FAN_H])
-                cube([DUCT_FLANGE, duct_w, FAN_H + DUCT_T]);
-        }
-
-        // Fan cutout on top plate (centred)
-        translate([duct_l/2 - FAN_W/2, duct_w/2 - FAN_W/2, -EPS])
-            cube([FAN_W, FAN_W, DUCT_T + 2*EPS]);
-
-        // Fan screw holes (40 mm fan, Ø3.2 at 32 mm BC)
-        for (dx = [-16, 16])
-            for (dy = [-16, 16])
-                translate([duct_l/2 + dx, duct_w/2 + dy, -EPS])
-                    cylinder(d=M3_D, h=DUCT_T + 2*EPS);
-
-        // Exhaust slot on rear wall (full width minus corners)
-        translate([duct_l - DUCT_T - EPS, 4, -FAN_H + 2])
-            cube([DUCT_T + 2*EPS, duct_w - 8, FAN_H - 2]);
-
-        // M3 flange attachment holes
-        for (y = [duct_w/4, 3*duct_w/4]) {
-            translate([-DUCT_FLANGE - EPS, y, -FAN_H/2])
-                rotate([0, 90, 0])
-                    cylinder(d=M3_D, h=DUCT_FLANGE + 2*EPS);
-            translate([duct_l + DUCT_T - EPS, y, -FAN_H/2])
-                rotate([0, 90, 0])
-                    cylinder(d=M3_D, h=DUCT_FLANGE + 2*EPS);
-        }
-    }
-}
-
-// ── Part 5: cable_clip ──────────────────────────────────────
-module cable_clip() {
-    difference() {
-        union() {
-            // Snap-wrap body
-            difference() {
-                cylinder(d=CLIP_OD + 2*SNAP_T, h=CLIP_W);
-                translate([0, 0, -EPS])
-                    cylinder(d=CLIP_ID, h=CLIP_W + 2*EPS);
-                // Front gap
-                translate([-CLIP_GAP/2, 0, -EPS])
-                    cube([CLIP_GAP, CLIP_OD, CLIP_W + 2*EPS]);
-            }
-
-            // Mounting tab for brace edge
-            translate([CLIP_OD/2 + SNAP_T - EPS, -SNAP_T, 0])
-                cube([8, SNAP_T*2, CLIP_W]);
-        }
-
-        // Tab screw hole
-        translate([CLIP_OD/2 + SNAP_T + 4, 0, CLIP_W/2])
-            rotate([90, 0, 0])
-                cylinder(d=M3_D, h=SNAP_T*2 + 2*EPS, center=true);
-    }
-}
-
-// ── Assembly ────────────────────────────────────────────────
-module assembly() {
-    // Base plate
-    color("SteelBlue")
-        tnut_base();
-
-    // Standoff posts (board hole pattern)
-    bx0 = BASE_L/2 - MH_SX/2;
-    by0 = BASE_W/2 - MH_SY/2;
-    for (dx = [0, MH_SX])
-        for (dy = [0, MH_SY])
-            color("DodgerBlue")
-                translate([bx0+dx, by0+dy, BASE_T])
-                    standoff_post();
-
-    // Side braces (left and right)
-    color("CornflowerBlue")
-        translate([0, 0, BASE_T])
-            side_brace();
-    color("CornflowerBlue")
-        translate([BASE_L, BRACE_W, BASE_T])
-            mirror([1, 0, 0])
-                mirror([0, 1, 0])
-                    side_brace();
-
-    // Board silhouette (translucent, for clearance visualisation)
-    color("ForestGreen", 0.25)
-        translate([BASE_L/2 - BOARD_L/2, BASE_W/2 - BOARD_W/2,
-                   BASE_T + POST_BASE_H + POST_H])
-            cube([BOARD_L, BOARD_W, BOARD_T]);
-
-    // Duct shroud (above board)
-    color("LightSteelBlue", 0.7)
-        translate([BRACE_T + 0.5, 0,
-                   BASE_T + POST_BASE_H + POST_H + BOARD_T + 2.0])
-            duct_shroud();
-
-    // Cable clips (on brace edge, 2×)
-    for (y = [BRACE_W/3, 2*BRACE_W/3])
-        color("SlateGray")
-            translate([BASE_L + 2, y, BASE_T + BRACE_H/2 - CLIP_W/2])
-                rotate([0, 90, 0])
-                    cable_clip();
-}
-
-// ── Dispatch ────────────────────────────────────────────────
-if      (RENDER == "tnut_base")     tnut_base();
-else if (RENDER == "standoff_post") standoff_post();
-else if (RENDER == "side_brace")    side_brace();
-else if (RENDER == "duct_shroud")   duct_shroud();
-else if (RENDER == "cable_clip")    cable_clip();
-else                                assembly();

chassis/phone_mount_bracket.scad

@@ -1,504 +0,0 @@
-// ============================================================
-// phone_mount_bracket.scad — Spring-Loaded Phone Mount for T-Slot Rail
-// Issue: #535  Agent: sl-mechanical  Date: 2026-03-07
-// ============================================================
-//
-// Parametric spring-loaded phone mount that clamps to the 2020 aluminium
-// T-slot sensor rail.  Adjustable phone width 60–85 mm.  Quick-release
-// cam lever for tool-free phone swap.  Vibration-damping flexure ribs
-// on grip pads absorb motor/terrain vibration (PETG compliance).
-//
-// Design overview:
-//   - Fixed jaw + sliding jaw on a 40 mm guide rail (M4 rod)
-//   - Coil spring (Ø8 × 30 mm) compressed between jaw and end-stop —
-//     spring pre-load keeps phone clamped at any width in range
-//   - Cam lever (printed PETG) rotates 90° to release / lock spring
-//   - Anti-vibration flexure ribs on both grip pad faces
-//   - Landscape or portrait orientation: bracket rotates on T-nut base
-//
-// Parts (STL exports):
-//   Part 1 — tnut_base()          Rail attachment base (universal)
-//   Part 2 — fixed_jaw()          Fixed bottom jaw + guide rail bosses
-//   Part 3 — sliding_jaw()        Spring-loaded sliding jaw
-//   Part 4 — cam_lever()          Quick-release cam lever
-//   Part 5 — grip_pad()           Flexure grip pad (print ×2, TPU optional)
-//   Part 6 — assembly_preview()   Full assembly
-//
-// Hardware BOM (per mount):
-//   1× M4 × 60 mm SHCS          guide rod + spring bolt
-//   1× M4 hex nut                end-stop on sliding jaw
-//   1× Ø8 × 30 mm coil spring   ~0.5 N/mm rate (spring clamping)
-//   2× M3 × 16 mm SHCS          T-nut base thumbscrew + arm bolts
-//   1× M3 hex nut                thumbscrew nut in T-nut
-//   4× M2 × 8 mm SHCS           grip pad retention bolts (optional)
-//
-// Dimensions:
-//   Phone width range : PHONE_W_MIN–PHONE_W_MAX (60–85 mm) parametric
-//   Phone thickness   : up to PHONE_THICK_MAX (12 mm) — open-front jaw
-//   Phone height held : GRIP_SPAN (22 mm each jaw) — portrait/landscape
-//   Overall bracket H : ~110 mm  W: ~90 mm  D: ~55 mm
-//
-// Print settings:
-//   Material  : PETG (tnut_base, fixed_jaw, sliding_jaw, cam_lever)
-//               TPU 95A optional for grip_pad (or PETG for rigidity)
-//   Perimeters: 5 (structural parts), 3 (grip_pad)
-//   Infill    : 40 % gyroid (jaws), 20 % (grip_pad)
-//   Supports  : none needed (designed for FDM orientation)
-//   Layer ht  : 0.2 mm
-//
-// Export commands:
-//   openscad phone_mount_bracket.scad -D 'RENDER="tnut_base_stl"'    -o pm_tnut_base.stl
-//   openscad phone_mount_bracket.scad -D 'RENDER="fixed_jaw_stl"'    -o pm_fixed_jaw.stl
-//   openscad phone_mount_bracket.scad -D 'RENDER="sliding_jaw_stl"'  -o pm_sliding_jaw.stl
-//   openscad phone_mount_bracket.scad -D 'RENDER="cam_lever_stl"'    -o pm_cam_lever.stl
-//   openscad phone_mount_bracket.scad -D 'RENDER="grip_pad_stl"'     -o pm_grip_pad.stl
-// ============================================================
-
-$fn = 64;
-e   = 0.01;   // epsilon for boolean clearance
-
-// ── Phone parameters (adjust to target device) ───────────────────────────────
-PHONE_W_MIN    = 60.0;   // narrowest phone width supported (mm)
-PHONE_W_MAX    = 85.0;   // widest phone width supported (mm)
-PHONE_THICK_MAX = 12.0;  // max phone body thickness incl. case (mm)
-
-// ── Rail geometry (must match sensor_rail.scad) ──────────────────────────────
-RAIL_W         = 20.0;
-SLOT_OPEN      =  6.0;
-SLOT_INNER_W   = 10.2;
-SLOT_INNER_H   =  5.8;
-SLOT_NECK_H    =  3.2;
-
-// ── T-nut constants ───────────────────────────────────────────────────────────
-TNUT_W         =  9.8;
-TNUT_H         =  5.5;
-TNUT_L         = 12.0;
-TNUT_M3_NUT_AF =  5.5;
-TNUT_M3_NUT_H  =  2.5;
-TNUT_BOLT_D    =  3.3;   // M3 clearance
-
-// ── Base plate geometry ───────────────────────────────────────────────────────
-BASE_FACE_W  = 30.0;
-BASE_FACE_H  = 25.0;
-BASE_FACE_T  = SLOT_NECK_H + 1.5;
-
-// ── Jaw geometry ─────────────────────────────────────────────────────────────
-JAW_BODY_W   = 88.0;    // jaw outer width (> PHONE_W_MAX for rim)
-JAW_BODY_H   = 28.0;    // jaw height (Z) — phone grip span
-JAW_BODY_T   = 14.0;    // jaw depth (Y) — phone cradled this deep
-JAW_WALL_T   =  4.0;    // jaw side wall thickness
-JAW_LIP_T    =  3.0;    // front retaining lip thickness
-JAW_LIP_H    =  5.0;    // front lip height (retains phone)
-PHONE_POCKET_D = PHONE_THICK_MAX + 0.5;  // pocket depth for phone
-
-// ── Guide rod / spring system ─────────────────────────────────────────────────
-GUIDE_ROD_D  =  4.3;    // M4 clearance bore in sliding jaw
-GUIDE_BOSS_D = 10.0;    // boss OD around guide bore
-GUIDE_BOSS_T =  6.0;    // boss length
-SPRING_OD    =  8.5;    // coil spring OD pocket (spring is Ø8)
-SPRING_L     = 32.0;    // spring pocket length (spring compressed ~22 mm)
-SPRING_SEAT_T =  3.0;   // spring seat wall at end-stop boss
-JAW_TRAVEL   = PHONE_W_MAX - PHONE_W_MIN + 4.0;   // max jaw travel (mm)
-ARM_SPAN     = PHONE_W_MAX + 2 * JAW_WALL_T + 8;  // fixed jaw total width
-
-// ── Cam lever geometry ────────────────────────────────────────────────────────
-CAM_R_MIN    =  5.0;    // cam small radius (engaged / clamped)
-CAM_R_MAX    =  9.0;    // cam large radius (released, spring compressed)
-CAM_THICK    =  8.0;    // cam disc thickness
-CAM_HANDLE_L = 45.0;    // lever arm length
-CAM_HANDLE_W =  8.0;    // lever handle width
-CAM_HANDLE_T =  5.0;    // lever handle thickness
-CAM_BORE_D   =  4.3;    // M4 pivot bore
-CAM_DETENT_D =  3.0;    // detent ball pocket (3 mm bearing)
-
-// ── Grip pad geometry (vibration dampening flexure ribs) ─────────────────────
-PAD_W        = JAW_BODY_W - 2*JAW_WALL_T - 2;  // pad width
-PAD_H        = JAW_BODY_H - 2;                  // pad height
-PAD_T        =  2.5;    // pad body thickness
-RIB_H        =  1.5;    // flexure rib height above pad face
-RIB_W        =  1.2;    // rib width
-RIB_PITCH    =  5.0;    // rib pitch (centre-to-centre)
-RIB_COUNT    = floor(PAD_W / RIB_PITCH) - 1;
-
-// ── Arm geometry (base to jaw body) ──────────────────────────────────────────
-ARM_REACH    = 38.0;    // distance from rail face to jaw centreline (+Y)
-ARM_T        =  4.0;    // arm thickness
-ARM_H        = BASE_FACE_H;
-
-// ── Fasteners ─────────────────────────────────────────────────────────────────
-M2_D = 2.4;
-M3_D = 3.3;
-M4_D = 4.3;
-M4_NUT_AF = 7.0;   // M4 hex nut across-flats
-M4_NUT_H  = 3.2;   // M4 hex nut height
-
-// ============================================================
-// RENDER DISPATCH
-// ============================================================
-RENDER = "assembly";
-
-if      (RENDER == "assembly")        assembly_preview();
-else if (RENDER == "tnut_base_stl")   tnut_base();
-else if (RENDER == "fixed_jaw_stl")   fixed_jaw();
-else if (RENDER == "sliding_jaw_stl") sliding_jaw();
-else if (RENDER == "cam_lever_stl")   cam_lever();
-else if (RENDER == "grip_pad_stl")    grip_pad();
-
-// ============================================================
-// ASSEMBLY PREVIEW
-// ============================================================
-module assembly_preview() {
-    // Ghost rail section (20 × 20 × 200)
-    %color("Silver", 0.30)
-        linear_extrude(200)
-            square([RAIL_W, RAIL_W], center = true);
-
-    // T-nut base at Z=80 on rail
-    color("OliveDrab", 0.85)
-        translate([0, 0, 80])
-            tnut_base();
-
-    // Fixed jaw assembly (centred, extending +Y from base)
-    color("DarkSlateGray", 0.85)
-        translate([0, SLOT_NECK_H + BASE_FACE_T + ARM_REACH, 80])
-            fixed_jaw();
-
-    // Sliding jaw — shown at mid-travel (phone ~72 mm wide)
-    color("SteelBlue", 0.85)
-        translate([PHONE_W_MIN + (PHONE_W_MAX - PHONE_W_MIN)/2,
-                   SLOT_NECK_H + BASE_FACE_T + ARM_REACH, 80])
-            sliding_jaw();
-
-    // Grip pads on both jaws
-    color("DimGray", 0.85) {
-        translate([0, SLOT_NECK_H + BASE_FACE_T + ARM_REACH, 80])
-            translate([JAW_WALL_T, JAW_BODY_T, JAW_BODY_H/2])
-                rotate([90, 0, 0])
-                    grip_pad();
-        translate([PHONE_W_MIN + (PHONE_W_MAX - PHONE_W_MIN)/2,
-                   SLOT_NECK_H + BASE_FACE_T + ARM_REACH, 80])
-            translate([-JAW_WALL_T - PAD_T, JAW_BODY_T, JAW_BODY_H/2])
-                rotate([90, 0, 180])
-                    grip_pad();
-    }
-
-    // Cam lever — shown in locked (clamped) position
-    color("OrangeRed", 0.85)
-        translate([ARM_SPAN/2 + 6,
-                   SLOT_NECK_H + BASE_FACE_T + ARM_REACH + GUIDE_BOSS_D/2,
-                   80 + JAW_BODY_H/2])
-            rotate([0, 0, 0])
-                cam_lever();
-}
-
-// ============================================================
-// PART 1 — T-NUT BASE
-// ============================================================
-// Standard 2020 T-slot rail attachment base.
-// Identical interface to sensor_rail_brackets.scad universal_tnut_base().
-// Arm extends in +Y; rail clamp bolt in -Y face.
-//
-// Print flat (face plate down), PETG, 5 perims, 60 % infill.
-module tnut_base() {
-    difference() {
-        union() {
-            // Face plate (flush against rail outer face)
-            translate([-BASE_FACE_W/2, -BASE_FACE_T, 0])
-                cube([BASE_FACE_W, BASE_FACE_T, BASE_FACE_H]);
-
-            // T-nut neck (enters rail slot)
-            translate([-TNUT_W/2, 0, (BASE_FACE_H - TNUT_L)/2])
-                cube([TNUT_W, SLOT_NECK_H + e, TNUT_L]);
-
-            // T-nut body (wider, inside T-groove)
-            translate([-TNUT_W/2, SLOT_NECK_H - e, (BASE_FACE_H - TNUT_L)/2])
-                cube([TNUT_W, TNUT_H - SLOT_NECK_H + e, TNUT_L]);
-
-            // Arm stub (face plate → jaw)
-            translate([-BASE_FACE_W/2, -BASE_FACE_T, 0])
-                cube([BASE_FACE_W, BASE_FACE_T + ARM_REACH, ARM_T]);
-        }
-
-        // M3 rail clamp bolt bore (centre of T-nut, through face plate)
-        translate([0, -BASE_FACE_T - e, BASE_FACE_H/2])
-            rotate([-90, 0, 0])
-                cylinder(d = TNUT_BOLT_D, h = BASE_FACE_T + TNUT_H + 2*e);
-
-        // M3 hex nut pocket (inside T-nut body)
-        translate([0, SLOT_NECK_H + 0.3, BASE_FACE_H/2])
-            rotate([-90, 0, 0])
-                cylinder(d = TNUT_M3_NUT_AF / cos(30),
-                         h = TNUT_M3_NUT_H + 0.3,
-                         $fn = 6);
-
-        // 2× M3 bolt holes for arm-to-jaw bolting
-        for (bx = [-10, 10])
-            translate([bx, ARM_REACH - BASE_FACE_T - e, ARM_T/2])
-                rotate([-90, 0, 0])
-                    cylinder(d = M3_D, h = 8 + 2*e);
-
-        // Lightening slot in arm
-        translate([0, -BASE_FACE_T/2 + ARM_REACH/2, ARM_T/2])
-            cube([BASE_FACE_W - 12, ARM_REACH - 16, ARM_T + 2*e],
-                 center = true);
-    }
-}
-
-// ============================================================
-// PART 2 — FIXED JAW
-// ============================================================
-// Fixed lower jaw of the clamping system.  Phone sits in the pocket
-// formed by the fixed jaw (bottom) and sliding jaw (top).
-// Two guide bosses on the right wall carry the M4 guide rod + spring.
-// The cam lever pivot boss is on the outer right face.
-//
-// Coordinate origin: centre-bottom of jaw body.
-// Phone entry face: +Y (open front), phone pocket opens toward +Y.
-// Fixed jaw left edge is at X = -JAW_BODY_W/2.
-//
-// Print jaw-pocket-face down, PETG, 5 perims, 40 % infill.
-module fixed_jaw() {
-    difference() {
-        union() {
-            // ── Main jaw body ────────────────────────────────────────────
-            translate([-JAW_BODY_W/2, -JAW_BODY_T/2, 0])
-                cube([JAW_BODY_W, JAW_BODY_T, JAW_BODY_H]);
-
-            // ── Front retaining lip (keeps phone from falling forward) ───
-            translate([-JAW_BODY_W/2, JAW_BODY_T/2 - JAW_LIP_T, 0])
-                cube([JAW_BODY_W, JAW_LIP_T, JAW_LIP_H]);
-
-            // ── Guide boss right (outer, carries spring + end-stop) ──────
-            translate([JAW_BODY_W/2, 0, JAW_BODY_H/2])
-                rotate([0, 90, 0])
-                    cylinder(d = GUIDE_BOSS_D, h = GUIDE_BOSS_T);
-
-            // ── Cam lever pivot boss (right face, above guide boss) ──────
-            translate([JAW_BODY_W/2, 0, JAW_BODY_H/2 + GUIDE_BOSS_D + 4])
-                rotate([0, 90, 0])
-                    cylinder(d = CAM_THICK + 4, h = 6);
-
-            // ── Arm attachment bosses (left side, connect to tnut_base) ──
-            for (bx = [-10, 10])
-                translate([bx, -JAW_BODY_T/2 - 8, ARM_T/2])
-                    cylinder(d = 8, h = 8);
-        }
-
-        // ── Phone pocket (open-top U channel centred in jaw) ────────────
-        // Pocket opens toward +Y (front), phone drops in from above.
-        translate([0, -JAW_BODY_T/2 - e,
-                   JAW_LIP_H])
-            cube([JAW_BODY_W - 2*JAW_WALL_T,
-                  PHONE_POCKET_D + JAW_WALL_T,
-                  JAW_BODY_H - JAW_LIP_H + e],
-                 center = [true, false, false]);
-
-        // ── Guide rod bore (M4 clearance, through both guide bosses) ────
-        translate([-JAW_BODY_W/2 - e, 0, JAW_BODY_H/2])
-            rotate([0, 90, 0])
-                cylinder(d = GUIDE_ROD_D,
-                         h = JAW_BODY_W + GUIDE_BOSS_T + 2*e);
-
-        // ── Spring pocket (coaxial with guide rod, in right boss) ────────
-        translate([JAW_BODY_W/2 + e, 0, JAW_BODY_H/2])
-            rotate([0, -90, 0])
-                cylinder(d = SPRING_OD, h = SPRING_L);
-
-        // ── M4 hex nut pocket in spring-seat wall (end-stop nut) ────────
-        translate([JAW_BODY_W/2 + GUIDE_BOSS_T + e, 0, JAW_BODY_H/2])
-            rotate([0, -90, 0])
-                cylinder(d = M4_NUT_AF / cos(30), h = M4_NUT_H + 0.5,
-                         $fn = 6);
-
-        // ── Cam pivot bore (M4 pivot, through pivot boss) ────────────────
-        translate([JAW_BODY_W/2 - e, 0, JAW_BODY_H/2 + GUIDE_BOSS_D + 4])
-            rotate([0, 90, 0])
-                cylinder(d = CAM_BORE_D, h = 6 + 2*e);
-
-        // ── Arm attachment bolt holes (M3, to tnut_base arm stubs) ──────
-        for (bx = [-10, 10])
-            translate([bx, -JAW_BODY_T/2 - 8 - e, ARM_T/2])
-                rotate([-90, 0, 0])
-                    cylinder(d = M3_D, h = 12 + 2*e);
-
-        // ── Grip pad seats (recessed Ø1.5 mm, 2 mm deep, optional) ──────
-        for (pz = [JAW_BODY_H * 0.3, JAW_BODY_H * 0.7])
-        for (px = [-PAD_W/4, PAD_W/4])
-            translate([px, -JAW_BODY_T/2 + PHONE_POCKET_D + 1, pz])
-                rotate([-90, 0, 0])
-                    cylinder(d = M2_D, h = 10);
-
-        // ── Lightening pockets (non-structural core removal) ─────────────
-        translate([0, 0, JAW_BODY_H/2])
-            cube([JAW_BODY_W - 2*JAW_WALL_T - 4,
-                  JAW_BODY_T - 2*JAW_WALL_T,
-                  JAW_BODY_H - JAW_LIP_H - 4],
-                 center = true);
-    }
-}
-
-// ============================================================
-// PART 3 — SLIDING JAW
-// ============================================================
-// Upper clamping jaw.  Slides along the M4 guide rod.
-// Spring pushes this jaw toward the phone (inward).
-// M4 hex nut on the guide rod limits maximum travel (full open).
-// Cam lever pushes on this jaw face to compress spring (release).
-//
-// Coordinate origin same convention as fixed_jaw() for assembly.
-// Jaw slides in +X direction (away from fixed jaw left wall).
-//
-// Print jaw-pocket-face down, PETG, 5 perims, 40 % infill.
-module sliding_jaw() {
-    difference() {
-        union() {
-            // ── Main jaw body ────────────────────────────────────────────
-            translate([-JAW_WALL_T, -JAW_BODY_T/2, 0])
-                cube([JAW_BODY_W/2 + JAW_WALL_T, JAW_BODY_T, JAW_BODY_H]);
-
-            // ── Front retaining lip ──────────────────────────────────────
-            translate([-JAW_WALL_T, JAW_BODY_T/2 - JAW_LIP_T, 0])
-                cube([JAW_BODY_W/2 + JAW_WALL_T, JAW_LIP_T, JAW_LIP_H]);
-
-            // ── Guide boss (carries guide rod, spring butts against face) ─
-            translate([-JAW_WALL_T - GUIDE_BOSS_T, 0, JAW_BODY_H/2])
-                rotate([0, 90, 0])
-                    cylinder(d = GUIDE_BOSS_D, h = GUIDE_BOSS_T);
-
-            // ── Cam follower ear (contacts cam lever) ────────────────────
-            translate([-JAW_WALL_T - 2, 0,
-                       JAW_BODY_H/2 + GUIDE_BOSS_D + 4])
-                cube([4, CAM_THICK + 2, CAM_THICK + 2], center = true);
-        }
-
-        // ── Phone pocket (inner face, contacts phone side) ───────────────
-        translate([-JAW_WALL_T - e, -JAW_BODY_T/2 - e, JAW_LIP_H])
-            cube([JAW_BODY_W/2 - JAW_WALL_T + e,
-                  PHONE_POCKET_D + JAW_WALL_T + 2*e,
-                  JAW_BODY_H - JAW_LIP_H + e]);
-
-        // ── Guide rod bore (M4 clearance through boss + jaw wall) ────────
-        translate([-JAW_WALL_T - GUIDE_BOSS_T - e, 0, JAW_BODY_H/2])
-            rotate([0, 90, 0])
-                cylinder(d = GUIDE_ROD_D,
-                         h = GUIDE_BOSS_T + JAW_WALL_T + 2*e);
-
-        // ── M4 nut pocket (end-stop nut, rear of guide boss) ────────────
-        translate([-JAW_WALL_T - GUIDE_BOSS_T - e, 0, JAW_BODY_H/2])
-            rotate([0, 90, 0])
-                cylinder(d = M4_NUT_AF / cos(30), h = M4_NUT_H + 1,
-                         $fn = 6);
-
-        // ── Cam follower bore (M4 pivot passes through ear) ─────────────
-        translate([-JAW_WALL_T - 2 - e, 0,
-                   JAW_BODY_H/2 + GUIDE_BOSS_D + 4])
-            rotate([0, 90, 0])
-                cylinder(d = CAM_BORE_D, h = 6 + 2*e);
-
-        // ── Grip pad seats ───────────────────────────────────────────────
-        for (pz = [JAW_BODY_H * 0.3, JAW_BODY_H * 0.7])
-        for (px = [JAW_BODY_W/8])
-            translate([px, -JAW_BODY_T/2 + PHONE_POCKET_D + 1, pz])
-                rotate([-90, 0, 0])
-                    cylinder(d = M2_D, h = 10);
-    }
-}
-
-// ============================================================
-// PART 4 — CAM LEVER (QUICK-RELEASE)
-// ============================================================
-// Eccentric cam disc + integral handle lever.
-// Rotates 90° on M4 pivot pin between CLAMPED and RELEASED states:
-//   CLAMPED  : cam small radius (CAM_R_MIN) toward jaw → spring pushes jaw
-//   RELEASED : cam large radius (CAM_R_MAX) toward jaw → compresses spring
-//               by (CAM_R_MAX - CAM_R_MIN) = 4 mm, opening jaw
-//
-// Detent ball pocket (Ø3 mm) snaps into rail-dimple for each position.
-// Handle points rearward (-Y) in clamped state for low profile.
-//
-// Print standing on cam edge (cam disc vertical), PETG, 5 perims, 40%.
-module cam_lever() {
-    cam_offset = (CAM_R_MAX - CAM_R_MIN) / 2;   // 2 mm eccentricity
-    union() {
-        difference() {
-            union() {
-                // ── Eccentric cam disc ───────────────────────────────────
-                // Offset so pivot bore is eccentric to disc profile
-                translate([cam_offset, 0, 0])
-                    cylinder(r = CAM_R_MAX, h = CAM_THICK, center = true);
-
-                // ── Lever handle arm ─────────────────────────────────────
-                hull() {
-                    translate([cam_offset, 0, 0])
-                        cylinder(r = CAM_R_MAX, h = CAM_THICK, center = true);
-                    translate([cam_offset + CAM_HANDLE_L, 0, 0])
-                        cylinder(r = CAM_HANDLE_W/2,
-                                 h = CAM_HANDLE_T, center = true);
-                }
-            }
-
-            // ── M4 pivot bore (through cam centre) ───────────────────────
-            cylinder(d = CAM_BORE_D, h = CAM_THICK + 2*e, center = true);
-
-            // ── Detent pockets (2× Ø3 mm, at 0° and 90°) ────────────────
-            // Pocket at 0° → clamped detent
-            translate([CAM_R_MAX - 2, 0, CAM_THICK/2 - 1.5])
-                cylinder(d = CAM_DETENT_D + 0.2, h = 2);
-            // Pocket at 90° → released detent
-            translate([0, CAM_R_MAX - 2, CAM_THICK/2 - 1.5])
-                cylinder(d = CAM_DETENT_D + 0.2, h = 2);
-
-            // ── Lightening recesses on cam disc face ─────────────────────
-            for (a = [0, 60, 120, 180, 240, 300])
-                translate([cam_offset + (CAM_R_MAX - 4) * cos(a),
-                           (CAM_R_MAX - 4) * sin(a), 0])
-                    cylinder(d = 4, h = CAM_THICK + 2*e, center = true);
-
-            // ── Handle grip grooves ──────────────────────────────────────
-            for (i = [0:4])
-                translate([cam_offset + 20 + i * 5, 0, 0])
-                    rotate([90, 0, 0])
-                        cylinder(d = 2.5, h = CAM_HANDLE_W + 2*e,
-                                 center = true);
-        }
-    }
-}
-
-// ============================================================
-// PART 5 — GRIP PAD (VIBRATION DAMPENING)
-// ============================================================
-// Flat pad with transverse flexure ribs that press against phone side.
-// The rib profile (thin PETG fins) provides compliance in Z (vertical)
-// absorbing vibration transmitted through the bracket.
-// Optional: print in TPU 95A for superior damping.
-// M2 bolts or adhesive-backed foam tape attach pad to jaw pocket face.
-//
-// Pad face (+Y) contacts phone.  Mounting face (-Y) bonds to jaw.
-// Ribs run parallel to Z axis (vertical).
-//
-// Print flat (mounting face down), PETG or TPU 95A, 3 perims, 20%.
-module grip_pad() {
-    union() {
-        // ── Base plate ───────────────────────────────────────────────────
-        translate([-PAD_W/2, -PAD_T, -PAD_H/2])
-            cube([PAD_W, PAD_T, PAD_H]);
-
-        // ── Flexure ribs (transverse, dampening in Z) ────────────────────
-        // RIB_COUNT ribs spaced RIB_PITCH apart, centred on pad
-        for (i = [0 : RIB_COUNT - 1]) {
-            rx = -PAD_W/2 + RIB_PITCH/2 + i * RIB_PITCH;
-            if (abs(rx) <= PAD_W/2 - RIB_W/2)   // stay within pad
-                translate([rx, 0, 0])
-                    cube([RIB_W, RIB_H, PAD_H - 4], center = true);
-        }
-
-        // ── Corner retention nubs (M2 boss for optional bolt-through) ────
-        for (px = [-PAD_W/2 + 5, PAD_W/2 - 5])
-        for (pz = [-PAD_H/2 + 5, PAD_H/2 - 5])
-            translate([px, -PAD_T/2, pz])
-                difference() {
-                    cylinder(d = 5, h = PAD_T, center = true);
-                    cylinder(d = M2_D, h = PAD_T + 2*e, center = true);
-                }
-    }
-}

chassis/prototype_baseplate.scad

@@ -65,7 +65,7 @@ CLAMP_ALIGN_D   =   4.1;   // Ø4 pin
 // D-cut bore clearance
 DCUT_CL         =  0.3;
 
-// FC mount — ESP32-S3 BALANCE 30.5 × 30.5 mm M3
+// FC mount — MAMBA F722S 30.5 × 30.5 mm M3
 FC_PITCH        = 30.5;
 FC_HOLE_D       =  3.2;
 // FC is offset toward front of plate (away from stem)
@@ -202,7 +202,7 @@ module base_plate() {
                 translate([STEM_FLANGE_BC/2, 0, -1])
                     cylinder(d=M5, h=PLATE_THICK + 2);
 
-        // ── FC mount (ESP32-S3 BALANCE 30.5 × 30.5 M3) ────────────────────────
+        // ── FC mount (MAMBA F722S 30.5 × 30.5 M3) ────────────────────────
         for (x = [FC_X_OFFSET - FC_PITCH/2, FC_X_OFFSET + FC_PITCH/2])
         for (y = [-FC_PITCH/2, FC_PITCH/2])
             translate([x, y, -1])

chassis/rover_electronics_bay.scad

@@ -11,7 +11,7 @@
 //          • Ventilation slots      — all 4 walls + lid
 //
 // Shared mounting patterns (swappable with SaltyLab):
-//   FC    : 30.5 × 30.5 mm M3 (ESP32-S3 BALANCE / Pixhawk)
+//   FC    : 30.5 × 30.5 mm M3 (MAMBA F722S / Pixhawk)
 //   Jetson: 58 × 49 mm M3    (Orin NX / Nano Devkit carrier)
 //
 // Coordinate: bay centred at origin; Z=0 = deck top face.

chassis/rplidar_mount.scad

@@ -1,343 +1,76 @@
 // ============================================================
-// RPLIDAR A1 Mount Bracket — Issue #596
+// rplidar_mount.scad — RPLIDAR A1M8 Anti-Vibration Ring  Rev A
-// Agent   : sl-mechanical
+// Agent: sl-mechanical   2026-02-28
-// Date    : 2026-03-14
+// ============================================================
-// Part catalogue:
+// Flat ring sits between platform and RPLIDAR A1M8.
-//   1. tnut_base     — 2020 T-slot rail interface plate with M5 T-nut captive pockets
+// Anti-vibration isolation via 4× M3 silicone grommets
-//   2. column        — hollow elevation column, 120 mm tall, 3 stiffening ribs, cable bore
+// (same type as FC vibration mounts — Ø6 mm silicone, M3).
-//   3. scan_platform — top plate with Ø40 mm BC M3 mounting pattern, vibration seats
-//   4. vibe_ring     — silicone FC-grommet isolation ring for scan_platform bolts
-//   5. cable_guide   — snap-on cable management clip for column body
 //
-// BOM:
+// Bolt stack (bottom → top):
-//   2 × M5×10 BHCS + M5 T-nuts   (tnut_base to rail)
+//   M3×30 SHCS → platform (8 mm) → grommet (8 mm) →
-//   4 × M3×8  SHCS                (scan_platform to RPLIDAR A1)
+//   ring (4 mm) → RPLIDAR bottom (threaded M3, ~6 mm engagement)
-//   4 × M3 silicone FC grommets Ø8.5 OD / Ø3.2 bore  (anti-vibe)
-//   4 × M3 hex nuts               (captured in scan_platform)
 //
-// Print settings (PETG):
+// RENDER options:
-//   tnut_base / column / scan_platform : 5 perimeters, 40 % gyroid, no supports
+//   "ring"       print-ready flat ring (default)
-//   vibe_ring                          : 3 perimeters, 20 % gyroid, no supports
+//   "assembly"   ring in position on platform stub
-//   cable_guide                        : 3 perimeters, 30 % gyroid, no supports
-//
-// Export commands:
-//   openscad -D 'RENDER="tnut_base"'     -o tnut_base.stl     rplidar_mount.scad
-//   openscad -D 'RENDER="column"'        -o column.stl        rplidar_mount.scad
-//   openscad -D 'RENDER="scan_platform"' -o scan_platform.stl rplidar_mount.scad
-//   openscad -D 'RENDER="vibe_ring"'     -o vibe_ring.stl     rplidar_mount.scad
-//   openscad -D 'RENDER="cable_guide"'   -o cable_guide.stl   rplidar_mount.scad
-//   openscad -D 'RENDER="assembly"'      -o assembly.png      rplidar_mount.scad
 // ============================================================
 
-// ── Render selector ─────────────────────────────────────────
+RENDER = "ring";
-RENDER = "assembly"; // tnut_base | column | scan_platform | vibe_ring | cable_guide | assembly
+
+// ── RPLIDAR A1M8 ─────────────────────────────────────────────
+RPL_BODY_D  = 70.0;          // body diameter
+RPL_BC      = 58.0;          // M3 mounting bolt circle
+
+// ── Mount ring ───────────────────────────────────────────────
+RING_OD     = 82.0;          // outer diameter (RPL_BODY_D + 12 mm)
+RING_ID     = 30.0;          // inner cutout (cable / airflow)
+RING_H      =  4.0;          // ring thickness
+
+BOLT_D      =  3.3;          // M3 clearance through-hole
+GROMMET_D   =  7.0;          // silicone grommet OD (seat recess on bottom)
+GROMMET_H   =  1.0;          // seating recess depth
 
-// ── Global constants ────────────────────────────────────────
 $fn = 64;
-EPS = 0.01;
+e   = 0.01;
 
-// 2020 rail
+// ─────────────────────────────────────────────────────────────
-RAIL_W       = 20.0;   // extrusion cross-section
+module rplidar_ring() {
-RAIL_H       = 20.0;
-SLOT_NECK_H  =  3.2;   // T-slot opening width
-TNUT_W       =  9.8;   // M5 T-nut width
-TNUT_H       =  5.5;   // T-nut height (depth into slot)
-TNUT_L       = 12.0;   // T-nut body length
-M5_D         =  5.2;   // M5 clearance bore
-M5_HEAD_D    =  9.5;   // M5 BHCS head diameter
-M5_HEAD_H    =  4.0;   // M5 BHCS head height
-
-// Base plate
-BASE_L       = 60.0;   // length along rail axis
-BASE_W       = 30.0;   // width across rail
-BASE_T       =  8.0;   // plate thickness
-BOLT_PITCH   = 40.0;   // M5 bolt pitch along rail (centre-to-centre)
-
-// Elevation column
-COL_OD       = 25.0;   // column outer diameter
-COL_ID       = 17.0;   // inner bore (cable routing)
-ELEV_H       = 120.0;  // scan plane above rail top face
-COL_WALL     = (COL_OD - COL_ID) / 2;
-RIB_W        =  3.0;   // stiffening rib width
-RIB_H        =  3.5;   // rib radial height
-CABLE_SLOT_W =  8.0;   // cable entry slot width
-CABLE_SLOT_H =  5.0;   // cable entry slot height
-
-// Scan platform
-PLAT_D       = 60.0;   // platform disc diameter (clears RPLIDAR body Ø100 mm well)
-PLAT_T       =  6.0;   // platform thickness
-RPL_BC_D     = 40.0;   // RPLIDAR M3 bolt circle diameter (4 bolts at 45 °)
-RPL_BORE_D   = 36.0;   // central pass-through for scan motor cable
-M3_D         =  3.2;   // M3 clearance bore
-M3_NUT_W     =  5.5;   // M3 hex nut across-flats
-M3_NUT_H     =  2.4;   // M3 hex nut height
-GROM_OD      =  8.5;   // FC silicone grommet OD
-GROM_ID      =  3.2;   // grommet bore
-GROM_H       =  3.0;   // grommet seat depth
-CONN_SLOT_W  = 12.0;   // connector side-exit slot width
-CONN_SLOT_H  =  5.0;   // connector slot height
-
-// Vibe ring
-VRING_OD     = GROM_OD + 1.6;  // printed retainer OD
-VRING_ID     = GROM_ID + 0.3;  // pass-through with grommet seated
-VRING_T      =  2.0;            // ring flange thickness
-
-// Cable guide clip
-CLIP_W       = 14.0;
-CLIP_T       =  3.5;
-CLIP_GAP     = COL_OD + 0.4;   // snap-fit gap (slight interference)
-SNAP_T       =  1.8;
-CABLE_CH_W   =  8.0;
-CABLE_CH_H   =  5.0;
-
-// ── Utility modules ─────────────────────────────────────────
-module chamfer_cube(size, ch=1.0) {
-    // simple chamfered box (bottom edge only for printability)
-    hull() {
-        translate([ch, ch, 0])
-            cube([size[0]-2*ch, size[1]-2*ch, EPS]);
-        translate([0, 0, ch])
-            cube(size - [0, 0, ch]);
-    }
-}
-
-module hex_pocket(af, depth) {
-    // hex nut pocket (flat-to-flat af)
-    cylinder(d = af / cos(30), h = depth, $fn = 6);
-}
-
-// ── Part 1: tnut_base ───────────────────────────────────────
-module tnut_base() {
     difference() {
-        // Body
+        cylinder(d = RING_OD, h = RING_H);
-        union() {
+
-            chamfer_cube([BASE_L, BASE_W, BASE_T], ch=1.5);
+        // Central cutout
-            // Column socket boss centred on plate top face
+        translate([0, 0, -e])
-            translate([BASE_L/2, BASE_W/2, BASE_T])
+            cylinder(d = RING_ID, h = RING_H + 2*e);
-                cylinder(d=COL_OD + 4.0, h=8.0);
+
+        // 4× M3 clearance holes on bolt circle
+        for (a = [45, 135, 225, 315]) {
+            translate([RPL_BC/2 * cos(a), RPL_BC/2 * sin(a), -e])
+                cylinder(d = BOLT_D, h = RING_H + 2*e);
         }
 
-        // M5 bolt holes (counterbored for BHCS heads from underneath)
+        // Grommet seating recesses — bottom face
-        for (x = [BASE_L/2 - BOLT_PITCH/2, BASE_L/2 + BOLT_PITCH/2])
+        for (a = [45, 135, 225, 315]) {
-            translate([x, BASE_W/2, -EPS]) {
+            translate([RPL_BC/2 * cos(a), RPL_BC/2 * sin(a), -e])
-                cylinder(d=M5_D, h=BASE_T + 8.0 + 2*EPS);
+                cylinder(d = GROMMET_D, h = GROMMET_H + e);
-                // counterbore from bottom
-                cylinder(d=M5_HEAD_D, h=M5_HEAD_H + EPS);
-            }
-
-        // T-nut captive pockets (accessible from bottom)
-        for (x = [BASE_L/2 - BOLT_PITCH/2, BASE_L/2 + BOLT_PITCH/2])
-            translate([x - TNUT_L/2, BASE_W/2 - TNUT_W/2, BASE_T - TNUT_H])
-                cube([TNUT_L, TNUT_W, TNUT_H + EPS]);
-
-        // Column bore into boss
-        translate([BASE_L/2, BASE_W/2, BASE_T - EPS])
-            cylinder(d=COL_OD + 0.3, h=8.0 + 2*EPS);
-
-        // Cable exit slot through base (offset 5 mm from column centre)
-        translate([BASE_L/2 - CABLE_SLOT_W/2, BASE_W/2 + COL_OD/4, -EPS])
-            cube([CABLE_SLOT_W, CABLE_SLOT_H, BASE_T + 8.0 + 2*EPS]);
-
-        // Weight relief pockets on underside
-        for (x = [BASE_L/2 - BOLT_PITCH/2 + 10, BASE_L/2 + BOLT_PITCH/2 - 10])
-            for (y = [7, BASE_W - 7])
-                translate([x - 5, y - 5, -EPS])
-                    cube([10, 10, BASE_T/2]);
-    }
-}
-
-// ── Part 2: column ──────────────────────────────────────────
-module column() {
-    // Actual column height: ELEV_H minus base boss engagement (8 mm) and platform seating (6 mm)
-    col_h = ELEV_H - 8.0 - PLAT_T;
-
-    difference() {
-        union() {
-            // Hollow tube
-            cylinder(d=COL_OD, h=col_h);
-
-            // Three 120°-spaced stiffening ribs along full height
-            for (a = [0, 120, 240])
-                rotate([0, 0, a])
-                    translate([COL_OD/2 - EPS, -RIB_W/2, 0])
-                        cube([RIB_H, RIB_W, col_h]);
-
-            // Bottom spigot (fits into base boss bore)
-            translate([0, 0, -6.0])
-                cylinder(d=COL_OD - 0.4, h=6.0 + EPS);
-
-            // Top spigot (seats into scan_platform recess)
-            translate([0, 0, col_h - EPS])
-                cylinder(d=COL_OD - 0.4, h=6.0);
         }
-
-        // Inner cable bore
-        translate([0, 0, -6.0 - EPS])
-            cylinder(d=COL_ID, h=col_h + 12.0 + 2*EPS);
-
-        // Cable entry slot at bottom (aligns with base slot)
-        translate([-CABLE_SLOT_W/2, -COL_OD/2 - EPS, 2.0])
-            cube([CABLE_SLOT_W, CABLE_SLOT_H + EPS, CABLE_SLOT_H]);
-
-        // Cable exit slot at top (90° rotated for tidy routing)
-        rotate([0, 0, 90])
-            translate([-CABLE_SLOT_W/2, -COL_OD/2 - EPS, col_h - CABLE_SLOT_H - 4.0])
-                cube([CABLE_SLOT_W, CABLE_SLOT_H + EPS, CABLE_SLOT_H]);
-
-        // Cable clip snap groove (at mid-height)
-        translate([0, 0, col_h / 2])
-            difference() {
-                cylinder(d=COL_OD + 2*RIB_H + 0.8, h=4.0, center=true);
-                cylinder(d=COL_OD - 0.2, h=4.0 + 2*EPS, center=true);
-            }
     }
 }
 
-// ── Part 3: scan_platform ───────────────────────────────────
+// ─────────────────────────────────────────────────────────────
-module scan_platform() {
+// Render selector
-    difference() {
+// ─────────────────────────────────────────────────────────────
-        union() {
+if (RENDER == "ring") {
-            // Main disc
+    rplidar_ring();
-            cylinder(d=PLAT_D, h=PLAT_T);
 
-            // Rim lip for stiffness
+} else if (RENDER == "assembly") {
-            translate([0, 0, PLAT_T])
+    // Platform stub
-                difference() {
+    color("Silver", 0.5)
-                    cylinder(d=PLAT_D, h=2.0);
+        difference() {
-                    cylinder(d=PLAT_D - 4.0, h=2.0 + EPS);
+            cylinder(d = 90, h = 8);
-                }
+            translate([0, 0, -e]) cylinder(d = 25.4, h = 8 + 2*e);
         }
-
+    // Ring floating 8 mm above (grommet gap)
-        // Central cable pass-through
+    color("SkyBlue", 0.9)
-        translate([0, 0, -EPS])
+        translate([0, 0, 8 + 8])
-            cylinder(d=RPL_BORE_D, h=PLAT_T + 4.0);
+            rplidar_ring();
-
-        // Column spigot socket (bottom recess)
-        translate([0, 0, -EPS])
-            cylinder(d=COL_OD - 0.4 + 0.4, h=6.0);
-
-        // RPLIDAR M3 mounting holes — 4× on Ø40 BC at 45°/135°/225°/315°
-        for (a = [45, 135, 225, 315])
-            rotate([0, 0, a])
-                translate([RPL_BC_D/2, 0, -EPS]) {
-                    // Through bore
-                    cylinder(d=M3_D, h=PLAT_T + 2*EPS);
-                    // Grommet seat (countersunk from top)
-                    translate([0, 0, PLAT_T - GROM_H])
-                        cylinder(d=GROM_OD + 0.3, h=GROM_H + EPS);
-                    // Captured M3 hex nut pocket (from bottom)
-                    translate([0, 0, 1.5])
-                        hex_pocket(M3_NUT_W + 0.3, M3_NUT_H + 0.2);
-                }
-
-        // Connector side-exit slots (2× opposing, at 0° and 180°)
-        for (a = [0, 180])
-            rotate([0, 0, a])
-                translate([-CONN_SLOT_W/2, PLAT_D/2 - CONN_SLOT_H, -EPS])
-                    cube([CONN_SLOT_W, CONN_SLOT_H + EPS, PLAT_T + 2*EPS]);
-
-        // Weight relief pockets (2× lateral)
-        for (a = [90, 270])
-            rotate([0, 0, a])
-                translate([-10, 15, 1.5])
-                    cube([20, 8, PLAT_T - 3.0]);
-    }
 }
-
-// ── Part 4: vibe_ring ───────────────────────────────────────
-// Printed silicone-grommet retainer ring — press-fits over M3 bolt with grommet seated
-module vibe_ring() {
-    difference() {
-        union() {
-            cylinder(d=VRING_OD, h=VRING_T + GROM_H);
-            // Flange
-            cylinder(d=VRING_OD + 2.0, h=VRING_T);
-        }
-        // Bore
-        translate([0, 0, -EPS])
-            cylinder(d=VRING_ID, h=VRING_T + GROM_H + 2*EPS);
-    }
-}
-
-// ── Part 5: cable_guide ─────────────────────────────────────
-// Snap-on cable clip for column mid-section
-module cable_guide() {
-    arm_t = SNAP_T;
-    gap   = CLIP_GAP;
-
-    difference() {
-        union() {
-            // Saddle body (U-shape wrapping column)
-            difference() {
-                cylinder(d=gap + 2*CLIP_T, h=CLIP_W);
-                translate([0, 0, -EPS])
-                    cylinder(d=gap, h=CLIP_W + 2*EPS);
-                // Open front slot for snap insertion
-                translate([-gap/2, 0, -EPS])
-                    cube([gap, gap/2 + CLIP_T + EPS, CLIP_W + 2*EPS]);
-            }
-
-            // Snap arms
-            for (s = [-1, 1])
-                translate([s*(gap/2 - arm_t), 0, 0])
-                    mirror([s < 0 ? 1 : 0, 0, 0])
-                        translate([0, -arm_t/2, 0])
-                            cube([arm_t + 1.5, arm_t, CLIP_W]);
-
-            // Cable channel bracket (side-mounted)
-            translate([gap/2 + CLIP_T, -(CABLE_CH_W/2 + CLIP_T), 0])
-                cube([CLIP_T + CABLE_CH_H, CABLE_CH_W + 2*CLIP_T, CLIP_W]);
-        }
-
-        // Cable channel cutout
-        translate([gap/2 + CLIP_T + CLIP_T - EPS, -CABLE_CH_W/2, -EPS])
-            cube([CABLE_CH_H + EPS, CABLE_CH_W, CLIP_W + 2*EPS]);
-
-        // Snap tip undercut (both arms)
-        for (s = [-1, 1])
-            translate([s*(gap/2 + CLIP_T + 1.0), -arm_t, -EPS])
-                rotate([0, 0, s*30])
-                    cube([2, arm_t*2, CLIP_W + 2*EPS]);
-    }
-}
-
-// ── Assembly / render dispatch ───────────────────────────────
-module assembly() {
-    // tnut_base at origin
-    color("SteelBlue")
-        tnut_base();
-
-    // column rising from base boss
-    color("DodgerBlue")
-        translate([BASE_L/2, BASE_W/2, BASE_T + 8.0 - 6.0])
-            column();
-
-    // scan_platform at top of column
-    col_h_actual = ELEV_H - 8.0 - PLAT_T;
-    color("CornflowerBlue")
-        translate([BASE_L/2, BASE_W/2, BASE_T + 8.0 - 6.0 + col_h_actual + 6.0 - EPS])
-            scan_platform();
-
-    // vibe rings (4×) seated in platform holes
-    for (a = [45, 135, 225, 315])
-        color("Gray", 0.7)
-            translate([BASE_L/2, BASE_W/2,
-                       BASE_T + 8.0 - 6.0 + col_h_actual + 6.0 + PLAT_T - GROM_H])
-                rotate([0, 0, a])
-                    translate([RPL_BC_D/2, 0, 0])
-                        vibe_ring();
-
-    // cable_guide clipped at column mid-height
-    color("LightSteelBlue")
-        translate([BASE_L/2, BASE_W/2,
-                   BASE_T + 8.0 - 6.0 + (ELEV_H - 8.0 - PLAT_T)/2 - CLIP_W/2])
-            cable_guide();
-}
-
-// ── Dispatch ────────────────────────────────────────────────
-if      (RENDER == "tnut_base")     tnut_base();
-else if (RENDER == "column")        column();
-else if (RENDER == "scan_platform") scan_platform();
-else if (RENDER == "vibe_ring")     vibe_ring();
-else if (RENDER == "cable_guide")   cable_guide();
-else                                assembly();

chassis/saltyrover_chassis_r2.scad

@@ -17,7 +17,7 @@
 //   • Weight target: <2 kg frame (excl. motors/electronics)
 //
 // Shared SaltyLab patterns (swappable electronics):
-//   FC  : 30.5 × 30.5 mm M3  (ESP32-S3 BALANCE / Pixhawk)
+//   FC  : 30.5 × 30.5 mm M3  (MAMBA F722S / Pixhawk)
 //   Jetson: 58 × 49 mm M3    (Orin NX / Nano carrier board)
 //   Stem  : Ø25 mm bore      (sensor head unchanged)
 //
@@ -87,7 +87,7 @@ STEM_COLLAR_OD = 50.0;
 STEM_COLLAR_H  = 20.0;   // raised boss height above deck top
 STEM_FLANGE_BC = 40.0;   // 4× M4 bolt circle for stem adapter
 
-// ── FC mount — ESP32-S3 BALANCE / Pixhawk (30.5 × 30.5 mm M3) ────────────────────
+// ── FC mount — MAMBA F722S / Pixhawk (30.5 × 30.5 mm M3) ────────────────────
 // Shared with SaltyLab — swappable electronics
 FC_PITCH    = 30.5;
 FC_HOLE_D   =  3.2;

chassis/uwb_anchor_mount.scad

@@ -1,341 +1,275 @@
 // ============================================================
-// uwb_anchor_mount.scad — Wall/Ceiling UWB Anchor Mount Bracket
+// uwb_anchor_mount.scad — Stem-Mounted UWB Anchor  Rev A
-// Issue: #564  Agent: sl-mechanical  Date: 2026-03-14
+// Agent: sl-mechanical   2026-03-01
-// (supersedes Rev A stem-collar mount — see git history)
+// Closes issues #57, #62
 // ============================================================
+// Clamp-on bracket for 2× MaUWB ESP32-S3 anchor modules on
+// SaltyBot 25 mm OD vertical stem.
+// Anchors spaced ANCHOR_SPACING = 250 mm apart.
 //
-// Parametric wall or ceiling mount bracket for ESP32 UWB Pro anchor.
+// Features:
-// Designed for fixed-infrastructure deployment: anchors screw into
+//   • Split D-collar with M4 clamping bolts + M4 set screw
-// wall or ceiling drywall/timber with standard M4 or #6 wood screws,
+//   • Anti-rotation flat tab that keys against a small pin
-// at a user-defined tilt angle so the UWB antenna faces the desired
+//     OR printed key tab that registers on the stem flat (if stem
-// coverage zone.
+//     has a ground flat) — see ANTI_ROT_MODE parameter
+//   • Module bracket: faces outward, tilted 10° from vertical
+//     so antenna clears stem and faces horizon
+//   • USB cable channel (power from Orin via USB-A) on collar
+//   • Tool-free capture: M4 thumbscrews (slot-head, hand-tighten)
+//   • UWB antenna area: NO material within 10 mm of PCB top face
 //
-// Architecture:
+// Components per mount:
-//   Wall base    -> flat backplate with 2x screw holes (wall or ceiling)
+//   2× collar_half        print in PLA/PETG, flat-face-down
-//   Tilt knuckle -> single-axis articulating joint; 15deg detent steps
+//   1× module_bracket     print in PLA/PETG, flat-face-down
-//                   locked with M3 nyloc bolt; range 0-90deg
-//   Anchor cradle-> U-cradle holding ESP32 UWB Pro PCB on M2.5 standoffs
-//   USB-C channel-> routed groove on tilt arm + exit slot in cradle back wall
-//   Label slot   -> rear window slot for printed anchor-ID card strip
-//
-// Part catalogue:
-//   Part 1 -- wall_base()       Backplate + 2-ear pivot block + detent arc
-//   Part 2 -- tilt_arm()        Pivoting arm with knuckle + cradle stub
-//   Part 3 -- anchor_cradle()   PCB cradle, standoffs, USB-C slot, label window
-//   Part 4 -- cable_clip()      Snap-on USB-C cable guide for tilt arm
-//   Part 5 -- assembly_preview()
-//
-// Hardware BOM:
-//   2x M4 x 30mm wood screws (or #6 drywall screws)  wall fasteners
-//   1x M3 x 20mm SHCS + M3 nyloc nut                 tilt pivot bolt
-//   4x M2.5 x 8mm SHCS                               PCB-to-cradle
-//   4x M2.5 hex nuts                                  captured in standoffs
-//   1x USB-C cable                                    anchor power
-//
-// ESP32 UWB Pro interface (verify with calipers):
-//   PCB size       : UWB_L x UWB_W x UWB_H  (55 x 28 x 10 mm default)
-//   Mounting holes : M2.5, 4x corners on UWB_HOLE_X x UWB_HOLE_Y pattern
-//   USB-C port     : centred on short edge, UWB_USBC_W x UWB_USBC_H
-//   Antenna area   : top face rear half -- 10mm keep-out of bracket material
-//
-// Tilt angles (15deg detent steps, set TILT_DEG before export):
-//   0deg  -> horizontal face-up   (ceiling, antenna faces down)
-//   30deg -> 30deg downward tilt  (wall near ceiling)  [default]
-//   45deg -> diagonal             (wall mid-height)
-//   90deg -> vertical face-out    (wall, antenna faces forward)
 //
 // RENDER options:
-//   "assembly"           full assembly at TILT_DEG (default)
+//   "assembly"       single mount assembled (default)
-//   "wall_base_stl"      Part 1
+//   "collar_front"   front collar half for slicing (×2 per mount × 2 mounts = 4)
-//   "tilt_arm_stl"       Part 2
+//   "collar_rear"    rear collar half
-//   "anchor_cradle_stl"  Part 3
+//   "bracket"        module bracket (×2 mounts)
-//   "cable_clip_stl"     Part 4
+//   "pair"           both mounts on 350 mm stem section
-//
-// Export commands:
-//   openscad uwb_anchor_mount.scad -D 'RENDER="wall_base_stl"'     -o uwb_wall_base.stl
-//   openscad uwb_anchor_mount.scad -D 'RENDER="tilt_arm_stl"'      -o uwb_tilt_arm.stl
-//   openscad uwb_anchor_mount.scad -D 'RENDER="anchor_cradle_stl"' -o uwb_anchor_cradle.stl
-//   openscad uwb_anchor_mount.scad -D 'RENDER="cable_clip_stl"'    -o uwb_cable_clip.stl
 // ============================================================
 
-$fn  = 64;
-e    = 0.01;
-
-// -- Tilt angle (override per anchor, 0-90deg, 15deg steps) ------------------
-TILT_DEG = 30;
-
-// -- ESP32 UWB Pro PCB dimensions (verify with calipers) ---------------------
-UWB_L         = 55.0;
-UWB_W         = 28.0;
-UWB_H         = 10.0;
-UWB_HOLE_X    = 47.5;
-UWB_HOLE_Y    = 21.0;
-UWB_USBC_W    =  9.5;
-UWB_USBC_H    =  4.0;
-UWB_ANTENNA_L = 20.0;
-
-// -- Wall base geometry -------------------------------------------------------
-BASE_W         = 60.0;
-BASE_H         = 50.0;
-BASE_T         =  5.0;
-BASE_SCREW_D   =  4.5;
-BASE_SCREW_HD  =  8.5;
-BASE_SCREW_HH  =  3.5;
-BASE_SCREW_SPC = 35.0;
-KNUCKLE_T      = BASE_T + 4.0;
-
-// -- Tilt arm geometry --------------------------------------------------------
-ARM_W         = 12.0;
-ARM_T         =  5.0;
-ARM_L         = 35.0;
-PIVOT_D       =  3.3;
-PIVOT_NUT_AF  =  5.5;
-PIVOT_NUT_H   =  2.4;
-DETENT_D      =  3.2;
-DETENT_R      =  8.0;
-
-// -- Anchor cradle geometry ---------------------------------------------------
-CRADLE_WALL_T  =  3.5;
-CRADLE_BACK_T  =  4.0;
-CRADLE_FLOOR_T =  3.0;
-CRADLE_LIP_H   =  4.0;
-CRADLE_LIP_T   =  2.5;
-STANDOFF_H     =  3.0;
-STANDOFF_OD    =  5.5;
-LABEL_W        = UWB_L - 4.0;
-LABEL_H        = UWB_W * 0.55;
-LABEL_T        =  1.2;
-
-// -- USB-C routing ------------------------------------------------------------
-USBC_CHAN_W   = 11.0;
-USBC_CHAN_H   =  7.0;
-
-// -- Cable clip ---------------------------------------------------------------
-CLIP_CABLE_D  =  4.5;
-CLIP_T        =  2.0;
-CLIP_BODY_W   = 16.0;
-CLIP_BODY_H   = 10.0;
-
-// -- Fasteners ----------------------------------------------------------------
-M2P5_D    = 2.7;
-M3_D      = 3.3;
-M3_NUT_AF = 5.5;
-M3_NUT_H  = 2.4;
-
-// ============================================================
-// RENDER DISPATCH
-// ============================================================
 RENDER = "assembly";
 
-if      (RENDER == "assembly")           assembly_preview();
+// ── ⚠ Verify with calipers ───────────────────────────────────
-else if (RENDER == "wall_base_stl")      wall_base();
+MAWB_L      = 50.0;   // PCB length
-else if (RENDER == "tilt_arm_stl")       tilt_arm();
+MAWB_W      = 25.0;   // PCB width
-else if (RENDER == "anchor_cradle_stl")  anchor_cradle();
+MAWB_H      = 10.0;   // PCB + components
-else if (RENDER == "cable_clip_stl")     cable_clip();
+MAWB_HOLE_X = 43.0;   // M2 mounting hole X span
+MAWB_HOLE_Y = 20.0;   // M2 mounting hole Y span
+M2_D        =  2.2;   // M2 clearance
 
-// ============================================================
+// ── Stem ─────────────────────────────────────────────────────
-// ASSEMBLY PREVIEW
+STEM_OD     = 25.0;
-// ============================================================
+STEM_BORE   = 25.4;   // +0.4 clearance
-module assembly_preview() {
+WALL        =  2.0;   // wall thickness (used in thumbscrew recess)
-    %color("Wheat", 0.22)
-        translate([-BASE_W/2, -10, -BASE_H/2])
-            cube([BASE_W, 10, BASE_H + 40]);
-    color("OliveDrab", 0.85)  wall_base();
-    color("SteelBlue", 0.85)
-        translate([0, KNUCKLE_T, 0]) rotate([TILT_DEG,0,0]) tilt_arm();
-    color("DarkSlateGray", 0.85)
-        translate([0, KNUCKLE_T, 0]) rotate([TILT_DEG,0,0])
-            translate([0, ARM_T, ARM_L]) anchor_cradle();
-    %color("ForestGreen", 0.38)
-        translate([0, KNUCKLE_T, 0]) rotate([TILT_DEG,0,0])
-            translate([-UWB_L/2, ARM_T+CRADLE_BACK_T,
-                       ARM_L+CRADLE_FLOOR_T+STANDOFF_H])
-                cube([UWB_L, UWB_W, UWB_H]);
-    color("DimGray", 0.70)
-        translate([ARM_W/2, KNUCKLE_T, 0]) rotate([TILT_DEG,0,0])
-            translate([0, ARM_T+e, ARM_L/2]) rotate([0,-90,90]) cable_clip();
-}
 
-// ============================================================
+// ── Collar ───────────────────────────────────────────────────
-// PART 1 -- WALL BASE
+COL_OD      = 52.0;
-// ============================================================
+COL_H       = 30.0;   // taller than sensor-head collar for rigidity
-// Flat backplate, 2x countersunk M4/#6 wood screws on 35mm centres.
+COL_BOLT_X  = 19.0;   // M4 bolt CL from stem axis
-// Two pivot ears straddle the tilt arm; M3 pivot bolt through both.
+COL_BOLT_D  =  4.5;   // M4 clearance
-// Detent arc on +X ear inner face: 7 notches at 15deg steps (0-90deg).
+THUMB_HEAD_D=  8.0;   // M4 thumbscrew head OD (slot for access)
-// Shallow rear recess for installation-zone label strip.
+COL_NUT_W   =  7.0;   // M4 hex nut A/F
-// Same part for wall mount and ceiling mount.
+COL_NUT_H   =  3.4;
-//
+
-// Print: backplate flat on bed, PETG, 5 perims, 40% gyroid.
+// Anti-rotation flat tab: a 3 mm wall tab that protrudes radially
-module wall_base() {
+// and bears against the bracket arm, preventing axial rotation
-    ear_h   = ARM_W + 3.0;
+// without needing a stem flat.
-    ear_t   = 6.0;
+ANTI_ROT_T  =  3.0;   // tab thickness (radial)
-    ear_sep = ARM_W + 1.0;
+ANTI_ROT_W  =  8.0;   // tab width (tangential)
+ANTI_ROT_Z  =  4.0;   // distance from collar base
+
+// USB cable channel: groove on collar outer surface, runs Z direction
+// Cable routes from anchor module down to base
+USB_CHAN_W  =  9.0;   // channel width (fits USB-A cable Ø6 mm)
+USB_CHAN_D  =  5.0;   // channel depth
+
+// ── Module bracket ───────────────────────────────────────────
+ARM_L       = 20.0;   // arm length from collar OD to bracket face
+ARM_W       = MAWB_W + 6.0; // bracket width (Y, includes side walls)
+ARM_H       =  6.0;   // arm thickness (Z)
+BRKT_TILT   = 10.0;   // tilt outward from vertical (antenna faces horizon)
+
+BRKT_BACK_T =  3.0;   // bracket back wall (module sits against this)
+BRKT_SIDE_T =  2.0;   // bracket side walls
+
+M2_STNDFF   =  3.0;   // M2 standoff height
+M2_STNDFF_OD=  4.5;
+
+// USB port access notch in bracket side wall (8×5 mm)
+USB_NOTCH_W = 10.0;
+USB_NOTCH_H =  7.0;
+
+// ── Spacing ───────────────────────────────────────────────────
+ANCHOR_SPACING = 250.0;  // centre-to-centre Z separation
+
+$fn = 64;
+e   = 0.01;
+
+// ─────────────────────────────────────────────────────────────
+// collar_half(side)
+//   split at Y=0 plane.  Bracket arm on front (+Y) half.
+//   Print flat-face-down.
+// ─────────────────────────────────────────────────────────────
+module collar_half(side = "front") {
+    y_front = (side == "front");
 
     difference() {
         union() {
-            translate([-BASE_W/2, -BASE_T, -BASE_H/2])
+            // D-shaped body
-                cube([BASE_W, BASE_T, BASE_H]);
+            intersection() {
-            for (ex = [-(ear_sep/2 + ear_t), ear_sep/2])
+                cylinder(d=COL_OD, h=COL_H);
-                translate([ex, -BASE_T+e, -ear_h/2])
+                translate([-COL_OD/2, y_front ? 0 : -COL_OD/2, 0])
-                    cube([ear_t, KNUCKLE_T+e, ear_h]);
+                    cube([COL_OD, COL_OD/2, COL_H]);
-            for (ex = [-(ear_sep/2 + ear_t), ear_sep/2])
+            }
-                hull() {
+
-                    translate([ex, -BASE_T, -ear_h/4])
+            // Anti-rotation tab (front half only, at +X side)
-                        cube([ear_t, BASE_T-1, ear_h/2]);
+            if (y_front) {
-                    translate([ex + (ex<0 ? ear_t*0.5 : 0), -BASE_T, -ear_h/6])
+                translate([COL_OD/2, -ANTI_ROT_W/2, ANTI_ROT_Z])
-                        cube([ear_t*0.5, 1, ear_h/3]);
+                    cube([ANTI_ROT_T, ANTI_ROT_W,
-                }
+                          COL_H - ANTI_ROT_Z - 4]);
+            }
+
+            // Bracket arm attachment boss (front half only, top centre)
+            if (y_front) {
+                translate([-ARM_W/2, COL_OD/2, COL_H * 0.3])
+                    cube([ARM_W, ARM_L, COL_H * 0.4]);
+            }
         }
-        for (sz = [-BASE_SCREW_SPC/2, BASE_SCREW_SPC/2]) {
+
-            translate([0, -BASE_T-e, sz]) rotate([-90,0,0])
+        // ── Stem bore ─────────────────────────────────────────
-                cylinder(d=BASE_SCREW_D, h=BASE_T+2*e);
+        translate([0,0,-e])
-            translate([0, -BASE_T-e, sz]) rotate([-90,0,0])
+            cylinder(d=STEM_BORE, h=COL_H + 2*e);
-                cylinder(d1=BASE_SCREW_HD, d2=BASE_SCREW_D, h=BASE_SCREW_HH+e);
+
+        // ── M4 clamping bolt holes (Y direction) ──────────────
+        for (bx=[-COL_BOLT_X, COL_BOLT_X]) {
+            translate([bx, y_front ? COL_OD/2 : 0, COL_H/2])
+                rotate([90,0,0])
+                    cylinder(d=COL_BOLT_D, h=COL_OD/2 + e);
+            // Thumbscrew head recess on outer face (front only — access side)
+            if (y_front) {
+                translate([bx, COL_OD/2 - WALL, COL_H/2])
+                    rotate([90,0,0])
+                        cylinder(d=THUMB_HEAD_D, h=8 + e);
+            }
+        }
+
+        // ── M4 hex nut pockets (rear half) ────────────────────
+        if (!y_front) {
+            for (bx=[-COL_BOLT_X, COL_BOLT_X]) {
+                translate([bx, -(COL_OD/4 + e), COL_H/2])
+                    rotate([90,0,0])
+                        cylinder(d=COL_NUT_W/cos(30), h=COL_NUT_H + e,
+                                 $fn=6);
+            }
+        }
+
+        // ── Set screw (height lock, front half) ───────────────
+        if (y_front) {
+            translate([0, COL_OD/2, COL_H * 0.8])
+                rotate([90,0,0])
+                    cylinder(d=COL_BOLT_D,
+                             h=COL_OD/2 - STEM_BORE/2 + e);
+        }
+
+        // ── USB cable routing channel (rear half, −X side) ────
+        if (!y_front) {
+            translate([-COL_OD/2, -USB_CHAN_W/2, -e])
+                cube([USB_CHAN_D, USB_CHAN_W, COL_H + 2*e]);
+        }
+
+        // ── M4 hole through arm boss (Z direction, for bracket bolt) ─
+        if (y_front) {
+            for (dx=[-ARM_W/4, ARM_W/4])
+                translate([dx, COL_OD/2 + ARM_L/2, COL_H * 0.35])
+                    cylinder(d=COL_BOLT_D, h=COL_H * 0.35 + e);
         }
-        translate([-(ear_sep/2+ear_t+e), KNUCKLE_T*0.55, 0])
-            rotate([0,90,0]) cylinder(d=PIVOT_D, h=ear_sep+2*ear_t+2*e);
-        translate([ear_sep/2+ear_t-PIVOT_NUT_H-0.4, KNUCKLE_T*0.55, 0])
-            rotate([0,90,0])
-                cylinder(d=PIVOT_NUT_AF/cos(30), h=PIVOT_NUT_H+0.5, $fn=6);
-        for (da = [0 : 15 : 90])
-            translate([ear_sep/2-e,
-                       KNUCKLE_T*0.55 + DETENT_R*sin(da),
-                       DETENT_R*cos(da)])
-                rotate([0,90,0]) cylinder(d=DETENT_D, h=ear_t*0.45+e);
-        translate([0, -BASE_T-e, 0]) rotate([-90,0,0])
-            cube([BASE_W-12, BASE_H-16, 1.6], center=true);
-        translate([0, -BASE_T+1.5, 0])
-            cube([BASE_W-14, BASE_T-3, BASE_H-20], center=true);
     }
 }
 
-// ============================================================
+// ─────────────────────────────────────────────────────────────
-// PART 2 -- TILT ARM
+// module_bracket()
-// ============================================================
+//   Bolts to collar arm boss. Holds MaUWB PCB facing outward.
-// Pivoting arm linking wall_base ears to anchor_cradle.
+//   Tilted BRKT_TILT° from vertical — antenna clears stem.
-// Knuckle (Z=0): M3 pivot bore + spring-plunger detent pocket (3mm).
+//   Print flat-face-down (back wall on bed).
-// Cradle end (Z=ARM_L): 2x M3 bolt attachment stub.
+// ─────────────────────────────────────────────────────────────
-// USB-C cable channel groove on outer +Y face, full arm length.
+module module_bracket() {
-//
+    bk = BRKT_BACK_T;
-// Print: knuckle face flat on bed, PETG, 5 perims, 40% gyroid.
+    sd = BRKT_SIDE_T;
-module tilt_arm() {
-    total_h = ARM_L + 10;
-    difference() {
-        union() {
-            translate([-ARM_W/2, 0, 0]) cube([ARM_W, ARM_T, total_h]);
-            translate([0, ARM_T/2, 0]) rotate([90,0,0])
-                cylinder(d=ARM_W, h=ARM_T, center=true);
-            translate([-ARM_W/2, 0, ARM_L])
-                cube([ARM_W, ARM_T+CRADLE_BACK_T, ARM_T]);
-        }
-        translate([-ARM_W/2-e, ARM_T/2, 0]) rotate([0,90,0])
-            cylinder(d=PIVOT_D, h=ARM_W+2*e);
-        translate([0, ARM_T+e, 0]) rotate([90,0,0])
-            cylinder(d=3.2, h=4+e);
-        translate([-USBC_CHAN_W/2, ARM_T-e, ARM_T+4])
-            cube([USBC_CHAN_W, USBC_CHAN_H, ARM_L-ARM_T-8]);
-        for (bx = [-ARM_W/4, ARM_W/4])
-            translate([bx, ARM_T/2, ARM_L+ARM_T/2]) rotate([90,0,0])
-                cylinder(d=M3_D, h=ARM_T+CRADLE_BACK_T+2*e);
-        for (bx = [-ARM_W/4, ARM_W/4])
-            translate([bx, ARM_T/2, ARM_L+ARM_T/2]) rotate([-90,0,0])
-                cylinder(d=M3_NUT_AF/cos(30), h=M3_NUT_H+0.5, $fn=6);
-        translate([0, ARM_T/2, ARM_L/2])
-            cube([ARM_W-4, ARM_T-2, ARM_L-18], center=true);
-    }
-}
-
-// ============================================================
-// PART 3 -- ANCHOR CRADLE
-// ============================================================
-// Open-front U-cradle for ESP32 UWB Pro PCB.
-// 4x M2.5 standoffs on UWB_HOLE_X x UWB_HOLE_Y pattern.
-// Back wall: USB-C exit slot + routing groove, label card slot,
-//            antenna keep-out cutout (material removed above antenna area).
-// Front retaining lip prevents PCB sliding out.
-// Two attachment tabs bolt to tilt_arm cradle stub via M3.
-//
-// Label card slot: insert paper/laminate strip to ID this anchor
-// (e.g. "UWB-A3 NE-CORNER"), accessible from open cradle end.
-//
-// Print: back wall flat on bed, PETG, 5 perims, 40% gyroid.
-module anchor_cradle() {
-    outer_l  = UWB_L + 2*CRADLE_WALL_T;
-    outer_w  = UWB_W + CRADLE_FLOOR_T;
-    pcb_z    = CRADLE_FLOOR_T + STANDOFF_H;
-    total_z  = pcb_z + UWB_H + 2;
 
     difference() {
         union() {
-            translate([-outer_l/2, 0, 0]) cube([outer_l, outer_w, total_z]);
+            // ── Back wall (mounts to collar arm boss) ─────────
-            translate([-outer_l/2, outer_w-CRADLE_LIP_T, 0])
+            cube([ARM_W, bk, MAWB_H + M2_STNDFF + 6]);
-                cube([outer_l, CRADLE_LIP_T, CRADLE_LIP_H]);
+
-            for (tx = [-ARM_W/4, ARM_W/4])
+            // ── Side walls ────────────────────────────────────
-                translate([tx-4, -CRADLE_BACK_T, 0])
+            for (sx=[0, ARM_W - sd])
-                    cube([8, CRADLE_BACK_T+1, total_z]);
+                translate([sx, bk, 0])
+                    cube([sd, MAWB_L + 2, MAWB_H + M2_STNDFF + 6]);
+
+            // ── M2 standoff posts (PCB mounts to these) ───────
+            for (hx=[0, MAWB_HOLE_X], hy=[0, MAWB_HOLE_Y])
+                translate([(ARM_W - MAWB_HOLE_X)/2 + hx,
+                           bk + (MAWB_L - MAWB_HOLE_Y)/2 + hy,
+                           0])
+                    cylinder(d=M2_STNDFF_OD, h=M2_STNDFF);
         }
-        translate([-UWB_L/2, 0, pcb_z]) cube([UWB_L, UWB_W+1, UWB_H+4]);
+
-        translate([0, -CRADLE_BACK_T-e, pcb_z+UWB_H/2-UWB_USBC_H/2])
+        // ── M2 bores through standoffs ────────────────────────
-            cube([UWB_USBC_W+2, CRADLE_BACK_T+2*e, UWB_USBC_H+2],
+        for (hx=[0, MAWB_HOLE_X], hy=[0, MAWB_HOLE_Y])
-                 center=[true,false,false]);
+            translate([(ARM_W - MAWB_HOLE_X)/2 + hx,
-        translate([0, -CRADLE_BACK_T-e, -e])
+                       bk + (MAWB_L - MAWB_HOLE_Y)/2 + hy,
-            cube([USBC_CHAN_W, USBC_CHAN_H, pcb_z+UWB_H/2+USBC_CHAN_H],
+                       -e])
-                 center=[true,false,false]);
+                cylinder(d=M2_D, h=M2_STNDFF + e);
-        translate([0, -CRADLE_BACK_T-e, pcb_z+UWB_H/2])
+
-            cube([LABEL_W, LABEL_T+0.3, LABEL_H], center=[true,false,false]);
+        // ── Antenna clearance cutout in back wall ─────────────
-        translate([0, -e, pcb_z+UWB_H-UWB_ANTENNA_L])
+        // Open slot near top of back wall so antenna is unobstructed
-            cube([UWB_L-4, CRADLE_BACK_T+2*e, UWB_ANTENNA_L+4],
+        translate([sd, -e, M2_STNDFF + 2])
-                 center=[true,false,false]);
+            cube([ARM_W - 2*sd, bk + 2*e, MAWB_H]);
-        for (tx = [-ARM_W/4, ARM_W/4])
+
-            translate([tx, ARM_T/2-CRADLE_BACK_T, total_z/2])
+        // ── USB port access notch on one side wall ────────────
-                rotate([-90,0,0])
+        translate([-e, bk + 2, M2_STNDFF - 1])
-                    cylinder(d=M3_D, h=ARM_T+CRADLE_BACK_T+2*e);
+            cube([sd + 2*e, USB_NOTCH_W, USB_NOTCH_H]);
-        for (side_x = [-outer_l/2-e, outer_l/2-CRADLE_WALL_T-e])
+
-            translate([side_x, 2, pcb_z+2])
+        // ── Mounting holes to collar arm boss (×2) ────────────
-                cube([CRADLE_WALL_T+2*e, UWB_W-4, UWB_H-4]);
+        for (dx=[-ARM_W/4, ARM_W/4])
+            translate([ARM_W/2 + dx, bk + ARM_L/2, -e])
+                cylinder(d=COL_BOLT_D, h=6 + e);
     }
-    for (hx = [-UWB_HOLE_X/2, UWB_HOLE_X/2])
-    for (hy = [(outer_w-UWB_W)/2 + (UWB_W-UWB_HOLE_Y)/2,
-               (outer_w-UWB_W)/2 + (UWB_W-UWB_HOLE_Y)/2 + UWB_HOLE_Y])
-        difference() {
-            translate([hx, hy, CRADLE_FLOOR_T-e])
-                cylinder(d=STANDOFF_OD, h=STANDOFF_H+e);
-            translate([hx, hy, CRADLE_FLOOR_T-2*e])
-                cylinder(d=M2P5_D, h=STANDOFF_H+4);
-        }
 }
 
-// ============================================================
+// ─────────────────────────────────────────────────────────────
-// PART 4 -- CABLE CLIP
+// single_anchor_assembly()
-// ============================================================
+// ─────────────────────────────────────────────────────────────
-// Snap-on C-clip retaining USB-C cable along tilt arm outer face.
+module single_anchor_assembly(show_phantom=false) {
-// Presses onto ARM_T-wide arm with flexible PETG snap tongues.
+    // Collar
-// Print x2-3 per anchor, spaced 25mm along arm.
+    color("SteelBlue", 0.9)   collar_half("front");
-//
+    color("CornflowerBlue", 0.9) mirror([0,1,0]) collar_half("rear");
-// Print: clip-opening face down, PETG, 3 perims, 20% infill.
+
-module cable_clip() {
+    // Bracket tilted BRKT_TILT° outward from top of arm boss
-    ch_r   = CLIP_CABLE_D/2 + CLIP_T;
+    color("LightSteelBlue", 0.85)
-    snap_t = 1.6;
+        translate([0, COL_OD/2 + ARM_L, COL_H * 0.3])
-    difference() {
+            rotate([BRKT_TILT, 0, 0])
-        union() {
+                translate([-ARM_W/2, 0, 0])
-            translate([-CLIP_BODY_W/2, 0, 0])
+                    module_bracket();
-                cube([CLIP_BODY_W, CLIP_T, CLIP_BODY_H]);
+
-            translate([0, CLIP_T+ch_r, CLIP_BODY_H/2]) rotate([0,90,0])
+    // Phantom UWB PCB
-                difference() {
+    if (show_phantom)
-                    cylinder(r=ch_r, h=CLIP_BODY_W, center=true);
+        color("ForestGreen", 0.4)
-                    cylinder(r=CLIP_CABLE_D/2, h=CLIP_BODY_W+2*e, center=true);
+            translate([-MAWB_L/2,
-                    translate([0, ch_r+e, 0])
+                       COL_OD/2 + ARM_L + BRKT_BACK_T,
-                        cube([CLIP_CABLE_D*0.85, ch_r*2+2*e, CLIP_BODY_W+2*e],
+                       COL_H * 0.3 + M2_STNDFF])
-                             center=true);
+                cube([MAWB_L, MAWB_W, MAWB_H]);
-                }
-            for (tx = [-CLIP_BODY_W/2+1.5, CLIP_BODY_W/2-1.5-snap_t])
-                translate([tx, -ARM_T-1, 0])
-                    cube([snap_t, ARM_T+1+CLIP_T, CLIP_BODY_H]);
-            for (tx = [-CLIP_BODY_W/2+1.5, CLIP_BODY_W/2-1.5-snap_t])
-                translate([tx+snap_t/2, -ARM_T-1, CLIP_BODY_H/2])
-                    rotate([0,90,0]) cylinder(d=2, h=snap_t, center=true);
-        }
-        translate([0, -ARM_T-1-e, CLIP_BODY_H/2])
-            cube([CLIP_BODY_W-6, ARM_T+2, CLIP_BODY_H-4], center=true);
-    }
 }
+
+// ─────────────────────────────────────────────────────────────
+// Render selector
+// ─────────────────────────────────────────────────────────────
+if (RENDER == "assembly") {
+    single_anchor_assembly(show_phantom=true);
+
+} else if (RENDER == "collar_front") {
+    collar_half("front");
+
+} else if (RENDER == "collar_rear") {
+    collar_half("rear");
+
+} else if (RENDER == "bracket") {
+    module_bracket();
+
+} else if (RENDER == "pair") {
+    // Both anchors at 250 mm spacing on a stem stub
+    color("Silver", 0.2)
+        translate([0, 0, -50])
+            cylinder(d=STEM_OD, h=ANCHOR_SPACING + COL_H + 100);
+
+    // Lower anchor (Z = 0)
+    single_anchor_assembly(show_phantom=true);
+
+    // Upper anchor (Z = ANCHOR_SPACING)
+    translate([0, 0, ANCHOR_SPACING])
+        single_anchor_assembly(show_phantom=true);
+}
+

chassis/vesc_mount.scad

@@ -1,296 +0,0 @@
-// ============================================================
-// vesc_mount.scad — FSESC 6.7 Pro Mini Dual ESC Mount Cradle
-// Issue #699 / sl-mechanical  2026-03-17
-// ============================================================
-// Open-top tray for Flipsky FSESC 6.7 Pro Mini Dual (~100 × 68 × 28 mm).
-// Attaches to 2020 aluminium T-slot rail via 4× M5 T-nuts
-// (2× per rail, two parallel rails, 60 mm bolt spacing in X,
-//  20 mm bolt spacing in Y matching 2020 slot pitch).
-//
-// Connector access:
-//   XT60 battery inputs    — X− end wall cutouts (2 connectors, side-by-side)
-//   XT30 motor outputs     — Y+ and Y− side wall cutouts (2 per side wall)
-//   CAN/UART terminal      — X+ end wall cutout (screw terminal, wire exit)
-//
-// Ventilation:
-//   Open top face          — heatsink fins fully exposed
-//   Floor grille slots     — under-board airflow
-//   Side vent louvres      — 4 slots on each Y± wall at heatsink height
-//
-// Retention: 4× M3 heat-set insert boss in floor — board screws down through
-// ESC mounting holes via M3×8 FHCS. Board sits on 4 mm raised posts for
-// under-board airflow.
-//
-// ⚠  VERIFY WITH CALIPERS BEFORE PRINTING:
-//    PCB_L, PCB_W                   board outline
-//    XT60_W, XT60_H                 XT60 shell at X− edge
-//    XT30_W, XT30_H                 XT30 shells at Y± edges
-//    TERM_W, TERM_H                 CAN screw terminal at X+ edge
-//    MOUNT_X1/X2, MOUNT_Y1/Y2      ESC board mounting hole pattern
-//
-// Print settings (PETG):
-//   3 perimeters, 40 % gyroid infill, no supports, 0.2 mm layer
-//   Print orientation: open face UP (as modelled)
-//
-// BOM:
-//   4 × M5×10 BHCS  +  4 × M5 slide-in T-nut  (2020 rail)
-//   4 × M3 heat-set insert (Voron-style, OD 4.5 mm × 4 mm deep)
-//   4 × M3×8 FHCS  (board retention)
-//
-// Export commands:
-//   openscad -D 'RENDER="mount"'    -o vesc_mount.stl    vesc_mount.scad
-//   openscad -D 'RENDER="assembly"' -o vesc_assembly.png vesc_mount.scad
-// ============================================================
-
-RENDER = "assembly"; // mount | assembly
-
-$fn = 48;
-EPS = 0.01;
-
-// ── ⚠ Verify before printing ─────────────────────────────────
-// FSESC 6.7 Pro Mini Dual PCB
-PCB_L    = 100.0;  // board length (X: XT60 end → CAN terminal end)
-PCB_W    =  68.0;  // board width  (Y)
-PCB_T    =  2.0;   // board thickness (incl. bottom-side components)
-COMP_H   =  26.0;  // tallest component above board top face (heatsink ~26 mm)
-
-// XT60 battery connectors at X− end (2 connectors, side-by-side)
-XT60_W   =  16.0;  // each XT60 shell width (Y)
-XT60_H   =  16.0;  // each XT60 shell height (Z) above board surface
-XT60_Z0  =   0.0;  // connector bottom offset above board surface
-// Y centres of each XT60 measured from PCB Y− edge
-XT60_Y1  =  16.0;
-XT60_Y2  =  52.0;
-
-// XT30 motor output connectors at Y± sides (2 per side)
-XT30_W   =  10.5;  // each XT30 shell width (X span)
-XT30_H   =  12.0;  // each XT30 shell height (Z) above board surface
-XT30_Z0  =   0.5;  // connector bottom offset above board surface
-// X centres measured from PCB X− edge (same layout both Y− and Y+ sides)
-XT30_X1  =  22.0;
-XT30_X2  =  78.0;
-
-// CAN / UART screw terminal block at X+ end (3-pos 3.5 mm pitch)
-TERM_W   =  14.0;  // terminal block Y span
-TERM_H   =  10.0;  // terminal block height above board surface
-TERM_Z0  =   0.5;  // terminal bottom offset above board surface
-TERM_Y_CTR = PCB_W / 2;
-
-// ── ESC board mounting hole pattern ──────────────────────────
-// 4 corner holes, 4 mm inset from each PCB edge
-MOUNT_INSET  =  4.0;
-MOUNT_X1     = MOUNT_INSET;
-MOUNT_X2     = PCB_L - MOUNT_INSET;
-MOUNT_Y1     = MOUNT_INSET;
-MOUNT_Y2     = PCB_W - MOUNT_INSET;
-
-M3_INSERT_OD =  4.6;   // Voron M3 heat-set insert press-fit OD
-M3_INSERT_H  =  4.0;   // insert depth
-M3_CLEAR_D   =  3.4;   // M3 clearance bore below insert
-
-// ── Cradle geometry ──────────────────────────────────────────
-WALL_T   =  2.8;   // side / end wall thickness
-FLOOR_T  =  4.5;   // floor plate thickness (fits M5 BHCS head pocket)
-POST_H   =  4.0;   // standoff post height (board lifts off floor for airflow)
-CL_SIDE  =  0.35;  // Y clearance per side
-CL_END   =  0.40;  // X clearance per end
-
-INN_W    = PCB_W + 2*CL_SIDE;
-INN_L    = PCB_L + 2*CL_END;
-INN_H    = POST_H + PCB_T + COMP_H + 1.5;
-
-OTR_W    = INN_W  + 2*WALL_T;
-OTR_L    = INN_L  + 2*WALL_T;
-OTR_H    = FLOOR_T + INN_H;
-
-PCB_X0   = WALL_T + CL_END;
-PCB_Y0   = WALL_T + CL_SIDE;
-PCB_Z0   = FLOOR_T + POST_H;
-
-// ── M5 T-nut mount (2020 rail) ────────────────────────────────
-// 4 bolts: 2 columns (X) × 2 rows (Y), centred on body
-M5_D       =  5.3;
-M5_HEAD_D  =  9.5;
-M5_HEAD_H  =  3.0;
-M5_SPAC_X  = 60.0;   // X bolt spacing
-M5_SPAC_Y  = 20.0;   // Y bolt spacing (2020 T-slot pitch)
-
-// ── Floor ventilation grille ──────────────────────────────────
-GRILLE_SLOT_W =  4.0;
-GRILLE_SLOT_T = FLOOR_T - 1.5;
-GRILLE_PITCH  = 10.0;
-GRILLE_X0     = WALL_T + 14;
-GRILLE_X_LEN  = OTR_L - 2*WALL_T - 28;
-GRILLE_N      = floor((INN_W - 10) / GRILLE_PITCH);
-
-// ── Side vent louvres on Y± walls ────────────────────────────
-LOUV_H     =  5.0;
-LOUV_W     = 12.0;
-LOUV_Z     = FLOOR_T + POST_H + PCB_T + 4.0;  // mid-heatsink height
-LOUV_N     =  4;
-LOUV_PITCH = (OTR_L - 2*WALL_T - 20) / max(LOUV_N - 1, 1);
-
-// ── CAN wire strain relief bosses (X+ end) ───────────────────
-SR_BOSS_OD =  7.0;
-SR_BOSS_H  =  6.0;
-SR_SLOT_W  =  3.5;
-SR_SLOT_T  =  2.2;
-SR_Y1      = WALL_T + INN_W * 0.25;
-SR_Y2      = WALL_T + INN_W * 0.75;
-SR_X       = OTR_L - WALL_T - SR_BOSS_OD/2 - 2.5;
-
-// ─────────────────────────────────────────────────────────────
-module m3_insert_boss() {
-    // Solid post with heat-set insert bore from top
-    post_h = FLOOR_T + POST_H;
-    difference() {
-        cylinder(d = M3_INSERT_OD + 3.2, h = post_h);
-        // Insert bore from top
-        translate([0, 0, post_h - M3_INSERT_H])
-            cylinder(d = M3_INSERT_OD, h = M3_INSERT_H + EPS);
-        // Clearance bore from bottom
-        translate([0, 0, -EPS])
-            cylinder(d = M3_CLEAR_D, h = post_h - M3_INSERT_H + EPS);
-    }
-}
-
-module vesc_mount() {
-    difference() {
-        union() {
-            // Main body
-            cube([OTR_L, OTR_W, OTR_H]);
-
-            // M3 insert bosses at board mounting corners
-            for (mx = [MOUNT_X1, MOUNT_X2])
-            for (my = [MOUNT_Y1, MOUNT_Y2])
-                translate([PCB_X0 + mx, PCB_Y0 + my, 0])
-                    m3_insert_boss();
-
-            // CAN strain relief bosses on X+ end
-            for (sy = [SR_Y1, SR_Y2])
-                translate([SR_X, sy, 0])
-                    cylinder(d = SR_BOSS_OD, h = SR_BOSS_H);
-        }
-
-        // ── Interior cavity (open top) ─────────────────────────
-        translate([WALL_T, WALL_T, FLOOR_T])
-            cube([INN_L, INN_W, INN_H + EPS]);
-
-        // ── XT60 cutouts at X− end (2 connectors) ──────────────
-        for (yc = [XT60_Y1, XT60_Y2])
-            translate([-EPS,
-                       PCB_Y0 + yc - (XT60_W + 2.0)/2,
-                       PCB_Z0 + XT60_Z0 - 0.5])
-                cube([WALL_T + 2*EPS, XT60_W + 2.0, XT60_H + 3.0]);
-
-        // ── XT30 cutouts at Y− side (2 connectors) ─────────────
-        for (xc = [XT30_X1, XT30_X2])
-            translate([PCB_X0 + xc - (XT30_W + 2.0)/2,
-                       -EPS,
-                       PCB_Z0 + XT30_Z0 - 0.5])
-                cube([XT30_W + 2.0, WALL_T + 2*EPS, XT30_H + 3.0]);
-
-        // ── XT30 cutouts at Y+ side (2 connectors) ─────────────
-        for (xc = [XT30_X1, XT30_X2])
-            translate([PCB_X0 + xc - (XT30_W + 2.0)/2,
-                       OTR_W - WALL_T - EPS,
-                       PCB_Z0 + XT30_Z0 - 0.5])
-                cube([XT30_W + 2.0, WALL_T + 2*EPS, XT30_H + 3.0]);
-
-        // ── CAN terminal cutout at X+ end ──────────────────────
-        translate([OTR_L - WALL_T - EPS,
-                   PCB_Y0 + TERM_Y_CTR - (TERM_W + 3.0)/2,
-                   PCB_Z0 + TERM_Z0 - 0.5])
-            cube([WALL_T + 2*EPS, TERM_W + 3.0, TERM_H + 5.0]);
-
-        // ── Floor ventilation grille ───────────────────────────
-        for (i = [0 : GRILLE_N - 1]) {
-            sy = WALL_T + 5 + i * GRILLE_PITCH;
-            translate([GRILLE_X0, sy, -EPS])
-                cube([GRILLE_X_LEN, GRILLE_SLOT_W, GRILLE_SLOT_T + EPS]);
-        }
-
-        // ── Side vent louvres — Y− wall ────────────────────────
-        for (i = [0 : LOUV_N - 1]) {
-            lx = WALL_T + 10 + i * LOUV_PITCH;
-            translate([lx, -EPS, LOUV_Z])
-                cube([LOUV_W, WALL_T + 2*EPS, LOUV_H]);
-        }
-
-        // ── Side vent louvres — Y+ wall ────────────────────────
-        for (i = [0 : LOUV_N - 1]) {
-            lx = WALL_T + 10 + i * LOUV_PITCH;
-            translate([lx, OTR_W - WALL_T - EPS, LOUV_Z])
-                cube([LOUV_W, WALL_T + 2*EPS, LOUV_H]);
-        }
-
-        // ── M5 BHCS head pockets (4 bolts, bottom face) ────────
-        for (mx = [OTR_L/2 - M5_SPAC_X/2, OTR_L/2 + M5_SPAC_X/2])
-        for (my = [OTR_W/2 - M5_SPAC_Y/2, OTR_W/2 + M5_SPAC_Y/2])
-            translate([mx, my, -EPS]) {
-                cylinder(d = M5_D,      h = FLOOR_T + 2*EPS);
-                cylinder(d = M5_HEAD_D, h = M5_HEAD_H + EPS);
-            }
-
-        // ── Zip-tie slots through CAN strain relief bosses ─────
-        for (sy = [SR_Y1, SR_Y2])
-            translate([SR_X, sy, SR_BOSS_H/2 - SR_SLOT_T/2])
-                rotate([0, 90, 0])
-                    cube([SR_SLOT_T, SR_SLOT_W, SR_BOSS_OD + 2*EPS],
-                         center = true);
-
-        // ── Weight-relief pocket in floor underside ─────────────
-        translate([WALL_T + 16, WALL_T + 6, -EPS])
-            cube([OTR_L - 2*WALL_T - 32, OTR_W - 2*WALL_T - 12,
-                  FLOOR_T - 2.0 + EPS]);
-    }
-}
-
-// ── Assembly preview ─────────────────────────────────────────
-if (RENDER == "assembly") {
-    color("DimGray", 0.93) vesc_mount();
-
-    // Phantom PCB
-    color("ForestGreen", 0.30)
-        translate([PCB_X0, PCB_Y0, PCB_Z0])
-            cube([PCB_L, PCB_W, PCB_T]);
-
-    // Phantom heatsink / component block
-    color("SlateGray", 0.22)
-        translate([PCB_X0, PCB_Y0, PCB_Z0 + PCB_T])
-            cube([PCB_L, PCB_W, COMP_H]);
-
-    // XT60 connector highlights (X− end)
-    for (yc = [XT60_Y1, XT60_Y2])
-        color("Gold", 0.85)
-            translate([-2,
-                       PCB_Y0 + yc - XT60_W/2,
-                       PCB_Z0 + XT60_Z0])
-                cube([WALL_T + 3, XT60_W, XT60_H]);
-
-    // XT30 connector highlights — Y− side
-    for (xc = [XT30_X1, XT30_X2])
-        color("OrangeRed", 0.80)
-            translate([PCB_X0 + xc - XT30_W/2,
-                       -2,
-                       PCB_Z0 + XT30_Z0])
-                cube([XT30_W, WALL_T + 3, XT30_H]);
-
-    // XT30 connector highlights — Y+ side
-    for (xc = [XT30_X1, XT30_X2])
-        color("OrangeRed", 0.80)
-            translate([PCB_X0 + xc - XT30_W/2,
-                       OTR_W - WALL_T - 1,
-                       PCB_Z0 + XT30_Z0])
-                cube([XT30_W, WALL_T + 3, XT30_H]);
-
-    // CAN terminal highlight
-    color("Tomato", 0.75)
-        translate([OTR_L - WALL_T - 1,
-                   PCB_Y0 + TERM_Y_CTR - TERM_W/2,
-                   PCB_Z0 + TERM_Z0])
-            cube([WALL_T + 3, TERM_W, TERM_H]);
-
-} else {
-    vesc_mount();
-}

docs/AGENTS.md

@@ -1,323 +0,0 @@
-# AGENTS.md — SaltyLab Agent Onboarding
-
-You're working on **SaltyLab**, a self-balancing two-wheeled indoor robot. Read this entire file before touching anything.
-
-## ⚠️ ARCHITECTURE — SAUL-TEE (finalised 2026-04-04)
-
-<<<<<<< HEAD
-Full hardware spec: `docs/SAUL-TEE-SYSTEM-REFERENCE.md` — **read it before writing firmware.**
-
-| Board | Role |
-|-------|------|
-| **ESP32-S3 BALANCE** | Waveshare Touch LCD 1.28 (CH343 USB). QMI8658 IMU, PID loop, CAN→VESC L(68)/R(56), GC9A01 LCD |
-| **ESP32-S3 IO** | Bare devkit (JTAG USB). TBS Crossfire RC (UART0), ELRS failover (UART2), BTS7960 motors, NFC/baro/ToF, WS2812, buzzer/horn/headlight/fan |
-| **Jetson Orin** | CANable2 USB→CAN. Cmds on 0x300–0x303, telemetry on 0x400–0x401 |
-
-```
-Jetson Orin ──CANable2──► CAN 500kbps ◄───────────────────────┐
-                                │                               │
-                         ESP32-S3 BALANCE ←─UART 460800─► ESP32-S3 IO
-                         (QMI8658, PID loop)              (BTS7960, RC, sensors)
-                                │ CAN 500kbps
-                      ┌─────────┴──────────┐
-                 VESC Left (ID 68)    VESC Right (ID 56)
-=======
-A hoverboard-based balancing robot with two compute layers:
-1. **ESP32-S3 BALANCE** — ESP32-S3 BALANCE (ESP32-S3RET6 + MPU6000 IMU). Runs a lean C balance loop at up to 8kHz. Talks UART to the hoverboard ESC. This is the safety-critical layer.
-2. **Jetson Orin Nano Super** — AI brain. ROS2, SLAM, person tracking. Sends velocity commands to FC via UART. Not safety-critical — FC operates independently.
-
-```
-Jetson (speed+steer via UART1)  ←→  ELRS RC (UART3, kill switch)
-         │
-         ▼
-   ESP32-S3 BALANCE (MPU6000 IMU, PID balance)
-         │
-         ▼ UART2
-   Hoverboard ESC (FOC) → 2× 8" hub motors
->>>>>>> 291dd68 (feat: remove all STM32/Mamba/BlackPill references — ESP32-S3 only)
-```
-
-Frame: `[0xAA][LEN][TYPE][PAYLOAD][CRC8]`  
-Legacy `src/` STM32 HAL code is **archived — do not extend.**
-
-## ⚠️ SAFETY — READ THIS OR PEOPLE GET HURT
-
-This is not a toy. 8" hub motors + 36V battery can crush fingers, break toes, and launch the frame. Every firmware change must preserve these invariants:
-
-1. **Motors NEVER spin on power-on.** Requires deliberate arming: hold button 3s while upright.
-2. **Tilt cutoff at ±25°** — motors to zero, require manual re-arm. No retry, no recovery.
-3. **Hardware watchdog (50ms)** — if firmware hangs, motors cut.
-4. **RC kill switch** — dedicated ELRS channel, checked every loop iteration. Always overrides.
-5. **Jetson UART timeout (200ms)** — if Jetson disconnects, motors cut.
-6. **Speed hard cap** — firmware limit, start at 10%. Increase only after proven stable.
-7. **Never test untethered** until PID is stable for 5+ minutes on a tether.
-
-**If you break any of these, you are removed from the project.**
-
-## Repository Layout
-
-```
-<<<<<<< HEAD
-firmware/              # Legacy ESP32/STM32 HAL firmware (PlatformIO, archived)
-=======
-firmware/              # ESP-IDF firmware (PlatformIO)
->>>>>>> 291dd68 (feat: remove all STM32/Mamba/BlackPill references — ESP32-S3 only)
-├── src/
-│   ├── main.c         # Entry point, clock config, main loop
-│   ├── icm42688.c     # QMI8658-P SPI driver (backup IMU — currently broken)
-│   ├── bmp280.c       # Barometer driver (disabled)
-│   └── status.c       # LED + buzzer status patterns
-├── include/
-│   ├── config.h       # Pin definitions, constants
-│   ├── icm42688.h
-│   ├── mpu6000.h      # MPU6000 driver header (primary IMU)
-│   ├── hoverboard.h   # Hoverboard ESC UART protocol
-│   ├── crsf.h         # ELRS CRSF protocol
-│   ├── bmp280.h
-│   └── status.h
-├── lib/USB_CDC/       # USB Serial (CH343) stack (serial over USB)
-│   ├── src/           # CDC implementation, USB descriptors, PCD config
-│   └── include/
-└── platformio.ini     # Build config
-
-cad/                   # OpenSCAD parametric parts (16 files)
-├── dimensions.scad    # ALL measurements live here — single source of truth
-├── assembly.scad      # Full robot assembly visualization
-├── motor_mount_plate.scad
-├── battery_shelf.scad
-├── fc_mount.scad      # Vibration-isolated FC mount
-├── jetson_shelf.scad
-├── esc_mount.scad
-├── sensor_tower_top.scad
-├── lidar_standoff.scad
-├── realsense_bracket.scad
-├── bumper.scad        # TPU bumpers (front + rear)
-├── handle.scad
-├── kill_switch_mount.scad
-├── tether_anchor.scad
-├── led_diffuser_ring.scad
-└── esp32c3_mount.scad
-
-ui/                    # Web UI (Three.js + WebSerial)
-└── index.html         # 3D board visualization, real-time IMU data
-
-SALTYLAB.md            # Master design doc — architecture, wiring, build phases
-SALTYLAB-DETAILED.md   # Power budget, weight budget, detailed schematics
-PLATFORM.md            # Hardware platform reference
-```
-
-## Hardware Quick Reference
-
-<<<<<<< HEAD
-### ESP32 BALANCE Flight Controller
-
-| Spec | Value |
-|------|-------|
-| MCU | ESP32RET6 (Cortex-M7, 216MHz, 512KB flash, 256KB RAM) |
-=======
-### ESP32-S3 BALANCE Flight Controller
-
-| Spec | Value |
-|------|-------|
-| MCU | ESP32-S3RET6 (Cortex-M7, 216MHz, 512KB flash, 256KB RAM) |
->>>>>>> 291dd68 (feat: remove all STM32/Mamba/BlackPill references — ESP32-S3 only)
-| Primary IMU | MPU6000 (WHO_AM_I = 0x68) |
-| IMU Bus | SPI1: PA5=SCK, PA6=MISO, PA7=MOSI, CS=PA4 |
-| IMU EXTI | PC4 (data ready interrupt) |
-| IMU Orientation | CW270 (Betaflight convention) |
-| Secondary IMU | QMI8658-P (on same SPI1, CS unknown — currently non-functional) |
-| Betaflight Target | DIAT-MAMBAF722_2022B |
-| USB | OTG FS (PA11/PA12), enumerates as /dev/cu.usbmodemSALTY0011 |
-| VID/PID | 0x0483/0x5740 |
-| LEDs | PC15 (LED1), PC14 (LED2), active low |
-| Buzzer | PB2 (inverted push-pull) |
-| Battery ADC | PC1=VBAT, PC3=CURR (ADC3) |
-| DFU | Hold yellow BOOT button + plug USB (or send 'R' over CDC) |
-
-### UART Assignments
-
-| UART | Pins | Connected To | Baud |
-|------|------|-------------|------|
-| USART1 | PA9/PA10 | Jetson Orin Nano Super | 115200 |
-| USART2 | PA2/PA3 | Hoverboard ESC | 115200 |
-| USART3 | PB10/PB11 | ELRS Receiver | 420000 (CRSF) |
-| UART4 | — | Spare | — |
-| UART5 | — | Spare | — |
-
-### Motor/ESC
-
-- 2× 8" pneumatic hub motors (36V, hoverboard type)
-- Hoverboard ESC with FOC firmware
-- UART protocol: `{0xABCD, int16 speed, int16 steer, uint16 checksum}` at 115200
-- Speed range: -1000 to +1000
-
-### Physical Dimensions (from `cad/dimensions.scad`)
-
-| Part | Key Measurement |
-|------|----------------|
-| FC mounting holes | 25.5mm spacing (NOT standard 30.5mm!) |
-| FC board size | ~36mm square |
-| Hub motor body | Ø200mm (~8") |
-| Motor axle | Ø12mm, 45mm long |
-| Jetson Orin Nano Super | 100×80×29mm, M2.5 holes at 86×58mm |
-| RealSense D435i | 90×25×25mm, 1/4-20 tripod mount |
-| RPLIDAR A1 | Ø70×41mm, 4× M2.5 on Ø67mm circle |
-| Kill switch hole | Ø22mm panel mount |
-| Battery pack | ~180×80×40mm |
-| Hoverboard ESC | ~80×50×15mm |
-| 2020 extrusion | 20mm square, M5 center bore |
-| Frame width | ~350mm (axle to axle) |
-| Frame height | ~500-550mm total |
-| Target weight | <8kg (current estimate: 7.4kg) |
-
-### 3D Printed Parts (16 files in `cad/`)
-
-| Part | Material | Infill |
-|------|----------|--------|
-| motor_mount_plate (350×150×6mm) | PETG | 80% |
-| battery_shelf | PETG | 60% |
-| esc_mount | PETG | 40% |
-| jetson_shelf | PETG | 40% |
-| sensor_tower_top | ASA | 80% |
-| lidar_standoff (Ø80×80mm) | ASA | 40% |
-| realsense_bracket | PETG | 60% |
-| fc_mount (vibration isolated) | TPU+PETG | — |
-| bumper front + rear (350×50×30mm) | TPU | 30% |
-| handle | PETG | 80% |
-| kill_switch_mount | PETG | 80% |
-| tether_anchor | PETG | 100% |
-| led_diffuser_ring (Ø120×15mm) | Clear PETG | 30% |
-| esp32c3_mount | PETG | 40% |
-
-## Firmware Architecture
-
-### Critical Lessons Learned (DON'T REPEAT THESE)
-
-1. **SysTick_Handler with HAL_IncTick() is MANDATORY** — without it, HAL_Delay() and every HAL timeout hangs forever. This bricked us multiple times.
-<<<<<<< HEAD
-2. **DCache breaks SPI on ESP32** — disable DCache or use cache-aligned DMA buffers with clean/invalidate. We disable it.
-=======
-2. **DCache breaks SPI on ESP32-S3** — disable DCache or use cache-aligned DMA buffers with clean/invalidate. We disable it.
->>>>>>> 291dd68 (feat: remove all STM32/Mamba/BlackPill references — ESP32-S3 only)
-3. **`-(int)0 == 0`** — checking `if (-result)` to detect errors doesn't work when result is 0 (success and failure look the same). Always use explicit error codes.
-4. **NEVER auto-run untested code on_boot** — we bricked the NSPanel 3x doing this. Test manually first.
-5. **USB Serial (CH343) needs ReceivePacket() primed in CDC_Init** — without it, the OUT endpoint never starts listening. No data reception.
-
-### DFU Reboot (Betaflight Method)
-
-The firmware supports reboot-to-DFU via USB command:
-1. Send `R` byte over USB Serial (CH343)
-2. Firmware writes `0xDEADBEEF` to RTC backup register 0
-3. `NVIC_SystemReset()` — clean hardware reset
-4. On boot, `checkForBootloader()` (called after `HAL_Init()`) reads the magic
-<<<<<<< HEAD
-5. If magic found: clears it, remaps system memory, jumps to ESP32 BALANCE bootloader at `0x1FF00000`
-=======
-5. If magic found: clears it, remaps system memory, jumps to ESP32-S3 bootloader at `0x1FF00000`
->>>>>>> 291dd68 (feat: remove all STM32/Mamba/BlackPill references — ESP32-S3 only)
-6. Board appears as DFU device, ready for `dfu-util` flash
-
-### Build & Flash
-
-```bash
-cd firmware/
-python3 -m platformio run                    # Build
-dfu-util -a 0 -s 0x08000000:leave -D .pio/build/f722/firmware.bin  # Flash
-```
-
-Dev machine: mbpm4 (seb@192.168.87.40), PlatformIO project at `~/Projects/saltylab-firmware/`
-
-### Clock Configuration
-
-```
-HSE 8MHz → PLL (M=8, N=432, P=2, Q=9) → SYSCLK 216MHz
-PLLSAI (N=384, P=8) → CLK48 48MHz (USB)
-APB1 = HCLK/4 = 54MHz
-APB2 = HCLK/2 = 108MHz
-Fallback: HSI 16MHz if HSE fails (PLL M=16)
-```
-
-## Current Status & Known Issues
-
-### Working
-- USB Serial (CH343) serial streaming (50Hz JSON: `{"ax":...,"ay":...,"az":...,"gx":...,"gy":...,"gz":...}`)
-- Clock config with HSE + HSI fallback
-- Reboot-to-DFU via USB 'R' command
-- LED status patterns (status.c)
-- Web UI with WebSerial + Three.js 3D visualization
-
-### Broken / In Progress
-- **QMI8658-P SPI reads return all zeros** — was the original IMU target, but SPI communication completely non-functional despite correct pin config. May be dead silicon. Switched to MPU6000 as primary.
-- **MPU6000 driver** — header exists but implementation needs completion
-- **PID balance loop** — not yet implemented
-- **Hoverboard ESC UART** — protocol defined, driver not written
-- **ELRS CRSF receiver** — protocol defined, driver not written
-- **Barometer (BMP280)** — I2C init hangs, disabled
-
-### TODO (Priority Order)
-1. Get MPU6000 streaming accel+gyro data
-2. Implement complementary filter (pitch angle)
-3. Write hoverboard ESC UART driver
-4. Write PID balance loop with safety checks
-5. Wire ELRS receiver, implement CRSF parser
-6. Bench test (ESC disconnected, verify PID output)
-7. First tethered balance test at 10% speed
-8. Jetson UART integration
-9. LED subsystem (ESP32-C3)
-
-## Communication Protocols
-
-### Jetson → FC (UART1, 50Hz)
-```c
-struct { uint8_t header=0xAA; int16_t speed; int16_t steer; uint8_t mode; uint8_t checksum; };
-// mode: 0=idle, 1=balance, 2=follow, 3=RC
-```
-
-### FC → Hoverboard ESC (UART2, loop rate)
-```c
-struct { uint16_t start=0xABCD; int16_t speed; int16_t steer; uint16_t checksum; };
-// speed/steer: -1000 to +1000
-```
-
-### FC → Jetson Telemetry (UART1 TX, 50Hz)
-```
-T:12.3,P:45,L:100,R:-80,S:3\n
-// T=tilt°, P=PID output, L/R=motor commands, S=state (0-3)
-```
-
-### FC → USB Serial (CH343) (50Hz JSON)
-```json
-{"ax":123,"ay":-456,"az":16384,"gx":10,"gy":-5,"gz":3,"t":250,"p":0,"bt":0}
-// Raw IMU values (int16), t=temp×10, p=pressure, bt=baro temp
-```
-
-## LED Subsystem (ESP32-C3)
-
-ESP32-C3 eavesdrops on FC→Jetson telemetry (listen-only tap on UART1 TX). No extra FC UART needed.
-
-| State | Pattern | Color |
-|-------|---------|-------|
-| Disarmed | Slow breathe | White |
-| Arming | Fast blink | Yellow |
-| Armed idle | Solid | Green |
-| Turning | Sweep direction | Orange |
-| Braking | Flash rear | Red |
-| Fault | Triple flash | Red |
-| RC lost | Alternating flash | Red/Blue |
-
-## Printing (Bambu Lab)
-
-- **X1C** (192.168.87.190) — for structural PETG/ASA parts
-- **A1** (192.168.86.161) — for TPU bumpers and prototypes
-- LAN access codes and MQTT details in main workspace MEMORY.md
-- STL export from OpenSCAD, slice in Bambu Studio
-
-## Rules for Agents
-
-1. **Read SALTYLAB.md fully** before making any design decisions
-2. **Never remove safety checks** from firmware — add more if needed
-3. **All measurements go in `cad/dimensions.scad`** — single source of truth
-4. **Test firmware on bench before any motor test** — ESC disconnected, verify outputs on serial
-5. **One variable at a time** — don't change PID and speed limit in the same test
-6. **Document what you change** — update this file if you add pins, change protocols, or discover hardware quirks
-7. **Ask before wiring changes** — wrong connections can fry the FC ($50+ board)

docs/FACE_LCD_ANIMATION.md

@@ -1,10 +1,6 @@
 # Face LCD Animation System (Issue #507)
 
-<<<<<<< HEAD
+Implements expressive face animations on an STM32 LCD display with 5 core emotions and smooth transitions.
-Implements expressive face animations on an ESP32 LCD display with 5 core emotions and smooth transitions.
-=======
-Implements expressive face animations on an ESP32-S3 LCD display with 5 core emotions and smooth transitions.
->>>>>>> 291dd68 (feat: remove all STM32/Mamba/BlackPill references — ESP32-S3 only)
 
 ## Features
 
@@ -86,11 +82,7 @@ STATUS      → Echo current emotion + idle state
 - Colors: Monochrome (1-bit) or RGB565
 
 ### Microcontroller
-<<<<<<< HEAD
+- STM32F7xx (Mamba F722S)
-- ESP32xx (ESP32 BALANCE)
-=======
-- ESP32-S3xx (ESP32-S3 BALANCE)
->>>>>>> 291dd68 (feat: remove all STM32/Mamba/BlackPill references — ESP32-S3 only)
 - Available UART: USART3 (PB10=TX, PB11=RX)
 - Clock: 216 MHz