Commit Graph

112 Commits

Author SHA1 Message Date
811f110174 auto-sync 2026-08-07 18:00 2026-08-07 18:00:15 -06:00
0dd2d63432 auto-sync 2026-08-04 18:00 2026-08-04 18:00:16 -06:00
13ea054090 auto-sync 2026-08-03 18:00 2026-08-03 18:00:18 -06:00
bc9750d258 auto-sync 2026-08-02 18:00 2026-08-02 18:00:05 -06:00
066ebe883c auto-sync 2026-08-01 18:00 2026-08-01 18:00:16 -06:00
b505cb35c2 v4 production package for JLCPCB: gerbers, BOM, CPL + audit
Fabrication Toolkit export of hbox-watchdog-v4 (EinarBoard 2.0), verified
before ordering. Board is 155.00 x 100.00 mm, 4 layers, 1.6 mm.

New in production/:
  HBOX_v4_PROD.zip             15 gerber + drill files
  HBOX_v4_PROD_bom.csv         102 lines, 25 with an LCSC number
  HBOX_v4_PROD_positions.csv   187 rows
  HBOX_v4_PROD_designators.csv toolkit by-product, not a JLC input

hbox-watchdog-v4.kicad_pcb is modified only because the toolkit's AUTO FILL
refilled zones and re-saved on export. Diffed before/after: 0 footprints
moved, 0 rotated, 0 changed side; tracks 1989 -> 1989, vias 351 -> 351,
zones 5 -> 5, filled polygons 41 -> 41. Zone fill data only.

Verification (details in the order walkthrough):
  - Row counts matched a prediction registered before the export existed:
    CPL 187, BOM 102, 35 machine-placed. No duplicate designators, no
    collisions from the toolkit's uppercasing of refdes, nothing truncated.
  - All 30 pre-registered rotation predictions matched exactly, 0 mismatches.
    The five previously-unproven packages resolved as J10 +0 deg and
    U10/U11/U13/U15 +270 deg.
  - Every non-zero rotation correction is externally backed: six packages
    (SOT-23, SOIC-8, SOIC-8-1EP, QFN-24-1EP, CP_Elec_6.3x7.7, Arduino_UNO_R3)
    are byte-identical to the v3 CPL that JLC built; the other four (LQFP-48,
    SOIC-16, SOIC-16W, TSSOP-28) match KiBot's published JLCPCB rotation
    table. KiBot's generic ^QFN- rule says 270 where the toolkit applied +90
    to U6 - v3 hardware settles it in the toolkit's favour.
  - Positions: 22 rows carry an AUTO TRANSLATE offset. 19 of 22 identical to
    the v3 export, 20 of 22 equal the pad bounding-box centroid to 0.02 mm.
    J10 is the only machine-placed part with a translation and it matches the
    centroid exactly.
  - Gerbers: 4 copper layers populated, both mask, both silk, F.Paste 40
    apertures. B_Paste empty is correct (the one bottom-side part has no
    paste). 523 PTH holes 0.30-1.63 mm, 6 NPTH at 3.20/3.25 mm.

Open before ordering: J10 (C12074 HR911105A) is the only through-hole part
carrying an LCSC number, so JLC's standard SMT line will not place it.
Also gitignore **/_to_delete/ (scratch folder for manual deletion).

Co-Authored-By: Claude <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01GSKKes8GsS4YHAMWJ44tCm
2026-08-01 06:57:17 +00:00
bfbf065e92 C14: netclass-scoped HV24 rule at 0.5 mm + copper fixes to satisfy it
The .kicad_dru held one unconditional (min 0.15mm).  A custom rule outranks
the netclass table and an unconditional rule matches every pair on the board,
so it was silently overriding the HV24 netclass's 0.5 mm everywhere: the
netclass said 0.5, DRC only ever enforced 0.15.

Rule file, three mutually-exclusive rules so order and specificity agree:
  1. neither item HV24                          -> 0.15 mm  (unchanged)
  2. either item HV24                           -> 0.50 mm
  3. except U2 pad-to-pad (its own land pattern)-> 0.15 mm

Rule 3 covers exactly one pair: U2 (MP1584EN, SOIC-8-EP) pad 7 (24V) to pad 9
(exposed thermal pad, GND) at 0.355 mm.  That is the manufacturer's qualified
land pattern, set by the package and not by routing.  U2's courtyard contains
9 pads and all 9 belong to U2, so the condition cannot match foreign copper;
the 24 foreign tracks/vias crossing that courtyard are excluded by the
A.Type == 'Pad' test and stay at the full 0.5 mm.

Copper: 13 of the 14 HV24-to-foreign gaps under 0.5 mm were routing, and all
13 are fixed.  No component was moved or rotated.

  3 width reductions (a narrower track can never reduce a clearance):
    479e5357  24V      -> U2.7     1.0 -> 0.6   U2's pads are 0.6 tall, so the
                                                pad was already the bottleneck
    854214dc  FREQ_FAN -> U2.6     1.0 -> 0.6   1.14 mm long, R~0.93 mohm,
                                                ~8 mV at 3 A; IPC-2221 gives
                                                ~1.9 A at 10 C rise for 0.6 mm
    30ed4012  24V      -> DzG1.3   1.5 -> 0.8   leaf branch into a BZX84C15
                                                SOT-23 clamp, sub-mA
  5 track-vertex moves (never a via centre, never a pad centre):
    /3V3_MODEM x3   corridor walks 0.55 mm east off the 24V bus
    /USB_CC2   x2   opposite ends of one 6.05 mm segment pivot apart, opening
                    pad Rrp1.1 and the GND via at the same time

Verification (shapely geometry over every pad/via/track, diffed against the
unedited baseline so nothing pre-existing is miscounted as new):
  HV24 inter-item pairs under 0.5 mm     13 -> 0
  cross-footprint pairs under 0.15 mm     0 (unchanged)
  pairs this edit created                 0 at 0.15, 0 at 0.30, 0 at 0.50
  per-net connectivity      180/180 nets whole, 0 orphan copper clusters
  static DRC   0 violations, byte-identical to the C13 run
  fab sweep    0 findings (edge clearance, drills, annular rings, outline)
  thinnest new margin  0.5650 mm (pad Rrp1.1 <-> trk 1fed5fbb), looser than
                       five pre-existing HV24 pairs on this board
  /24V_IN and IGN_IN copper byte-identical; 24V differs only in two width tokens

Pour reflow: the 0.5 mm rule widens the zone pullback around HV24 from 0.3 to
0.5 mm.  Simulated the refill on all four pours at both values — the anchor
partition is identical (F.Cu 547 anchors / 35 groups, B.Cu 222/2, In1 33/5,
In2 220/7), so pressing B strands nothing.  Area loss 115 mm2 on F.Cu, 4.6 mm2
on each of the other three.

Press B to refill zones before running DRC.
2026-08-01 05:45:07 +00:00
449588649a C13: clear the last KiCad 10 DRC error - stranded GND_POUR_FCU island (EinarBoard 2.0)
Leo's post-C12 DRC run left exactly one error:

  [unconnected_items] Zone 'GND_POUR_FCU' [GND] on F.Cu <-> Zone 'GND_POUR_FCU' [GND] on F.Cu

KiCad prints only the zone anchor (60.1917, 40.3231) for both endpoints, so the
report cannot localise the stranded island. Located it analytically instead.

Root cause: U11 pad 9 [GND] @ (91.1275, 55.7600). It is the only GND item on the
board whose item-only connectivity cluster never reaches the In2.Cu GND plane
(two independent fill-independent proofs agree: layer-reach and In2-anchor). An
island survives KiCad's isolated-island removal only if some item props it up,
so pad 9 was propping up a GND_POUR_FCU island that touches nothing else.
island_removal_mode cannot fix that - it needs copper.

Pad 9 is fenced on all four sides (LQFP-48 lead ring, pad 8's westward /3V3_ETH
escape, pad 10's eastward /ETH_RSET escape, the /ETH_RXP chain under the body).
A 0.05mm grid router reached only 227 of 20883 legal cells and found no way to
touch existing GND copper without a via, so a through via is mandatory. A
0.005mm sweep of every legal via site in that pocket picked the best one on the
board's existing drill inventory - no third drill size added.

  + F.Cu GND track w0.3  (91.1275,55.7600) -> (90.1000,55.7600) -> (89.9950,55.8900)
  + F.Cu-B.Cu GND via 0.6/0.3 @ (89.9950,55.8900)
  * U11 pad 9 -> (zone_connect 2)

Both track legs hold +0.2000mm clearance - the structural ceiling for a 0.3mm
track between 0.3mm leads on 0.5mm pitch. The via holds +0.1758mm copper and
+2.9705mm hole. The site sits inside GND_POUR_FCU, GND_POUR_BCU, P3V3_PLANE_IN1
and GND_PLANE_IN2 and outside MAGJACK_NO_POUR, with the nearest In2 signal
copper 1.10mm away, so the barrel lands on solid In2 GND plane.

zone_connect 2 mirrors the landed C12 treatment of pad 29: pads 8 and 10 each
knock 0.5mm of pour out around themselves, covering the whole pad-9 lane
(0.10mm tall < min_thickness 0.25), so the pour cannot reach pad 9 in any
connect mode. Solid mode removes the pad from the minimum-spoke test rather
than leaving a starved thermal behind.

Verified on the output file:
  drc_c12.py   0 hard clearance violations, same 49 sub-epsilon marginals as C12
  proof_c13.py 0 GND clusters without an In2 GND-plane anchor (was 1)
  fcu_only.py  0 F.Cu-only GND clusters (was 1 = pad 9)
  24V / /24V_IN / IGN_IN copper byte-identical (45 segments)
  segments 1984->1986  vias 351->352  zones 5->5  footprints 189->189

Backup: .mcp-backups/hbox-watchdog-v4.kicad_pcb.pre-C13 (md5 042efd5d)
Pushed:  md5 94d36711d60985eef109913fcee36b09, 3502885 bytes

Co-Authored-By: Claude Fable 5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01GSKKes8GsS4YHAMWJ44tCm
2026-08-01 02:08:00 +00:00
2662a3277a housekeeping: untrack KiCad ~*.lck session locks, archive v4-drc.rpt
The .lck files are per-session editor locks picked up by an auto-sync commit;
they should never be versioned. v4-drc.rpt is Leo's KiCad 10 DRC run that C12
was built against (84 raw / 83 unique, 7 errors) - kept as the before-record.

Co-Authored-By: Claude Fable 5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01GSKKes8GsS4YHAMWJ44tCm
2026-08-01 01:10:32 +00:00
9512aa48cb C12: clear all 3 KiCad 10 DRC errors + dangling-via warning (EinarBoard 2.0)
E1  clearance 0.1433 < 0.15  (/LED_A via vs /I2C_SCL via, 4 raw reports)
    Relocated the /LED_A via 202c8cb4 from (147.15,85.85) to (147.25,86.22),
    dead centre of the U13.1/U13.2 gap. uuid preserved; both attached segment
    endpoints carried (In1.Cu 375e8fa7, B.Cu dee4fa4e). Worst gap now +0.2405.

E2  unconnected_items x2 + starved_thermal x1 -- ONE root cause.
    The F.Cu GND pour pocket around U11 pad 29 was an island: it touched the
    pad with a single thermal spoke but was fenced in by the LQFP-48 lead ring
    and the escape routing, so it reached nothing else. Gave pad 29 a real
    copper escape west to a new GND via that punches through to the In2 GND
    plane, and set the pad to solid zone connection so the 2-spoke thermal
    rule stops applying to a pad the pour can only reach from one side.
      seg F.Cu w0.3 GND (99.4525,55.26)->(98.65,55.26)   margin +0.2000
      seg F.Cu w0.3 GND (98.65,55.26)->(97.55,54.45)     margin +0.2000
      via 0.6/0.3 F.Cu-B.Cu GND @(97.55,54.45)           copper +0.2718
      U11 pad 29 -> (zone_connect 2)
    +0.2000 is the structural ceiling for a 0.5mm-pitch lead escape with a
    0.3 track, and matches the neighbouring /3V3_ETH and /ETH_XI escapes.

E3  via_dangling  /3V3_ETH via 3b0bb378 @(87.18,55.23) connected on F.Cu only.
    Deleted. Touch test: 4 touching F.Cu segments, zero on In1/In2/B.Cu. The
    F.Cu run at x=87.18 is collinear and continuous without it.

Verified: static DRC 0 hard violations (49 pre-existing marginals inside
KiCad's 0.0005 epsilon, unchanged). Per-net islands unchanged at 1 for
/LED_A /3V3_ETH /I2C_SCL /ETH_XI /ETH_RSET. New via lands inside
GND_PLANE_IN2 + GND_POUR_BCU, outside MAGJACK_NO_POUR. U11 is a plain
LQFP-48 with no exposed pad, so the under-body via is clear. Leo's 24V-class
copper (24V /24V_IN IGN_IN, 45 segments) byte-identical.

Backup: .mcp-backups/hbox-watchdog-v4.kicad_pcb.pre-C12 (md5 7c2202cb)
New:    md5 042efd5dd0cf99fdcfd27974b7bcb3c1  3502425 bytes

Co-Authored-By: Claude Fable 5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01GSKKes8GsS4YHAMWJ44tCm
2026-08-01 01:09:55 +00:00
54d5018878 auto-sync 2026-07-31 18:00 2026-07-31 18:00:15 -06:00
f2232e9e4e 1.1 Phase C11: clear all DRC findings on EinarBoard 2.0 (v4)
Static-DRC battery (true pad geometry: circle/oval/roundrect/rect, NPTH as
hole-only) over 693 pads / 351 vias / 1982 segments -> 0 violations at the
project rule of 0.15mm min clearance, 0.25mm hole-to-hole.

Fixed:
 [1] hole-to-hole -0.300  duplicate GND stitching via coincident at
     (94.79,60.30) -- JLCPCB would have drilled the same hole twice. Removed.
 [2] U11.13 (NC)  +0.100  GND pad14 stub zigzag -> one straight lane x93.01
 [3] U13.3 (GND)  +0.130  I2C_SCL y=87.6 excursion -> single lane y=87.5277;
     the GND stitcher the zigzag was dodging moved 0.138 north onto U13.2
     pad copper (same uuid/net, still bonded to its track)
 [4] ETH_LINKLED  +0.130  3V3_ETH under-body via/rung -> y=57.455, the exact
     centre of the only legal B.Cu window (RSET@56.89 / LINKLED@58.07);
     165000nm both ways
 [5] U11.17        +0.140  GND pad16 lane x94.14/94.15 -> single lane x94.10
 [6][7] U11.46/47  +0.150  ETH_PMODE north lane y=49.31 -> 49.24
 [8] stranded 1.5x1.5mm rule area (tracks/vias/pour not_allowed) nested in
     U3's footprint but stranded ~22mm east of it with zero copper within
     3mm -- a phantom no-route trap. Removed.
 [9] stranded /3V3_ETH web on In2.Cu (the GND inner plane): orphaned remains
     of the pad17 via removed in C10e, connected to nothing, punching a
     clearance void in the GND plane. Removed.

Verified: paren balance 0; 188/188 footprints intact (only U3 shrinks, by the
nested rule area); top-level block census unchanged but segment 1992->1982 and
via 352->351; every touched net resolves to exactly ONE copper island
(/3V3_ETH went 2 -> 1); 24V-class hand-routed copper byte-identical
(24V 23 segs, /24V_IN 12 segs, IGN_IN 10 segs).

Pre-C11 board preserved at .mcp-backups/hbox-watchdog-v4.kicad_pcb.pre-C11

Co-Authored-By: Claude Fable 5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01GSKKes8GsS4YHAMWJ44tCm
2026-07-31 23:22:16 +00:00
cdc3bfe8f6 auto-sync 2026-07-30 18:00 2026-07-30 18:00:16 -06:00
e06387d6a7 1.1 Phase C10: production footprint corrections + LCSC + silk rev (PRE-FAB GATE)
CRITICAL FIXES - parts only exist in these packages:
- U11 W5500: QFN-48-1EP -> LQFP-48_7x7mm_P0.5mm (ring 3.4375->4.1625, EP+paste
  deleted, courtyard 10.3mm sq, 48 track retargets, RXN/RXP/RSET/GND(3,23,38-48)/
  3V3_ETH(15,17,28)/1V2(22)/XI/PMODE/ACTLED/LINKLED reworked under+around body)
- U13 PCF8574: SOIC-16 narrow -> SOIC-16W_7.5x10.3mm (pads +-4.65, SW_BAT neck,
  FAN_PWM/SCL/LED_A rework)
- U12 MP1584: stays plain SOIC-8 (EP addition attempted, reverted: SYS5V+COMP
  route through EP zone; belly-over-mask accepted at 150mA load - flagged)
- LCSC fields (board+sch): W5500 C32843, SC16IS752 C57156, MP1584 C15051,
  PCF8574T C7605, SP3485 C8963, MAX3232 C15846, HR911105A C12074, SS34 C8678 x2
- sch footprint fields synced (U11/U13); silk rev 'HBOX v4 - 2026-07';
  toolkit ARCHIVE_NAME HBOX_v4_PROD
- verify: seg/via clearance 0 hits <0.125; SMD pad-aware 0 hits <0.09;
  census 0 opens (GND pads U11.9/U11.29 pour-served by design)
2026-07-30 23:21:58 +00:00
010800d72f 1.1 Phase C9b: Leo's zone refill save (fills baked, +1 via) 2026-07-30 23:21:35 +00:00
cd0626d377 1.1 Phase C9: stitching-via alignment + silkscreen distance check
- 54 of 90 free GND stitching vias aligned into rows/columns (axis equalize +
  even spacing, move cap 2.0mm, largest 1.3mm); 8 track-connected free vias frozen
- every move clearance-validated (>=0.15mm to other-net copper, keepout excluded)
- +1 GND via at (92.25,59.8): W5500 AGND cluster (C93/C94/U11.14/16) was
  pour-served only — now hard-bonded to the In2 plane
- silkscreen re-audit under new via field: 164 refs re-derived by the uniform
  0.15mm-gap rule, 8 re-placed, 0 left unplaced
- verify: census 0 open nets, clearance-lite 0 hits <0.125mm
- NOTE: zone fills stale around moved vias — refill (B) in pcbnew
2026-07-30 21:33:03 +00:00
438cd028f7 1.1 Phase C8b: Leo's GND via stitching + zone refill (+88 vias incl. 90 free stitchers, +28 seg) 2026-07-30 21:32:43 +00:00
e3c566a663 1.1 Phase C8: outer GND pours + silkscreen tidy
- GND_POUR_FCU / GND_POUR_BCU zones added (full board, params mirror In2 plane:
  clearance 0.3, min 0.25, thermals 0.5/0.5); unfilled — press B in pcbnew
- 164 reference designators re-placed at consistent spots (above-center preferred,
  below/left/right fallback), collision-checked vs pads/courtyards/vias/texts/edge;
  fonts normalized to 1.0mm/0.15
- 3 orphaned MOD1 pin labels (3V3/SW5V/GND) re-homed to the module's new position
- verified: copper untouched (census 0 opens, clearance clean), non-silk content
  byte-identical
2026-07-30 08:48:07 +00:00
c235016447 1.1 Phase C7b: Leo's hand-finish — all 20 opens closed (+179 seg, +29 via), In1/In2 zones filled
Census: 0 open nets, 0 orphans (GND+3V3 plane modes). Clearance-lite: 0 hits <0.125mm.
Nets touched: GND 3V3 /3V3_ETH /BAT_PLUS FREQ_FAN /MAIN5V BST_FAN /VEH5V /ETH_LINKLED
/ETH_FB /ETH_RSET /RS485_A + minor reroutes.
2026-07-30 08:47:52 +00:00
dda2cdf626 1.1 Phase C7: Freerouting session imported file-level (1773 seg / 232 via, 135 nets)
- Leo's hand-routed 24V / /24V_IN / IGN_IN kept byte-identical (SES echo verified subset)
- /ETH_RXN via slid 0.24mm along In2 exit: RXN/RXP via pair gap 0.11 -> 0.156mm
- clearance-lite clean at <0.125mm hard threshold; only non-track content untouched (verified)
- 20 open connections remain for hand-finish (W5500 supplies/RSET/LINKLED, U6 buck pins,
  P15 RS485_A, U2 BST/FREQ_FAN, GND locals incl. magjack keepout area)
- includes Leo's Freerouting artifacts (PROD dsn/ses/rules) + track-width presets in .kicad_pro
- NOTE: broken MCP import_ses had gutted the on-disk board (0 tracks, 133/190 footprints)
  at 07:07; recovered from container-staged 5a65eefb copy == git HEAD blob
2026-07-30 07:29:29 +00:00
ff1bdf5a42 1.1 Phase C6-pre: Leo's serial/ethernet hand-routing + RS485 fix baseline before SES import
Co-Authored-By: Claude Fable 5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01GSKKes8GsS4YHAMWJ44tCm
2026-07-30 07:07:26 +00:00
aa7f5a674b 1.1 Phase C5: MH1/MH3 deleted, first critical copper hand-routed
- MH1 and MH3 mounting holes removed per review (4-corner mounting via
  MH2/MH4/MH5/MH6 remains); Leo's placement pass B7 baselined first
- 54 new F.Cu segments (20 verified hops): buck SW node U12-C100-L8-D11 at
  0.8mm, SYS5V+FB+COMP chains, XI crystal loop (U11-Y1-C95), SER_XTAL1
  (U10-Y2-C82), TXP tap R92-J10 legs, RX terminations R94/R95->C97, TCT
  island J10.4-C98-R92.2/R93.2
- Leo's 46 hand-routed 24V/IGN segments byte-preserved; 0 cross-net
  clearance violations (0.2mm), parens balanced
- Remaining 16 congested hops (QFN fan-out, XO, RCT tail, 3V3_ETH trunks)
  deliberately left for Freerouting push-and-shove

Co-Authored-By: Claude Fable 5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01GSKKes8GsS4YHAMWJ44tCm
2026-07-30 03:17:52 +00:00
bdb2e3ab42 1.1 Phase C3+C4: line tidy passes + IGN divider fix (Rigb1 3.3k)
- C3: 22 detected component lines evened (edge-gap distribution between line
  endpoints), 58 parts nudged; everything touched by the hand-routed 24V/IGN
  tracks frozen (P1,Q10,D10,DzG1,C10,C11,C22,Rig1,Ren1,U2)
- C4: finer pass — pairs included (33 lines total, 17 more parts), 8 R/C
  rotations normalized 180->0 / 270->90 (unpolarized only, pad angles kept
  consistent), TOL 1.0mm
- IGN divider: Rigb1 10k -> 3.3k in sch+board (24V ign -> 3.13V at PA5, FT-pin
  safe incl. 35V transients; was 7.5V, out of spec). Fleet rework note: same
  swap recommended on the 10 EinarBoard 1.0 units
- Leo's 46 track segments byte-identical through both passes; 0 courtyard
  conflicts; parens balanced

Co-Authored-By: Claude Fable 5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01GSKKes8GsS4YHAMWJ44tCm
2026-07-30 02:53:25 +00:00
1ddf4b1798 1.1 Phase C3-pre: Leo hand-routes the 24V entry — 1.5mm on 24V/24V_IN/IGN_IN at P1
44 segments at 1.5mm (24V x22, /24V_IN x12, IGN_IN x10) + 2 GND stubs.
Board resaved by KiCad 10 (format normalized, 2.46MB -> 0.97MB).

Co-Authored-By: Claude Fable 5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01GSKKes8GsS4YHAMWJ44tCm
2026-07-30 02:52:53 +00:00
21a907600f 1.1 Phase C2: alignment pass on the Ethernet corner + aesthetics
- Column A (R94,R95,C97,C98,C95): x=83.9, even pitch 3.575 (y 54.2-68.5)
- Column B (R92,C92,C93,C94,R96): x=87.5, even pitch 3.175 (y 50.3-63.0;
  top pulled below MH1 which R92 would have hit at Leo's y46.4)
- C102/C90/C91 row: even x pitch (92.2 / 95.85 / 99.5 at y63.9)
- Serial column (C82,C83,R82,JP5): x=72.5, even pitch 4.4; Y2 centered on
  the U10/U15 column (x=72); C85-C87 even pitch 2.4
- C96 kept at Leo's spot (Y1-centerline slot blocked by Y1/Rig1 courtyards)
- Verified: 0 pairwise courtyard conflicts

Co-Authored-By: Claude Fable 5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01GSKKes8GsS4YHAMWJ44tCm
2026-07-29 19:33:51 +00:00
548b69f177 1.1 Phase C1: W5500 datasheet verification — 2 bugs fixed, Ethernet unblocked
Checked against WIZnet W5500 datasheet v1.1.0 (official pin table):
- CONFIRMED correct: pin 23 RSVD->GND, pin 18 VBG floating, EXRES1 12.4k/1%,
  PMODE[2:0]=111 autoneg via pins 43-45, LINKLED/ACTLED pins 25/27 active-low
  sink topology, TXN/TXP/RXN/RXP order (1/2/5/6), SPI on 32-37
- BUG FIXED: RSVD pins 38-42 were floating; datasheet requires GND. Added
  5 GND stubs on U11 in the schematic + (net GND) on board pads 38-42
- BUG FIXED: TOCAP/1V2O caps were 10uF/4.7uF; datasheet requires 4.7uF/10nF.
  C90 -> 4.7uF, C91 -> 10nF (sch + board values; footprints unchanged)
- R83 board value harmonized to sch's 12.4k/1%
Magjack HR911105A: wiring matches the standard table (TX 1/2, RX 3/6,
TCT pin4->3V3_ETH, RCT pin5->6.8nF, internal Bob Smith). Bench-check with
DMM before flash: pins 4/5 CT assignment + LED anode/cathode on 9-12.

Co-Authored-By: Claude Fable 5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01GSKKes8GsS4YHAMWJ44tCm
2026-07-29 18:12:51 +00:00
f9023d069a 1.1 Phase C0: routing prep — snap/align placement, strip all copper
- All footprint origins snapped to 0.1mm; 37 near-aligned row/column members
  equalized (same-prefix groups within 0.35mm)
- ALL tracks erased for the clean re-route: 1100 segments + 237 vias removed;
  zones kept (GND pour definitions + MAGJACK_NO_POUR rule area)
- Verified on Leo's B6 placement: 0 courtyard conflicts, nothing outside the
  outline, parens balanced

Co-Authored-By: Claude Fable 5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01GSKKes8GsS4YHAMWJ44tCm
2026-07-29 18:03:45 +00:00
df6fd8c826 1.1 Phase B6: manual placement pass (Leo) — board arranged in KiCad
Co-Authored-By: Claude Fable 5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01GSKKes8GsS4YHAMWJ44tCm
2026-07-29 18:01:12 +00:00
c4dad2d600 1.1 Phase B5: ArduSimple +25mm (silk outline on the board edge), SW4G1 to the modem
- MOD1 shifted +25mm east of B4: its silkscreen outline (module body incl.
  USB/SMA overhangs, 24.16mm west of the pad hull) now lands 0.8mm inside the
  left board edge — connectors overhang the front as intended; pad hull
  x85.5-131.8. U10 no longer displaced (module clears its Phase B spot)
- SW4G1 (4G NTRIP reset) moved beside the XBee sockets J7/J8 at (188,98.8),
  2 stale stubs ripped; frees the bottom-edge strip x143-153
- P15/P16 dropped 0.7mm (origin y133.1) so their bodies clear the module's
  bottom pad row; entry faces overhang the edge 1.3mm
- C103 clear of the module top pad row at (88,75.4)
- Verified: 0 pairwise courtyard conflicts; module's 32 pad holes clear of
  all courtyards/pads; silk min-x 61.03 vs edge 60.19

Co-Authored-By: Claude Fable 5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01GSKKes8GsS4YHAMWJ44tCm
2026-07-29 15:54:21 +00:00
5eb1ed3239 1.1 Phase B4: correct module mixup — ArduSimple (MOD1) to front-left, Blackpill restored
J1/J2 are the STM32 Blackpill sockets, not the GNSS module; B2/B3 moved the
wrong part. This rebuilds from the Phase B baseline (0af0373):
- Blackpill J1/J2 back at original position/rotation with v3 routing intact
- MOD1 (ArduSimple simpleRTK2B Pro, the 10/8/6/8 socket pattern) moved 44.8mm
  left: hull now x60.5-106.8, west edge 0.3mm from the board edge; 18 stale
  pad stubs ripped for re-route
- P15/P16 into the bottom-edge window MOD1 vacated; U10 tucked between the
  module rows (1.2mm TSSOP under ~8.5mm standoff); C103 clear of the top row
- ANT_CORRIDOR keepout retired (module owns the front-left; antenna exits there)
- 3D model vars repointed KICAD6/7 -> KICAD10 (58 refs)
- Verified: 0 pairwise courtyard conflicts; MOD1's 32 pad holes individually
  checked clear of all courtyards and pads

Co-Authored-By: Claude Fable 5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01GSKKes8GsS4YHAMWJ44tCm
2026-07-29 15:40:54 +00:00
b9791a11d7 1.1 Phase B3: ArduSimple vertical, flush along the left edge; front cleared
- J1/J2 rotated to vertical rows: J2 (outer) x63.77, J1 (inner) x78.77,
  y52.8-101.1 — module hugs the front edge full-length, USB end (J1 pad20
  /SYS5V) at the top-front corner; antenna exits directly at the front
- Front edge cleared: P15 (RS-485) -> top edge between MH5/MH1, P16 (RS-232)
  -> bottom edge west of the modem pad row, H4 TTL -> top strip next to P5
- RJ45 kept at the bottom-left of the front edge (no other edge window fits
  a 19x22.3mm magjack) with the no-pour zone moved under it
- Serial cluster re-laid east of the module; W5500 satellites auto-placed
  by greedy collision-free placer; 0 pairwise courtyard conflicts (190 fp)

Co-Authored-By: Claude Fable 5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01GSKKes8GsS4YHAMWJ44tCm
2026-07-29 05:42:46 +00:00
61064fe76c 1.1 Phase B2: SimpleRTK2B module to the front-left edge per review
- J1/J2 socket pair translated -43.43mm: rows now x62.0-113.8, USB end
  (J1 pad20 /SYS5V) at the left board edge; 49 stale J1/J2 pad stubs ripped
- Ethernet corner rebuilt lower-left: RJ45 J10 on left edge y106-125 inside
  relocated MAGJACK_NO_POUR zone, W5500+25MHz+terminations below the serial
  stack, clear of the existing R5/R6/R7/D1/C5/C7 LED cluster
- ANT_CORRIDOR_KEEPOUT retired (antenna now exits at the module end itself)
- Rig1 nudged below Rigb1 (was inside J2's new courtyard band), stub ripped
- 3D models: 58 legacy KICAD6/KICAD7 3DMODEL_DIR refs repointed at
  KICAD10_3DMODEL_DIR so new parts render in the 3D viewer
- Verified: 190 footprints, 0 pairwise courtyard conflicts, parens balanced

Co-Authored-By: Claude Fable 5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01GSKKes8GsS4YHAMWJ44tCm
2026-07-29 05:20:21 +00:00
0af0373def 1.1 Phase B: board grown to 155x100 (20mm left), placement for blocks M/N/O
- Outline left edge 80.19->60.19; MH5/MH6 mounting holes cloned to new corners
- Antenna corridor keepout front-left (notched around MH6) + magjack no-pour/no-via zone
- RJ45 J10 + RS-485 P15 + RS-232 P16 on new left edge behind antenna corridor
- W5500 U11 + 25MHz + terminations between jack and P5; 3V3_ETH buck U12/L8/D11
  in the freed P13/H3 gap under the module (low-profile), bulk caps at load
- SC16IS752 U10 serial cluster behind P15/P16; MAX3232 U15, SP3485 U14
- PCF8574 U13 clear of MOD1 pad ring; RGB JST P14 on right edge (freed P3 slot)
- H4 TTL header moved to front edge (was under module, on D5)
- 24V entry block relocated beside P1 (Q10/C10 in P12 lane, D10/DzG1/Rrp1 pocket);
  old cross-board 24V routing ripped for HV24 re-route
- P3/P13/H3 depopulated; J1/J2/DB pad nets updated (ETH SPI, SER_IRQ, LED flip)
- Fix Phase A miss: SC16IS752 pins 13/14 (I2C SCL/SDA) now wired in sch + board
- Placement verified: 190 footprints, 0 courtyard conflicts, 0 corridor intrusions,
  all new nets 2-ended (verify_phase_b.py)

Co-Authored-By: Claude Fable 5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01GSKKes8GsS4YHAMWJ44tCm
2026-07-29 04:39:35 +00:00
f79b10bc22 Bump firmware submodule to v3.0 (36d8ff4)
Co-Authored-By: Claude Fable 5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01GSKKes8GsS4YHAMWJ44tCm
2026-07-29 03:49:47 +00:00
ca96c94ad6 HBOX v4: project renamed hbox-watchdog-v4 (199 sch + 113 pcb refs); v3-PROD files restored to as-fabricated as the frozen EinarBoard 1.0 record; ERC endpoint_off_grid muted on v4
v4 = the live 1.1/Phase-A design (J1 renumbered, blocks M/N/O, HV24, PFI 4.40V). v3-PROD trio = exact as-fabbed state from 9892279 (mirrored J1 as the bench/fleet boards physically are) - do not edit. dru/prl carried to v4. Off-grid warning backlog stays visible-but-muted; real geometry sweep slated for Phase D.

Co-Authored-By: Claude Fable 5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01GSKKes8GsS4YHAMWJ44tCm
2026-07-29 03:34:46 +00:00
7798d9c4f9 Phase A ERC fixes: regenerate blocks on-grid, own-column stub geometry (kills all 23 errors incl. the C85-C89 net fusion / GND-3V3 short), PWR_FLAGs SYS5V+3V3_ETH, direct LED nets, R61 preserved, netclass patterns re-applied after KiCad session clobber
Root cause of 23 ERC errors: vertically-stacked 2-pin parts closer than 15.24mm shared stub columns -> KiCad merged collinear overlapping stubs -> orphaned pins + fused nets (C85-C89 chain shorted C1N/C2P/VP/VN/GND/3V3; RGB chain fused). Regenerated from pre-Phase-A base with grid-snapped origins, one x-column per part, geometry auditor (collinear overlap + T-touch + label-anchor collision checks) now part of the generator. P13 depop made surgical (R61 FB wire preserved). PF10/PF11 added. rjmap LED/TCT nets direct (no alias bridges). Netclass patterns re-applied onto KiCad-canonical pro; note: pro file is vulnerable to open-KiCad resave clobber.

Co-Authored-By: Claude Fable 5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01GSKKes8GsS4YHAMWJ44tCm
2026-07-29 03:28:55 +00:00
0b1d542e3b 1.1 Phase A: schematic blocks M/N/O (SC16IS752+RS485+RS232, W5500+MagJack+3V3_ETH buck, PCF8574+RGB), gauge->expander frees SPI2, depop P3/P13/H3
59 new parts from official KiCad libs (pinouts verified, extends-flattened). Gauge LEDs flipped common-anode (PCF8574 sinks). PB12-15 -> W5500 SPI2; PA15/PB2/PB8 unlocked (ETH_RST/ETH_INT/SER_IRQ). SC16IS752 strapped 0x4D (0x48 collides with TMP102). 220uF VEH5V bulk cap (C78). Netclass patterns slash-fixed; HV24 exclusively owns 24V/ignition nets. RevNum_EJ1 footprint saved to Drogheda.pretty + fp-lib-table. Paper A1. VERIFY flags in Notes: W5500 RSVD/VBG/TOCAP, magjack termination + LED pin order. ERC in KiCad UI pending (Leo).

Co-Authored-By: Claude Fable 5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01GSKKes8GsS4YHAMWJ44tCm
2026-07-29 02:17:05 +00:00
0f82a667c4 EinarBoard 1.1 design brief: locked decisions (RS-485+RS-232 via SC16IS752, on-board W5500 Ethernet, RGB status LED, board growth) + execution phases
Keystone: gauge moves to PCF8574 on I2C1 -> frees SPI2 for W5500; SC16IS752 dual-UART bridge on I2C gives RS-485 (Modbus RTU) + RS-232/TTL with zero MCU pins. New 3V3_ETH rail from SYS5V (survives stack power-cycles). Carry-over errata state + depop list + phases A-E.

Co-Authored-By: Claude Fable 5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01GSKKes8GsS4YHAMWJ44tCm
2026-07-29 01:58:39 +00:00
bca0d36032 auto-sync 2026-07-25 18:00 2026-07-25 18:00:14 -06:00
19c15e2864 EinarBoard respin WIP: E-J1 pad renumber, PFI 4.40V (R51 270k), HV24 24V clearance class, J1 nets ripped for reroute
J1 pads renumbered end-for-end (positions/uuids kept, nets follow numbers, lib id renamed Drogheda:..._RevNum_EJ1 so library-update cannot revert); verified pad-by-pad against the module landing map. R51 287k->270k on board+schematic (PFI trip 4.60->4.40V falling, per 24-Jul bench data). HV24 class (0.5mm clearance) assigned to /24V_IN, 24V, IGN_IN, Q10_GATE after the 23-Jul inner-layer bridge incident. 177 segments/vias ripped on the 11 J1 signal nets + 5 power stubs: reroute pending in the inter-socket channel. NOTE: pre-existing PWR_HI/PWR_MID netclass patterns lack the '/' prefix and likely never matched.

Co-Authored-By: Claude Fable 5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01GSKKes8GsS4YHAMWJ44tCm
2026-07-25 04:04:12 +00:00
9f7d43ba93 auto-sync 2026-07-24 18:00 2026-07-24 18:00:14 -06:00
914a3fd2a9 Firmware review: v2.3 as EinarBoard 1.0 production candidate (2026-07-24)
Verified findings: millis()-rollover recovery-gate collapse (uint32-modelled), fan-tach false-fault on 2-wire fans, PROD silicon undriven (CHRG_EN/STAT/FAULT, BYP_CTRL/K1, NTC PB1, gauge). v3.0 scope in doc section 4. Bumps firmware submodule to ea1d84c (v2.2+v2.3 source + tools/hostsim harness).

Co-Authored-By: Claude Fable 5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01GSKKes8GsS4YHAMWJ44tCm
2026-07-24 01:27:20 +00:00
98922790c2 auto-sync 2026-07-23 18:00 2026-07-23 18:00:14 -06:00
0182051d6a auto-sync 2026-07-22 18:00 2026-07-22 18:00:14 -06:00
b2d74bc145 auto-sync 2026-07-20 18:00 2026-07-20 18:00:14 -06:00
de9a4f97a8 auto-sync 2026-07-13 18:00 2026-07-13 18:00:15 -06:00
677ca33ac1 auto-sync 2026-07-12 18:00 2026-07-12 18:00:14 -06:00
7790a7227d auto-sync 2026-07-11 18:00 2026-07-11 18:00:15 -06:00
3d25a79cf5 auto-sync 2026-07-10 18:00 2026-07-10 18:00:15 -06:00
0b984b6a0f auto-sync 2026-07-09 18:00 2026-07-09 18:00:14 -06:00