astra/nema17-stepper-motor-controller-spring-clamp-rp2040

VALIDATION.md

# Lever connector revision 1.4.0 validation — 2026-09-28

Circuit JSON SHA-256: `6168bd8088646af2ad3acc1a8d587e1e299f41d2b06c0f2df26a75ad552110e1`

- Exact C7472748 supplier OBJ/STEP model assigned to J1; generated 3D board preview visually reviewed.
- Copper traces, vias, pads, drill geometry, outline and ground pours match 1.3.1 exactly. The connector body, CAD model, BOM and schematic part identity change to the side-entry part.
- Pinned tscircuit build and TypeScript typecheck: passed.
- Circuit regression tests: 21 passed, 0 failed, 2581 assertions.
- Firmware host tests: 23 passed, including the 4 kHz alarm setting.
- Exact original outline equality verified: 42.30 × 42.32 mm; original mounting holes retained.
- Embedded DRC and independent routing errors: 0.
- CLI check: 0 errors, 135 nonblocking warnings. These include supplier footprint comparisons, catalog/metadata, trace-length and schematic guidance; see reports/tsci-check.log.
- Gerber-derived shorts check: no shorts on all four copper layers.
- Physical ground audit: one connected network with six retained pour regions. Geometry-guarded selection removes 91 independently identified floating pour fragments before final DRC.
- All six motor paths retain the regression limits: at least 0.35 mm width, continuous sub-0.5 mm necks shorter than 1.5 mm, estimated individual trace resistance below 0.05 ohm at 20°C assuming 18 µm copper, no more than three vias per path. This is not thermal qualification.
- Connector regression verifies eight 1.2 mm holes, 3.5 mm pole pitch, 5 mm row spacing, paired tails and four isolated motor potentials.
- Placement was checked with routing disabled. Final routing and stale-route/pour guards are enabled.
- PCB top and bottom views, motor-driver and alarm schematics visually reviewed. Schematic snapshot updated.
- Validation, physical ground and fabrication audit hashes match the delivered circuit JSON.

J1 is WAGO 2601-1104, JLCPCB C7472748, with four horizontal hinged levers and side wire entry. BZ1 is the smaller KLJ-4020, C556936; D_BUZZER is B5819WS, C64886. The outline and all test points are retained. Nine populated support components are on the underside: the SMT BOM/CPL contains 91 top and nine bottom placements. Review bottom-side placement rotations with the assembler. The optional encoder remains DNP. J1 is excluded from SMT files and included in manual-assembly-bom.csv for wave or hand soldering of all eight tails.

The connector is approximately 12.75 mm high and extends approximately 4.7 mm past the right PCB edge, as approved. Wire entry faces outward parallel to the PCB; allow additional lever/wire access. This revision has not been fabricated or tested on physical hardware. Verify connector fit, underside and motor/enclosure clearance, alarm loudness and operation on a prototype. Retain baseline current, thermal and power-transient acceptance checks.