techmannih/nema34-mounted-stepper-controller

engineering/mechanical/harness-layout.json

{
  "status": "Connected J2 motor harness and J3 brake assembly; nominal CAD only, physical fit and resistor/cooling duty unqualified",
  "coordinate_system": "PCB X/Y; Z height; millimetres",
  "sources": {
    "VH": "https://www.jst-mfg.com/product/pdf/eng/eVH.pdf",
    "PHD": "https://www.jst-mfg.com/product/pdf/eng/ePHD.pdf",
    "motor": "engineering/mechanical/34HS31-6004S1-manufacturer.zip"
  },
  "mates": [
    {
      "reference": "J2",
      "part": "VHR-4N",
      "width_mm": 15.78,
      "depth_mm": 10.6,
      "height_mm": 13.3,
      "mated_height_mm": 16.5,
      "wire_od_mm": 2.3876,
      "wire_exit_direction_y": -1,
      "wire_free_height_mm": 30,
      "description": "Four motor phase pigtails, black/green/red/blue; connect to factory leads via four insulated splices"
    },
    {
      "reference": "J3",
      "part": "VHR-2N",
      "width_mm": 7.86,
      "depth_mm": 10.6,
      "height_mm": 13.3,
      "mated_height_mm": 16.5,
      "wire_od_mm": 2.3876,
      "wire_exit_direction_y": 1,
      "description": "Two 16 AWG Alpha3057 leads from SVH-41T-P1.1 contacts to TE152883 M4 rings; VMOTOR red, BRAKE_RETURN black (not chassis ground)"
    }
  ],
  "motor_cable": {
    "cad_tip_plane_y_mm": -114.491325,
    "cad_tip_x_mm": [
      -1.25,
      -1.25,
      1.25,
      1.25
    ],
    "cad_tip_z_from_rear_mm": [
      -67.425797,
      -64.925797,
      -67.425797,
      -64.925797
    ],
    "tip_identity_note": "Four end-face centres measured from the locked motor mesh. STEP is uncoloured: their colour assignment is illustrative, not evidence of factory conductor ordering. Use manufacturer winding colours and continuity checks.",
    "splice_y_mm": -92,
    "splice_length_envelope_mm": 32.131,
    "splice_diameter_envelope_mm": 5.6134,
    "splice_note": "TE 320559 manufacturer STEP AE, nominal 32.131 mm axial span / 5.6134 mm radial envelope. V6 drawing length 32.13 mm max is the rounded 1.265 inch value. STEP dimensions are not a finished-crimp tolerance or physical fit approval.",
    "splice_x_mm": [
      -12,
      -4,
      4,
      12
    ],
    "splice_z_mm": -77,
    "loop_y_mm": -190,
    "length_note": "Factory 1 m cable is trimmed and rerouted in the assembly. Cut lengths in harness-geometry.json are CAD centreline plus stated termination allowance; physical first-article confirmation required. Vendor STEP cable geometry past Y=-70 is replaced; motor body and terminal housing are unchanged.",
    "pigtail_wire": "Alpha Wire 3057, 16 AWG stranded, 300 V; 2.3368 mm nominal OD, +/-0.0508 mm",
    "pigtail_wire_od_max_mm": 2.3876,
    "cad_clip_plane_y_mm": -70,
    "jacket_section_center_z_from_rear_mm": -66.1757965,
    "jacket_diameter_mm": 7.5,
    "jacket_end_y_mm": -92,
    "jacket_end_z_mm": -47,
    "splice_top_z_mm": 6,
    "bend_top_z_mm": 45,
    "pigtail_minimum_bend_radius_mm": 23.876
  },
  "usb_envelopes": {
    "references": [],
    "body_length_mm": 18,
    "body_width_mm": 12,
    "body_height_mm": 6,
    "body_start_x_mm": -44,
    "plug_center_z_mm": 2.6,
    "cable_od_mm": 5,
    "note": "Generic straight-plug access gauges, not supplier CAD or evidence of EPR/data capability; final cables must fit these envelopes."
  },
  "minimum_nominal_clearance_mm": 0.2,
  "not_modeled": [
    "Rear encoder magnet/holder: rotating rear shaft unavailable",
    "USB source/host cables: product candidates identified in external-system.md; actual plug CAD, access and negotiation unqualified, no free tails rendered"
  ],
  "limitations": [
    "TE 320559 manufacturer STEP geometry is hash-locked; V6 drawing does not specify an exterior OD tolerance. Finished crimp envelope still needs physical verification.",
    "Crimps, wire bend radius, termination allowance and retention must be qualified by the harness manufacturer",
    "Unsupported adapter-mounted cable clamp removed; no physical strain-relief qualification or replacement bracket claimed.",
    "J3 contacts and TE152883 use clearly labeled nominal envelopes, not tooling CAD; housing latch, finished crimps, guards, heat clearance and strain relief require first-article checks.",
    "Brake heatsink and terminal guard are installation concepts; no cooling capability or production mechanical approval implied."
  ],
  "brake": {
    "resistor_part": "LPS0300H10R0GB",
    "resistance_ohm": 10,
    "tolerance_percent": 2,
    "rated_power_W_at_case_85C": 300,
    "thermal_qualified": false,
    "resistor_base_z_mm": 20,
    "resistor_center_y_mm": 145,
    "resistor_terminals_step_xy_mm": [
      [
        -18,
        -17.5
      ],
      [
        18,
        16.5
      ]
    ],
    "resistor_mount_step_xy_mm": [
      [
        0,
        -28.5
      ],
      [
        0,
        28.5
      ]
    ],
    "terminal_seat_step_z_mm": 25.9,
    "step_to_pcb_transform": "[stepY, 145-stepX, 20.2+stepZ]; no scaling; ceramic bottom stepZ=-0.2 at PCB Z=20",
    "wire": "Alpha Wire 3057, 16 AWG, 300 V",
    "wire_od_max_mm": 2.3876,
    "minimum_bend_radius_mm": 23.876,
    "bend_radius_mm": 28,
    "ring_part": "TE 152883",
    "ring_hole_mm": 4.3,
    "ring_tongue_thickness_mm": 0.79,
    "ring_length_mm": 20.45,
    "ring_envelope_width_mm": 8,
    "ring_barrel_envelope_diameter_mm": 5,
    "ring_barrel_axis_above_seat_mm": 2,
    "ring_model_status": "Catalogue length/hole/tongue thickness; width/barrel profile are explicit nominal visualization envelopes. Official STEP/drawing download returned HTTP403; no exact ring geometry or installed fit claimed.",
    "heatsink_envelope_mm": [
      80,
      80,
      30
    ],
    "heatsink_status": "Illustrative finned cooling interface only, not a selected/orderable or thermally qualified heatsink; 10 mm base and 20 mm fins, top Z=20",
    "terminal_cover_status": "Illustrative removable guard with paired cable slots, material/retention/tool access unqualified",
    "thermal_boundary": "At 53 V and 10 ohm: 5.3 A / 280.9 W while on. At 50 C ambient and 85 C case target, combined case-to-ambient <=0.1246 C/W for continuous dissipation. Geometry is not a thermal rating."
  }
}