# Final control and harness integration review

**PASS for the tested nominal CAD geometry.** The four controls clear the final harness and retained fixture supports through their selected travel ranges. This is a geometric verification, not a physical actuation, material-strength or switch-overtravel certification.

Final integrated manifest: `77d9a0a5675bf7fb0d123d983df8f920fc91d25a51c6047403f8f0ce551e793d`.

## Travel and limited off-centre probes

| Control | Selected travel (mm) | Conservative continuous clearance bound (mm) | Midstroke rocking probes | Evidence |
|---|---:|---:|---|---|
| P03 — Play | 0.50 | 0.408333 | 8 clear | Unchanged-input and removal-only proof |
| P05 — PTT | 0.45 | 0.262500 | 8 clear | Final full-reference rerun |
| P06 — Volume up | 0.45 | 0.762500 | 8 clear | Unchanged-input and removal-only proof |
| P07 — Volume down | 0.45 | 0.762500 | 8 clear | Unchanged-input and removal-only proof |

The clearance bounds cover all intermediate translations. They use positive endpoint distance bounds and the fact that rigid translation changes distance by no more than the travel distance. They are conservative bounds, not manufacturing tolerances or exact closest-gap rankings.

Each control also has eight midstroke probes: ±0.25° and ±0.50° about each of two axes. These tested poses clear the harness and are not blocked by the rigid printed parts or screw proxies. They do not describe every possible rocking pose or simulate bending, guide deformation, cable movement or return friction.

## What was checked

The complete predecessor audit covered all four moving printed controls, their contact pads and the moving PTT grip/bond against 147 reference bodies and 5 fixture additions as actually retained in the integrated shells. This includes the nine J9 wires, eleven J9 termination envelopes, connector gauges, insulation, tape, strain restraints and the other routed harnesses.

Only each control's own geometrically identified switch-plunger proxy may receive intended nub/contact-pad compression. The five fixed housing/terminal solids in each switch proxy remain obstacles. No whole-switch or whole-harness collision exclusion is used. Contact-pad compression and the real electrical switching event are not simulated.

The prior printed-part/hardware translation and insertion proof remains linked through exact canonical-part hashes and the core geometry provenance record. The final PTT rerun uses every final reference/support, including the trimmed rear pad. Its midpoint rocking checks also test all printed parts and screws.

## Final corrections and inherited evidence

The historical full audit found eight contacts, all between P05 and the old PTT rear pad. The final pad removes only the 0.50 mm outboard overhang and preserves the measured switch/cradle bearing areas. PTT was then rerun against the full final reference set.

Play and both volume controls passed the original full audit. Every shared input is byte-unchanged except K03; the old rear-pad reference is replaced by its trimmed subset. Both changes are proven to remove material only. They cannot introduce a new collision with those unchanged controls. No inherited rocking pose was blocked by K03, so its relief does not invalidate the selected rocking-pose set. The historical failing report is retained unchanged for traceability.

## Simultaneous pressing

All four controls were recomputed at their selected stops. All six pairs of moving control groups clear; pads and the PTT grip/bond are included.

| Moving groups | Conservative separation bound (mm) |
|---|---:|
| P03 / P05 | 25.838392 |
| P03 / P06 | 49.710889 |
| P03 / P07 | 25.380554 |
| P05 / P06 | 66.800000 |
| P05 / P07 | 66.800000 |
| P06 / P07 | 10.200000 |

## Evidence

- [Final control integration proof](FINAL_CONTROL_INTEGRATION_REVIEW.json)
- [Final PTT/full-reference rerun](final_ptt_harness.json)
- [Preserved full predecessor audit](../Verification/controls/history/final_control_harness_6fdae.json)
- [Core geometry provenance](../Verification/controls/core_geometry_provenance.json)
- [Printed-part, hardware and insertion checks](../Verification/controls/COMBINED_CONTROL_CHECKS.md)
- [K03 removal-only proof](K03_final_removal_delta.json)
- [PTT pad support, motion and subset proof](../Verification/fixtures/PTT_PAD_MOTION_CORRECTION_CHECKS.json)
- [Final native exterior provenance](../Verification/controls/exterior_native_final/FINAL_NATIVE_PROVENANCE_BRIDGE.json)

## Required physical qualification

Verify the selected switches' actuation and allowable overtravel with the actual hardware, then confirm that each positive stop engages at the intended travel without holding the switch closed. Qualify the process-fit coupons, guide running clearance, soft-stock thickness/placement, off-centre return, wire retention and screw seating before an assembled first article is accepted. Repeat the documented actuation and service-cycle checks. A geometric pass does not establish fatigue life or guarantee that printed parts cannot break.