[ { "id": "R36-PA-01", "components": [ "P01", "P02" ], "location": "Four closure joints at X +/-33.4, Y +/-56", "failure_mechanism": "Short receiving threads strip or pull out; a long screw can still engage only a short thin receiver.", "loading_situation": "Initial thread formation, tightening, ten service cycles and case pull-apart load.", "evidence": "Original axis sections show only 2.00 mm pilot-surrounding stock; M2.5 x14 reference extends into open cavity.", "treatment": "Extend receivers to Z -6.0, retaining D2.1 pilots and original axes/head seats; add supported outboard ribs. Potential threaded material increases to 5.35 mm.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Qualify tap/thread-forming method and low seating torque on coupons. Run ten complete service cycles; reject any split, stripped thread or loose closure.", "source_register": "audit/passive/risk_register.json", "r36_status": "CAD treatment prepared; physical qualification pending", "status": "REVIEWED; current nominal checks and physical qualification remain distinct", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Extend receivers to Z -6.0, retaining D2.1 pilots and original axes/head seats; add supported outboard ribs. Potential threaded material increases to 5.35 mm.", "baseline_evidence": "Original axis sections show only 2.00 mm pilot-surrounding stock; M2.5 x14 reference extends into open cavity.", "current_treatment": "Original outer faces retained. Integrated three switch seats, broader PTT bearing and PCB stop, repositioned PCB supports, open cable channels, revised LED and speaker seats. Original outer faces/seam retained. Obsolete adapter/PCB stock removed; paired PCB pads and battery supports preserved around the connected cable routes. Battery slack belongs in the centre bay." }, { "id": "R36-PA-02", "components": [ "P01" ], "location": "Upper receiver inboard faces beside maximum battery", "failure_mechanism": "Enlarged bosses can consume pouch clearance; aggressive relief can leave a fragile unsupported wall.", "loading_situation": "Battery installation, closed-case shock and tightening.", "evidence": "Original D4.6 receiver reaches X31.1 while maximum battery reaches X31.0.", "treatment": "Relieve inboard stock to X +/-31.4 below Z -7.75; preserve outboard support continuously. Local pilot-side wall is 0.95 mm, not a free snap arm.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Confirm residual printed wall is sound, receiver thread survives qualification and pack does not contact hardware at lateral travel limits.", "source_register": "audit/passive/risk_register.json", "r36_status": "CAD treatment prepared; physical qualification pending", "status": "REVIEWED; current nominal checks and physical qualification remain distinct", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Relieve inboard stock to X +/-31.4 below Z -7.75; preserve outboard support continuously. Local pilot-side wall is 0.95 mm, not a free snap arm.", "baseline_evidence": "Original D4.6 receiver reaches X31.1 while maximum battery reaches X31.0.", "current_treatment": "Original outer faces retained. Integrated three switch seats, broader PTT bearing and PCB stop, repositioned PCB supports, open cable channels, revised LED and speaker seats." }, { "id": "R36-PA-03", "components": [ "P02" ], "location": "Rear closure countersinks and surrounding shell", "failure_mechanism": "Countersink wedge loads split the seat or dish the rear skin.", "loading_situation": "Tightening and case closure.", "evidence": "Original head recesses sit in curved corners; external head seats are fixed by the user constraint.", "treatment": "Add four inboard-biased internal head bolsters ending at Z -17.2; retain original countersink and D2.9 shaft clearance.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Use measured compatible 90-degree heads, establish seating torque on coupons, and confirm closure without screws pulling parts together.", "source_register": "audit/passive/risk_register.json", "r36_status": "CAD treatment prepared; physical qualification pending", "status": "REVIEWED; current nominal checks and physical qualification remain distinct", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Add four inboard-biased internal head bolsters ending at Z -17.2; retain original countersink and D2.9 shaft clearance.", "baseline_evidence": "Original head recesses sit in curved corners; external head seats are fixed by the user constraint.", "current_treatment": "Original outer faces/seam retained. Obsolete adapter/PCB stock removed; paired PCB pads and battery supports preserved around the connected cable routes. Battery slack belongs in the centre bay." }, { "id": "R36-PA-04", "components": [ "P01", "P02", "F01" ], "location": "Exterior and mating seam", "failure_mechanism": "A local reinforcement changes outside shape, creates an interference, or causes closure distortion.", "loading_situation": "Printing, fitting bumper and final closure.", "evidence": "Exterior frozen to original R3.4 including 78 x150 x24 mm bare case, all openings, buttons, grille and seam.", "treatment": "Construct only local internal masks from the original; retain F01 exactly. Review each changed interface with both shells present.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Printed halves must seat by hand before any screw is tightened; verify seam and bumper fit after ten openings.", "source_register": "audit/passive/risk_register.json", "r36_status": "CAD treatment prepared; physical qualification pending", "status": "REVIEWED; current nominal checks and physical qualification remain distinct", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Construct only local internal masks from the original; retain F01 exactly. Review each changed interface with both shells present.", "baseline_evidence": "Exterior frozen to original R3.4 including 78 x150 x24 mm bare case, all openings, buttons, grille and seam.", "current_treatment": "Original outer faces retained. Integrated three switch seats, broader PTT bearing and PCB stop, repositioned PCB supports, open cable channels, revised LED and speaker seats. Original outer faces/seam retained. Obsolete adapter/PCB stock removed; paired PCB pads and battery supports preserved around the connected cable routes. Battery slack belongs in the centre bay. Original contour/openings fixed. Flexible material remains a distinct manufacturing requirement; fit after closure screws." }, { "id": "R36-PA-05", "components": [ "P11", "P12" ], "location": "Speaker screw ears and transverse beams", "failure_mechanism": "Narrow countersink ligaments split; thin beam bends into the speaker or loses retention.", "loading_situation": "Loose handling, screw seating, vibration and servicing.", "evidence": "Original keeper 1.4 mm thick x4.4 mm wide, approximately 0.24 mm side ligament at countersink mouth.", "treatment": "Replace with 2.2 mm thick x7.2 mm wide capsule beams and D7.2 ears; D4.2 countersink mouth leaves 1.5 mm side ligament. Original contact plane Z -4.95 retained.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Establish gentle screw seating; test keeper with 5 N central padded load outside device; inspect ears after ten installations. Load speaker frame only.", "source_register": "audit/passive/risk_register.json", "r36_status": "CAD treatment prepared; physical qualification pending", "status": "REVIEWED; current nominal checks and physical qualification remain distinct", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Replace with 2.2 mm thick x7.2 mm wide capsule beams and D7.2 ears; D4.2 countersink mouth leaves 1.5 mm side ligament. Original contact plane Z -4.95 retained.", "baseline_evidence": "Original keeper 1.4 mm thick x4.4 mm wide, approximately 0.24 mm side ligament at countersink mouth.", "current_treatment": "One short radial keeper with one M2x5 pan screw.6.8x2.2mm section, hard seating boss, supported silicone contact on the frame. Second short removable keeper uses a recessed M2x4 pan screw with1.2mm bearing floor and0.35mm maximum-pouch head clearance; it permits straight speaker fitting/removal. A long bridge or permanent lip would obstruct service. Speaker frame rotates45deg about the unchanged acoustic centre." }, { "id": "R36-PA-06", "components": [ "P01", "P11", "P12" ], "location": "Speaker blind screw pilots", "failure_mechanism": "Screw bottoms before clamp seats or breaks the front skin.", "loading_situation": "Assembly tightening.", "evidence": "Original upper screw reference has approximately 0.09 mm floor margin.", "treatment": "Use matched M2 x5 countersunk length at Z -7.15; pilot floor Z -1.5 gives 0.65 mm nominal tip clearance and 2.80 mm potential engagement.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Measure actual screw length and print hole depth; verify sample seating without bottoming. Do not substitute longer screws.", "source_register": "audit/passive/risk_register.json", "r36_status": "CAD treatment prepared; physical qualification pending", "status": "REVIEWED; current nominal checks and physical qualification remain distinct", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Use matched M2 x5 countersunk length at Z -7.15; pilot floor Z -1.5 gives 0.65 mm nominal tip clearance and 2.80 mm potential engagement.", "baseline_evidence": "Original upper screw reference has approximately 0.09 mm floor margin.", "current_treatment": "Original outer faces retained. Integrated three switch seats, broader PTT bearing and PCB stop, repositioned PCB supports, open cable channels, revised LED and speaker seats. One short radial keeper with one M2x5 pan screw.6.8x2.2mm section, hard seating boss, supported silicone contact on the frame. Second short removable keeper uses a recessed M2x4 pan screw with1.2mm bearing floor and0.35mm maximum-pouch head clearance; it permits straight speaker fitting/removal. A long bridge or permanent lip would obstruct service. Speaker frame rotates45deg about the unchanged acoustic centre." }, { "id": "R36-PA-07", "components": [ "P13", "P01" ], "location": "Microphone keeper screw seats", "failure_mechanism": "Countersink wedging or blind-hole bottoming; reinforcement may collide with PTT.", "loading_situation": "Screw tightening, control movement and servicing.", "evidence": "Original reinforced keeper 1.85 mm thick; original screw floor margin approximately 0.29 mm. Prior pan-head attempt collided with the old long PTT rod.", "treatment": "Thicken the relieved ring rearward to 2.65 mm while preserving the optical/acoustic board datum; fill countersinks to broad D5.8 flat ears with 1.85 mm seating thickness, D2.3 clearance holes, M2 x5 pan heads and D4.4 rear head relief. Deepen pilots to -1.3 for 0.65 mm tip margin.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Verify board support, screw seating and full PTT edge presses with case tightened; measure real screw dimensions.", "source_register": "audit/passive/risk_register.json", "r36_status": "CAD treatment prepared; physical qualification pending", "status": "REVIEWED; current nominal checks and physical qualification remain distinct", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Thicken the relieved ring rearward to 2.65 mm while preserving the optical/acoustic board datum; fill countersinks to broad D5.8 flat ears with 1.85 mm seating thickness, D2.3 clearance holes, M2 x5 pan heads and D4.4 rear head relief. Deepen pilots to -1.3 for 0.65 mm tip margin.", "baseline_evidence": "Original reinforced keeper 1.85 mm thick; original screw floor margin approximately 0.29 mm. Prior pan-head attempt collided with the old long PTT rod.", "current_treatment": "Original outer faces retained. Integrated three switch seats, broader PTT bearing and PCB stop, repositioned PCB supports, open cable channels, revised LED and speaker seats. Broad open exit for the low-profile solder row and SEL jumper. Two M2x4 pan screws preserve1.4mm bearing material; acoustic datum remains fixed." }, { "id": "R36-PA-08", "components": [ "P13", "MIC", "MIC_SEAL" ], "location": "Mic board, bottom acoustic port and offset seal", "failure_mechanism": "Fastening bends board, crushes components or blocks acoustic path.", "loading_situation": "Seating, pad compression and acoustic operation.", "evidence": "Original microphone port is offset and seal reserves about 1.8 mm installed space; rear reliefs avoid components.", "treatment": "Preserve board lands, port alignment and component reliefs. Keep screw clamp load on hard keeper/boss seats, use only the measured installed compliant stack.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Check actual populated breakout and seal grade/thickness; acoustic test after closure; reject board bow or pad-induced component loading.", "source_register": "audit/passive/risk_register.json", "r36_status": "CAD treatment prepared; physical qualification pending", "status": "REVIEWED; current nominal checks and physical qualification remain distinct", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Preserve board lands, port alignment and component reliefs. Keep screw clamp load on hard keeper/boss seats, use only the measured installed compliant stack.", "baseline_evidence": "Original microphone port is offset and seal reserves about 1.8 mm installed space; rear reliefs avoid components.", "current_treatment": "Broad open exit for the low-profile solder row and SEL jumper. Two M2x4 pan screws preserve1.4mm bearing material; acoustic datum remains fixed." }, { "id": "R36-PA-09", "components": [ "P14", "P01" ], "location": "LED keeper screw ears and blind pilots", "failure_mechanism": "Countersink splitting, keeper bending or screw bottoming.", "loading_situation": "Insertion, tightening and removal.", "evidence": "Original small saddle, countersinks and approximately 0.29 mm tip floor margin.", "treatment": "Broaden flat bearing stock to D6.0 around two M2 x5 pan-head joints; D2.3 holes, seat -10.9, head rear -12.5; retain optical saddle/lead relief.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Confirm no torque transferred into lamp package or leads, no saddle crack, and repeat ten service cycles.", "source_register": "audit/passive/risk_register.json", "r36_status": "CAD treatment prepared; physical qualification pending", "status": "REVIEWED; current nominal checks and physical qualification remain distinct", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Broaden flat bearing stock to D6.0 around two M2 x5 pan-head joints; D2.3 holes, seat -10.9, head rear -12.5; retain optical saddle/lead relief.", "baseline_evidence": "Original small saddle, countersinks and approximately 0.29 mm tip floor margin.", "current_treatment": "Original outer faces retained. Integrated three switch seats, broader PTT bearing and PCB stop, repositioned PCB supports, open cable channels, revised LED and speaker seats. One flat plate holds the original LED upright beside the PCB. One M2x4 screw, open four-lead exit, hard-supported seat." }, { "id": "R36-PA-10", "components": [ "P14", "LED", "L02" ], "location": "LED package, coupler and four lead exits", "failure_mechanism": "Keeper preload chips optics or cracks lamp; wire pull bends soldered leads.", "loading_situation": "Lamp installation, cable connection and servicing.", "evidence": "Four insulated leads share limited rear space with the keeper and light coupler.", "treatment": "Retain supported saddle and original optical datum; seat keeper on hard stops and preserve insulated lead exit/strain-relief path.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Measure actual lamp, lead bends, insulation and coupling film; electrical/optical test in tightened case.", "source_register": "audit/passive/risk_register.json", "r36_status": "CAD treatment prepared; physical qualification pending", "status": "REPLACED_BY_CONNECTED_ROUTING; current audit plus physical dressing/strain-relief test required", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Retain supported saddle and original optical datum; seat keeper on hard stops and preserve insulated lead exit/strain-relief path.", "baseline_evidence": "Four insulated leads share limited rear space with the keeper and light coupler.", "current_treatment": "Superseded routes/restraints are retired. Current named J2/J3/J10/J9/J8/J5/J7 envelopes, open channels and harness instructions govern; electrical mapping corrected. Factory battery and RF cables remain intact." }, { "id": "R36-PA-11", "components": [ "P01", "L01" ], "location": "Lens rear flange pocket and fixed visible throat", "failure_mechanism": "A brittle interference fit chips lens or splits the seat.", "loading_situation": "Insertion/removal and an external finger press.", "evidence": "Original D5.4 flange in D5.6 rear seat gives 0.10 mm radial nominal clearance; neck D4.7 in a fixed D4.8 throat is tighter.", "treatment": "Enlarge only hidden rear flange pocket to D6.0; preserve shoulder Z -2.15 and all visible lens/aperture geometry. Use drop fit and rear capture, not press-fit retention.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Measure real clear polymer part and cleaned throat. If fixed throat fails coupon fit, adjust manufacturing compensation/finishing to nominal; do not force or enlarge nominal exterior.", "source_register": "audit/passive/risk_register.json", "r36_status": "CAD treatment prepared; physical qualification pending", "status": "REVIEWED; current nominal checks and physical qualification remain distinct", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Enlarge only hidden rear flange pocket to D6.0; preserve shoulder Z -2.15 and all visible lens/aperture geometry. Use drop fit and rear capture, not press-fit retention.", "baseline_evidence": "Original D5.4 flange in D5.6 rear seat gives 0.10 mm radial nominal clearance; neck D4.7 in a fixed D4.8 throat is tighter.", "current_treatment": "Original outer faces retained. Integrated three switch seats, broader PTT bearing and PCB stop, repositioned PCB supports, open cable channels, revised LED and speaker seats. Original exterior lens and throat retained. Existing optical part can be reused if undamaged; printed opaque proxy is only a fit gauge." }, { "id": "R36-PA-12", "components": [ "L01" ], "location": "Lens flange and visible cap", "failure_mechanism": "Thin radial shoulder chips during loose handling or overloading.", "loading_situation": "Handling before capture and pressing after assembly.", "evidence": "Flange D5.4 x1.35 axial thickness; continuous annular shoulder rather than a cantilever arm.", "treatment": "Retain geometry with continuous supported seating and rear retention; handle in a tray and fit only after the receiver is clean.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Inspect clear production material for chips; confirm captured lens resists a modest finger press without movement. Opaque printed proxy only checks fit.", "source_register": "audit/passive/risk_register.json", "r36_status": "Retained geometry with documented supported use and fit qualification", "status": "REVIEWED; current nominal checks and physical qualification remain distinct", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Retain geometry with continuous supported seating and rear retention; handle in a tray and fit only after the receiver is clean.", "baseline_evidence": "Flange D5.4 x1.35 axial thickness; continuous annular shoulder rather than a cantilever arm.", "current_treatment": "Original exterior lens and throat retained. Existing optical part can be reused if undamaged; printed opaque proxy is only a fit gauge." }, { "id": "R36-PA-13", "components": [ "L02", "OPTICAL_FILM" ], "location": "Right-angle coupler and thin coupling film", "failure_mechanism": "Small optic chips under uneven compression; adhesive squeeze-out blocks light.", "loading_situation": "Assembly, keeper seating and thermal cycling.", "evidence": "Original coupler is compact 4.2 x4.2 x5.55 mm; coupling film is 0.05 mm installed space.", "treatment": "Retain optical geometry and supported saddle; use a single controlled thin coupling layer and remove compressive load from the fastener path.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Use clear optical polymer and a qualified coupling/bond process; inspect for squeeze-out and test light output.", "source_register": "audit/passive/risk_register.json", "r36_status": "Retained geometry; functional clear optics require physical test", "status": "REVIEWED; current nominal checks and physical qualification remain distinct", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Retain optical geometry and supported saddle; use a single controlled thin coupling layer and remove compressive load from the fastener path.", "baseline_evidence": "Original coupler is compact 4.2 x4.2 x5.55 mm; coupling film is 0.05 mm installed space.", "current_treatment": "New4x3mm clear periscope to the relocated original LED, with two broad adhesive tabs and45deg turning faces. Optical output must be tested; opaque printing is a fit proxy only." }, { "id": "R36-PA-14", "components": [ "M04", "GRILLE_MESH", "SCRIM" ], "location": "Grille locating lip and mesh/scrim perimeter", "failure_mechanism": "1.2 mm lip chips while loose; force fitting distorts grille; bond peels during removal.", "loading_situation": "Support removal, mesh installation, handling and servicing.", "evidence": "Original M04 lip 1.2 mm and plate envelope 1.65 mm; installed perimeter is broadly supported by shell and adhesive.", "treatment": "Retain exact exterior and grille geometry; use JP01 clearance handling tray for support and a non-interference locating fit. Finish mesh edges, use one controlled perimeter bond stack.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Trim burrs while supported; test bond with actual finish/stock, prevent scrim from obstructing seating, and avoid levering the lip during removal.", "source_register": "audit/passive/risk_register.json", "r36_status": "Retained geometry with assembly support and bond qualification", "status": "REVIEWED; current nominal checks and physical qualification remain distinct", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Retain exact exterior and grille geometry; use JP01 clearance handling tray for support and a non-interference locating fit. Finish mesh edges, use one controlled perimeter bond stack.", "baseline_evidence": "Original M04 lip 1.2 mm and plate envelope 1.65 mm; installed perimeter is broadly supported by shell and adhesive.", "current_treatment": "Original grille geometry, mesh and acoustic stack fixed. Handle on a flat tray; avoid force fits." }, { "id": "R36-PA-15", "components": [ "F01" ], "location": "Flexible rim, corner turns and opening bridges", "failure_mechanism": "Tearing at thin bridges, excessive stretch or brittle rigid-material substitution.", "loading_situation": "Installation/removal and corner impact.", "evidence": "Original sampled minimum about 1.187 mm; contour is frozen.", "treatment": "Retain exact flexible contour; select a flexible process/material and qualify stretch/tear behavior. Seat gradually around the perimeter on a closed, unforced shell.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Ten rim installation/removal cycles plus edge inspection in each proposed flexible material. A rigid proxy cannot establish durability.", "source_register": "audit/passive/risk_register.json", "r36_status": "Retained contour; material/process must satisfy flex and tear tests", "status": "REVIEWED; current nominal checks and physical qualification remain distinct", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Retain exact flexible contour; select a flexible process/material and qualify stretch/tear behavior. Seat gradually around the perimeter on a closed, unforced shell.", "baseline_evidence": "Original sampled minimum about 1.187 mm; contour is frozen.", "current_treatment": "Original contour/openings fixed. Flexible material remains a distinct manufacturing requirement; fit after closure screws." }, { "id": "R36-PA-16", "components": [ "F02", "PTT_BOND" ], "location": "Talk grip and its 0.10 mm bond stack", "failure_mechanism": "Edge peel, tearing or excess bond thickness blocks return.", "loading_situation": "Side presses, repeated control use and removal.", "evidence": "Grip is 1.30 mm thick with 0.10 mm nominal bond; visible outline/protrusion are fixed.", "treatment": "Retain exact grip and bond datum; use full supported bond area on the revised carrier with no adhesive entering guides/stops.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Adhesive compatibility and 1,000 centre/end actuations with force/release check; inspect edge peel and grip shear.", "source_register": "audit/passive/risk_register.json", "r36_status": "Retained exterior; bond and cyclic test required", "status": "REVIEWED; current nominal checks and physical qualification remain distinct", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Retain exact grip and bond datum; use full supported bond area on the revised carrier with no adhesive entering guides/stops.", "baseline_evidence": "Grip is 1.30 mm thick with 0.10 mm nominal bond; visible outline/protrusion are fixed.", "current_treatment": "Original visible shape and0.10mm bond stack fixed. Separate flexible material; test peel and end presses." }, { "id": "R36-PA-17", "components": [ "SOFT_STOCK", "P01", "P02" ], "location": "All pads, films, seals and component contact surfaces", "failure_mechanism": "Doubled layers or free-stock thickness adds preload; foam creep unloads capture or bows electronics.", "loading_situation": "Initial assembly, closure, temperature exposure and servicing.", "evidence": "Original reference uses installed-space proxies, not purchased free thickness or validated compression behavior.", "treatment": "Replace superseded battery/antenna/control layers per new schedules; keep one ledger of installed thickness including adhesive. Hard-seated retainers define closure, not foam compression.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Measure free and installed thickness/force of selected stock; verify no PCB bow, pouch pressure or unintended button activation; reject doubled legacy shims.", "source_register": "audit/passive/risk_register.json", "r36_status": "CAD treatment prepared; physical qualification pending", "status": "REVIEWED; current nominal checks and physical qualification remain distinct", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Replace superseded battery/antenna/control layers per new schedules; keep one ledger of installed thickness including adhesive. Hard-seated retainers define closure, not foam compression.", "baseline_evidence": "Original reference uses installed-space proxies, not purchased free thickness or validated compression behavior.", "current_treatment": "Original outer faces retained. Integrated three switch seats, broader PTT bearing and PCB stop, repositioned PCB supports, open cable channels, revised LED and speaker seats. Original outer faces/seam retained. Obsolete adapter/PCB stock removed; paired PCB pads and battery supports preserved around the connected cable routes. Battery slack belongs in the centre bay." }, { "id": "R36-PA-18", "components": [ "ALL_PRINTED", "ALL_HARDWARE" ], "location": "Support removal, loose handling, driver access and teardown", "failure_mechanism": "A sound assembled component breaks before installation or during removal.", "loading_situation": "Postprocessing and every service step.", "evidence": "Failure photos and user reports show damage during assembly, so in-use strength alone is insufficient.", "treatment": "Use broad removable parts, clearance insertion, a supported work surface and documented removal order. Include every added part/tool in manifest; avoid pushing tiny features to release supports.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Ten complete assembly/service cycles with magnified inspections, consistent tooling and recorded failures. No power driver until a qualified torque process exists.", "source_register": "audit/passive/risk_register.json", "r36_status": "CAD treatment prepared; physical qualification pending", "status": "REVIEWED; current nominal checks and physical qualification remain distinct", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Use broad removable parts, clearance insertion, a supported work surface and documented removal order. Include every added part/tool in manifest; avoid pushing tiny features to release supports.", "baseline_evidence": "Failure photos and user reports show damage during assembly, so in-use strength alone is insufficient.", "current_treatment": "Functional stock/hardware retained only as named in assembly_index.json; obsolete stock retired there. Use installed thicknesses and current assembly sequence." }, { "id": "R36-PA-19", "components": [ "QP01", "QP02", "QP03", "QP04", "JP01" ], "location": "Process qualification coupons and grille handling tray", "failure_mechanism": "Coupon does not reproduce weak direction or support removal, producing a misleading pass.", "loading_situation": "Coupon printing, postprocessing and destructive tests.", "evidence": "Geometry coupons reproduce pilot, bearing and support features; test bodies are not product parts.", "treatment": "Print in the same material, orientation, cure/thermal treatment and machine profile as the actual feature. Label variants using the coupon map.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Record actual dimensions, screw seating/strip behavior, beam load/deflection, lens fit and handling; a failed coupon blocks that process/profile.", "source_register": "audit/passive/risk_register.json", "r36_status": "CAD treatment prepared; physical qualification pending", "status": "REVIEWED; current nominal checks and physical qualification remain distinct", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Print in the same material, orientation, cure/thermal treatment and machine profile as the actual feature. Label variants using the coupon map.", "baseline_evidence": "Geometry coupons reproduce pilot, bearing and support features; test bodies are not product parts.", "current_treatment": "Functional stock/hardware retained only as named in assembly_index.json; obsolete stock retired there. Use installed thicknesses and current assembly sequence." }, { "id": "R36-PA-20", "components": [ "P13" ], "location": "Long microphone-frame rails and corner transitions", "failure_mechanism": "Thin ring bends or breaks before installation; unsupported point loading can damage a retained but unbroken part.", "loading_situation": "Loose-part handling, seating and pad reaction.", "evidence": "Original long rails approximately1.55mm wide by1.85mm thick; a two-rail5N simplified screen exceeds the hypothetical8MPa allowable.", "treatment": "Increase ring thickness rearward to2.65mm, preserving screw-seat plane and central component/wire opening. Retain original rounded corners; no forced flex during insertion.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Test5N total over both rails and2.5N separately per rail; no crack or residual set. The part must be handled by broad ear/rail regions, not levered on a corner.", "source_register": "audit/passive/risk_register.json", "r36_status": "CAD treatment prepared; physical qualification pending", "status": "REVIEWED; current nominal checks and physical qualification remain distinct", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Increase ring thickness rearward to2.65mm, preserving screw-seat plane and central component/wire opening. Retain original rounded corners; no forced flex during insertion.", "baseline_evidence": "Original long rails approximately1.55mm wide by1.85mm thick; a two-rail5N simplified screen exceeds the hypothetical8MPa allowable.", "current_treatment": "Broad open exit for the low-profile solder row and SEL jumper. Two M2x4 pan screws preserve1.4mm bearing material; acoustic datum remains fixed." }, { "id": "R36-PA-21", "components": [ "P01", "speaker", "speaker gasket" ], "location": "Speaker upper central tab, X +/-6, Y67.61..68.90", "failure_mechanism": "Original rigid speaker tab intersects the inner curved case by4.234mm3, forcing assembly or lifting its seat.", "loading_situation": "Speaker insertion, keeper tightening and closure.", "evidence": "Independent Common on original R3.4 and original speaker reproduces the same overlap.", "treatment": "Rounded internal12.6x1.9mm relief, floorZ-2.35, nominal0.30mm tab clearance, unchanged external upper fillet.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Measure actual speaker tab/gaskets and confirm seated acoustic component without keeper force. Inspect roof under assembly/handling.", "source_register": "audit/passive/risk_register.json", "r36_status": "CAD revised; physical qualification pending", "status": "REVIEWED; current nominal checks and physical qualification remain distinct", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Rounded internal12.6x1.9mm relief, floorZ-2.35, nominal0.30mm tab clearance, unchanged external upper fillet.", "baseline_evidence": "Independent Common on original R3.4 and original speaker reproduces the same overlap.", "current_treatment": "Original outer faces retained. Integrated three switch seats, broader PTT bearing and PCB stop, repositioned PCB supports, open cable channels, revised LED and speaker seats." }, { "id": "R36-PCB-01", "components": [ "P01", "P02", "PCB", "PCB_SUPPORT_STOCK" ], "location": "Four original front/rear support pairs", "failure_mechanism": "Small supports flex, split at roots or transmit concentrated pad load into board.", "loading_situation": "Loose handling, closure, connector insertion/pull and service.", "evidence": "All eight original soft supports are2.5x4.5mm footprints at(-27,-33.7),(-27,10.2),(27,8),(27,17).", "treatment": "Retain the four paired contact datums and stock envelopes; add tapered root backing to both shells. Left front upper root flares away from PTT terminals; left rear lower root fits between J10 andUSB.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Confirm each printed root is continuous/sound and inspect after ten service cycles. Measure pad compression rather than assuming free stock thickness.", "source_register": "audit/pcb/risk_register_pcb.json", "r36_status": "CAD treatment prepared; integrated and physical gates pending", "status": "REDESIGNED; current geometry audit and physical support-force test required", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Retain the four paired contact datums and stock envelopes; add tapered root backing to both shells. Left front upper root flares away from PTT terminals; left rear lower root fits between J10 andUSB.", "baseline_evidence": "All eight original soft supports are2.5x4.5mm footprints at(-27,-33.7),(-27,10.2),(27,8),(27,17).", "current_treatment": "Four paired supports and four defined pads replace eleven pads; complete PCB moved with all component envelopes including U6. Wider supported right edge stop takes USB load.1.8mm laminate bound and original front datum retained." }, { "id": "R36-PCB-02", "components": [ "P01", "P02", "PCB", "PCB_SUPPORT_STOCK" ], "location": "Lower-right PCB edge nearJ1", "failure_mechanism": "Large unsupported board overhang permits board bending and connector stress.", "loading_situation": "Connector insertion, closure and service.", "evidence": "Original has no lower-right support pair; actual laminate boundsY-53.04..26.96,Z-14.3015..-12.9715.", "treatment": "Add matching front/rear4.8x1.2mm contact lands at(25,-52.1), with broad tapered roots. Rearroot flares toward lowerY so it clearsJ1 by0.3944mm.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Check actual boardedge/J1 solder and pad stack; narrow availablecontact must sit entirely on bare laminate. No preload-induced board bow.", "source_register": "audit/pcb/risk_register_pcb.json", "r36_status": "CAD treatment prepared; integrated and physical gates pending", "status": "REDESIGNED; current geometry audit and physical support-force test required", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Add matching front/rear4.8x1.2mm contact lands at(25,-52.1), with broad tapered roots. Rearroot flares toward lowerY so it clearsJ1 by0.3944mm.", "baseline_evidence": "Original has no lower-right support pair; actual laminate boundsY-53.04..26.96,Z-14.3015..-12.9715.", "current_treatment": "Four paired supports and four defined pads replace eleven pads; complete PCB moved with all component envelopes including U6. Wider supported right edge stop takes USB load.1.8mm laminate bound and original front datum retained." }, { "id": "R36-PCB-03", "components": [ "P01", "P02", "PCB", "PCB_SUPPORT_STOCK" ], "location": "Mid-right front backing under side-header area", "failure_mechanism": "PCB bends when a side connector is inserted or operated.", "loading_situation": "Mating and cable insertion.", "evidence": "Selected sideheaders occupy rear board area; adding a rear block directly behind them would collide.", "treatment": "Add3.2x4.0mm supportedfrontland at(27,-40.2). Preserve header poses; harness strain retention takes cable pull.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Support connector housings by hand during mating; verify actual boarddeflection and cable strain retention, not pad friction alone.", "source_register": "audit/pcb/risk_register_pcb.json", "r36_status": "CAD treatment prepared; integrated and physical gates pending", "status": "REDESIGNED; current geometry audit and physical support-force test required", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Add3.2x4.0mm supportedfrontland at(27,-40.2). Preserve header poses; harness strain retention takes cable pull.", "baseline_evidence": "Selected sideheaders occupy rear board area; adding a rear block directly behind them would collide.", "current_treatment": "Four paired supports and four defined pads replace eleven pads; complete PCB moved with all component envelopes including U6. Wider supported right edge stop takes USB load.1.8mm laminate bound and original front datum retained." }, { "id": "R36-PCB-04", "components": [ "P01", "P02", "PCB", "PCB_SUPPORT_STOCK" ], "location": "Long surrounding board edge/location rails", "failure_mechanism": "Thin edge rail or cut wire window cracks; lateral board movement loads fixedUSB/header interfaces.", "loading_situation": "PCB insertion/removal, wire routing and connector pull.", "evidence": "Original sections atZ-12.7,-8,-15.02,-18 show continuous host-backed shell walls/rails and discrete support lands; antenna cablebridge is replaced separately.", "treatment": "Retain host-backed locating walls; addrootbacking at load stations. Cablecutouts use single broad open windows with supported remaining walls instead of thin fins.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "PCB must drop into locators without forced flex; confirm USBalignment and lateral reaction under actual connector use and ten servicecycles.", "source_register": "audit/pcb/risk_register_pcb.json", "r36_status": "CAD treatment prepared; integrated and physical gates pending", "status": "REDESIGNED; current geometry audit and physical support-force test required", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Retain host-backed locating walls; addrootbacking at load stations. Cablecutouts use single broad open windows with supported remaining walls instead of thin fins.", "baseline_evidence": "Original sections atZ-12.7,-8,-15.02,-18 show continuous host-backed shell walls/rails and discrete support lands; antenna cablebridge is replaced separately.", "current_treatment": "Four paired supports and four defined pads replace eleven pads; complete PCB moved with all component envelopes including U6. Wider supported right edge stop takes USB load.1.8mm laminate bound and original front datum retained." }, { "id": "R36-PCB-05", "components": [ "P01", "P02", "PCB", "PCB_SUPPORT_STOCK" ], "location": "Eleven installed PCB pad locations after revision", "failure_mechanism": "Doubled stock, adhesive thickness or excessive compression bows the board.", "loading_situation": "Case closure and thermal/service cycling.", "evidence": "Originalfrontinstalled0.2615mm/rear0.7085mm; three added stockpieces use same matchingfaces.", "treatment": "Keep one layer perlistedlocation including adhesive. Retain original8, add3; qualify selectedinsulating stock for actual compression.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Measure actual free/installed stack and record boardflatness. Case must close byhand without screwdrawdown, rocking or unintended actuation.", "source_register": "audit/pcb/risk_register_pcb.json", "r36_status": "CAD treatment prepared; integrated and physical gates pending", "status": "REDESIGNED; current geometry audit and physical support-force test required", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Keep one layer perlistedlocation including adhesive. Retain original8, add3; qualify selectedinsulating stock for actual compression.", "baseline_evidence": "Originalfrontinstalled0.2615mm/rear0.7085mm; three added stockpieces use same matchingfaces.", "current_treatment": "Four paired supports and four defined pads replace eleven pads; complete PCB moved with all component envelopes including U6. Wider supported right edge stop takes USB load.1.8mm laminate bound and original front datum retained." }, { "id": "R36-BAT01", "components": [ "P02", "battery" ], "location": "Main bay and upper corners", "failure_mechanism": "Zero-clearance forced insertion splits tall rails; oversize pouch clashes with originalcorner skin", "loading_situation": "Top insertion/removal and package dimensional variation", "evidence": "Original bare60.52\u00d736.52 with0.26liners reduced tonominal60\u00d736, whilelinkedmaximum62\u00d738.5\u00d78.5", "treatment": "Bare62.6\u00d739.1 lowcradle, no defaultside liners, originalexterior retained; repositionmaxbody toY27.28\u202665.78/Z\u221216.6\u2026\u22128.1", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Rootexactfullouterboundaryproof; actualprintfit; localthin curvedcorner handling/loadqualification", "source_register": "audit/battery/risk_register_battery.json", "r36_status": "CAD screened; physical qualification pending", "status": "REVIEWED; current nominal checks and physical qualification remain distinct", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Bare62.6\u00d739.1 lowcradle, no defaultside liners, originalexterior retained; repositionmaxbody toY27.28\u202665.78/Z\u221216.6\u2026\u22128.1", "baseline_evidence": "Original bare60.52\u00d736.52 with0.26liners reduced tonominal60\u00d736, whilelinkedmaximum62\u00d738.5\u00d78.5", "current_treatment": "Original outer faces/seam retained. Obsolete adapter/PCB stock removed; paired PCB pads and battery supports preserved around the connected cable routes. Battery slack belongs in the centre bay." }, { "id": "R36-BAT02", "components": [ "P01" ], "location": "Upper bay and four head pockets", "failure_mechanism": "Internalclearancecuts maythin rigid exterior skin", "loading_situation": "Handling/case closure/point impact", "evidence": "New-headpocketmin1.098307mm afteranchorinboardmove; skin mapsinclude changedfaces and approximatearea/span", "treatment": "Anchors|X|33.4; matched localhead/toe/plateclearance ratherthan broad exteriorchanges", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Nativewatertight export and localprocessskinqualification; rootcompleteexteriorproof", "source_register": "audit/battery/risk_register_battery.json", "r36_status": "CAD screened; physical qualification pending", "status": "REVIEWED; current nominal checks and physical qualification remain distinct", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Anchors|X|33.4; matched localhead/toe/plateclearance ratherthan broad exteriorchanges", "baseline_evidence": "New-headpocketmin1.098307mm afteranchorinboardmove; skin mapsinclude changedfaces and approximatearea/span", "current_treatment": "Original outer faces retained. Integrated three switch seats, broader PTT bearing and PCB stop, repositioned PCB supports, open cable channels, revised LED and speaker seats." }, { "id": "R36-BAT19", "components": [ "P19" ], "location": "Plate, neck, ears, locating toe and outward-open wire port", "failure_mechanism": "Neck bending, hole-edge splitting, pouch pointload, or wire pinching", "loading_situation": "5Nservice perkeeper; conservativeone-ear concentration included", "evidence": "3mmmainplate,2.6mmoutboardneck/seat,2mminboardtransition,OD4.8ear/D2.4hole; fullsingle-ear grosssectionstressmax7.42MPa againsthypothetical8MPa", "treatment": "Wideplate androundedroots, supported deepoutboardneck, twoseparatedcontactfilms perkeeper, removablefastening onrigidstops; no pouchpreload", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Printactualcouponand5Nscreen, screwfit, tenservicecycles andretention/rocking inspection; notch/screw/plate stressconcentrations notcertifiedbybeammodel", "source_register": "audit/battery/risk_register_battery.json", "r36_status": "CAD screened; physical qualification pending", "status": "REPLACED_BY_CONNECTED_ROUTING; current audit plus physical dressing/strain-relief test required", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Wideplate androundedroots, supported deepoutboardneck, twoseparatedcontactfilms perkeeper, removablefastening onrigidstops; no pouchpreload", "baseline_evidence": "3mmmainplate,2.6mmoutboardneck/seat,2mminboardtransition,OD4.8ear/D2.4hole; fullsingle-ear grosssectionstressmax7.42MPa againsthypothetical8MPa", "current_treatment": "Superseded routes/restraints are retired. Current named J2/J3/J10/J9/J8/J5/J7 envelopes, open channels and harness instructions govern; electrical mapping corrected. Factory battery and RF cables remain intact." }, { "id": "R36-BAT20", "components": [ "P20" ], "location": "Plate, neck, ears, locating toe and outward-open wire port", "failure_mechanism": "Neck bending, hole-edge splitting, pouch pointload, or wire pinching", "loading_situation": "5Nservice perkeeper; conservativeone-ear concentration included", "evidence": "3mmmainplate,2.6mmoutboardneck/seat,2mminboardtransition,OD4.8ear/D2.4hole; fullsingle-ear grosssectionstressmax7.42MPa againsthypothetical8MPa", "treatment": "Wideplate androundedroots, supported deepoutboardneck, twoseparatedcontactfilms perkeeper, removablefastening onrigidstops; no pouchpreload", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Printactualcouponand5Nscreen, screwfit, tenservicecycles andretention/rocking inspection; notch/screw/plate stressconcentrations notcertifiedbybeammodel", "source_register": "audit/battery/risk_register_battery.json", "r36_status": "CAD screened; physical qualification pending", "status": "REPLACED_BY_CONNECTED_ROUTING; current audit plus physical dressing/strain-relief test required", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Wideplate androundedroots, supported deepoutboardneck, twoseparatedcontactfilms perkeeper, removablefastening onrigidstops; no pouchpreload", "baseline_evidence": "3mmmainplate,2.6mmoutboardneck/seat,2mminboardtransition,OD4.8ear/D2.4hole; fullsingle-ear grosssectionstressmax7.42MPa againsthypothetical8MPa", "current_treatment": "Superseded routes/restraints are retired. Current named J2/J3/J10/J9/J8/J5/J7 envelopes, open channels and harness instructions govern; electrical mapping corrected. Factory battery and RF cables remain intact." }, { "id": "R36-BAT03", "components": [ "P02", "4newkeeperposts", "4M2\u00d76screws" ], "location": "AnchorsX\u00b133.4;leftY44.4/50.9,right37.5/50.9", "failure_mechanism": "Pilot interference or excess tightening splits post; insufficient thread engagement strips receiver", "loading_situation": "Keeper installation/removal", "evidence": "OD4.6 clippedatbayface31.3;D1.7pilot,minlocalpilotwall1.25;3.4threadengagement,1.2tipfloor;headmaxD4\u00d71.6", "treatment": "Broad lowroots mergeintooriginalsideskin; hardseat\u22128.4,panseat\u22125.8; screwforcebypasses pouch", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "ActualM2head dimensions, pilotcoupon1.6\u20131.9 processselection, tenassemblycycles; no unverifiedtightening torque prescribed", "source_register": "audit/battery/risk_register_battery.json", "r36_status": "CAD screened; physical qualification pending", "status": "REVIEWED; current nominal checks and physical qualification remain distinct", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Broad lowroots mergeintooriginalsideskin; hardseat\u22128.4,panseat\u22125.8; screwforcebypasses pouch", "baseline_evidence": "OD4.6 clippedatbayface31.3;D1.7pilot,minlocalpilotwall1.25;3.4threadengagement,1.2tipfloor;headmaxD4\u00d71.6", "current_treatment": "Original outer faces/seam retained. Obsolete adapter/PCB stock removed; paired PCB pads and battery supports preserved around the connected cable routes. Battery slack belongs in the centre bay." }, { "id": "R36-BAT04", "components": [ "2rear support pads", "4defaultcontactfilms", "2toe liners" ], "location": "Rear support, front keeper faces and lower toe faces", "failure_mechanism": "Over-thick stock preloads pouch; absentstock allows rattling/rubbing", "loading_situation": "Pack retention andservice travel", "evidence": "Rear14.5\u00d727.5\u00d70.70;contacts7.5\u00d73\u00d70.10;toeliners8.7\u00d70.20\u00d72.2, allinstalledthicknessincladhesive", "treatment": "Soft nonabrasive insulating purchasedstock; keepcontacts separate fromtabport; clear defaultmax pack .20front and .10lowerY", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Measureinstalledstock andactualpouch; rejecthard/abrasiveprintsubstitutes, bubbling/stacking or compressednegativegap", "source_register": "audit/battery/risk_register_battery.json", "r36_status": "CAD screened; physical qualification pending", "status": "REVIEWED; current nominal checks and physical qualification remain distinct", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Soft nonabrasive insulating purchasedstock; keepcontacts separate fromtabport; clear defaultmax pack .20front and .10lowerY", "baseline_evidence": "Rear14.5\u00d727.5\u00d70.70;contacts7.5\u00d73\u00d70.10;toeliners8.7\u00d70.20\u00d72.2, allinstalledthicknessincladhesive", "current_treatment": "Functional stock/hardware retained only as named in assembly_index.json; obsolete stock retired there. Use installed thicknesses and current assembly sequence." }, { "id": "R36-BAT05", "components": [ "4optional NOMINAL_ONLY frontpads" ], "location": "Samefourcontactlocations", "failure_mechanism": "Usingthick nominalpackpads withmaximum pack squeezes pouch", "loading_situation": "Assembly variantselection", "evidence": "Optional1.40installed replaces0.10films; maximum8.5packwouldinterfere, explicitlydisallowed", "treatment": "Useonlywhere measuredlocalgap\u22651.60; fourpads7.5\u00d73; neverstackwithdefaultfilm", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Recordselectedstock;maxgaugeconfiguration mustdefaultto0.10films", "source_register": "audit/battery/risk_register_battery.json", "r36_status": "CAD screened; physical qualification pending", "status": "REVIEWED; current nominal checks and physical qualification remain distinct", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Useonlywhere measuredlocalgap\u22651.60; fourpads7.5\u00d73; neverstackwithdefaultfilm", "baseline_evidence": "Optional1.40installed replaces0.10films; maximum8.5packwouldinterfere, explicitlydisallowed", "current_treatment": "Functional stock/hardware retained only as named in assembly_index.json; obsolete stock retired there. Use installed thicknesses and current assembly sequence." }, { "id": "R36-BAT06", "components": [ "battery", "PCB", "2toe liners" ], "location": "Lowerpouch edge atY27.18min versusPCBedgeY26.96", "failure_mechanism": "Pouch abrasion onPCBedge due movement/tolerance/rocking", "loading_situation": "Removal,packtilt andretention", "evidence": "Centredgap.32;bare\u2212.30Ytravelwouldleave.02;0.20toe linerslimitnominalminimumto.22", "treatment": "Broadfrontsidetoes abovePCBplussoftendliners; insert/removeinZ withfrontandkeepersremoved, keepclear ofPCBedge", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "HOLD release ifactualboard/pouch/print/padstack orrockingloses apositive nonabrasivegap. Translationcheck isnotsoftpouch/tiltsimulation.", "source_register": "audit/battery/risk_register_battery.json", "r36_status": "CAD screened; physical qualification pending", "status": "REVIEWED; current nominal checks and physical qualification remain distinct", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Broadfrontsidetoes abovePCBplussoftendliners; insert/removeinZ withfrontandkeepersremoved, keepclear ofPCBedge", "baseline_evidence": "Centredgap.32;bare\u2212.30Ytravelwouldleave.02;0.20toe linerslimitnominalminimumto.22", "current_treatment": "Functional stock/hardware retained only as named in assembly_index.json; obsolete stock retired there. Use installed thicknesses and current assembly sequence." }, { "id": "R36-BAT07", "components": [ "factorybattery lead", "factoryPHplug", "protectedtab", "keeperports" ], "location": "Righttab after180\u00b0inplanerotation; risersY47.65", "failure_mechanism": "Wirepinch, damagedprotectedtab, insufficientleadlength orincorrectadapterpolarity", "loading_situation": "Caseclosure andservice", "evidence": "Originalnominaltabpose retained/rotated; publishedrectangularmaxdoesnotverifyreceivedtabdress", "treatment": "Preservefactorylead/plug/tape/protection; fixturesownscompactremovableadapter androutedconductors;bothkeeperportsopenoutward", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Actual intactlead/connector/tabmeasurements, finalrouteclearance/strainrelief/polaritycheck; no cut/reterminateauthorization inferred", "source_register": "audit/battery/risk_register_battery.json", "r36_status": "CAD screened; physical qualification pending", "status": "REPLACED_BY_CONNECTED_ROUTING; current audit plus physical dressing/strain-relief test required", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Preservefactorylead/plug/tape/protection; fixturesownscompactremovableadapter androutedconductors;bothkeeperportsopenoutward", "baseline_evidence": "Originalnominaltabpose retained/rotated; publishedrectangularmaxdoesnotverifyreceivedtabdress", "current_treatment": "Superseded routes/restraints are retired. Current named J2/J3/J10/J9/J8/J5/J7 envelopes, open channels and harness instructions govern; electrical mapping corrected. Factory battery and RF cables remain intact." }, { "id": "R36-BAT08", "components": [ "QB01", "QB02", "QB03variants", "QB04" ], "location": "Inertmaxgauge, XYfitcoupon androot/keepertestcoupons", "failure_mechanism": "Uncalibrated print givesfalsefit; couponpassing mistakenforfullpartqualification", "loading_situation": "Shopcalibration andfirstarticle", "evidence": "Rectangularmax62\u00d738.5\u00d78.5;barecoupon62.6\u00d739.1;postpilot1.6/1.7/1.8/1.9;exactcroppedkeeper", "treatment": "Measuregaugefirst; useintendedprocess/orientation/finish; selectpiloton coupon thenupdateapplicableCADexplicitly", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Couponandfullcase fit/load/servicechecks; neverforce liveLiPoforinspection", "source_register": "audit/battery/risk_register_battery.json", "r36_status": "CAD screened; physical qualification pending", "status": "REVIEWED; current nominal checks and physical qualification remain distinct", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Measuregaugefirst; useintendedprocess/orientation/finish; selectpiloton coupon thenupdateapplicableCADexplicitly", "baseline_evidence": "Rectangularmax62\u00d738.5\u00d78.5;barecoupon62.6\u00d739.1;postpilot1.6/1.7/1.8/1.9;exactcroppedkeeper", "current_treatment": "Functional stock/hardware retained only as named in assembly_index.json; obsolete stock retired there. Use installed thicknesses and current assembly sequence." }, { "id": "R36-BAT_FINAL_CONTACT", "components": [ "P01", "P19", "P20", "upper volume switch" ], "location": "P19 lower ear near(-33.4,44.4); P20 outboard lower locating toe", "failure_mechanism": "Interference in final assembly transfers closure/retention force into a keeper or switch terminal.", "loading_situation": "Shell closure and battery service.", "evidence": "Full integration found0.398281mm\u00b3 P19/P01 and0.210934mm\u00b3 P20/upper-volume terminal overlaps.", "treatment": "Bounded P01 pocket preserves1.75mm pilot-side stock at adjacent P18 receiver and remains2.449mm from classified exterior. P20 toe notch removes1.561mm\u00b3 while retaining8.55mm full-height toe width,3.0mm lower and1.7mm upper local stock; liner and keeper anchors remain intact.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Root exact all-component/native boundary checks; printed toe/ear and adjacent receiver handling qualification.", "source_register": "audit/battery/risk_register_battery.json", "r36_status": "CAD correction delivered for final native integration.", "status": "REVIEWED; current nominal checks and physical qualification remain distinct", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Bounded P01 pocket preserves1.75mm pilot-side stock at adjacent P18 receiver and remains2.449mm from classified exterior. P20 toe notch removes1.561mm\u00b3 while retaining8.55mm full-height toe width,3.0mm lower and1.7mm upper local stock; liner and keeper anchors remain intact.", "baseline_evidence": "Full integration found0.398281mm\u00b3 P19/P01 and0.210934mm\u00b3 P20/upper-volume terminal overlaps.", "current_treatment": "Original outer faces retained. Integrated three switch seats, broader PTT bearing and PCB stop, repositioned PCB supports, open cable channels, revised LED and speaker seats. Broad removable plate retained. One broad keyed left mount atY46.2 clears the PTT guide and speaker rise; the obsolete window is filled. Pouch remains uncompressed. Broad plate and original right anchors retained. Open factory-lead and volume-return clearance; no thin snap features." }, { "id": "R36-CTRL_P03", "components": [ "P03", "P01" ], "location": "Play cap, bar ends and root connections", "failure_mechanism": "Cap flexure, broken capture bars or pocket binding", "loading_situation": "Loose handling, edge pressing, insertion and hard stop", "evidence": "Original bars29x2.4x1.2mm; exterior cap fixed.", "treatment": "Bars29x3.2x1.8mm; matched0.3mm side gaps; direct shell-backed bar stop floors at0.50mm.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Measure edge travel, printed fit and return;10 service and1000 actuation cycles. No endurance test performed.", "source_register": "audit/controls/risk_register_controls.json", "r36_status": "CAD revised; physical qualification pending", "status": "REVIEWED; current nominal checks and physical qualification remain distinct", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Bars29x3.2x1.8mm; matched0.3mm side gaps; direct shell-backed bar stop floors at0.50mm.", "baseline_evidence": "Original bars29x2.4x1.2mm; exterior cap fixed.", "current_treatment": "Original outer faces retained. Integrated three switch seats, broader PTT bearing and PCB stop, repositioned PCB supports, open cable channels, revised LED and speaker seats. Fixed visible form and broad R3.6 capture bars retained. Separate moving member remains necessary; screen0.50mm travel and physical release." }, { "id": "R36-CTRL_P04", "components": [ "P04", "original P04 countersunk screws" ], "location": "Clamp beam, raised ring, mounting ears and solder access", "failure_mechanism": "Beam flexure, screw-seat splitting, terminal pinch", "loading_situation": "Switch load, tightening and service", "evidence": "Original plate1.4; fixed PCB blocks pan-head conversion.", "treatment": "Plate1.75, arms2.75, ears\u00d86.8. Original countersink datums retained. Two\u00d82 terminal-access bores remove1.33424mm3 total; source switch seat unchanged.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Actual switch seating, preload, torque-to-seat, PCB gap and terminal joints; use original M2x8CS screws.", "source_register": "audit/controls/risk_register_controls.json", "r36_status": "CAD revised; physical qualification pending", "status": "REVIEWED; current nominal checks and physical qualification remain distinct", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Plate1.75, arms2.75, ears\u00d86.8. Original countersink datums retained. Two\u00d82 terminal-access bores remove1.33424mm3 total; source switch seat unchanged.", "baseline_evidence": "Original plate1.4; fixed PCB blocks pan-head conversion.", "current_treatment": "Clear tilted PCB and insulated play terminals; one paired PCB support now grows from this stationary clamp. Retain two original screw axes and supported bearing surfaces." }, { "id": "R36-CTRL_P05", "components": [ "P05" ], "location": "PTT skin, internal backing, slider roots and heads", "failure_mechanism": "Broken long rods/webs, skin bending and switch overtravel", "loading_situation": "Uncaptured handling, end/centre press and hard press", "evidence": "Original\u00d82.4 long rods,1.2webs/skin and1.05heads. End-only stop model predicted0.47mm extra centre flex at10N.", "treatment": "Rods eliminated;3.4x8.6 broad sliders and6x8.6x1.8heads. Added inset internal backing/lower spine. Direct central P01 bridge shortens hard-stop load path.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Physical off-axis fit, coupled guides and actual installed switch travel margin including elastic deflection.", "source_register": "audit/controls/risk_register_controls.json", "r36_status": "CAD revised; physical qualification pending", "status": "REVIEWED; current nominal checks and physical qualification remain distinct", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Rods eliminated;3.4x8.6 broad sliders and6x8.6x1.8heads. Added inset internal backing/lower spine. Direct central P01 bridge shortens hard-stop load path.", "baseline_evidence": "Original\u00d82.4 long rods,1.2webs/skin and1.05heads. End-only stop model predicted0.47mm extra centre flex at10N.", "current_treatment": "Retain the short captured R3.6 mechanism, broad roots, original visible shape and end stops. Physical end presses remain required." }, { "id": "R36-CTRL_P06", "components": [ "P06" ], "location": "Original visible cap and new stem/flange roots", "failure_mechanism": "Root/head break, cap bending and slider rocking", "loading_situation": "Handling, edge press, outward pull and overtravel", "evidence": "Reported broken volume legs; original1.2mm legs/1.05heads.", "treatment": "9.2x2.0 stem,R0.45 roots;11.2x2.0x2.6 flange; broad cap-face stop lands; full cap/nub preserved.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "First-article edge travel and return; actual process/force,1000 actuations; simple beam models do not certify local point contact or fatigue.", "source_register": "audit/controls/risk_register_controls.json", "r36_status": "CAD revised; physical qualification pending", "status": "REVIEWED; current nominal checks and physical qualification remain distinct", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "9.2x2.0 stem,R0.45 roots;11.2x2.0x2.6 flange; broad cap-face stop lands; full cap/nub preserved.", "baseline_evidence": "Reported broken volume legs; original1.2mm legs/1.05heads.", "current_treatment": "Broad captured slider replaces the original fragile legs. Independent motion retained; do not glue to the combined rail." }, { "id": "R36-CTRL_P07", "components": [ "P07" ], "location": "Original visible cap and new stem/flange roots", "failure_mechanism": "Root/head break, cap bending and slider rocking", "loading_situation": "Handling, edge press, outward pull and overtravel", "evidence": "Reported broken volume legs; original1.2mm legs/1.05heads.", "treatment": "9.2x2.0 stem,R0.45 roots;11.2x2.0x2.6 flange; broad cap-face stop lands; full cap/nub preserved.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "First-article edge travel and return; actual process/force,1000 actuations; simple beam models do not certify local point contact or fatigue.", "source_register": "audit/controls/risk_register_controls.json", "r36_status": "CAD revised; physical qualification pending", "status": "REVIEWED; current nominal checks and physical qualification remain distinct", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "9.2x2.0 stem,R0.45 roots;11.2x2.0x2.6 flange; broad cap-face stop lands; full cap/nub preserved.", "baseline_evidence": "Reported broken volume legs; original1.2mm legs/1.05heads.", "current_treatment": "Same broad slider principle, independent return and fixed visible shape; new button harness passes through an open neighbouring channel." }, { "id": "R36-CTRL_P08", "components": [ "P08", "P01" ], "location": "Cradle roof and side rails", "failure_mechanism": "Roof/rail damage, switch mis-seat or terminal strain", "loading_situation": "Loose handling, assembly and switch force", "evidence": "Original roof1.0mm; nominal NOT_OEM switch geometry.", "treatment": "Roof1.6 toward front with paired P01 relief. Original seating and terminal geometry retained; face-down assembly without snap flex.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Measure actual switch and solder joints; avoid loading terminals; retain cradles until closure.10N direct roof load is outside accepted service screen.", "source_register": "audit/controls/risk_register_controls.json", "r36_status": "CAD revised; physical qualification pending", "status": "REVIEWED; current nominal checks and physical qualification remain distinct", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Roof1.6 toward front with paired P01 relief. Original seating and terminal geometry retained; face-down assembly without snap flex.", "baseline_evidence": "Original roof1.0mm; nominal NOT_OEM switch geometry.", "current_treatment": "Original outer faces retained. Integrated three switch seats, broader PTT bearing and PCB stop, repositioned PCB supports, open cable channels, revised LED and speaker seats. Now part of P01, with a broad supported inner bearing around the insulated terminal exits. No loose cradle to handle or force into place." }, { "id": "R36-CTRL_P09", "components": [ "P09", "P01" ], "location": "Cradle roof and side rails", "failure_mechanism": "Roof/rail damage, switch mis-seat or terminal strain", "loading_situation": "Loose handling, assembly and switch force", "evidence": "Original roof1.0mm; nominal NOT_OEM switch geometry.", "treatment": "Roof1.6 toward front with paired P01 relief. Original seating and terminal geometry retained; face-down assembly without snap flex.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Measure actual switch and solder joints; avoid loading terminals; retain cradles until closure.10N direct roof load is outside accepted service screen.", "source_register": "audit/controls/risk_register_controls.json", "r36_status": "CAD revised; physical qualification pending", "status": "REVIEWED; current nominal checks and physical qualification remain distinct", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Roof1.6 toward front with paired P01 relief. Original seating and terminal geometry retained; face-down assembly without snap flex.", "baseline_evidence": "Original roof1.0mm; nominal NOT_OEM switch geometry.", "current_treatment": "Original outer faces retained. Integrated three switch seats, broader PTT bearing and PCB stop, repositioned PCB supports, open cable channels, revised LED and speaker seats. Now part of P01; open rear access accepts a prewired switch without snapping rails." }, { "id": "R36-CTRL_P10", "components": [ "P10", "P01" ], "location": "Cradle roof and side rails", "failure_mechanism": "Roof/rail damage, switch mis-seat or terminal strain", "loading_situation": "Loose handling, assembly and switch force", "evidence": "Original roof1.0mm; nominal NOT_OEM switch geometry.", "treatment": "Roof1.6 toward front with paired P01 relief. Original seating and terminal geometry retained; face-down assembly without snap flex.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Measure actual switch and solder joints; avoid loading terminals; retain cradles until closure.10N direct roof load is outside accepted service screen.", "source_register": "audit/controls/risk_register_controls.json", "r36_status": "CAD revised; physical qualification pending", "status": "REVIEWED; current nominal checks and physical qualification remain distinct", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Roof1.6 toward front with paired P01 relief. Original seating and terminal geometry retained; face-down assembly without snap flex.", "baseline_evidence": "Original roof1.0mm; nominal NOT_OEM switch geometry.", "current_treatment": "Original outer faces retained. Integrated three switch seats, broader PTT bearing and PCB stop, repositioned PCB supports, open cable channels, revised LED and speaker seats. Now part of P01; keep the wired terminal pair inside the modeled insulation envelope." }, { "id": "R36-CTRL_P17", "components": [ "P17", "P01", "P02" ], "location": "PTT keeper roof, recessed ears and end stop", "failure_mechanism": "Guide break, pinching, coupled binding or ear splitting", "loading_situation": "Screw tightening, edge pressing, outward capture", "evidence": "Original tube wall/ear1.2mm and0.1radial gap.", "treatment": "Broad captured guides with1.5roof;2mm recessed ear floors; hard seats;0.3nominal guide gaps. Recessed M2x6 pan heads.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Both keepers and P01 central stop must match stroke. Native combined audit plus measured guide return and service cycles.", "source_register": "audit/controls/risk_register_controls.json", "r36_status": "CAD revised; physical qualification pending", "status": "REVIEWED; current nominal checks and physical qualification remain distinct", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Broad captured guides with1.5roof;2mm recessed ear floors; hard seats;0.3nominal guide gaps. Recessed M2x6 pan heads.", "baseline_evidence": "Original tube wall/ear1.2mm and0.1radial gap.", "current_treatment": "Original outer faces retained. Integrated three switch seats, broader PTT bearing and PCB stop, repositioned PCB supports, open cable channels, revised LED and speaker seats. Original outer faces/seam retained. Obsolete adapter/PCB stock removed; paired PCB pads and battery supports preserved around the connected cable routes. Battery slack belongs in the centre bay. Short supported guide and two accessible screws. Keeping it separate preserves the LED/wiring corridor." }, { "id": "R36-CTRL_P18", "components": [ "P18", "P01", "P02" ], "location": "PTT keeper roof, recessed ears and end stop", "failure_mechanism": "Guide break, pinching, coupled binding or ear splitting", "loading_situation": "Screw tightening, edge pressing, outward capture", "evidence": "Original tube wall/ear1.2mm and0.1radial gap.", "treatment": "Broad captured guides with1.5roof;2mm recessed ear floors; hard seats;0.3nominal guide gaps. Recessed M2x6 pan heads.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Both keepers and P01 central stop must match stroke. Native combined audit plus measured guide return and service cycles.", "source_register": "audit/controls/risk_register_controls.json", "r36_status": "CAD revised; physical qualification pending", "status": "REVIEWED; current nominal checks and physical qualification remain distinct", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Broad captured guides with1.5roof;2mm recessed ear floors; hard seats;0.3nominal guide gaps. Recessed M2x6 pan heads.", "baseline_evidence": "Original tube wall/ear1.2mm and0.1radial gap.", "current_treatment": "Original outer faces retained. Integrated three switch seats, broader PTT bearing and PCB stop, repositioned PCB supports, open cable channels, revised LED and speaker seats. Original outer faces/seam retained. Obsolete adapter/PCB stock removed; paired PCB pads and battery supports preserved around the connected cable routes. Battery slack belongs in the centre bay. Second short guide maintains local support and PTT end-press control; no unsupported joining bridge." }, { "id": "R36-CTRL_K01", "components": [ "K01", "P02" ], "location": "Volume keeper roof, stop lands, screw ears and supporting floor", "failure_mechanism": "Roof bending, stop fracture or seat damage", "loading_situation": "Edge press, hard press and screw tightening", "evidence": "5N at top cap edge gives10.92N guide reaction over4.35mm bearing span.", "treatment": "Roof2.0; nominal floor1.7; broad stopwall and cap-face lands; screw hard seats.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Actual material, local load distribution and deflection; pilot coupon then10 service/1000 actuations.", "source_register": "audit/controls/risk_register_controls.json", "r36_status": "CAD revised; physical qualification pending", "status": "REVIEWED; current nominal checks and physical qualification remain distinct", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Roof2.0; nominal floor1.7; broad stopwall and cap-face lands; screw hard seats.", "baseline_evidence": "5N at top cap edge gives10.92N guide reaction over4.35mm bearing span.", "current_treatment": "Original outer faces/seam retained. Obsolete adapter/PCB stock removed; paired PCB pads and battery supports preserved around the connected cable routes. Battery slack belongs in the centre bay. Both stationary retainers become one shell-supported rail. Four original screws and independent travel stops retained; the joining span has a continuous rear bed." }, { "id": "R36-CTRL_K02", "components": [ "K02", "P02" ], "location": "Volume keeper roof, stop lands, screw ears and supporting floor", "failure_mechanism": "Roof bending, stop fracture or seat damage", "loading_situation": "Edge press, hard press and screw tightening", "evidence": "5N at top cap edge gives10.92N guide reaction over4.35mm bearing span.", "treatment": "Roof2.0; nominal floor1.7; broad stopwall and cap-face lands; screw hard seats.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Actual material, local load distribution and deflection; pilot coupon then10 service/1000 actuations.", "source_register": "audit/controls/risk_register_controls.json", "r36_status": "CAD revised; physical qualification pending", "status": "REVIEWED; current nominal checks and physical qualification remain distinct", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Roof2.0; nominal floor1.7; broad stopwall and cap-face lands; screw hard seats.", "baseline_evidence": "5N at top cap edge gives10.92N guide reaction over4.35mm bearing span.", "current_treatment": "Original outer faces/seam retained. Obsolete adapter/PCB stock removed; paired PCB pads and battery supports preserved around the connected cable routes. Battery slack belongs in the centre bay. Now part of K01. No second loose rail." }, { "id": "R36-CTRL_RECEIVERS", "components": [ "P01", "P02", "all control ADD/CUT/RESTORE masks" ], "location": "Guide bases, joint roots and preserved outer skin", "failure_mechanism": "Receiver fracture, residual wall damage or exterior changes", "loading_situation": "Press loads, screw preload, case opening", "evidence": "Exact original trimmed skins needed because nominal rounded apertures did not reproduce master outer trims.", "treatment": "Exact original skin restoration after relief; new keepers trimmed0.3 farther inward. Broad seated guides and direct play/PTT stops.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Root combined exterior, closure and all-pair checks; physical service test. Backed skin patches are not generic minimum wall recommendations.", "source_register": "audit/controls/risk_register_controls.json", "r36_status": "CAD revised; physical qualification pending", "status": "REVIEWED; current nominal checks and physical qualification remain distinct", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Exact original skin restoration after relief; new keepers trimmed0.3 farther inward. Broad seated guides and direct play/PTT stops.", "baseline_evidence": "Exact original trimmed skins needed because nominal rounded apertures did not reproduce master outer trims.", "current_treatment": "Original outer faces retained. Integrated three switch seats, broader PTT bearing and PCB stop, repositioned PCB supports, open cable channels, revised LED and speaker seats. Original outer faces/seam retained. Obsolete adapter/PCB stock removed; paired PCB pads and battery supports preserved around the connected cable routes. Battery slack belongs in the centre bay." }, { "id": "R36-CTRL_PTT_CENTRE", "components": [ "P01", "P02", "PTT keeper pad" ], "location": "Central bridge, flanking pillars and pad seat", "failure_mechanism": "Centre skin flexure adds travel beyond end stops", "loading_situation": "Hard press after nominal stroke", "evidence": "End-only actual-section screen predicted up to0.47mm at10N.", "treatment": "Fixed P01 bridge contacts lower backing at0.45; P02 relief permits it. TopZ\u221212.7 retains original pad support datum. Side pillars bypass switch/cradle for hard-stop force.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Measure remaining local cap/receiver compliance against actual permitted switch travel; alternate stroke requires matched P01.", "source_register": "audit/controls/risk_register_controls.json", "r36_status": "CAD revised; physical qualification pending", "status": "REVIEWED; current nominal checks and physical qualification remain distinct", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Fixed P01 bridge contacts lower backing at0.45; P02 relief permits it. TopZ\u221212.7 retains original pad support datum. Side pillars bypass switch/cradle for hard-stop force.", "baseline_evidence": "End-only actual-section screen predicted up to0.47mm at10N.", "current_treatment": "Original outer faces retained. Integrated three switch seats, broader PTT bearing and PCB stop, repositioned PCB supports, open cable channels, revised LED and speaker seats. Original outer faces/seam retained. Obsolete adapter/PCB stock removed; paired PCB pads and battery supports preserved around the connected cable routes. Battery slack belongs in the centre bay." }, { "id": "R36-CTRL_HC_K01_M2x6_PAN_1_REFERENCE", "components": [ "HC_K01_M2x6_PAN_1_REFERENCE" ], "location": "Keeper screw, pilot and driver approach", "failure_mechanism": "Pilot stripping, split boss or head collision", "loading_situation": "Tightening and10 service cycles", "evidence": "Conservative pan head\u00d84x1.6; threads omitted from model.", "treatment": "All8new keeper screws M2x6;\u00d81.8pilots and\u00d82.2clearance; hard seats.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Actual screw/process pilot coupon and torque-to-seat; no torque rating asserted.", "source_register": "audit/controls/risk_register_controls.json", "r36_status": "CAD revised; physical qualification pending", "status": "REVIEWED; current nominal checks and physical qualification remain distinct", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "All8new keeper screws M2x6;\u00d81.8pilots and\u00d82.2clearance; hard seats.", "baseline_evidence": "Conservative pan head\u00d84x1.6; threads omitted from model.", "current_treatment": "Functional stock/hardware retained only as named in assembly_index.json; obsolete stock retired there. Use installed thicknesses and current assembly sequence." }, { "id": "R36-CTRL_HC_K01_M2x6_PAN_2_REFERENCE", "components": [ "HC_K01_M2x6_PAN_2_REFERENCE" ], "location": "Keeper screw, pilot and driver approach", "failure_mechanism": "Pilot stripping, split boss or head collision", "loading_situation": "Tightening and10 service cycles", "evidence": "Conservative pan head\u00d84x1.6; threads omitted from model.", "treatment": "All8new keeper screws M2x6;\u00d81.8pilots and\u00d82.2clearance; hard seats.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Actual screw/process pilot coupon and torque-to-seat; no torque rating asserted.", "source_register": "audit/controls/risk_register_controls.json", "r36_status": "CAD revised; physical qualification pending", "status": "REVIEWED; current nominal checks and physical qualification remain distinct", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "All8new keeper screws M2x6;\u00d81.8pilots and\u00d82.2clearance; hard seats.", "baseline_evidence": "Conservative pan head\u00d84x1.6; threads omitted from model.", "current_treatment": "Functional stock/hardware retained only as named in assembly_index.json; obsolete stock retired there. Use installed thicknesses and current assembly sequence." }, { "id": "R36-CTRL_HC_K02_M2x6_PAN_1_REFERENCE", "components": [ "HC_K02_M2x6_PAN_1_REFERENCE" ], "location": "Keeper screw, pilot and driver approach", "failure_mechanism": "Pilot stripping, split boss or head collision", "loading_situation": "Tightening and10 service cycles", "evidence": "Conservative pan head\u00d84x1.6; threads omitted from model.", "treatment": "All8new keeper screws M2x6;\u00d81.8pilots and\u00d82.2clearance; hard seats.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Actual screw/process pilot coupon and torque-to-seat; no torque rating asserted.", "source_register": "audit/controls/risk_register_controls.json", "r36_status": "CAD revised; physical qualification pending", "status": "REVIEWED; current nominal checks and physical qualification remain distinct", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "All8new keeper screws M2x6;\u00d81.8pilots and\u00d82.2clearance; hard seats.", "baseline_evidence": "Conservative pan head\u00d84x1.6; threads omitted from model.", "current_treatment": "Functional stock/hardware retained only as named in assembly_index.json; obsolete stock retired there. Use installed thicknesses and current assembly sequence." }, { "id": "R36-CTRL_HC_K02_M2x6_PAN_2_REFERENCE", "components": [ "HC_K02_M2x6_PAN_2_REFERENCE" ], "location": "Keeper screw, pilot and driver approach", "failure_mechanism": "Pilot stripping, split boss or head collision", "loading_situation": "Tightening and10 service cycles", "evidence": "Conservative pan head\u00d84x1.6; threads omitted from model.", "treatment": "All8new keeper screws M2x6;\u00d81.8pilots and\u00d82.2clearance; hard seats.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Actual screw/process pilot coupon and torque-to-seat; no torque rating asserted.", "source_register": "audit/controls/risk_register_controls.json", "r36_status": "CAD revised; physical qualification pending", "status": "REVIEWED; current nominal checks and physical qualification remain distinct", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "All8new keeper screws M2x6;\u00d81.8pilots and\u00d82.2clearance; hard seats.", "baseline_evidence": "Conservative pan head\u00d84x1.6; threads omitted from model.", "current_treatment": "Functional stock/hardware retained only as named in assembly_index.json; obsolete stock retired there. Use installed thicknesses and current assembly sequence." }, { "id": "R36-CTRL_HC_P17_M2x6_PAN_1_REFERENCE", "components": [ "HC_P17_M2x6_PAN_1_REFERENCE" ], "location": "Keeper screw, pilot and driver approach", "failure_mechanism": "Pilot stripping, split boss or head collision", "loading_situation": "Tightening and10 service cycles", "evidence": "Conservative pan head\u00d84x1.6; threads omitted from model.", "treatment": "All8new keeper screws M2x6;\u00d81.8pilots and\u00d82.2clearance; hard seats.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Actual screw/process pilot coupon and torque-to-seat; no torque rating asserted.", "source_register": "audit/controls/risk_register_controls.json", "r36_status": "CAD revised; physical qualification pending", "status": "REVIEWED; current nominal checks and physical qualification remain distinct", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "All8new keeper screws M2x6;\u00d81.8pilots and\u00d82.2clearance; hard seats.", "baseline_evidence": "Conservative pan head\u00d84x1.6; threads omitted from model.", "current_treatment": "Functional stock/hardware retained only as named in assembly_index.json; obsolete stock retired there. Use installed thicknesses and current assembly sequence." }, { "id": "R36-CTRL_HC_P17_M2x6_PAN_2_REFERENCE", "components": [ "HC_P17_M2x6_PAN_2_REFERENCE" ], "location": "Keeper screw, pilot and driver approach", "failure_mechanism": "Pilot stripping, split boss or head collision", "loading_situation": "Tightening and10 service cycles", "evidence": "Conservative pan head\u00d84x1.6; threads omitted from model.", "treatment": "All8new keeper screws M2x6;\u00d81.8pilots and\u00d82.2clearance; hard seats.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Actual screw/process pilot coupon and torque-to-seat; no torque rating asserted.", "source_register": "audit/controls/risk_register_controls.json", "r36_status": "CAD revised; physical qualification pending", "status": "REVIEWED; current nominal checks and physical qualification remain distinct", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "All8new keeper screws M2x6;\u00d81.8pilots and\u00d82.2clearance; hard seats.", "baseline_evidence": "Conservative pan head\u00d84x1.6; threads omitted from model.", "current_treatment": "Functional stock/hardware retained only as named in assembly_index.json; obsolete stock retired there. Use installed thicknesses and current assembly sequence." }, { "id": "R36-CTRL_HC_P18_M2x6_PAN_1_REFERENCE", "components": [ "HC_P18_M2x6_PAN_1_REFERENCE" ], "location": "Keeper screw, pilot and driver approach", "failure_mechanism": "Pilot stripping, split boss or head collision", "loading_situation": "Tightening and10 service cycles", "evidence": "Conservative pan head\u00d84x1.6; threads omitted from model.", "treatment": "All8new keeper screws M2x6;\u00d81.8pilots and\u00d82.2clearance; hard seats.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Actual screw/process pilot coupon and torque-to-seat; no torque rating asserted.", "source_register": "audit/controls/risk_register_controls.json", "r36_status": "CAD revised; physical qualification pending", "status": "REVIEWED; current nominal checks and physical qualification remain distinct", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "All8new keeper screws M2x6;\u00d81.8pilots and\u00d82.2clearance; hard seats.", "baseline_evidence": "Conservative pan head\u00d84x1.6; threads omitted from model.", "current_treatment": "Functional stock/hardware retained only as named in assembly_index.json; obsolete stock retired there. Use installed thicknesses and current assembly sequence." }, { "id": "R36-CTRL_HC_P18_M2x6_PAN_2_REFERENCE", "components": [ "HC_P18_M2x6_PAN_2_REFERENCE" ], "location": "Keeper screw, pilot and driver approach", "failure_mechanism": "Pilot stripping, split boss or head collision", "loading_situation": "Tightening and10 service cycles", "evidence": "Conservative pan head\u00d84x1.6; threads omitted from model.", "treatment": "All8new keeper screws M2x6;\u00d81.8pilots and\u00d82.2clearance; hard seats.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Actual screw/process pilot coupon and torque-to-seat; no torque rating asserted.", "source_register": "audit/controls/risk_register_controls.json", "r36_status": "CAD revised; physical qualification pending", "status": "REVIEWED; current nominal checks and physical qualification remain distinct", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "All8new keeper screws M2x6;\u00d81.8pilots and\u00d82.2clearance; hard seats.", "baseline_evidence": "Conservative pan head\u00d84x1.6; threads omitted from model.", "current_treatment": "Functional stock/hardware retained only as named in assembly_index.json; obsolete stock retired there. Use installed thicknesses and current assembly sequence." }, { "id": "R36-CTRL_QC01_VOLUME_RECEIVER_PROCESS_COUPON", "components": [ "QC01_VOLUME_RECEIVER_PROCESS_COUPON" ], "location": "Process coupon contacts", "failure_mechanism": "False confidence from different process or incomplete scope", "loading_situation": "Print qualification", "evidence": "Exact receiver geometry on test foundation;6pilot diameters,7mm depth.", "treatment": "QC01volume;QC02lower PTTstation;QC03pilots.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Same material/orientation/postprocessing; coupons do not prove full PTTalignment or endurance.", "source_register": "audit/controls/risk_register_controls.json", "r36_status": "CAD revised; physical qualification pending", "status": "REVIEWED; current nominal checks and physical qualification remain distinct", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "QC01volume;QC02lower PTTstation;QC03pilots.", "baseline_evidence": "Exact receiver geometry on test foundation;6pilot diameters,7mm depth.", "current_treatment": "Functional stock/hardware retained only as named in assembly_index.json; obsolete stock retired there. Use installed thicknesses and current assembly sequence." }, { "id": "R36-CTRL_QC02_PTT_RECEIVER_PROCESS_COUPON", "components": [ "QC02_PTT_RECEIVER_PROCESS_COUPON" ], "location": "Process coupon contacts", "failure_mechanism": "False confidence from different process or incomplete scope", "loading_situation": "Print qualification", "evidence": "Exact receiver geometry on test foundation;6pilot diameters,7mm depth.", "treatment": "QC01volume;QC02lower PTTstation;QC03pilots.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Same material/orientation/postprocessing; coupons do not prove full PTTalignment or endurance.", "source_register": "audit/controls/risk_register_controls.json", "r36_status": "CAD revised; physical qualification pending", "status": "REVIEWED; current nominal checks and physical qualification remain distinct", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "QC01volume;QC02lower PTTstation;QC03pilots.", "baseline_evidence": "Exact receiver geometry on test foundation;6pilot diameters,7mm depth.", "current_treatment": "Functional stock/hardware retained only as named in assembly_index.json; obsolete stock retired there. Use installed thicknesses and current assembly sequence." }, { "id": "R36-CTRL_QC03_SCREW_PILOT_COUPON", "components": [ "QC03_SCREW_PILOT_COUPON" ], "location": "Process coupon contacts", "failure_mechanism": "False confidence from different process or incomplete scope", "loading_situation": "Print qualification", "evidence": "Exact receiver geometry on test foundation;6pilot diameters,7mm depth.", "treatment": "QC01volume;QC02lower PTTstation;QC03pilots.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Same material/orientation/postprocessing; coupons do not prove full PTTalignment or endurance.", "source_register": "audit/controls/risk_register_controls.json", "r36_status": "CAD revised; physical qualification pending", "status": "REVIEWED; current nominal checks and physical qualification remain distinct", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "QC01volume;QC02lower PTTstation;QC03pilots.", "baseline_evidence": "Exact receiver geometry on test foundation;6pilot diameters,7mm depth.", "current_treatment": "Functional stock/hardware retained only as named in assembly_index.json; obsolete stock retired there. Use installed thicknesses and current assembly sequence." }, { "id": "R36-CTRL_PADS_RETURN", "components": [ "P03", "P05", "P06", "P07", "P04", "P08", "P09", "P10", "contact pads", "rear keeper pads" ], "location": "Actual switches, rest gap, pad compression and return", "failure_mechanism": "No click, preload, sticking, coupled controls or overtravel", "loading_situation": "Normal presses, hard stops and tolerance stack", "evidence": "Source switches are NOMINAL/NOT_OEM; inherited gap\u22480.15mm and travel assumptions unmeasured.", "treatment": "Contact datums preserved; default side0.45 and play0.50. Volume keeper alternatives0.30/0.40/0.50/0.60; PTT alternates require matched P01.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Follow CONTROLS.md measurement procedure, select shortest reliable travel, verify return and elastic overtravel, then10 service and1000 actuation cycles/control.", "source_register": "audit/controls/risk_register_controls.json", "r36_status": "CAD revised; physical qualification pending", "status": "REVIEWED; current nominal checks and physical qualification remain distinct", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Contact datums preserved; default side0.45 and play0.50. Volume keeper alternatives0.30/0.40/0.50/0.60; PTT alternates require matched P01.", "baseline_evidence": "Source switches are NOMINAL/NOT_OEM; inherited gap\u22480.15mm and travel assumptions unmeasured.", "current_treatment": "Fixed visible form and broad R3.6 capture bars retained. Separate moving member remains necessary; screen0.50mm travel and physical release. Clear tilted PCB and insulated play terminals; one paired PCB support now grows from this stationary clamp. Retain two original screw axes and supported bearing surfaces. Retain the short captured R3.6 mechanism, broad roots, original visible shape and end stops. Physical end presses remain required. Broad captured slider replaces the original fragile legs. Independent motion retained; do not glue to the combined rail. Same broad slider principle, independent return and fixed visible shape; new button harness passes through an open neighbouring channel. Now part of P01, with a broad supported inner bearing around the insulated terminal exits. No loose cradle to handle or force into place. Now part of P01; open rear access accepts a prewired switch without snapping rails. Now part of P01; keep the wired terminal pair inside the modeled insulation envelope." }, { "id": "R36-FX-P15", "components": [ "P15", "original nylon antenna hardware" ], "location": "Lower antenna frame, X\u00b117,Y\u221236.5..\u221227.5", "failure_mechanism": "Original narrow bridge and thin seats can bend or split; bottoming/preload can overload the antenna flex.", "loading_situation": "Screw tightening, handling and5N service load", "evidence": "Measured revised9\u00d72.2mm span;\u00d82.3 clearance holes;1.2mm locally relieved seats and minimum1.85mm radial stock. Original M2\u00d73 nylon hardware retained.", "treatment": "Broad clamp over four compliant contact locations, PET carrier and controlled pilot floor; original coax rerouted clear of clamp.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Print/cure/orientation and nylon screw torque/strip/bottoming, pad compression and10cycles must be tested.", "source_register": "audit/fixtures/risk_register_fixtures.json", "r36_status": "NOMINAL_CAD_TREATMENT; PHYSICAL_QUALIFICATION_OPEN", "status": "REMOVED_OR_REPLACED_MECHANISM; physical replacement qualification pending", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Broad clamp over four compliant contact locations, PET carrier and controlled pilot floor; original coax rerouted clear of clamp.", "baseline_evidence": "Measured revised9\u00d72.2mm span;\u00d82.3 clearance holes;1.2mm locally relieved seats and minimum1.85mm radial stock. Original M2\u00d73 nylon hardware retained.", "current_treatment": "Superseded mechanism removed from the current assembly. Direct J2/J10 PH connections, adhesive antenna mounting and current routing replace it; see current reference assembly." }, { "id": "R36-FX-P16", "components": [ "P16", "original nylon antenna hardware" ], "location": "Upper antenna frame,Y57..67", "failure_mechanism": "Thin cable bridge/ear bending or antenna preload can crack a printed frame.", "loading_situation": "Handling, clamp preload, cable snag", "evidence": "Revised10\u00d72.2mm main section,1.2mm local seats,\u00d82.3 bores with minimum2.05mm radial ear stock.", "treatment": "Broad end clamp without an enclosed fragile cable bridge; route and strap take cable loads separately.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Actual printed part, layer/cure strength, nylon fastener preload and pad force remain unverified.", "source_register": "audit/fixtures/risk_register_fixtures.json", "r36_status": "NOMINAL_CAD_TREATMENT; PHYSICAL_QUALIFICATION_OPEN", "status": "REMOVED_OR_REPLACED_MECHANISM; physical replacement qualification pending", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Broad end clamp without an enclosed fragile cable bridge; route and strap take cable loads separately.", "baseline_evidence": "Revised10\u00d72.2mm main section,1.2mm local seats,\u00d82.3 bores with minimum2.05mm radial ear stock.", "current_treatment": "Superseded mechanism removed from the current assembly. Direct J2/J10 PH connections, adhesive antenna mounting and current routing replace it; see current reference assembly." }, { "id": "R36-FX-REAR-BED", "components": [ "P02 antenna bed", "P02 pilot floors", "P02" ], "location": "X\u00b111.25,Y\u221235.5..62.5,Z\u221222.10; four nylon pilots", "failure_mechanism": "Broad skin recess lowers stiffness; pilot floor or edge may split if screws bottom.", "loading_situation": "External handling, screw installation, closure pressure", "evidence": "Nominal broad skin2.2\u21921.9mm; plate-thickness stiffness scaling0.644; local pilot-floor axial skin1.25mm. Nylon tip\u221222.13 vs floor\u221222.75 gives0.62mm tip clearance.", "treatment": "Bounded0.30mm internal recess, separate PET dielectric; keep original outer geometry.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Thickness/impact and screw-coupon proof in actual production material; no universal process guarantee.", "source_register": "audit/fixtures/risk_register_fixtures.json", "r36_status": "NOMINAL_CAD_TREATMENT; PHYSICAL_QUALIFICATION_OPEN", "status": "REVIEWED; current nominal checks and physical qualification remain distinct", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Bounded0.30mm internal recess, separate PET dielectric; keep original outer geometry.", "baseline_evidence": "Nominal broad skin2.2\u21921.9mm; plate-thickness stiffness scaling0.644; local pilot-floor axial skin1.25mm. Nylon tip\u221222.13 vs floor\u221222.75 gives0.62mm tip clearance.", "current_treatment": "Original outer faces/seam retained. Obsolete adapter/PCB stock removed; paired PCB pads and battery supports preserved around the connected cable routes. Battery slack belongs in the centre bay." }, { "id": "R36-FX-ANT-RF", "components": [ "original Taoglas FXUB63 antenna", "maximum battery", "PCB electronics" ], "location": "Rear central antenna footprint", "failure_mechanism": "Detuning and efficiency loss despite mechanically clear surfaces.", "loading_situation": "Powered radio operation", "evidence": "Antenna-to-maximum-battery planar gap5.15mm and PCB rear-plane gap7.4485mm are below Taoglas10mm minimum metal recommendation; components can be closer.", "treatment": "Retain nylon hardware and dielectric; explicitly preserve RF qualification limit.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Actual-device antenna matching/efficiency/radiated qualification.", "source_register": "audit/fixtures/risk_register_fixtures.json", "r36_status": "NOMINAL_CAD_TREATMENT; PHYSICAL_QUALIFICATION_OPEN", "status": "REVIEWED; current nominal checks and physical qualification remain distinct", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Retain nylon hardware and dielectric; explicitly preserve RF qualification limit.", "baseline_evidence": "Antenna-to-maximum-battery planar gap5.15mm and PCB rear-plane gap7.4485mm are below Taoglas10mm minimum metal recommendation; components can be closer.", "current_treatment": "Functional stock/hardware retained only as named in assembly_index.json; obsolete stock retired there. Use installed thicknesses and current assembly sequence." }, { "id": "R36-FX-K03", "components": [ "K03 cover", "P01 adapter cradle", "extra B2B-PH header", "passive FR4 carrier", "K03", "P01" ], "location": "X~14.4..29.6,Y\u221212.3..0,Z\u221210.55..\u22122", "failure_mechanism": "Mating forces, solder-joint fatigue, printed root/cover fracture or wire pullout.", "loading_situation": "Factory plug mating/unmating and pigtail service pull", "evidence": "Carrier8\u00d76\u00d71mm; four installed0.25mm edge pads; broad cover bridge1.8mm and side arms\u22652.2mm. Dedicated outgoing insulated-wire grommet.", "treatment": "Use the final correction register and Fixture_Final_Corrections.md. The earlier RTV tacks, flat J8 strap, Y-axis adapter, old hardware poses and untrimmed microphone facing are excluded; use Adapter_Final_Seat_and_Fasteners.md for the final adapter.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Apply the selected final correction coupon and assembly protocol; this historical entry is not a physical pass.", "source_register": "audit/fixtures/risk_register_fixtures.json", "r36_status": "SUPERSEDED HISTORICAL RECORD \u2014 NOT SELECTED FOR ASSEMBLY", "status": "REMOVED_OR_REPLACED_MECHANISM; physical replacement qualification pending", "r37_note": "Old adapter mechanism removed; removal does not resolve direct J2 fit.", "previous_status": "REMOVED_MECHANISM_IN_WORKING_CANDIDATE", "baseline_treatment": "Use the final correction register and Fixture_Final_Corrections.md. The earlier RTV tacks, flat J8 strap, Y-axis adapter, old hardware poses and untrimmed microphone facing are excluded; use Adapter_Final_Seat_and_Fasteners.md for the final adapter.", "baseline_evidence": "Carrier8\u00d76\u00d71mm; four installed0.25mm edge pads; broad cover bridge1.8mm and side arms\u22652.2mm. Dedicated outgoing insulated-wire grommet.", "current_treatment": "Superseded mechanism removed from the current assembly. Direct J2/J10 PH connections, adhesive antenna mounting and current routing replace it; see current reference assembly." }, { "id": "R36-FX-HA-1", "components": [ "R36_HA_ADAPTER_M2x6_PAN_1_ENVELOPE" ], "location": "Adapter transverse fastener axes", "failure_mechanism": "Printed threads strip, root splits or screw bottoms before clamping.", "loading_situation": "Hand assembly and repeated service", "evidence": "M2\u00d76 pan maximum head\u00d84\u00d71.6; nominal4.4mm material overlap with3.4mm design full-thread allowance after1mm lead/runout reserve,0.95mm tip margin,\u00d81.7 pilot.", "treatment": "Use the final correction register and Fixture_Final_Corrections.md. The earlier RTV tacks, flat J8 strap, Y-axis adapter, old hardware poses and untrimmed microphone facing are excluded; use Adapter_Final_Seat_and_Fasteners.md for the final adapter.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Apply the selected final correction coupon and assembly protocol; this historical entry is not a physical pass.", "source_register": "audit/fixtures/risk_register_fixtures.json", "r36_status": "SUPERSEDED HISTORICAL RECORD \u2014 NOT SELECTED FOR ASSEMBLY", "status": "REMOVED_OR_REPLACED_MECHANISM; physical replacement qualification pending", "r37_note": "Old adapter mechanism removed; removal does not resolve direct J2 fit.", "previous_status": "REMOVED_MECHANISM_IN_WORKING_CANDIDATE", "baseline_treatment": "Use the final correction register and Fixture_Final_Corrections.md. The earlier RTV tacks, flat J8 strap, Y-axis adapter, old hardware poses and untrimmed microphone facing are excluded; use Adapter_Final_Seat_and_Fasteners.md for the final adapter.", "baseline_evidence": "M2\u00d76 pan maximum head\u00d84\u00d71.6; nominal4.4mm material overlap with3.4mm design full-thread allowance after1mm lead/runout reserve,0.95mm tip margin,\u00d81.7 pilot.", "current_treatment": "Superseded mechanism removed from the current assembly. Direct J2/J10 PH connections, adhesive antenna mounting and current routing replace it; see current reference assembly." }, { "id": "R36-FX-HA-2", "components": [ "R36_HA_ADAPTER_M2x6_PAN_2_ENVELOPE" ], "location": "Adapter transverse fastener axes", "failure_mechanism": "Printed threads strip, root splits or screw bottoms before clamping.", "loading_situation": "Hand assembly and repeated service", "evidence": "M2\u00d76 pan maximum head\u00d84\u00d71.6; nominal4.4mm material overlap with3.4mm design full-thread allowance after1mm lead/runout reserve,0.95mm tip margin,\u00d81.7 pilot.", "treatment": "Use the final correction register and Fixture_Final_Corrections.md. The earlier RTV tacks, flat J8 strap, Y-axis adapter, old hardware poses and untrimmed microphone facing are excluded; use Adapter_Final_Seat_and_Fasteners.md for the final adapter.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Apply the selected final correction coupon and assembly protocol; this historical entry is not a physical pass.", "source_register": "audit/fixtures/risk_register_fixtures.json", "r36_status": "SUPERSEDED HISTORICAL RECORD \u2014 NOT SELECTED FOR ASSEMBLY", "status": "REMOVED_OR_REPLACED_MECHANISM; physical replacement qualification pending", "r37_note": "Old adapter mechanism removed; removal does not resolve direct J2 fit.", "previous_status": "REMOVED_MECHANISM_IN_WORKING_CANDIDATE", "baseline_treatment": "Use the final correction register and Fixture_Final_Corrections.md. The earlier RTV tacks, flat J8 strap, Y-axis adapter, old hardware poses and untrimmed microphone facing are excluded; use Adapter_Final_Seat_and_Fasteners.md for the final adapter.", "baseline_evidence": "M2\u00d76 pan maximum head\u00d84\u00d71.6; nominal4.4mm material overlap with3.4mm design full-thread allowance after1mm lead/runout reserve,0.95mm tip margin,\u00d81.7 pilot.", "current_treatment": "Superseded mechanism removed from the current assembly. Direct J2/J10 PH connections, adhesive antenna mounting and current routing replace it; see current reference assembly." }, { "id": "R36-FX-CK-J2", "components": [ "J2 CK socket", "original J2 PH PCB header" ], "location": "Fixed original J2 header", "failure_mechanism": "Wrong socket variant/wire-center datum, insulation displacement failure, extraction load or excessive current.", "loading_situation": "Mating, cable routing and electrical operation", "evidence": "JST catalog explicitly supports PH mating;6.9mm mounted height and maximum OD1.05 wire envelope. Socket cavity/pin details are not OEM STEP.", "treatment": "Use matching normal/reverse cable-side CK variant, approved UL1061/UL10272 wire; keep original PCB header.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Actual sample mating, exit Z, contact engagement, pin1/net map, selected wire termination and load/current qualification.", "source_register": "audit/fixtures/risk_register_fixtures.json", "r36_status": "NOMINAL_CAD_TREATMENT; PHYSICAL_QUALIFICATION_OPEN", "status": "REMOVED_OR_REPLACED_MECHANISM; physical replacement qualification pending", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Use matching normal/reverse cable-side CK variant, approved UL1061/UL10272 wire; keep original PCB header.", "baseline_evidence": "JST catalog explicitly supports PH mating;6.9mm mounted height and maximum OD1.05 wire envelope. Socket cavity/pin details are not OEM STEP.", "current_treatment": "Superseded mechanism removed from the current assembly. Direct J2/J10 PH connections, adhesive antenna mounting and current routing replace it; see current reference assembly." }, { "id": "R36-FX-CK-J3", "components": [ "J3 CK socket", "original J3 PH PCB header" ], "location": "Fixed original J3 header", "failure_mechanism": "Wrong socket variant/wire-center datum, insulation displacement failure, extraction load or excessive current.", "loading_situation": "Mating, cable routing and electrical operation", "evidence": "JST catalog explicitly supports PH mating;6.9mm mounted height and maximum OD1.05 wire envelope. Socket cavity/pin details are not OEM STEP.", "treatment": "Use matching normal/reverse cable-side CK variant, approved UL1061/UL10272 wire; keep original PCB header.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Actual sample mating, exit Z, contact engagement, pin1/net map, selected wire termination and load/current qualification.", "source_register": "audit/fixtures/risk_register_fixtures.json", "r36_status": "NOMINAL_CAD_TREATMENT; PHYSICAL_QUALIFICATION_OPEN", "status": "REPLACED_BY_CONNECTED_ROUTING; current audit plus physical dressing/strain-relief test required", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Use matching normal/reverse cable-side CK variant, approved UL1061/UL10272 wire; keep original PCB header.", "baseline_evidence": "JST catalog explicitly supports PH mating;6.9mm mounted height and maximum OD1.05 wire envelope. Socket cavity/pin details are not OEM STEP.", "current_treatment": "Superseded routes/restraints are retired. Current named J2/J3/J10/J9/J8/J5/J7 envelopes, open channels and harness instructions govern; electrical mapping corrected. Factory battery and RF cables remain intact." }, { "id": "R36-FX-CK-J10", "components": [ "J10 CK socket", "original J10 PH PCB header" ], "location": "Fixed original J10 header", "failure_mechanism": "Wrong socket variant/wire-center datum, insulation displacement failure, extraction load or excessive current.", "loading_situation": "Mating, cable routing and electrical operation", "evidence": "JST catalog explicitly supports PH mating;6.9mm mounted height and maximum OD1.05 wire envelope. Socket cavity/pin details are not OEM STEP.", "treatment": "Use matching normal/reverse cable-side CK variant, approved UL1061/UL10272 wire; keep original PCB header.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Actual sample mating, exit Z, contact engagement, pin1/net map, selected wire termination and load/current qualification.", "source_register": "audit/fixtures/risk_register_fixtures.json", "r36_status": "NOMINAL_CAD_TREATMENT; PHYSICAL_QUALIFICATION_OPEN", "status": "REMOVED_OR_REPLACED_MECHANISM; physical replacement qualification pending", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Use matching normal/reverse cable-side CK variant, approved UL1061/UL10272 wire; keep original PCB header.", "baseline_evidence": "JST catalog explicitly supports PH mating;6.9mm mounted height and maximum OD1.05 wire envelope. Socket cavity/pin details are not OEM STEP.", "current_treatment": "Superseded mechanism removed from the current assembly. Direct J2/J10 PH connections, adhesive antenna mounting and current routing replace it; see current reference assembly." }, { "id": "R36-FX-PH-J8", "components": [ "J8 PHR4", "four PH crimp contacts" ], "location": "Original side-entry J8", "failure_mechanism": "Plug housing or wire exit can hit wall; crimp pull can load header solder.", "loading_situation": "Mating and service cable pull", "evidence": "Catalog6.85mm housing length/4.5mm depth, unchanged header pose; four OD1.05 selected routes.", "treatment": "Ordinary PH plug retained; bound housing gauge and route; pair with final mechanical restraint.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Actual housing/crimp/exit and pull restraint; connector catalog geometry is not production tolerance proof.", "source_register": "audit/fixtures/risk_register_fixtures.json", "r36_status": "NOMINAL_CAD_TREATMENT; PHYSICAL_QUALIFICATION_OPEN", "status": "REPLACED_BY_CONNECTED_ROUTING; current audit plus physical dressing/strain-relief test required", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Ordinary PH plug retained; bound housing gauge and route; pair with final mechanical restraint.", "baseline_evidence": "Catalog6.85mm housing length/4.5mm depth, unchanged header pose; four OD1.05 selected routes.", "current_treatment": "Superseded routes/restraints are retired. Current named J2/J3/J10/J9/J8/J5/J7 envelopes, open channels and harness instructions govern; electrical mapping corrected. Factory battery and RF cables remain intact." }, { "id": "R36-FX-LED-JOINTS", "components": [ "LED insulated joint1", "LED insulated joint2", "LED insulated joint3", "LED insulated joint4" ], "location": "Four distal LED leads at1.27mm pitch", "failure_mechanism": "Oversized solder/insulation sleeves crowd neighboring legs and cause bending or shorts.", "loading_situation": "Harness dressing and service vibration", "evidence": "Each final joint reserve is maximum\u00d81.15\u00d73mm including insulation; nominal separation0.12mm. Earlier\u00d81.7 candidate failed and is not released.", "treatment": "Use a measured small lap joint with qualified thin individual insulation; no solder bulge outside envelope, preserve original lead/body pose.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Fabricated joint profile, insulation integrity and pull inspection; if infeasible, redesign distal forming/joint layout rather than force fit.", "source_register": "audit/fixtures/risk_register_fixtures.json", "r36_status": "NOMINAL_CAD_TREATMENT; PHYSICAL_QUALIFICATION_OPEN", "status": "REPLACED_BY_CONNECTED_ROUTING; current audit plus physical dressing/strain-relief test required", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Use a measured small lap joint with qualified thin individual insulation; no solder bulge outside envelope, preserve original lead/body pose.", "baseline_evidence": "Each final joint reserve is maximum\u00d81.15\u00d73mm including insulation; nominal separation0.12mm. Earlier\u00d81.7 candidate failed and is not released.", "current_treatment": "Superseded routes/restraints are retired. Current named J2/J3/J10/J9/J8/J5/J7 envelopes, open channels and harness instructions govern; electrical mapping corrected. Factory battery and RF cables remain intact." }, { "id": "R36-FX-SPK-LEADS", "components": [ "two shortened speaker factory leads", "two staggered speaker lap splices" ], "location": "Left front harness and X\u221223.6/Y5..13, X\u221226.8/Y\u22125..3", "failure_mechanism": "Speaker lead exit uncertainty, bulky splice or unsupported pull can break a lead or pinch it against a support.", "loading_situation": "Speaker assembly and service removal", "evidence": "Stock speaker leads152\u00b15mm; original reference lacks terminal exits. Candidate OD1.3 routes and maximum\u00d83.2\u00d78 staggered sleeves.", "treatment": "Shorten speaker leads as needed, connect to approved CK pigtails; keep protected battery leads untouched.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Actual factory speaker exit/OD, sleeve insulation, strain restraint and required length plus termination allowance.", "source_register": "audit/fixtures/risk_register_fixtures.json", "r36_status": "NOMINAL_CAD_TREATMENT; PHYSICAL_QUALIFICATION_OPEN", "status": "REPLACED_BY_CONNECTED_ROUTING; current audit plus physical dressing/strain-relief test required", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Shorten speaker leads as needed, connect to approved CK pigtails; keep protected battery leads untouched.", "baseline_evidence": "Stock speaker leads152\u00b15mm; original reference lacks terminal exits. Candidate OD1.3 routes and maximum\u00d83.2\u00d78 staggered sleeves.", "current_treatment": "Superseded routes/restraints are retired. Current named J2/J3/J10/J9/J8/J5/J7 envelopes, open channels and harness instructions govern; electrical mapping corrected. Factory battery and RF cables remain intact." }, { "id": "R36-FX-BAT-LEADS", "components": [ "two intact factory battery leads", "factory battery PHR2 plug" ], "location": "Right keeper service opening and front speaker annulus", "failure_mechanism": "Lead forced around screw head, sharp edge, insufficient length or pouch-tab pull.", "loading_situation": "Battery insertion, closure and service", "evidence": "Two100mm OD1.5 nominal curves preserve old CAD assumption; actual free length/OD/exit was not measured. R3.75 is an engineering assumption.", "treatment": "Preserve factory cable and plug; nested slack paths and explicit screw/keeper relief, remote captured passive adapter.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Measure received free cable and protected tab; verify bend/slack/dressing with no pouch pressure or tension. Never cut/solder battery assembly to match a drawing.", "source_register": "audit/fixtures/risk_register_fixtures.json", "r36_status": "NOMINAL_CAD_TREATMENT; PHYSICAL_QUALIFICATION_OPEN", "status": "REPLACED_BY_CONNECTED_ROUTING; current audit plus physical dressing/strain-relief test required", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Preserve factory cable and plug; nested slack paths and explicit screw/keeper relief, remote captured passive adapter.", "baseline_evidence": "Two100mm OD1.5 nominal curves preserve old CAD assumption; actual free length/OD/exit was not measured. R3.75 is an engineering assumption.", "current_treatment": "Superseded routes/restraints are retired. Current named J2/J3/J10/J9/J8/J5/J7 envelopes, open channels and harness instructions govern; electrical mapping corrected. Factory battery and RF cables remain intact." }, { "id": "R36-FX-MIC-WINDOW", "components": [ "P01 microphone wire window", "P02 microphone wire window", "P01", "P02" ], "location": "Left wall nearY\u221228..\u221222", "failure_mechanism": "Several close round bores leave thin fins or sever a PCB/guide support.", "loading_situation": "Wire insertion and shell handling", "evidence": "Joined rounded front/rear windows replace adjacent close grooves; front nominal retained web\u22656.3mm.", "treatment": "Open broad window, no P13 terminal drilling; root-integrated support geometry is checked separately.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Actual edge finish and print strength, no hidden sharp edge or wire rubbing.", "source_register": "audit/fixtures/risk_register_fixtures.json", "r36_status": "NOMINAL_CAD_TREATMENT; PHYSICAL_QUALIFICATION_OPEN", "status": "REPLACED_BY_CONNECTED_ROUTING; current audit plus physical dressing/strain-relief test required", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Open broad window, no P13 terminal drilling; root-integrated support geometry is checked separately.", "baseline_evidence": "Joined rounded front/rear windows replace adjacent close grooves; front nominal retained web\u22656.3mm.", "current_treatment": "Superseded routes/restraints are retired. Current named J2/J3/J10/J9/J8/J5/J7 envelopes, open channels and harness instructions govern; electrical mapping corrected. Factory battery and RF cables remain intact." }, { "id": "R36-FX-MIC-SADDLE", "components": [ "P01 integral mic saddle", "mic silicone facing", "mic polyester strap", "P01" ], "location": "X\u221221.5..\u221215.5,Y\u221233..\u221217", "failure_mechanism": "Adhesive peel, wire slip or saddle break lets pull reach microphone/PCB joints.", "loading_situation": "5N service pull and repeated assembly", "evidence": "6\u00d716mm broad saddle,0.25mm installed silicone and0.10mm tape; two2mm bond lands.", "treatment": "Route five wires over compliant facing and bond replaceable strap; keep new play bars clear.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Tape/print-surface adhesion after cure and temperature exposure, grip and10service cycles; no adhesive rating inferred.", "source_register": "audit/fixtures/risk_register_fixtures.json", "r36_status": "NOMINAL_CAD_TREATMENT; PHYSICAL_QUALIFICATION_OPEN", "status": "REPLACED_BY_CONNECTED_ROUTING; current audit plus physical dressing/strain-relief test required", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Route five wires over compliant facing and bond replaceable strap; keep new play bars clear.", "baseline_evidence": "6\u00d716mm broad saddle,0.25mm installed silicone and0.10mm tape; two2mm bond lands.", "current_treatment": "Superseded routes/restraints are retired. Current named J2/J3/J10/J9/J8/J5/J7 envelopes, open channels and harness instructions govern; electrical mapping corrected. Factory battery and RF cables remain intact." }, { "id": "R36-FX-COAX", "components": [ "original150mm coax", "fixed original J5 plug", "two formed nonconductive silicone tacks" ], "location": "New right-side rear route", "failure_mechanism": "Cable bend/abrasion or unretained loop pulls RF connector or antenna feed.", "loading_situation": "Assembly and service handling", "evidence": "Explicit150mm centerline,\u00d81.37 actual cable gauge, R5 and feed coordinate are assumptions; larger clearance envelope and two4mm-long formed silicone tacks.", "treatment": "Use the final correction register and Fixture_Final_Corrections.md. The earlier RTV tacks, flat J8 strap, Y-axis adapter, old hardware poses and untrimmed microphone facing are excluded; use Adapter_Final_Seat_and_Fasteners.md for the final adapter.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Apply the selected final correction coupon and assembly protocol; this historical entry is not a physical pass.", "source_register": "audit/fixtures/risk_register_fixtures.json", "r36_status": "SUPERSEDED HISTORICAL RECORD \u2014 NOT SELECTED FOR ASSEMBLY", "status": "REPLACED_BY_CONNECTED_ROUTING; current audit plus physical dressing/strain-relief test required", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Use the final correction register and Fixture_Final_Corrections.md. The earlier RTV tacks, flat J8 strap, Y-axis adapter, old hardware poses and untrimmed microphone facing are excluded; use Adapter_Final_Seat_and_Fasteners.md for the final adapter.", "baseline_evidence": "Explicit150mm centerline,\u00d81.37 actual cable gauge, R5 and feed coordinate are assumptions; larger clearance envelope and two4mm-long formed silicone tacks.", "current_treatment": "Superseded routes/restraints are retired. Current named J2/J3/J10/J9/J8/J5/J7 envelopes, open channels and harness instructions govern; electrical mapping corrected. Factory battery and RF cables remain intact." }, { "id": "R36-FX-J8-SADDLE", "components": [ "P01 J8 saddle", "J8 silicone facing", "J8 polyester strap", "P01" ], "location": "X15.5..18.8,Y\u221242.5..\u221226.2", "failure_mechanism": "Adhesive peel or bundle slip passes load to the PH header or LED legs; a crossing control wire can be pinched.", "loading_situation": "Cable insertion,5N service pull and closure", "evidence": "Broad integral support with4/3.3mm tape bond lands,24.09mm\u00b2 total nominal bond area;0.25mm silicone and0.10mm tape.\u00d81.85 rear-open passage preserves J9 pin1 atY\u221235/Z\u22129.7.", "treatment": "Use the final correction register and Fixture_Final_Corrections.md. The earlier RTV tacks, flat J8 strap, Y-axis adapter, old hardware poses and untrimmed microphone facing are excluded; use Adapter_Final_Seat_and_Fasteners.md for the final adapter.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Apply the selected final correction coupon and assembly protocol; this historical entry is not a physical pass.", "source_register": "audit/fixtures/risk_register_fixtures.json", "r36_status": "SUPERSEDED HISTORICAL RECORD \u2014 NOT SELECTED FOR ASSEMBLY", "status": "REPLACED_BY_CONNECTED_ROUTING; current audit plus physical dressing/strain-relief test required", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Use the final correction register and Fixture_Final_Corrections.md. The earlier RTV tacks, flat J8 strap, Y-axis adapter, old hardware poses and untrimmed microphone facing are excluded; use Adapter_Final_Seat_and_Fasteners.md for the final adapter.", "baseline_evidence": "Broad integral support with4/3.3mm tape bond lands,24.09mm\u00b2 total nominal bond area;0.25mm silicone and0.10mm tape.\u00d81.85 rear-open passage preserves J9 pin1 atY\u221235/Z\u22129.7.", "current_treatment": "Superseded routes/restraints are retired. Current named J2/J3/J10/J9/J8/J5/J7 envelopes, open channels and harness instructions govern; electrical mapping corrected. Factory battery and RF cables remain intact." }, { "id": "R36-FX-STOCK-R36_STOCK_ANTENNA_CARRIER_ADHESIVE_0p05", "components": [ "R36_STOCK_ANTENNA_CARRIER_ADHESIVE_0p05" ], "location": "[[-10.2, -34.2, -22.1], [10.2, 61.2, -22.05]]", "failure_mechanism": "Incorrect installed thickness, creep, compression set or delamination changes preload and wire grip.", "loading_situation": "Assembly preload, temperature and service cycles", "evidence": "Explicit installed envelope; valid=True, solids=1.", "treatment": "Cut/select measured stock; keep intended contact only and replace old stock, never stack.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Actual stock material/thickness, compression/adhesion and physical cycling are not established by CAD.", "source_register": "audit/fixtures/risk_register_fixtures.json", "r36_status": "NOMINAL_CAD_TREATMENT; PHYSICAL_QUALIFICATION_OPEN", "status": "REVIEWED; current nominal checks and physical qualification remain distinct", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Cut/select measured stock; keep intended contact only and replace old stock, never stack.", "baseline_evidence": "Explicit installed envelope; valid=True, solids=1.", "current_treatment": "Functional stock/hardware retained only as named in assembly_index.json; obsolete stock retired there. Use installed thicknesses and current assembly sequence." }, { "id": "R36-FX-STOCK-R36_STOCK_ANTENNA_END_PAD_1_INSTALLED_0p42", "components": [ "R36_STOCK_ANTENNA_END_PAD_1_INSTALLED_0p42" ], "location": "[[-9.5, -33.75, -21.75], [-4.5, -29.75, -21.33]]", "failure_mechanism": "Incorrect installed thickness, creep, compression set or delamination changes preload and wire grip.", "loading_situation": "Assembly preload, temperature and service cycles", "evidence": "Explicit installed envelope; valid=True, solids=1.", "treatment": "Cut/select measured stock; keep intended contact only and replace old stock, never stack.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Actual stock material/thickness, compression/adhesion and physical cycling are not established by CAD.", "source_register": "audit/fixtures/risk_register_fixtures.json", "r36_status": "NOMINAL_CAD_TREATMENT; PHYSICAL_QUALIFICATION_OPEN", "status": "REMOVED_OR_REPLACED_MECHANISM; physical replacement qualification pending", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Cut/select measured stock; keep intended contact only and replace old stock, never stack.", "baseline_evidence": "Explicit installed envelope; valid=True, solids=1.", "current_treatment": "Superseded mechanism removed from the current assembly. Direct J2/J10 PH connections, adhesive antenna mounting and current routing replace it; see current reference assembly." }, { "id": "R36-FX-STOCK-R36_STOCK_ANTENNA_END_PAD_2_INSTALLED_0p42", "components": [ "R36_STOCK_ANTENNA_END_PAD_2_INSTALLED_0p42" ], "location": "[[4.5, -33.75, -21.75], [9.5, -29.75, -21.33]]", "failure_mechanism": "Incorrect installed thickness, creep, compression set or delamination changes preload and wire grip.", "loading_situation": "Assembly preload, temperature and service cycles", "evidence": "Explicit installed envelope; valid=True, solids=1.", "treatment": "Cut/select measured stock; keep intended contact only and replace old stock, never stack.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Actual stock material/thickness, compression/adhesion and physical cycling are not established by CAD.", "source_register": "audit/fixtures/risk_register_fixtures.json", "r36_status": "NOMINAL_CAD_TREATMENT; PHYSICAL_QUALIFICATION_OPEN", "status": "REMOVED_OR_REPLACED_MECHANISM; physical replacement qualification pending", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Cut/select measured stock; keep intended contact only and replace old stock, never stack.", "baseline_evidence": "Explicit installed envelope; valid=True, solids=1.", "current_treatment": "Superseded mechanism removed from the current assembly. Direct J2/J10 PH connections, adhesive antenna mounting and current routing replace it; see current reference assembly." }, { "id": "R36-FX-STOCK-R36_STOCK_ANTENNA_END_PAD_3_INSTALLED_0p42", "components": [ "R36_STOCK_ANTENNA_END_PAD_3_INSTALLED_0p42" ], "location": "[[-9.5, 57.25, -21.75], [-4.5, 61.25, -21.33]]", "failure_mechanism": "Incorrect installed thickness, creep, compression set or delamination changes preload and wire grip.", "loading_situation": "Assembly preload, temperature and service cycles", "evidence": "Explicit installed envelope; valid=True, solids=1.", "treatment": "Cut/select measured stock; keep intended contact only and replace old stock, never stack.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Actual stock material/thickness, compression/adhesion and physical cycling are not established by CAD.", "source_register": "audit/fixtures/risk_register_fixtures.json", "r36_status": "NOMINAL_CAD_TREATMENT; PHYSICAL_QUALIFICATION_OPEN", "status": "REMOVED_OR_REPLACED_MECHANISM; physical replacement qualification pending", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Cut/select measured stock; keep intended contact only and replace old stock, never stack.", "baseline_evidence": "Explicit installed envelope; valid=True, solids=1.", "current_treatment": "Superseded mechanism removed from the current assembly. Direct J2/J10 PH connections, adhesive antenna mounting and current routing replace it; see current reference assembly." }, { "id": "R36-FX-STOCK-R36_STOCK_ANTENNA_END_PAD_4_INSTALLED_0p42", "components": [ "R36_STOCK_ANTENNA_END_PAD_4_INSTALLED_0p42" ], "location": "[[4.5, 57.25, -21.75], [9.5, 61.25, -21.33]]", "failure_mechanism": "Incorrect installed thickness, creep, compression set or delamination changes preload and wire grip.", "loading_situation": "Assembly preload, temperature and service cycles", "evidence": "Explicit installed envelope; valid=True, solids=1.", "treatment": "Cut/select measured stock; keep intended contact only and replace old stock, never stack.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Actual stock material/thickness, compression/adhesion and physical cycling are not established by CAD.", "source_register": "audit/fixtures/risk_register_fixtures.json", "r36_status": "NOMINAL_CAD_TREATMENT; PHYSICAL_QUALIFICATION_OPEN", "status": "REMOVED_OR_REPLACED_MECHANISM; physical replacement qualification pending", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Cut/select measured stock; keep intended contact only and replace old stock, never stack.", "baseline_evidence": "Explicit installed envelope; valid=True, solids=1.", "current_treatment": "Superseded mechanism removed from the current assembly. Direct J2/J10 PH connections, adhesive antenna mounting and current routing replace it; see current reference assembly." }, { "id": "R36-FX-STOCK-R36_STOCK_ANTENNA_PET_DIELECTRIC_0p10", "components": [ "R36_STOCK_ANTENNA_PET_DIELECTRIC_0p10" ], "location": "[[-10.2, -34.2, -22.05], [10.2, 61.2, -21.95]]", "failure_mechanism": "Incorrect installed thickness, creep, compression set or delamination changes preload and wire grip.", "loading_situation": "Assembly preload, temperature and service cycles", "evidence": "Explicit installed envelope; valid=True, solids=1.", "treatment": "Cut/select measured stock; keep intended contact only and replace old stock, never stack.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Actual stock material/thickness, compression/adhesion and physical cycling are not established by CAD.", "source_register": "audit/fixtures/risk_register_fixtures.json", "r36_status": "NOMINAL_CAD_TREATMENT; PHYSICAL_QUALIFICATION_OPEN", "status": "REVIEWED; current nominal checks and physical qualification remain distinct", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Cut/select measured stock; keep intended contact only and replace old stock, never stack.", "baseline_evidence": "Explicit installed envelope; valid=True, solids=1.", "current_treatment": "Functional stock/hardware retained only as named in assembly_index.json; obsolete stock retired there. Use installed thicknesses and current assembly sequence." }, { "id": "R36-FX-STOCK-R36_STOCK_ADAPTER_CARRIER_EDGE_PAD_1_FRONT_INSTALLED_0p25", "components": [ "R36_STOCK_ADAPTER_CARRIER_EDGE_PAD_1_FRONT_INSTALLED_0p25" ], "location": "[[18.0, -4.0, -10.3], [18.8, -3.75, -4.3]]", "failure_mechanism": "Incorrect installed thickness, creep, compression set or delamination changes preload and wire grip.", "loading_situation": "Assembly preload, temperature and service cycles", "evidence": "Explicit installed envelope; valid=True, solids=1.", "treatment": "Cut/select measured stock; keep intended contact only and replace old stock, never stack.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Actual stock material/thickness, compression/adhesion and physical cycling are not established by CAD.", "source_register": "audit/fixtures/risk_register_fixtures.json", "r36_status": "NOMINAL_CAD_TREATMENT; PHYSICAL_QUALIFICATION_OPEN", "status": "REMOVED_OR_REPLACED_MECHANISM; physical replacement qualification pending", "r37_note": "Old adapter mechanism removed; removal does not resolve direct J2 fit.", "previous_status": "REMOVED_MECHANISM_IN_WORKING_CANDIDATE", "baseline_treatment": "Cut/select measured stock; keep intended contact only and replace old stock, never stack.", "baseline_evidence": "Explicit installed envelope; valid=True, solids=1.", "current_treatment": "Superseded mechanism removed from the current assembly. Direct J2/J10 PH connections, adhesive antenna mounting and current routing replace it; see current reference assembly." }, { "id": "R36-FX-STOCK-R36_STOCK_ADAPTER_CARRIER_EDGE_PAD_1_REAR_INSTALLED_0p25", "components": [ "R36_STOCK_ADAPTER_CARRIER_EDGE_PAD_1_REAR_INSTALLED_0p25" ], "location": "[[18.0, -5.25, -10.3], [18.8, -5.0, -4.3]]", "failure_mechanism": "Incorrect installed thickness, creep, compression set or delamination changes preload and wire grip.", "loading_situation": "Assembly preload, temperature and service cycles", "evidence": "Explicit installed envelope; valid=True, solids=1.", "treatment": "Cut/select measured stock; keep intended contact only and replace old stock, never stack.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Actual stock material/thickness, compression/adhesion and physical cycling are not established by CAD.", "source_register": "audit/fixtures/risk_register_fixtures.json", "r36_status": "NOMINAL_CAD_TREATMENT; PHYSICAL_QUALIFICATION_OPEN", "status": "REMOVED_OR_REPLACED_MECHANISM; physical replacement qualification pending", "r37_note": "Old adapter mechanism removed; removal does not resolve direct J2 fit.", "previous_status": "REMOVED_MECHANISM_IN_WORKING_CANDIDATE", "baseline_treatment": "Cut/select measured stock; keep intended contact only and replace old stock, never stack.", "baseline_evidence": "Explicit installed envelope; valid=True, solids=1.", "current_treatment": "Superseded mechanism removed from the current assembly. Direct J2/J10 PH connections, adhesive antenna mounting and current routing replace it; see current reference assembly." }, { "id": "R36-FX-STOCK-R36_STOCK_ADAPTER_CARRIER_EDGE_PAD_2_FRONT_INSTALLED_0p25", "components": [ "R36_STOCK_ADAPTER_CARRIER_EDGE_PAD_2_FRONT_INSTALLED_0p25" ], "location": "[[25.2, -4.0, -10.3], [26.0, -3.75, -4.3]]", "failure_mechanism": "Incorrect installed thickness, creep, compression set or delamination changes preload and wire grip.", "loading_situation": "Assembly preload, temperature and service cycles", "evidence": "Explicit installed envelope; valid=True, solids=1.", "treatment": "Cut/select measured stock; keep intended contact only and replace old stock, never stack.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Actual stock material/thickness, compression/adhesion and physical cycling are not established by CAD.", "source_register": "audit/fixtures/risk_register_fixtures.json", "r36_status": "NOMINAL_CAD_TREATMENT; PHYSICAL_QUALIFICATION_OPEN", "status": "REMOVED_OR_REPLACED_MECHANISM; physical replacement qualification pending", "r37_note": "Old adapter mechanism removed; removal does not resolve direct J2 fit.", "previous_status": "REMOVED_MECHANISM_IN_WORKING_CANDIDATE", "baseline_treatment": "Cut/select measured stock; keep intended contact only and replace old stock, never stack.", "baseline_evidence": "Explicit installed envelope; valid=True, solids=1.", "current_treatment": "Superseded mechanism removed from the current assembly. Direct J2/J10 PH connections, adhesive antenna mounting and current routing replace it; see current reference assembly." }, { "id": "R36-FX-STOCK-R36_STOCK_ADAPTER_CARRIER_EDGE_PAD_2_REAR_INSTALLED_0p25", "components": [ "R36_STOCK_ADAPTER_CARRIER_EDGE_PAD_2_REAR_INSTALLED_0p25" ], "location": "[[25.2, -5.25, -10.3], [26.0, -5.0, -4.3]]", "failure_mechanism": "Incorrect installed thickness, creep, compression set or delamination changes preload and wire grip.", "loading_situation": "Assembly preload, temperature and service cycles", "evidence": "Explicit installed envelope; valid=True, solids=1.", "treatment": "Cut/select measured stock; keep intended contact only and replace old stock, never stack.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Actual stock material/thickness, compression/adhesion and physical cycling are not established by CAD.", "source_register": "audit/fixtures/risk_register_fixtures.json", "r36_status": "NOMINAL_CAD_TREATMENT; PHYSICAL_QUALIFICATION_OPEN", "status": "REMOVED_OR_REPLACED_MECHANISM; physical replacement qualification pending", "r37_note": "Old adapter mechanism removed; removal does not resolve direct J2 fit.", "previous_status": "REMOVED_MECHANISM_IN_WORKING_CANDIDATE", "baseline_treatment": "Cut/select measured stock; keep intended contact only and replace old stock, never stack.", "baseline_evidence": "Explicit installed envelope; valid=True, solids=1.", "current_treatment": "Superseded mechanism removed from the current assembly. Direct J2/J10 PH connections, adhesive antenna mounting and current routing replace it; see current reference assembly." }, { "id": "R36-FX-STOCK-R36_STOCK_ADAPTER_SPLIT_SILICONE_GROMMET_INSTALLED", "components": [ "R36_STOCK_ADAPTER_SPLIT_SILICONE_GROMMET_INSTALLED" ], "location": "[[19.1, -12.3, -8.600000001016], [24.9, -10.3, -5.999999998983999]]", "failure_mechanism": "Incorrect installed thickness, creep, compression set or delamination changes preload and wire grip.", "loading_situation": "Assembly preload, temperature and service cycles", "evidence": "Explicit installed envelope; valid=True, solids=2.", "treatment": "Cut/select measured stock; keep intended contact only and replace old stock, never stack.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Actual stock material/thickness, compression/adhesion and physical cycling are not established by CAD.", "source_register": "audit/fixtures/risk_register_fixtures.json", "r36_status": "NOMINAL_CAD_TREATMENT; PHYSICAL_QUALIFICATION_OPEN", "status": "REMOVED_OR_REPLACED_MECHANISM; physical replacement qualification pending", "r37_note": "Old adapter mechanism removed; removal does not resolve direct J2 fit.", "previous_status": "REMOVED_MECHANISM_IN_WORKING_CANDIDATE", "baseline_treatment": "Cut/select measured stock; keep intended contact only and replace old stock, never stack.", "baseline_evidence": "Explicit installed envelope; valid=True, solids=2.", "current_treatment": "Superseded mechanism removed from the current assembly. Direct J2/J10 PH connections, adhesive antenna mounting and current routing replace it; see current reference assembly." }, { "id": "R36-FX-STOCK-R36_STOCK_COAX_FORMED_SILICONE_TACK_1_L4", "components": [ "R36_STOCK_COAX_FORMED_SILICONE_TACK_1_L4" ], "location": "[[30.149999899999997, -26.0000001, -22.085000100000002], [32.833986543971, -21.9999999, -19.649999899999997]]", "failure_mechanism": "Incorrect installed thickness, creep, compression set or delamination changes preload and wire grip.", "loading_situation": "Assembly preload, temperature and service cycles", "evidence": "Explicit installed envelope; valid=True, solids=1.", "treatment": "Use the final correction register and Fixture_Final_Corrections.md. The earlier RTV tacks, flat J8 strap, Y-axis adapter, old hardware poses and untrimmed microphone facing are excluded; use Adapter_Final_Seat_and_Fasteners.md for the final adapter.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Apply the selected final correction coupon and assembly protocol; this historical entry is not a physical pass.", "source_register": "audit/fixtures/risk_register_fixtures.json", "r36_status": "SUPERSEDED HISTORICAL RECORD \u2014 NOT SELECTED FOR ASSEMBLY", "status": "REPLACED_BY_CONNECTED_ROUTING; current audit plus physical dressing/strain-relief test required", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Use the final correction register and Fixture_Final_Corrections.md. The earlier RTV tacks, flat J8 strap, Y-axis adapter, old hardware poses and untrimmed microphone facing are excluded; use Adapter_Final_Seat_and_Fasteners.md for the final adapter.", "baseline_evidence": "Explicit installed envelope; valid=True, solids=1.", "current_treatment": "Superseded routes/restraints are retired. Current named J2/J3/J10/J9/J8/J5/J7 envelopes, open channels and harness instructions govern; electrical mapping corrected. Factory battery and RF cables remain intact." }, { "id": "R36-FX-STOCK-R36_STOCK_COAX_FORMED_SILICONE_TACK_2_L4", "components": [ "R36_STOCK_COAX_FORMED_SILICONE_TACK_2_L4" ], "location": "[[30.15, -9.0, -22.085], [32.83398644397425, -5.0, -19.65]]", "failure_mechanism": "Incorrect installed thickness, creep, compression set or delamination changes preload and wire grip.", "loading_situation": "Assembly preload, temperature and service cycles", "evidence": "Explicit installed envelope; valid=True, solids=1.", "treatment": "Use the final correction register and Fixture_Final_Corrections.md. The earlier RTV tacks, flat J8 strap, Y-axis adapter, old hardware poses and untrimmed microphone facing are excluded; use Adapter_Final_Seat_and_Fasteners.md for the final adapter.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Apply the selected final correction coupon and assembly protocol; this historical entry is not a physical pass.", "source_register": "audit/fixtures/risk_register_fixtures.json", "r36_status": "SUPERSEDED HISTORICAL RECORD \u2014 NOT SELECTED FOR ASSEMBLY", "status": "REPLACED_BY_CONNECTED_ROUTING; current audit plus physical dressing/strain-relief test required", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Use the final correction register and Fixture_Final_Corrections.md. The earlier RTV tacks, flat J8 strap, Y-axis adapter, old hardware poses and untrimmed microphone facing are excluded; use Adapter_Final_Seat_and_Fasteners.md for the final adapter.", "baseline_evidence": "Explicit installed envelope; valid=True, solids=1.", "current_treatment": "Superseded routes/restraints are retired. Current named J2/J3/J10/J9/J8/J5/J7 envelopes, open channels and harness instructions govern; electrical mapping corrected. Factory battery and RF cables remain intact." }, { "id": "R36-FX-FINAL-J8-CORNER", "components": [ "P01 J8 saddle", "CUT_P01_J8_REAR_OPEN_J9_CORNER_FINAL", "P01" ], "location": "X15.4\u202618.9,Y\u221242.6\u2026\u221240.6,Z\u221210.5\u2026\u22127.79", "failure_mechanism": "J9 clearance sweep leaves0.65mm lip that can fracture or trap a control wire.", "loading_situation": "Assembly, cable pull, control service", "evidence": "Rear-open corner removes lip; one connected saddle/root; finalwiregap0.5081mm.", "treatment": "Open the back of the crossing and wrap strap onto retained vertical face.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Exact final shell/export andQF04B5Npull, tape peel and10servicecycles.", "source_register": "audit/fixtures/risk_register_final_corrections.json", "r36_status": "GEOMETRY_CHECKED_PHYSICAL_QUALIFICATION_OPEN", "status": "REPLACED_BY_CONNECTED_ROUTING; current audit plus physical dressing/strain-relief test required", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Open the back of the crossing and wrap strap onto retained vertical face.", "baseline_evidence": "Rear-open corner removes lip; one connected saddle/root; finalwiregap0.5081mm.", "current_treatment": "Superseded routes/restraints are retired. Current named J2/J3/J10/J9/J8/J5/J7 envelopes, open channels and harness instructions govern; electrical mapping corrected. Factory battery and RF cables remain intact." }, { "id": "R36-FX-FINAL-J8-STRAP", "components": [ "R36_STOCK_J8_FORMED_END_WRAP_STRAP_0p10_FINAL" ], "location": "J8 saddle rear face and newY\u221240.6 end face", "failure_mechanism": "Insufficient bonded land or wire abrasion permits slip and loads solder joints.", "loading_situation": "5Nservice pull and repeated assembly", "evidence": "26.3175mm\u00b2 nominal contact:6.93lower+10.89upper+8.4975vertical; pin4gap0.3711mm.", "treatment": "Form0.10mmmaximum polyester strap around end, apply only to clean qualified print lands; replace old strap.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Actual tape thickness/adhesion, fold radius, pull/slip,10cycles; do not stack oldstrap.", "source_register": "audit/fixtures/risk_register_final_corrections.json", "r36_status": "GEOMETRY_CHECKED_PHYSICAL_QUALIFICATION_OPEN", "status": "REVIEWED; current nominal checks and physical qualification remain distinct", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Form0.10mmmaximum polyester strap around end, apply only to clean qualified print lands; replace old strap.", "baseline_evidence": "26.3175mm\u00b2 nominal contact:6.93lower+10.89upper+8.4975vertical; pin4gap0.3711mm.", "current_treatment": "Functional stock/hardware retained only as named in assembly_index.json; obsolete stock retired there. Use installed thicknesses and current assembly sequence." }, { "id": "R36-FX-FINAL-COAX-STRAP-1", "components": [ "R36_STOCK_COAX_CURVED_LAND_STRAP_1_0p10_FINAL" ], "location": "Right rear cable runY\u221237\u2026\u221233", "failure_mechanism": "Chemical bond to FEP is unreliable; flat tape contours enter curved wall; axial cable slip loads RF feed/plug.", "loading_situation": "Cable dressing and5Nservice screen", "evidence": "PrimaryTaoglasFXUB63drawing namesFEP; selected feet conform to unchangedR7.8wall with16.765mm\u00b2 conservative printed-land contact.", "treatment": "WithdrawRTVtacks. Use mechanical tape/silicone clamp with printed-land adhesion; no FEP adhesive credit.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "QF05 actual printedfinish,tape,saddle andcoax: axial/lateral grip withoutcrush,kink,peel or electrical/impedance change; confirm actualbend limit.", "source_register": "audit/fixtures/risk_register_final_corrections.json", "r36_status": "GEOMETRY_CHECKED_PHYSICAL_QUALIFICATION_OPEN", "status": "REPLACED_BY_CONNECTED_ROUTING; current audit plus physical dressing/strain-relief test required", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "WithdrawRTVtacks. Use mechanical tape/silicone clamp with printed-land adhesion; no FEP adhesive credit.", "baseline_evidence": "PrimaryTaoglasFXUB63drawing namesFEP; selected feet conform to unchangedR7.8wall with16.765mm\u00b2 conservative printed-land contact.", "current_treatment": "Superseded routes/restraints are retired. Current named J2/J3/J10/J9/J8/J5/J7 envelopes, open channels and harness instructions govern; electrical mapping corrected. Factory battery and RF cables remain intact." }, { "id": "R36-FX-FINAL-COAX-PAD-1", "components": [ "R36_STOCK_COAX_UNBONDED_HALF_SADDLE_1_0p40_INSTALLED" ], "location": "Under coax within existing clearance channel", "failure_mechanism": "Pad too hard/thick crushes coax; too soft/thin loses preload and friction.", "loading_situation": "Strap installation, dwell, service pull", "evidence": "0.40mm radial installed half-saddle,0.45mmfree starting thickness; cable and shell contacts intentional.", "treatment": "Use nonadhesive soft insulating silicone formed beneath cable, grade/compression chosen bycoupon.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Actual material, compression set, clamp preload and cable RF/electricalintegrity. No untesteddurometer/pressure prescribed.", "source_register": "audit/fixtures/risk_register_final_corrections.json", "r36_status": "GEOMETRY_CHECKED_PHYSICAL_QUALIFICATION_OPEN", "status": "REPLACED_BY_CONNECTED_ROUTING; current audit plus physical dressing/strain-relief test required", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Use nonadhesive soft insulating silicone formed beneath cable, grade/compression chosen bycoupon.", "baseline_evidence": "0.40mm radial installed half-saddle,0.45mmfree starting thickness; cable and shell contacts intentional.", "current_treatment": "Superseded routes/restraints are retired. Current named J2/J3/J10/J9/J8/J5/J7 envelopes, open channels and harness instructions govern; electrical mapping corrected. Factory battery and RF cables remain intact." }, { "id": "R36-FX-FINAL-COAX-STRAP-2", "components": [ "R36_STOCK_COAX_CURVED_LAND_STRAP_2_0p10_FINAL" ], "location": "Right rear cable runY\u221222\u2026\u221218", "failure_mechanism": "Chemical bond to FEP is unreliable; flat tape contours enter curved wall; axial cable slip loads RF feed/plug.", "loading_situation": "Cable dressing and5Nservice screen", "evidence": "PrimaryTaoglasFXUB63drawing namesFEP; selected feet conform to unchangedR7.8wall with16.765mm\u00b2 conservative printed-land contact.", "treatment": "WithdrawRTVtacks. Use mechanical tape/silicone clamp with printed-land adhesion; no FEP adhesive credit.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "QF05 actual printedfinish,tape,saddle andcoax: axial/lateral grip withoutcrush,kink,peel or electrical/impedance change; confirm actualbend limit.", "source_register": "audit/fixtures/risk_register_final_corrections.json", "r36_status": "GEOMETRY_CHECKED_PHYSICAL_QUALIFICATION_OPEN", "status": "REPLACED_BY_CONNECTED_ROUTING; current audit plus physical dressing/strain-relief test required", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "WithdrawRTVtacks. Use mechanical tape/silicone clamp with printed-land adhesion; no FEP adhesive credit.", "baseline_evidence": "PrimaryTaoglasFXUB63drawing namesFEP; selected feet conform to unchangedR7.8wall with16.765mm\u00b2 conservative printed-land contact.", "current_treatment": "Superseded routes/restraints are retired. Current named J2/J3/J10/J9/J8/J5/J7 envelopes, open channels and harness instructions govern; electrical mapping corrected. Factory battery and RF cables remain intact." }, { "id": "R36-FX-FINAL-COAX-PAD-2", "components": [ "R36_STOCK_COAX_UNBONDED_HALF_SADDLE_2_0p40_INSTALLED" ], "location": "Under coax within existing clearance channel", "failure_mechanism": "Pad too hard/thick crushes coax; too soft/thin loses preload and friction.", "loading_situation": "Strap installation, dwell, service pull", "evidence": "0.40mm radial installed half-saddle,0.45mmfree starting thickness; cable and shell contacts intentional.", "treatment": "Use nonadhesive soft insulating silicone formed beneath cable, grade/compression chosen bycoupon.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Actual material, compression set, clamp preload and cable RF/electricalintegrity. No untesteddurometer/pressure prescribed.", "source_register": "audit/fixtures/risk_register_final_corrections.json", "r36_status": "GEOMETRY_CHECKED_PHYSICAL_QUALIFICATION_OPEN", "status": "REPLACED_BY_CONNECTED_ROUTING; current audit plus physical dressing/strain-relief test required", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Use nonadhesive soft insulating silicone formed beneath cable, grade/compression chosen bycoupon.", "baseline_evidence": "0.40mm radial installed half-saddle,0.45mmfree starting thickness; cable and shell contacts intentional.", "current_treatment": "Superseded routes/restraints are retired. Current named J2/J3/J10/J9/J8/J5/J7 envelopes, open channels and harness instructions govern; electrical mapping corrected. Factory battery and RF cables remain intact." }, { "id": "R36-FX-FINAL-SPEAKER-LEAD2", "components": [ "R36_SPEAKER_FACTORY_LEAD_2_J9_BYPASS_OD1p3_R3_FINAL" ], "location": "Left front route withX\u221227.4,Y22\u202610,Z\u22128.9", "failure_mechanism": "Factory lead crosses fixedPTTsignal/common wires or rubs new channel.", "loading_situation": "Speaker insertion/service", "evidence": "45.716mmcenterline,OD1.3,R3; factory assumedstart andfixedspliceend unchanged; localpaired0.4shellrelief.", "treatment": "Route behind the fixedPTTjoints andretainfullfactory-insulationrun; cutonlyspeakerlead asqualified, neverbattery cable.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Receivedspeakerexit/diameter, actualroute+5mmterminationallowance, edgefinish/strainretention, finalJ9combinedcheck.", "source_register": "audit/fixtures/risk_register_final_corrections.json", "r36_status": "GEOMETRY_CHECKED_PHYSICAL_QUALIFICATION_OPEN", "status": "REPLACED_BY_CONNECTED_ROUTING; current audit plus physical dressing/strain-relief test required", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Route behind the fixedPTTjoints andretainfullfactory-insulationrun; cutonlyspeakerlead asqualified, neverbattery cable.", "baseline_evidence": "45.716mmcenterline,OD1.3,R3; factory assumedstart andfixedspliceend unchanged; localpaired0.4shellrelief.", "current_treatment": "Superseded routes/restraints are retired. Current named J2/J3/J10/J9/J8/J5/J7 envelopes, open channels and harness instructions govern; electrical mapping corrected. Factory battery and RF cables remain intact." }, { "id": "R36-FX-FINAL-SPEAKER-SLEEVE1", "components": [ "R36_SPEAKER_LAP_SPLICE_1_FORWARD_0p30_FINAL" ], "location": "X\u221223.6,Y5\u202613,Z\u22124.4", "failure_mechanism": "ClosePTTsignal adjacency or insufficient insulation creates rubbing/short risk.", "loading_situation": "Harness dressing andvibration", "evidence": "Full\u00d83.2\u00d78sleeve moves0.30forward; originalwireentries retainedwithinendsection, factoryradialreserve~0.279mm.", "treatment": "Shift complete insulatedjointenvelope; addpaired0.4shellrelief, noinsulationtrimming.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Fabricatedjoint dimensions, requiredinsulationthickness/coverage andsliptest; sleeve is anenvelope not electricallyqualifiedconstruction.", "source_register": "audit/fixtures/risk_register_final_corrections.json", "r36_status": "GEOMETRY_CHECKED_PHYSICAL_QUALIFICATION_OPEN", "status": "REVIEWED; current nominal checks and physical qualification remain distinct", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Shift complete insulatedjointenvelope; addpaired0.4shellrelief, noinsulationtrimming.", "baseline_evidence": "Full\u00d83.2\u00d78sleeve moves0.30forward; originalwireentries retainedwithinendsection, factoryradialreserve~0.279mm.", "current_treatment": "Functional stock/hardware retained only as named in assembly_index.json; obsolete stock retired there. Use installed thicknesses and current assembly sequence." }, { "id": "R36-FX-FINAL-KEEPER-PORTS", "components": [ "P19", "P20" ], "location": "Openwireports andupperanchor neckedges", "failure_mechanism": "Clearance cuts might sever a narrow neck or screw-seat roof.", "loading_situation": "5Nkeeper service andscrewpreload", "evidence": "P19delta0.00223mm\u00b3,P20delta0.04410; spines4\u00d72.3\u00d73 and2.5\u00d77\u00d73 remain100%; conservative deep-neck screen6.98MPa using4.549mmwidth.", "treatment": "Retainmainspines/seat; limitclearance to freeportedge and0.05083mmedgetrim.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "HypotheticalE1000MPa/allowable8MPa only; actualnotch/anisotropy/pilot/preload andservicecouponqualification.", "source_register": "audit/fixtures/risk_register_final_corrections.json", "r36_status": "GEOMETRY_CHECKED_PHYSICAL_QUALIFICATION_OPEN", "status": "REPLACED_BY_CONNECTED_ROUTING; current audit plus physical dressing/strain-relief test required", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Retainmainspines/seat; limitclearance to freeportedge and0.05083mmedgetrim.", "baseline_evidence": "P19delta0.00223mm\u00b3,P20delta0.04410; spines4\u00d72.3\u00d73 and2.5\u00d77\u00d73 remain100%; conservative deep-neck screen6.98MPa using4.549mmwidth.", "current_treatment": "Superseded routes/restraints are retired. Current named J2/J3/J10/J9/J8/J5/J7 envelopes, open channels and harness instructions govern; electrical mapping corrected. Factory battery and RF cables remain intact." }, { "id": "R36-FX-COUPON-QF04B_J8_REAR_OPEN_CORNER_AND_FORMED_STRAP_TEST_BASE", "components": [ "QF04B_J8_REAR_OPEN_CORNER_AND_FORMED_STRAP_TEST_BASE" ], "location": "Testcoupon", "failure_mechanism": "Unrepresentativeprocess orsurfacefinish makes test misleading.", "loading_situation": "Firstarticle qualification", "evidence": "Exactproductionfeaturecoupon, validSTEP/watertightSTL; no physicaltestdone.", "treatment": "Printwithproductionorientation/material/finish; followcorrectionnotes.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Dimensions, grip, damageinspection andassemblycycling; passingcoupon doesnotcertifywholeproduct.", "source_register": "audit/fixtures/risk_register_final_corrections.json", "r36_status": "GEOMETRY_CHECKED_PHYSICAL_QUALIFICATION_OPEN", "status": "REVIEWED; current nominal checks and physical qualification remain distinct", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Printwithproductionorientation/material/finish; followcorrectionnotes.", "baseline_evidence": "Exactproductionfeaturecoupon, validSTEP/watertightSTL; no physicaltestdone.", "current_treatment": "Functional stock/hardware retained only as named in assembly_index.json; obsolete stock retired there. Use installed thicknesses and current assembly sequence." }, { "id": "R36-FX-COUPON-QF05_COAX_CURVED_LANDS_AND_CABLE_SADDLE_TEST_BASE", "components": [ "QF05_COAX_CURVED_LANDS_AND_CABLE_SADDLE_TEST_BASE" ], "location": "Testcoupon", "failure_mechanism": "Unrepresentativeprocess orsurfacefinish makes test misleading.", "loading_situation": "Firstarticle qualification", "evidence": "Exactproductionfeaturecoupon, validSTEP/watertightSTL; no physicaltestdone.", "treatment": "Printwithproductionorientation/material/finish; followcorrectionnotes.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Dimensions, grip, damageinspection andassemblycycling; passingcoupon doesnotcertifywholeproduct.", "source_register": "audit/fixtures/risk_register_final_corrections.json", "r36_status": "GEOMETRY_CHECKED_PHYSICAL_QUALIFICATION_OPEN", "status": "REPLACED_BY_CONNECTED_ROUTING; current audit plus physical dressing/strain-relief test required", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Printwithproductionorientation/material/finish; followcorrectionnotes.", "baseline_evidence": "Exactproductionfeaturecoupon, validSTEP/watertightSTL; no physicaltestdone.", "current_treatment": "Superseded routes/restraints are retired. Current named J2/J3/J10/J9/J8/J5/J7 envelopes, open channels and harness instructions govern; electrical mapping corrected. Factory battery and RF cables remain intact." }, { "id": "R36-FX-FINAL-BATTERY-INWARD-RISERS", "components": [ "P01", "P20", "R36_FACTORY_BATTERY_LEAD_1_100mm_INWARD_RISER_FINAL", "R36_FACTORY_BATTERY_LEAD_2_100mm_INWARD_RISER_FINAL" ], "location": "Right battery lead rise and keeper port, Y about39\u202646mm", "failure_mechanism": "Outer wire-clearance sweep breached the fixed curved front exterior; inward reroute can pinch a wire against a head or weaken its keeper port.", "loading_situation": "Battery insertion, hand closure and service cable dressing", "evidence": "OriginalCUT_ROUTE15 removed3.08277mm\u00b2 of outerface. Replacement100mm routes have0.20mm pairgap; exact newchannel-face-to-originaloutside minima1.74808mm and0.999932mm. No originalpatch/classifiedouterarea intersection. NewP20cut2.11862mm\u00b3 leaves full2.5\u00d77\u00d73mm spine and removes0stockfrom bothanchor necks.", "treatment": "Rebuild omittingoldfactorywire14/15masks. Installpaired inwardrisers with matchednewclearance; preservefactorystart,plugend,insulation,tabprotection andmodeled100mm length. Do notrestoreoutsidebyaddingstockoverwire.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Actual100mmfactorylead availability/OD/tabdress, printdistortion, local~1mmcurvedskin handling, keeper free-portcorner andcompleteclosure/service tests. No physicalpass claimed. Support the keeper during support removal and feed wires gently; no levering on the1.336mm free-port shelf.", "source_register": "audit/fixtures/risk_register_battery_riser.json", "r36_status": "CAD CANDIDATE CHECKED; FINAL INTEGRATION AND PHYSICAL QUALIFICATION REQUIRED", "status": "REPLACED_BY_CONNECTED_ROUTING; current audit plus physical dressing/strain-relief test required", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Rebuild omittingoldfactorywire14/15masks. Installpaired inwardrisers with matchednewclearance; preservefactorystart,plugend,insulation,tabprotection andmodeled100mm length. Do notrestoreoutsidebyaddingstockoverwire.", "baseline_evidence": "OriginalCUT_ROUTE15 removed3.08277mm\u00b2 of outerface. Replacement100mm routes have0.20mm pairgap; exact newchannel-face-to-originaloutside minima1.74808mm and0.999932mm. No originalpatch/classifiedouterarea intersection. NewP20cut2.11862mm\u00b3 leaves full2.5\u00d77\u00d73mm spine and removes0stockfrom bothanchor necks.", "current_treatment": "Superseded routes/restraints are retired. Current named J2/J3/J10/J9/J8/J5/J7 envelopes, open channels and harness instructions govern; electrical mapping corrected. Factory battery and RF cables remain intact." }, { "id": "R36-FX-ADAPTER-FINAL-BASE", "components": [ "P01", "ADD_P01_ADAPTER_FULL_CLEARANCE_SUPPORTED_SEAT_FINAL" ], "location": "Adapter seat and two rear-access receiver posts", "failure_mechanism": "Old roots overlapped the carrier and all four pads. Simply widening the old pocket would leave a 0.05 mm pilot wall. Wire relief can also weaken a receiver.", "loading_situation": "Carrier insertion, connector mating, tapping, cable pull and service", "evidence": "Full original-host replay is valid one solid after every operation. Carrier gap 0.25 mm; lateral/end allowance 0.30 mm; header gap 0.399 mm. Final pilot-to-wire ligaments 1.20548 mm left and 0.96161 mm right; right carrier-side minimum 0.95 mm. Pilot-floor to original outside 1.8999 mm.", "treatment": "Replace the old base and Y-axis pilots. Use rear-access posts with controlled M2 tapping and full supported cover seats. The CK2 manufactured front lane moves 1 mm inboard; J9 and factory battery leads remain fixed.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Qualify actual material, orientation, tapping, screw dimensions and torque on QF01B, then 5 N separate plug/cable pulls and ten service cycles. No physical pass is recorded.", "source_register": "audit/fixtures/risk_register_adapter_final.json", "r36_status": "NOMINAL CAD CHECKED; PHYSICAL QUALIFICATION OPEN", "status": "REMOVED_OR_REPLACED_MECHANISM; physical replacement qualification pending", "r37_note": "Old adapter mechanism removed; removal does not resolve direct J2 fit.", "previous_status": "REMOVED_MECHANISM_IN_WORKING_CANDIDATE", "baseline_treatment": "Replace the old base and Y-axis pilots. Use rear-access posts with controlled M2 tapping and full supported cover seats. The CK2 manufactured front lane moves 1 mm inboard; J9 and factory battery leads remain fixed.", "baseline_evidence": "Full original-host replay is valid one solid after every operation. Carrier gap 0.25 mm; lateral/end allowance 0.30 mm; header gap 0.399 mm. Final pilot-to-wire ligaments 1.20548 mm left and 0.96161 mm right; right carrier-side minimum 0.95 mm. Pilot-floor to original outside 1.8999 mm.", "current_treatment": "Superseded mechanism removed from the current assembly. Direct J2/J10 PH connections, adhesive antenna mounting and current routing replace it; see current reference assembly." }, { "id": "R36-FX-ADAPTER-FINAL-COVER", "components": [ "K03" ], "location": "Rear-access cover, grommet webs and 2 mm screw ears", "failure_mechanism": "A screw head inside an old grommet web prevents assembly; cutting away head support can leave a fragile cover.", "loading_situation": "Tightening, wire grip, connector pull and installation", "evidence": "Final cover 580eec is valid one solid; full host, corrected carrier, pads, screws and termination are clear. Ear thickness 2 mm. Lower/upper rail minima 2.025/2.14 mm over 6 mm depth; independent rails receive 10 N screen. Corrected insulation clearance 0.36 mm.", "treatment": "Use final termination-clearance cover and preassemble the complete carrier/header/insulation/pad/grommet module outside the shell. Insert from open rear before PCB and dress the flexible lead afterward. The cover-only path past fixed solder joints is unsuitable.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Qualify actual material, orientation, tapping, screw dimensions and torque on QF01B, then 5 N separate plug/cable pulls and ten service cycles. No physical pass is recorded.", "source_register": "audit/fixtures/risk_register_adapter_final.json", "r36_status": "NOMINAL CAD CHECKED; PHYSICAL QUALIFICATION OPEN", "status": "REMOVED_OR_REPLACED_MECHANISM; physical replacement qualification pending", "r37_note": "Old adapter mechanism removed; removal does not resolve direct J2 fit.", "previous_status": "REMOVED_MECHANISM_IN_WORKING_CANDIDATE", "baseline_treatment": "Use final termination-clearance cover and preassemble the complete carrier/header/insulation/pad/grommet module outside the shell. Insert from open rear before PCB and dress the flexible lead afterward. The cover-only path past fixed solder joints is unsuitable.", "baseline_evidence": "Final cover 580eec is valid one solid; full host, corrected carrier, pads, screws and termination are clear. Ear thickness 2 mm. Lower/upper rail minima 2.025/2.14 mm over 6 mm depth; independent rails receive 10 N screen. Corrected insulation clearance 0.36 mm.", "current_treatment": "Superseded mechanism removed from the current assembly. Direct J2/J10 PH connections, adhesive antenna mounting and current routing replace it; see current reference assembly." }, { "id": "R36-FX-ADAPTER-FINAL-SCREW-1", "components": [ "R36_HA_ADAPTER_M2x6_PAN_1_REAR_ACCESS_FINAL" ], "location": "Adapter screw axis X15.6, Y\u22126.05", "failure_mechanism": "Pilot cracking, thread strip, bottoming or crushed carrier pads from uncontrolled tightening.", "loading_situation": "Assembly tightening and repeated removal", "evidence": "M2\u00d76 pan envelope 4\u00d71.6 mm; headZ\u221210.1\u2026\u22128.5, cover seat\u22126.5, point\u22122.5, pilot floor\u22121.9. Nominal material engagement 4.0 mm; design full-thread allowance 3.0 mm after 1.0 mm tip/runout reserve. Point clearance 0.60 mm.", "treatment": "Machine screw in a controlled hand-tapped M2\u00d70.4 pilot, not a forced self-tapping installation. Set torque through coupon strip/seat tests.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Qualify actual material, orientation, tapping, screw dimensions and torque on QF01B, then 5 N separate plug/cable pulls and ten service cycles. No physical pass is recorded.", "source_register": "audit/fixtures/risk_register_adapter_final.json", "r36_status": "NOMINAL CAD CHECKED; PHYSICAL QUALIFICATION OPEN", "status": "REMOVED_OR_REPLACED_MECHANISM; physical replacement qualification pending", "r37_note": "Old adapter mechanism removed; removal does not resolve direct J2 fit.", "previous_status": "REMOVED_MECHANISM_IN_WORKING_CANDIDATE", "baseline_treatment": "Machine screw in a controlled hand-tapped M2\u00d70.4 pilot, not a forced self-tapping installation. Set torque through coupon strip/seat tests.", "baseline_evidence": "M2\u00d76 pan envelope 4\u00d71.6 mm; headZ\u221210.1\u2026\u22128.5, cover seat\u22126.5, point\u22122.5, pilot floor\u22121.9. Nominal material engagement 4.0 mm; design full-thread allowance 3.0 mm after 1.0 mm tip/runout reserve. Point clearance 0.60 mm.", "current_treatment": "Superseded mechanism removed from the current assembly. Direct J2/J10 PH connections, adhesive antenna mounting and current routing replace it; see current reference assembly." }, { "id": "R36-FX-ADAPTER-FINAL-SCREW-2", "components": [ "R36_HA_ADAPTER_M2x6_PAN_2_REAR_ACCESS_FINAL" ], "location": "Adapter screw axis X28.1, Y\u22126.05", "failure_mechanism": "Pilot cracking, thread strip, bottoming or crushed carrier pads from uncontrolled tightening.", "loading_situation": "Assembly tightening and repeated removal", "evidence": "M2\u00d76 pan envelope 4\u00d71.6 mm; headZ\u221210.1\u2026\u22128.5, cover seat\u22126.5, point\u22122.5, pilot floor\u22121.9. Nominal material engagement 4.0 mm; design full-thread allowance 3.0 mm after 1.0 mm tip/runout reserve. Point clearance 0.60 mm.", "treatment": "Machine screw in a controlled hand-tapped M2\u00d70.4 pilot, not a forced self-tapping installation. Set torque through coupon strip/seat tests.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Qualify actual material, orientation, tapping, screw dimensions and torque on QF01B, then 5 N separate plug/cable pulls and ten service cycles. No physical pass is recorded.", "source_register": "audit/fixtures/risk_register_adapter_final.json", "r36_status": "NOMINAL CAD CHECKED; PHYSICAL QUALIFICATION OPEN", "status": "REMOVED_OR_REPLACED_MECHANISM; physical replacement qualification pending", "r37_note": "Old adapter mechanism removed; removal does not resolve direct J2 fit.", "previous_status": "REMOVED_MECHANISM_IN_WORKING_CANDIDATE", "baseline_treatment": "Machine screw in a controlled hand-tapped M2\u00d70.4 pilot, not a forced self-tapping installation. Set torque through coupon strip/seat tests.", "baseline_evidence": "M2\u00d76 pan envelope 4\u00d71.6 mm; headZ\u221210.1\u2026\u22128.5, cover seat\u22126.5, point\u22122.5, pilot floor\u22121.9. Nominal material engagement 4.0 mm; design full-thread allowance 3.0 mm after 1.0 mm tip/runout reserve. Point clearance 0.60 mm.", "current_treatment": "Superseded mechanism removed from the current assembly. Direct J2/J10 PH connections, adhesive antenna mounting and current routing replace it; see current reference assembly." }, { "id": "R36-FX-ADAPTER-FINAL-PAD-LANDS", "components": [ "R36_STOCK_ADAPTER_CARRIER_EDGE_PAD_1_FRONT_INSTALLED_0p25", "R36_STOCK_ADAPTER_CARRIER_EDGE_PAD_1_REAR_INSTALLED_0p25", "R36_STOCK_ADAPTER_CARRIER_EDGE_PAD_2_FRONT_INSTALLED_0p25", "R36_STOCK_ADAPTER_CARRIER_EDGE_PAD_2_REAR_INSTALLED_0p25" ], "location": "Four carrier edge pads and front backing columns", "failure_mechanism": "Thin unsupported ledges bend; excessive pad compression or misassembly loads the carrier/header pins.", "loading_situation": "Mating/pull load and cover tightening", "evidence": "Front support is 2.8\u00d73.0 mm; 0.6 of each 0.8 mm pad width is supported, giving 3.6 mm\u00b2 contact per front pad. Unbacked outer 0.2 mm is soft pad only. Rear pads retain cover contact.", "treatment": "Seat the carrier/pads before the cover. The cover closes onto hard supports; it must not be tightened to force a warped carrier into place.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Qualify actual material, orientation, tapping, screw dimensions and torque on QF01B, then 5 N separate plug/cable pulls and ten service cycles. No physical pass is recorded.", "source_register": "audit/fixtures/risk_register_adapter_final.json", "r36_status": "NOMINAL CAD CHECKED; PHYSICAL QUALIFICATION OPEN", "status": "REMOVED_OR_REPLACED_MECHANISM; physical replacement qualification pending", "r37_note": "Old adapter mechanism removed; removal does not resolve direct J2 fit.", "previous_status": "REMOVED_MECHANISM_IN_WORKING_CANDIDATE", "baseline_treatment": "Seat the carrier/pads before the cover. The cover closes onto hard supports; it must not be tightened to force a warped carrier into place.", "baseline_evidence": "Front support is 2.8\u00d73.0 mm; 0.6 of each 0.8 mm pad width is supported, giving 3.6 mm\u00b2 contact per front pad. Unbacked outer 0.2 mm is soft pad only. Rear pads retain cover contact.", "current_treatment": "Superseded mechanism removed from the current assembly. Direct J2/J10 PH connections, adhesive antenna mounting and current routing replace it; see current reference assembly." }, { "id": "R36-FX-ADAPTER-FINAL-GROMMET", "components": [ "R36_STOCK_ADAPTER_SPLIT_SILICONE_GROMMET_INSTALLED" ], "location": "Outgoing insulated CK pair at K03", "failure_mechanism": "Cable pull reaching solder joints, insulation abrasion or silicone slip.", "loading_situation": "Cable dressing and 5 N service pull", "evidence": "Final cover preserves the split-grommet pose and cable endpoints. Corrected termination clears grommet 0.3414 mm and final cover 0.36 mm. Its load is retained through grommet and reinforced rails, not contact against insulation.", "treatment": "Use the specified installed split grommet around intact insulation and close the matching cover before loading the cable.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Qualify actual material, orientation, tapping, screw dimensions and torque on QF01B, then 5 N separate plug/cable pulls and ten service cycles. No physical pass is recorded.", "source_register": "audit/fixtures/risk_register_adapter_final.json", "r36_status": "NOMINAL CAD CHECKED; PHYSICAL QUALIFICATION OPEN", "status": "REMOVED_OR_REPLACED_MECHANISM; physical replacement qualification pending", "r37_note": "Old adapter mechanism removed; removal does not resolve direct J2 fit.", "previous_status": "REMOVED_MECHANISM_IN_WORKING_CANDIDATE", "baseline_treatment": "Use the specified installed split grommet around intact insulation and close the matching cover before loading the cable.", "baseline_evidence": "Final cover preserves the split-grommet pose and cable endpoints. Corrected termination clears grommet 0.3414 mm and final cover 0.36 mm. Its load is retained through grommet and reinforced rails, not contact against insulation.", "current_treatment": "Superseded mechanism removed from the current assembly. Direct J2/J10 PH connections, adhesive antenna mounting and current routing replace it; see current reference assembly." }, { "id": "R36-FX-ADAPTER-FINAL-CK2", "components": [ "R36_J2_CK_PIGTAIL_2_ADAPTER_LIGAMENT_FINAL" ], "location": "Manufactured CK2 front lane", "failure_mechanism": "A channel too close to the pilot leaves a thin torque-loaded wall; poor wire dressing can rub or pull contacts.", "loading_situation": "Assembly and service motion", "evidence": "Only the front lane moved 1 mm inboard. Endpoints and R3/OD1.05 mm routing assumptions remain. Left pilot-channel ligament grows 0.404\u21921.20548 mm. No new checked reference collision.", "treatment": "Install the selected final route and replacement clearance mask; do not retain the old CK2 reference or stack both routes.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Qualify actual material, orientation, tapping, screw dimensions and torque on QF01B, then 5 N separate plug/cable pulls and ten service cycles. No physical pass is recorded.", "source_register": "audit/fixtures/risk_register_adapter_final.json", "r36_status": "NOMINAL CAD CHECKED; PHYSICAL QUALIFICATION OPEN", "status": "REMOVED_OR_REPLACED_MECHANISM; physical replacement qualification pending", "r37_note": "Old adapter mechanism removed; removal does not resolve direct J2 fit.", "previous_status": "REMOVED_MECHANISM_IN_WORKING_CANDIDATE", "baseline_treatment": "Install the selected final route and replacement clearance mask; do not retain the old CK2 reference or stack both routes.", "baseline_evidence": "Only the front lane moved 1 mm inboard. Endpoints and R3/OD1.05 mm routing assumptions remain. Left pilot-channel ligament grows 0.404\u21921.20548 mm. No new checked reference collision.", "current_treatment": "Superseded mechanism removed from the current assembly. Direct J2/J10 PH connections, adhesive antenna mounting and current routing replace it; see current reference assembly." }, { "id": "R36-FX-ADAPTER-FINAL-COUPON", "components": [ "QF01B_REAR_ACCESS_ADAPTER_ACTUAL_SEAT_AND_WIRE_RELIEF" ], "location": "Qualification coupon", "failure_mechanism": "A generic post coupon can miss the final thin ligaments, pad/backer geometry and wire channels.", "loading_situation": "Print qualification before first assembled article", "evidence": "QF01B is cropped from the actual final P01 after all wire cuts, with both rear pilots, floor skins and carrier lands. STEP one solid; STL watertight and consistent.", "treatment": "Replace old Y-axis QF01. Use actual final K03, corrected carrier, pads, grommet and purchased screws as mating pieces.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Qualify actual material, orientation, tapping, screw dimensions and torque on QF01B, then 5 N separate plug/cable pulls and ten service cycles. No physical pass is recorded.", "source_register": "audit/fixtures/risk_register_adapter_final.json", "r36_status": "NOMINAL CAD CHECKED; PHYSICAL QUALIFICATION OPEN", "status": "REMOVED_OR_REPLACED_MECHANISM; physical replacement qualification pending", "r37_note": "Old adapter mechanism removed; removal does not resolve direct J2 fit.", "previous_status": "REMOVED_MECHANISM_IN_WORKING_CANDIDATE", "baseline_treatment": "Replace old Y-axis QF01. Use actual final K03, corrected carrier, pads, grommet and purchased screws as mating pieces.", "baseline_evidence": "QF01B is cropped from the actual final P01 after all wire cuts, with both rear pilots, floor skins and carrier lands. STEP one solid; STL watertight and consistent.", "current_treatment": "Superseded mechanism removed from the current assembly. Direct J2/J10 PH connections, adhesive antenna mounting and current routing replace it; see current reference assembly." }, { "id": "R36-FX-MIC-FACING-FINAL", "components": [ "R36_STOCK_MIC_SADDLE_SILICONE_TRIMMED_6x10p5x0p25_FINAL", "R36_STOCK_MIC_SADDLE_POLYESTER_STRAP_0p10", "P01 microphone harness saddle", "P01" ], "location": "Microphone facing at X\u221221.5\u2026\u221215.5, Y\u221230\u2026\u221219.5, Z\u22128.975\u2026\u22128.725", "failure_mechanism": "The original facing overlapped the rising formed strap by 0.147692 mm\u00b3, risking a folded edge, uncontrolled preload or strap lift.", "loading_situation": "Tape application, cable dressing and microphone bundle pull", "evidence": "Upper facing edge shortened by 0.50 mm. New facing is 6.0 \u00d7 10.5 \u00d7 0.25 mm, retaining 63/66 mm\u00b2 (95.45%). Strap overlap is zero; minimum normal gap is 0.121268 mm. All five original wire contact rows remain supported; upper edge extends 0.965 mm beyond the last wire surface.", "treatment": "Replace only the silicone facing with the trimmed stock. Keep the existing shell saddle, formed strap and both 2 mm printed bond lands. No material interpenetration or compression is credited at the ramp.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Verify installed 0.25 mm thickness and edge placement, adhesive bond and jacket contact on QF03. Apply 5 N bundle pull and ten service cycles; reject lift, slip, damage or rubbing. No physical test was performed.", "source_register": "audit/fixtures/risk_register_mic_facing_final.json", "r36_status": "NOMINAL STOCK FIT CHECKED; PHYSICAL QUALIFICATION OPEN", "status": "REPLACED_BY_CONNECTED_ROUTING; current audit plus physical dressing/strain-relief test required", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Replace only the silicone facing with the trimmed stock. Keep the existing shell saddle, formed strap and both 2 mm printed bond lands. No material interpenetration or compression is credited at the ramp.", "baseline_evidence": "Upper facing edge shortened by 0.50 mm. New facing is 6.0 \u00d7 10.5 \u00d7 0.25 mm, retaining 63/66 mm\u00b2 (95.45%). Strap overlap is zero; minimum normal gap is 0.121268 mm. All five original wire contact rows remain supported; upper edge extends 0.965 mm beyond the last wire surface.", "current_treatment": "Superseded routes/restraints are retired. Current named J2/J3/J10/J9/J8/J5/J7 envelopes, open channels and harness instructions govern; electrical mapping corrected. Factory battery and RF cables remain intact." }, { "id": "R36-J9-ROUTES", "components": [ "J9 PHR-5", "five connector leads", "three common links", "short upper-volume pigtail" ], "location": "Original side-entryJ9 to the four unchanged switch locations", "failure_mechanism": "Wire pinch, scraping, sharp bends or cable forces transmitted to connector/solder joints.", "loading_situation": "Assembly, control presses and opening/service.", "evidence": "Nine OD1.05mm wire solids with R3 static bends; fixed PHR5 gauge6.85\u00d711.8\u00d74.5mm. Exact route metadata and all cut lengths are recorded.", "treatment": "Keep fixed header/PCB positions. Route around locating stock and controls. Common-return chain removes the large central junction.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Confirm received latch/exit geometry, selected wireOD\u22641.05, static bend suitability, actual routing and connector-body access. Do not force a connector or wire into position.", "source_register": "audit/fixtures/risk_register_j9.json", "r36_status": "CAD geometry prepared; physical and electrical release gates remain", "status": "REPLACED_BY_CONNECTED_ROUTING; current audit plus physical dressing/strain-relief test required", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Keep fixed header/PCB positions. Route around locating stock and controls. Common-return chain removes the large central junction.", "baseline_evidence": "Nine OD1.05mm wire solids with R3 static bends; fixed PHR5 gauge6.85\u00d711.8\u00d74.5mm. Exact route metadata and all cut lengths are recorded.", "current_treatment": "Superseded routes/restraints are retired. Current named J2/J3/J10/J9/J8/J5/J7 envelopes, open channels and harness instructions govern; electrical mapping corrected. Factory battery and RF cables remain intact." }, { "id": "R36-J9-SHELLS", "components": [ "P01", "P02" ], "location": "Local cable channels and terminal pockets", "failure_mechanism": "Internal relief removes load-bearing stock or changes the locked exterior.", "loading_situation": "Shell closure and fastener loads.", "evidence": "Wire clearance\u00d81.65 gives0.30mm radial allowance. The outboardP01 lane reachesX31.075, preserving the retained locating core throughX30.8 with0.275mm separation.", "treatment": "Cut exact routed sweeps only, after all shell additions. Preserve core/contact faces. Add matching wire supports.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Root exact exterior/seam proof, full native assembly and load-path review of the smallP02 exit notches. First-article wall/fit checks remain required.", "source_register": "audit/fixtures/risk_register_j9.json", "r36_status": "CAD geometry prepared; physical and electrical release gates remain", "status": "REPLACED_BY_CONNECTED_ROUTING; current audit plus physical dressing/strain-relief test required", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Cut exact routed sweeps only, after all shell additions. Preserve core/contact faces. Add matching wire supports.", "baseline_evidence": "Wire clearance\u00d81.65 gives0.30mm radial allowance. The outboardP01 lane reachesX31.075, preserving the retained locating core throughX30.8 with0.275mm separation.", "current_treatment": "Superseded routes/restraints are retired. Current named J2/J3/J10/J9/J8/J5/J7 envelopes, open channels and harness instructions govern; electrical mapping corrected. Factory battery and RF cables remain intact." }, { "id": "R36-J9-TERMINALS", "components": [ "ten insulated terminal joints", "four original switches" ], "location": "Nominal switch legs", "failure_mechanism": "Bare solder, wrong contact pairing, oversized sleeves, or bending a terminal against a printed cradle.", "loading_situation": "Soldering, wire dressing and control operation.", "evidence": "Original switch geometry is explicitly non-OEM nominal. Joint envelopes\u00d81.5\u00d72.0\u20133.2mm overlap only intended tabs; play approaches use existing X-direction access.", "treatment": "One wire per used switch leg. Fully insulate exposed conductor and solder. Preserve switch body/seat positions.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Verify actual switch legs and same-contact pairs by continuity, confirm J9 PCB net mapping, qualify solder/insulation and inspect for shorts before power. Geometric pin-row labels are not a verified electrical pinout.", "source_register": "audit/fixtures/risk_register_j9.json", "r36_status": "CAD geometry prepared; physical and electrical release gates remain", "status": "REPLACED_BY_CONNECTED_ROUTING; current audit plus physical dressing/strain-relief test required", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "One wire per used switch leg. Fully insulate exposed conductor and solder. Preserve switch body/seat positions.", "baseline_evidence": "Original switch geometry is explicitly non-OEM nominal. Joint envelopes\u00d81.5\u00d72.0\u20133.2mm overlap only intended tabs; play approaches use existing X-direction access.", "current_treatment": "Superseded routes/restraints are retired. Current named J2/J3/J10/J9/J8/J5/J7 envelopes, open channels and harness instructions govern; electrical mapping corrected. Factory battery and RF cables remain intact." }, { "id": "R36-J9-COMMON-JUNCTION", "components": [ "upper-volume common junction", "short pigtail" ], "location": "X17\u202623,Y23.4,Z\u221211.25", "failure_mechanism": "A bulky or exposed branch joint collides with PCB, battery toe or control guide.", "loading_situation": "Harness assembly and service pull.", "evidence": "One fully insulated three-way junction has maximum\u00d82.4\u00d76mm; straight short pigtail\u22487.489mm links the original rear-common terminal.", "treatment": "Keep the junction in its defined saddle and within the sleeve envelope. Two common links meet inside this sleeve; no naked crossing is allowed.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Qualified joint fabrication and insulation coverage. Validate actual sleeve dimensions and strain relief with a gentle pull and operation test.", "source_register": "audit/fixtures/risk_register_j9.json", "r36_status": "CAD geometry prepared; physical and electrical release gates remain", "status": "REPLACED_BY_CONNECTED_ROUTING; current audit plus physical dressing/strain-relief test required", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Keep the junction in its defined saddle and within the sleeve envelope. Two common links meet inside this sleeve; no naked crossing is allowed.", "baseline_evidence": "One fully insulated three-way junction has maximum\u00d82.4\u00d76mm; straight short pigtail\u22487.489mm links the original rear-common terminal.", "current_treatment": "Superseded routes/restraints are retired. Current named J2/J3/J10/J9/J8/J5/J7 envelopes, open channels and harness instructions govern; electrical mapping corrected. Factory battery and RF cables remain intact." }, { "id": "R36-J9-PTT-SUPPORT", "components": [ "P01 PTT wire support", "PTT signal", "PTT common return", "P01" ], "location": "X\u221225.5\u2026\u221220.5,Y\u221215.5\u2026\u221212.5", "failure_mechanism": "Support splitting or an unremovable wire forced through a printed passage.", "loading_situation": "Wire insertion and service loads.", "evidence": "Upper nominal\u00d81.65 bore; lower\u00d81.65 rear-open channel; side ligaments1.675mm.", "treatment": "Broad front-rooted support. Feed the upper signal before terminal soldering; lay lower return in the open channel. The harness stays on the front shell during ordinary service.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Actual process coupon, no forced insertion,5N retention screen and10service cycles. Check bore/root stress concentrations and actual material direction/creep.", "source_register": "audit/fixtures/risk_register_j9.json", "r36_status": "CAD geometry prepared; physical and electrical release gates remain", "status": "REPLACED_BY_CONNECTED_ROUTING; current audit plus physical dressing/strain-relief test required", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Broad front-rooted support. Feed the upper signal before terminal soldering; lay lower return in the open channel. The harness stays on the front shell during ordinary service.", "baseline_evidence": "Upper nominal\u00d81.65 bore; lower\u00d81.65 rear-open channel; side ligaments1.675mm.", "current_treatment": "Superseded routes/restraints are retired. Current named J2/J3/J10/J9/J8/J5/J7 envelopes, open channels and harness instructions govern; electrical mapping corrected. Factory battery and RF cables remain intact." }, { "id": "R36-J9-PTT-TAPE", "components": [ "PTT rear retaining tape" ], "location": "5\u00d73\u00d70.10mm installed rear strip", "failure_mechanism": "Adhesive peels and the return leaves its groove.", "loading_situation": "Service handling and cable movement.", "evidence": "Two rear lands total\u224810.05mm\u00b2;0.10mm installed insulating polyester strip.", "treatment": "Use compatible tape, clean printed lands, replace after opening. Grip connector housings and support wires during service.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Require5N tape/support coupon screen and10service cycles on the actual print material. Average5N/land area\u22480.50MPa is only a load calculation; no tape strength is assumed. Hold release if peeling occurs.", "source_register": "audit/fixtures/risk_register_j9.json", "r36_status": "CAD geometry prepared; physical and electrical release gates remain", "status": "REPLACED_BY_CONNECTED_ROUTING; current audit plus physical dressing/strain-relief test required", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Use compatible tape, clean printed lands, replace after opening. Grip connector housings and support wires during service.", "baseline_evidence": "Two rear lands total\u224810.05mm\u00b2;0.10mm installed insulating polyester strip.", "current_treatment": "Superseded routes/restraints are retired. Current named J2/J3/J10/J9/J8/J5/J7 envelopes, open channels and harness instructions govern; electrical mapping corrected. Factory battery and RF cables remain intact." }, { "id": "R36-J9-JUNCTION-SUPPORT", "components": [ "P01 common-junction support", "silicone facing", "P01" ], "location": "Shelf X17\u202629.5,Y18.5\u202624.8; root X25\u202629.5,Y14.5\u202618.5", "failure_mechanism": "Unsupported splice bends solder joints or support interferes with nearby wiring.", "loading_situation": "Wire dressing and service pull.", "evidence": "Support has a 3\u00d71.2 mm through-slot in a 2.15 mm shelf, with a 1.85 mm local pad seat. It joins the retained PCB backing4. Facing3.5\u00d70.8\u00d70.30 mm installed, including adhesive.", "treatment": "Outboard front root and broad shelf below the factory-wire plane; matched wire relief. Soft facing cushions the insulated joint. PCB contact stock is preserved.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Physical support/film fit, no exposed solder, no adhesive contamination and5N/10cycle retention check. Beam numbers exclude notch, material anisotropy and creep.", "source_register": "audit/fixtures/risk_register_j9.json", "r36_status": "CAD geometry prepared; physical and electrical release gates remain", "status": "REPLACED_BY_CONNECTED_ROUTING; current audit plus physical dressing/strain-relief test required", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Outboard front root and broad shelf below the factory-wire plane; matched wire relief. Soft facing cushions the insulated joint. PCB contact stock is preserved.", "baseline_evidence": "Support has a 3\u00d71.2 mm through-slot in a 2.15 mm shelf, with a 1.85 mm local pad seat. It joins the retained PCB backing4. Facing3.5\u00d70.8\u00d70.30 mm installed, including adhesive.", "current_treatment": "Superseded routes/restraints are retired. Current named J2/J3/J10/J9/J8/J5/J7 envelopes, open channels and harness instructions govern; electrical mapping corrected. Factory battery and RF cables remain intact." }, { "id": "R36-J9-JUNCTION-LOOP", "components": [ "insulating polyester loop" ], "location": "2.5mm wide loop through the support slot", "failure_mechanism": "Loop loosens or adhesive fails, loading the three-way joint.", "loading_situation": "Service pull and vibration.", "evidence": "0.10mm installed tape; initial2.5\u00d740mm stock,\u226510mm self-bond overlap. Routed loop clears the battery toe by\u22480.408 mm and the intact factory leads by at least\u22480.35 mm; short-pigtail gap\u22480.183 mm is a tight dressing gate.", "treatment": "Thread through fixed slot and wrap the insulated junction; snug only, without pulling solder joints. Replace after service.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Verify folded thickness, no pinch,\u226510mm overlap and5N pull on actual tape/material. Do not interpret the model as supplier tape qualification.", "source_register": "audit/fixtures/risk_register_j9.json", "r36_status": "CAD geometry prepared; physical and electrical release gates remain", "status": "REPLACED_BY_CONNECTED_ROUTING; current audit plus physical dressing/strain-relief test required", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Thread through fixed slot and wrap the insulated junction; snug only, without pulling solder joints. Replace after service.", "baseline_evidence": "0.10mm installed tape; initial2.5\u00d740mm stock,\u226510mm self-bond overlap. Routed loop clears the battery toe by\u22480.408 mm and the intact factory leads by at least\u22480.35 mm; short-pigtail gap\u22480.183 mm is a tight dressing gate.", "current_treatment": "Superseded routes/restraints are retired. Current named J2/J3/J10/J9/J8/J5/J7 envelopes, open channels and harness instructions govern; electrical mapping corrected. Factory battery and RF cables remain intact." }, { "id": "R36-J9-COUPONS", "components": [ "QJ01", "QJ02" ], "location": "Standalone exact-support print coupons", "failure_mechanism": "A failed print process is used directly in the complete shell.", "loading_situation": "Pilot printing and assembly qualification.", "evidence": "Coupons include the actual final support geometry on a sacrificial base; stock is listed separately.", "treatment": "Print at the same orientation/material/process as the corresponding front-shell features and measure the channels/slot.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Use actual wire and tape for insertion/5N/10cycle checks. Coupon success is necessary but does not certify whole-case drops or life.", "source_register": "audit/fixtures/risk_register_j9.json", "r36_status": "CAD geometry prepared; physical and electrical release gates remain", "status": "REPLACED_BY_CONNECTED_ROUTING; current audit plus physical dressing/strain-relief test required", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Print at the same orientation/material/process as the corresponding front-shell features and measure the channels/slot.", "baseline_evidence": "Coupons include the actual final support geometry on a sacrificial base; stock is listed separately.", "current_treatment": "Superseded routes/restraints are retired. Current named J2/J3/J10/J9/J8/J5/J7 envelopes, open channels and harness instructions govern; electrical mapping corrected. Factory battery and RF cables remain intact." }, { "id": "R36-J9-SERVICE", "components": [ "PHR-5", "all J9 wires", "P01", "PCB" ], "location": "Rear opening and PCB removal", "failure_mechanism": "Insufficient accessible slack pulls solder joints or thin printed features apart.", "loading_situation": "Assembly, maintenance and disassembly.", "evidence": "CAD defines installed routes, not a certified opening angle or stored service loop. Stock+20mm is a cutting allowance.", "treatment": "Keep PCB and front assembly supported together. UnplugPHR5 by its body before lifting PCB. Feed the PTT upper wire before final soldering. Replace removable tape after access.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Demonstrate unpowered opening/disconnection without tension, scraping or pinching. Trim stock to the verified route; do not hide the20mm allowance in an unmodelled loop. Full front-shell replacement may require contact depinning or solder service.", "source_register": "audit/fixtures/risk_register_j9.json", "r36_status": "CAD geometry prepared; physical and electrical release gates remain", "status": "REPLACED_BY_CONNECTED_ROUTING; current audit plus physical dressing/strain-relief test required", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Keep PCB and front assembly supported together. UnplugPHR5 by its body before lifting PCB. Feed the PTT upper wire before final soldering. Replace removable tape after access.", "baseline_evidence": "CAD defines installed routes, not a certified opening angle or stored service loop. Stock+20mm is a cutting allowance.", "current_treatment": "Superseded routes/restraints are retired. Current named J2/J3/J10/J9/J8/J5/J7 envelopes, open channels and harness instructions govern; electrical mapping corrected. Factory battery and RF cables remain intact." }, { "id": "R36-ADAPTER_FAB_01", "components": [ "fabricated FR4 carrier", "B2B-PH-K-S(LF)(SN) header" ], "location": "Two holes atX21/23,Z\u22126.7 throughY\u22125\u2026\u22124", "failure_mechanism": "Incorrect hole row or finished drill/plating forces or bends the header tails; loose or damaged anchorage.", "loading_situation": "Header population and connector mating/service.", "evidence": "Old holes offset0.6mm produced0.6432mm\u00b3 source-pin overlap. Corrected holes yield0 overlap and0.07145mm nominal modeled pin-to-bore gap. JST reference hole is0.7+0.1/0 and notes hard-FR4 enlargement may be needed.", "treatment": "Corrected hole row; two\u00d80.95\u00b10.03 plated holes, isolated\u00d81.6 pads, finished8x6x1 outside envelope, body-grip service and separate soft-supported seat.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Measure finished carrier and fit received header freely; verify pad/barrel solder anchorage and10 service cycles.", "source_register": "audit/fixtures/risk_register_adapter_fabrication.json", "r36_status": "CAD_PASS_PHYSICAL_GATE", "status": "REMOVED_OR_REPLACED_MECHANISM; physical replacement qualification pending", "r37_note": "Old adapter mechanism removed; removal does not resolve direct J2 fit.", "previous_status": "REMOVED_MECHANISM_IN_WORKING_CANDIDATE", "baseline_treatment": "Corrected hole row; two\u00d80.95\u00b10.03 plated holes, isolated\u00d81.6 pads, finished8x6x1 outside envelope, body-grip service and separate soft-supported seat.", "baseline_evidence": "Old holes offset0.6mm produced0.6432mm\u00b3 source-pin overlap. Corrected holes yield0 overlap and0.07145mm nominal modeled pin-to-bore gap. JST reference hole is0.7+0.1/0 and notes hard-FR4 enlargement may be needed.", "current_treatment": "Superseded mechanism removed from the current assembly. Direct J2/J10 PH connections, adhesive antenna mounting and current routing replace it; see current reference assembly." }, { "id": "R36-ADAPTER_FAB_02", "components": [ "two CK pigtail direct-lap joints", "two insulating sleeves", "rear pad coatings" ], "location": "X21/23,Y\u22129.96\u2026\u22125,Z\u22128.23\u2026\u22125.8", "failure_mechanism": "Cold lap, damaged strands, exposed pin or solder bridge; pull load reaches the joint or insulation rubs the cover.", "loading_situation": "Soldering, wire dressing, installation and5N service pull.", "evidence": "Source bare tails and modeled\u00d80.48 cores are wholly contained in the new insulation envelope. Two insulated envelopes retain0.20mm nominal gap; K03 gap0.60374mm and split clamp gap0.34139mm.", "treatment": "Direct wire-to-metal-tail lap, each branch independently sleeved and rear-pad covered; preserve fixed jacket endpoints and use the separate split-silicone clamp. No solder/insulation outside checked maximum envelopes.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Qualify actual core/strip length, solder wetting and insulation material/coverage, sleeve separation and5N/10cycle retention; do not power an unverified joint.", "source_register": "audit/fixtures/risk_register_adapter_fabrication.json", "r36_status": "CAD_PASS_FABRICATION_GATE", "status": "REMOVED_OR_REPLACED_MECHANISM; physical replacement qualification pending", "r37_note": "Old adapter mechanism removed; removal does not resolve direct J2 fit.", "previous_status": "REMOVED_MECHANISM_IN_WORKING_CANDIDATE", "baseline_treatment": "Direct wire-to-metal-tail lap, each branch independently sleeved and rear-pad covered; preserve fixed jacket endpoints and use the separate split-silicone clamp. No solder/insulation outside checked maximum envelopes.", "baseline_evidence": "Source bare tails and modeled\u00d80.48 cores are wholly contained in the new insulation envelope. Two insulated envelopes retain0.20mm nominal gap; K03 gap0.60374mm and split clamp gap0.34139mm.", "current_treatment": "Superseded mechanism removed from the current assembly. Direct J2/J10 PH connections, adhesive antenna mounting and current routing replace it; see current reference assembly." }, { "id": "R36-ADAPTER_FAB_03", "components": [ "passive adapter two isolated connections", "main-board battery input", "intact factory battery plug" ], "location": "A/B paths on the adapter and their board endpoints", "failure_mechanism": "Reversed polarity, A-B short or excess resistance/current heating despite mechanical fit.", "loading_situation": "First connection, operation and charging.", "evidence": "Geometric A/B labels do not establish electrical pin numbering. JST2A rating is specified withAWG24; routed26AWG assembly is not electrically qualified.", "treatment": "No cross-net copper or traces; current travels through direct wire-to-tail lap. Preserve factory pack leads/plug, map actual polarity and board nets with documentation/continuity, grip connector bodies.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Verify battery polarity and board mapping, A/B continuity and isolation, actual current/contact/temperature limits and strain relief before energized assembly.", "source_register": "audit/fixtures/risk_register_adapter_fabrication.json", "r36_status": "ELECTRICAL_RELEASE_HOLD", "status": "REMOVED_OR_REPLACED_MECHANISM; physical replacement qualification pending", "r37_note": "Old adapter mechanism removed; removal does not resolve direct J2 fit.", "previous_status": "REMOVED_MECHANISM_IN_WORKING_CANDIDATE", "baseline_treatment": "No cross-net copper or traces; current travels through direct wire-to-tail lap. Preserve factory pack leads/plug, map actual polarity and board nets with documentation/continuity, grip connector bodies.", "baseline_evidence": "Geometric A/B labels do not establish electrical pin numbering. JST2A rating is specified withAWG24; routed26AWG assembly is not electrically qualified.", "current_treatment": "Superseded mechanism removed from the current assembly. Direct J2/J10 PH connections, adhesive antenna mounting and current routing replace it; see current reference assembly." }, { "id": "R36-CTRL_K03_REAR_ACCESS", "components": [ "K03", "P01", "H10", "QF01B" ], "location": "Adapter receiver and cable-grommet cover", "failure_mechanism": "Former horizontal screw heads/shafts occupied grommet webs; thin receiver ligament may split during thread formation; carrier can be pinched by an incorrect seat.", "loading_situation": "Tightening, cable pull, installation and repeated service.", "evidence": [ "K03_pair_and_access.json", "K03_local_strength.json", "K03_REAR_ACCESS_REVIEW.md", "K03_preassembled_insertion.json", "K03_final_removal_delta.json" ], "treatment": "Two rear-access M2x6 pan screws,2mm hard-seated ears,6mm-deep grommet crossbar with independently supported minimum2.025/2.14mm rails, rounded positive-clearance insulation passage, controlled pilot/thread qualification; original electronics/exterior fixed.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Print QF01B in final process; qualify actual pilot/thread method, head size, ten service cycles and cable retention. No screw torque/thread strength or cable pull rating is certified.", "source_register": "audit/controls/risk_register_k03_final.json", "r36_status": "Nominal geometry and bounded analytical screens pass; physical qualification open.", "status": "REMOVED_OR_REPLACED_MECHANISM; physical replacement qualification pending", "r37_note": "Old adapter mechanism removed; removal does not resolve direct J2 fit.", "previous_status": "REMOVED_MECHANISM_IN_WORKING_CANDIDATE", "baseline_treatment": "Two rear-access M2x6 pan screws,2mm hard-seated ears,6mm-deep grommet crossbar with independently supported minimum2.025/2.14mm rails, rounded positive-clearance insulation passage, controlled pilot/thread qualification; original electronics/exterior fixed.", "baseline_evidence": [ "K03_pair_and_access.json", "K03_local_strength.json", "K03_REAR_ACCESS_REVIEW.md", "K03_preassembled_insertion.json", "K03_final_removal_delta.json" ], "current_treatment": "Superseded mechanism removed from the current assembly. Direct J2/J10 PH connections, adhesive antenna mounting and current routing replace it; see current reference assembly." }, { "id": "R36-PTT-PAD-MOTION", "components": [ "PTT fixed rear keeper facing", "P05 moving carrier", "P08 switch cradle", "P01 central support", "R36_STOCK_PTT_REAR_PAD_TRIMMED_5p2x9x0p50_FINAL", "P05", "P08", "P01" ], "location": "Fixed facing outboard edgeX-36.7,Y12.5..21.5,Z-12.7..-12.2", "failure_mechanism": "Old facing overhang enters moving carrier after0.25mm travel, adding drag or sustained preload and potentially preventing release.", "loading_situation": "PTT press/release through0.45mm travel and off-centre handling.", "evidence": "Old pad overlap0.225mm\u00b3 at0.30mm travel. A0.50mm edge trim retains91.23% overall facing area and all exact fixed housing/cradle/shell contact areas. The new stock is a strict subset of the old reference.", "treatment": "Trim only outboard edge; preserve0.50mm installed thickness, inboard datum and all rigid support contact areas. No rubbing or forced compression is credited.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Root final full-motion run after integration, actual cut-edge placement/installed thickness, reliable electrical release,10 service cycles and1000 PTT actuations without drag or pad creep.", "source_register": "audit/fixtures/risk_register_ptt_pad_correction.json", "r36_status": "LOCAL_CAD_PASS_FULL_MOTION_RERUN_REQUIRED", "status": "REVIEWED; current nominal checks and physical qualification remain distinct", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Trim only outboard edge; preserve0.50mm installed thickness, inboard datum and all rigid support contact areas. No rubbing or forced compression is credited.", "baseline_evidence": "Old pad overlap0.225mm\u00b3 at0.30mm travel. A0.50mm edge trim retains91.23% overall facing area and all exact fixed housing/cradle/shell contact areas. The new stock is a strict subset of the old reference.", "current_treatment": "Original outer faces retained. Integrated three switch seats, broader PTT bearing and PCB stop, repositioned PCB supports, open cable channels, revised LED and speaker seats. Retain the short captured R3.6 mechanism, broad roots, original visible shape and end stops. Physical end presses remain required. Now part of P01, with a broad supported inner bearing around the insulated terminal exits. No loose cradle to handle or force into place." }, { "id": "R36-ACCESS-FRONT-ORDER", "components": [ "P01", "P04", "P11", "P12", "P13", "P14", "P17", "P18", "K03", "F01", "C28_R2_REF_PCB_fb5acde7_SHA30578154", "R36_J8_LED_PH_LEAD_2_OD1p05_R3", "R36_J8_LED_PH_LEAD_3_OD1p05_R3", "R36_J8_LED_PH_LEAD_4_OD1p05_R3" ], "location": "Front retainer, PTT and adapter screw-driver corridors", "failure_mechanism": "A driver can load the installed PCB, wires or opposite shell when attempting a front screw after those items are installed.", "loading_situation": "Initial fastening and service with a straight hand driver.", "evidence": "All front fastener paths clear with the rear subassembly/PCB absent; one lower speaker tool crosses the final J8 wires. K03 driver paths are blocked by the installed PCB. audit/fixtures/driver_access_final/FINAL_DRIVER_ACCESS_REPORT.json (manifest 77d9a0a5675bf7fb0d123d983df8f920fc91d25a51c6047403f8f0ce551e793d)", "treatment": "Fasten front retainers and the preassembled adapter before PCB installation, with F01/rear assembly separate. Dress J8 after the speaker screws are seated; remove board and release local dressing for service.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Actual bit/drive and handle fit, tool alignment, printed tolerance, hand tightening and ten assembly/service cycles.", "source_register": "audit/fixtures/risk_register_driver_access.json", "r36_status": "NOMINAL STAGED CAD ACCESS CLEAR; PHYSICAL QUALIFICATION OPEN", "status": "REMOVED_OR_REPLACED_MECHANISM; physical replacement qualification pending", "r37_note": "Old adapter mechanism removed; removal does not resolve direct J2 fit.", "previous_status": "REMOVED_MECHANISM_IN_WORKING_CANDIDATE", "baseline_treatment": "Fasten front retainers and the preassembled adapter before PCB installation, with F01/rear assembly separate. Dress J8 after the speaker screws are seated; remove board and release local dressing for service.", "baseline_evidence": "All front fastener paths clear with the rear subassembly/PCB absent; one lower speaker tool crosses the final J8 wires. K03 driver paths are blocked by the installed PCB. audit/fixtures/driver_access_final/FINAL_DRIVER_ACCESS_REPORT.json (manifest 77d9a0a5675bf7fb0d123d983df8f920fc91d25a51c6047403f8f0ce551e793d)", "current_treatment": "Superseded mechanism removed from the current assembly. Direct J2/J10 PH connections, adhesive antenna mounting and current routing replace it; see current reference assembly." }, { "id": "R36-ACCESS-REAR-WIRE-ORDER", "components": [ "P02", "P15", "P16", "P19", "P20", "K01", "K02", "F01", "R36_FACTORY_BATTERY_LEAD_2_100mm_INWARD_RISER_FINAL", "J9_COMMON_LINK_1_OD1p05_R3" ], "location": "Rear antenna, battery and volume keeper tool paths", "failure_mechanism": "A driver can pinch or abrade a final dressed lead, or strike the battery while attempting an upper antenna screw.", "loading_situation": "Rear keeper fastening and later component removal.", "evidence": "Battery screw 3 crosses factory lead 2 by 1.1174 mm\u00b3; K01 screw 1 and K02 screw 2 cross J9 common link 1 by 2.5612/0.7011 mm\u00b3. Upper antenna tools cross the maximum pack. All clear with the named staged items absent. audit/fixtures/driver_access_final/FINAL_DRIVER_ACCESS_REPORT.json (manifest 77d9a0a5675bf7fb0d123d983df8f920fc91d25a51c6047403f8f0ce551e793d)", "treatment": "Work with front assembly/PCB and F01 separate; fit antenna before battery. Fasten K01/K02 before J9 common-link dressing and battery keepers before intact factory lead2 dressing. Release local dressing for service; never use the tool to displace a lead.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Demonstrate the intact leads can remain free and be dressed without tension, pinch, abrasion or unqualified bends. Confirm actual tool/tolerances and ten service cycles.", "source_register": "audit/fixtures/risk_register_driver_access.json", "r36_status": "NOMINAL STAGED CAD ACCESS CLEAR; FLEXIBLE HANDLING UNTESTED", "status": "REPLACED_BY_CONNECTED_ROUTING; current audit plus physical dressing/strain-relief test required", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Work with front assembly/PCB and F01 separate; fit antenna before battery. Fasten K01/K02 before J9 common-link dressing and battery keepers before intact factory lead2 dressing. Release local dressing for service; never use the tool to displace a lead.", "baseline_evidence": "Battery screw 3 crosses factory lead 2 by 1.1174 mm\u00b3; K01 screw 1 and K02 screw 2 cross J9 common link 1 by 2.5612/0.7011 mm\u00b3. Upper antenna tools cross the maximum pack. All clear with the named staged items absent. audit/fixtures/driver_access_final/FINAL_DRIVER_ACCESS_REPORT.json (manifest 77d9a0a5675bf7fb0d123d983df8f920fc91d25a51c6047403f8f0ce551e793d)", "current_treatment": "Superseded routes/restraints are retired. Current named J2/J3/J10/J9/J8/J5/J7 envelopes, open channels and harness instructions govern; electrical mapping corrected. Factory battery and RF cables remain intact." }, { "id": "R36-ACCESS-CLOSURE-BUMPER", "components": [ "F01", "P01", "P02", "C27_R2_HW_Closure_-33_4_-56", "C27_R2_HW_Closure_33_4_-56", "C27_R2_HW_Closure_-33_4_56", "C27_R2_HW_Closure_33_4_56" ], "location": "Four rear case-closure screw tool paths under F01", "failure_mechanism": "Attempting closure or service through the fitted bumper would damage the bumper or prevent straight bit engagement.", "loading_situation": "Case closure and opening.", "evidence": "Each outward \u00d83 \u00d7 30 mm closure tool intersects fitted F01 by 6.4340 mm\u00b3; every other selected object clears. audit/fixtures/driver_access_final/FINAL_DRIVER_ACCESS_REPORT.json (manifest 77d9a0a5675bf7fb0d123d983df8f920fc91d25a51c6047403f8f0ce551e793d)", "treatment": "Hand-seat the populated halves and tighten all four closure screws with F01 off. Fit the removable flexible bumper afterward; remove it first for service.", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "remaining_gate": "Qualify bumper installation/removal without damage, actual bit/handle fit and ten closure/service cycles.", "source_register": "audit/fixtures/risk_register_driver_access.json", "r36_status": "NOMINAL STAGED CAD ACCESS CLEAR; PHYSICAL QUALIFICATION OPEN", "status": "REVIEWED; current nominal checks and physical qualification remain distinct", "r37_note": "Prior nominal checks do not qualify the new connector/PCB/route configuration. Reassess before final export.", "previous_status": "REOPENED_FOR_CONNECTED_REVISION", "baseline_treatment": "Hand-seat the populated halves and tighten all four closure screws with F01 off. Fit the removable flexible bumper afterward; remove it first for service.", "baseline_evidence": "Each outward \u00d83 \u00d7 30 mm closure tool intersects fitted F01 by 6.4340 mm\u00b3; every other selected object clears. audit/fixtures/driver_access_final/FINAL_DRIVER_ACCESS_REPORT.json (manifest 77d9a0a5675bf7fb0d123d983df8f920fc91d25a51c6047403f8f0ce551e793d)", "current_treatment": "Original outer faces retained. Integrated three switch seats, broader PTT bearing and PCB stop, repositioned PCB supports, open cable channels, revised LED and speaker seats. Original outer faces/seam retained. Obsolete adapter/PCB stock removed; paired PCB pads and battery supports preserved around the connected cable routes. Battery slack belongs in the centre bay. Original contour/openings fixed. Flexible material remains a distinct manufacturing requirement; fit after closure screws." }, { "id": "FIT-01", "components": [ "J2", "J3", "J10", "P02" ], "location": "Upright connector tails", "failure_mechanism": "Case cannot seat; plug/wire or PCB is loaded by closure.", "loading_situation": "Inserting complete PCB and closing case.", "evidence": "Catalog PH bodies extend to Z -22.3865; original rear surface is near -21.8. The CAD housing envelope overlaps wall by approximately 0.5865 mm before wire bend.", "treatment": "Resolve pose/clearance with actual connected heights; ordinary pigtails alone cannot remove this body height.", "status": "REVIEWED; current nominal checks and physical qualification remain distinct", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "previous_status": "BLOCKED \u2014 actual fully mated body and natural wire-turn heights requested.", "baseline_treatment": "Resolve pose/clearance with actual connected heights; ordinary pigtails alone cannot remove this body height.", "baseline_evidence": "Catalog PH bodies extend to Z -22.3865; original rear surface is near -21.8. The CAD housing envelope overlaps wall by approximately 0.5865 mm before wire bend.", "current_treatment": "Original outer faces/seam retained. Obsolete adapter/PCB stock removed; paired PCB pads and battery supports preserved around the connected cable routes. Battery slack belongs in the centre bay." }, { "id": "FIT-02", "components": [ "PCB", "P01", "P02" ], "location": "Laminate and solder-pin datums", "failure_mechanism": "Incorrect supports squeeze/bow board or collision occurs at solder tips.", "loading_situation": "Installation, closure, USB insertion.", "evidence": "Source STEP laminate is 1.33 mm; earlier owner reading ~1.7 mm was provisional. Source headers and laminate differ by 0.085 mm at mounting surface.", "treatment": "Reconcile actual thickness and both face datums; include real underside solder projections and U6 height.", "status": "REDESIGNED; current geometry audit and physical support-force test required", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "previous_status": "BLOCKED \u2014 received board dimensions required before support freeze.", "baseline_treatment": "Reconcile actual thickness and both face datums; include real underside solder projections and U6 height.", "baseline_evidence": "Source STEP laminate is 1.33 mm; earlier owner reading ~1.7 mm was provisional. Source headers and laminate differ by 0.085 mm at mounting surface.", "current_treatment": "Four paired supports and four defined pads replace eleven pads; complete PCB moved with all component envelopes including U6. Wider supported right edge stop takes USB load.1.8mm laminate bound and original front datum retained." }, { "id": "FIT-03", "components": [ "J7", "PCB" ], "location": "USB shoulder and insertion corridor", "failure_mechanism": "A PCB move clears rear plugs but prevents the actual USB cable seating.", "loading_situation": "USB insertion/removal and connector side loads.", "evidence": "Opening is fixed 14 x 9.6 mm; old 12 x 8 mm gauge permits only 0.8 mm centred vertical translation before rounded-corner/tolerance checks.", "treatment": "Measure actual cable and run insertion/removal sweep at chosen PCB pose.", "status": "REVIEWED; current nominal checks and physical qualification remain distinct", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "previous_status": "BLOCKED \u2014 actual overmold width/thickness/metal length requested.", "baseline_treatment": "Measure actual cable and run insertion/removal sweep at chosen PCB pose.", "baseline_evidence": "Opening is fixed 14 x 9.6 mm; old 12 x 8 mm gauge permits only 0.8 mm centred vertical translation before rounded-corner/tolerance checks.", "current_treatment": "Functional stock/hardware retained only as named in assembly_index.json; obsolete stock retired there. Use installed thicknesses and current assembly sequence." }, { "id": "FIT-04", "components": [ "J9", "J8" ], "location": "Electrical pin order versus old CAD labels", "failure_mechanism": "Harness terminated to wrong PCB nets.", "loading_situation": "Harness fabrication and first power-up.", "evidence": "Released X2 Gerber reverses the old geometric row ordering at J8/J9; J3 full Pin_1..5 identities are present in Gerber despite truncation in IPC.", "treatment": "Use extracted verified map. Identify actual housing pin 1 and continuity-check completed harness before use.", "status": "REPLACED_BY_CONNECTED_ROUTING; current audit plus physical dressing/strain-relief test required", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "previous_status": "DESIGN MAP VERIFIED; physical continuity outstanding.", "baseline_treatment": "Use extracted verified map. Identify actual housing pin 1 and continuity-check completed harness before use.", "baseline_evidence": "Released X2 Gerber reverses the old geometric row ordering at J8/J9; J3 full Pin_1..5 identities are present in Gerber despite truncation in IPC.", "current_treatment": "Superseded routes/restraints are retired. Current named J2/J3/J10/J9/J8/J5/J7 envelopes, open channels and harness instructions govern; electrical mapping corrected. Factory battery and RF cables remain intact." }, { "id": "FIT-05", "components": [ "P04", "P14", "PCB" ], "location": "Front obstructions during PCB relocation", "failure_mechanism": "Fixing rear connector space creates clamp/head/LED interference.", "loading_situation": "Assembly and closure.", "evidence": "A +0.5 mm laminate shift already intersects P04 and LED screw-head envelopes; larger moves reach purchased switch/LED references.", "treatment": "Resolve supports, functional LED alignment and switch load path together with board pose.", "status": "REVIEWED; current nominal checks and physical qualification remain distinct", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "previous_status": "BLOCKED \u2014 no relocation accepted.", "baseline_treatment": "Resolve supports, functional LED alignment and switch load path together with board pose.", "baseline_evidence": "A +0.5 mm laminate shift already intersects P04 and LED screw-head envelopes; larger moves reach purchased switch/LED references.", "current_treatment": "Clear tilted PCB and insulated play terminals; one paired PCB support now grows from this stationary clamp. Retain two original screw axes and supported bearing surfaces. One flat plate holds the original LED upright beside the PCB. One M2x4 screw, open four-lead exit, hard-supported seat." }, { "id": "FIT-06", "components": [ "J3", "P13" ], "location": "SPH0645 solder row, ribbon and SEL jumper", "failure_mechanism": "Wiring is trapped by microphone keeper or relocated PCB.", "loading_situation": "Mic insertion and closure.", "evidence": "Photos show blue SPH0645, direct soldered ribbon and a green SEL jumper; previous exact wire paths do not establish this installed envelope.", "treatment": "Measure combined local height and reserve its bend/dressing space; preserve acoustic seal and port alignment.", "status": "REVIEWED; current nominal checks and physical qualification remain distinct", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "previous_status": "OPEN \u2014 photo identifies arrangement, not exact installed height.", "baseline_treatment": "Measure combined local height and reserve its bend/dressing space; preserve acoustic seal and port alignment.", "baseline_evidence": "Photos show blue SPH0645, direct soldered ribbon and a green SEL jumper; previous exact wire paths do not establish this installed envelope.", "current_treatment": "Broad open exit for the low-profile solder row and SEL jumper. Two M2x4 pan screws preserve1.4mm bearing material; acoustic datum remains fixed." }, { "id": "FIT-07", "components": [ "J10", "P11", "P12" ], "location": "Speaker terminal exits and two splices", "failure_mechanism": "Splices occupy unmodeled volume or transmit pull to delicate leads.", "loading_situation": "Speaker insertion/service and case closure.", "evidence": "Two insulated splices are visible in IMG_3292; old terminal positions and splice envelopes were assumed.", "treatment": "Keep staggered, measured splice envelopes in an open supported bay and use straightforward shortened non-battery leads.", "status": "REVIEWED; current nominal checks and physical qualification remain distinct", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "previous_status": "OPEN \u2014 final route/actual splice dimensions outstanding.", "baseline_treatment": "Keep staggered, measured splice envelopes in an open supported bay and use straightforward shortened non-battery leads.", "baseline_evidence": "Two insulated splices are visible in IMG_3292; old terminal positions and splice envelopes were assumed.", "current_treatment": "One short radial keeper with one M2x5 pan screw.6.8x2.2mm section, hard seating boss, supported silicone contact on the frame. Second short removable keeper uses a recessed M2x4 pan screw with1.2mm bearing floor and0.35mm maximum-pouch head clearance; it permits straight speaker fitting/removal. A long bridge or permanent lip would obstruct service. Speaker frame rotates45deg about the unchanged acoustic centre." }, { "id": "FIT-08", "components": [ "Battery", "J2", "P19", "P20" ], "location": "Protected pouch exit and lead slack", "failure_mechanism": "Lead is pinched/pulled or pack compressed.", "loading_situation": "Battery installation, board connection and service.", "evidence": "Factory leads and plug must remain intact; prior 100 mm path was a placeholder to the now-removed adapter.", "treatment": "Measure available factory length and protected exit; reserve loose dressing/slack without load on pouch or connector.", "status": "REPLACED_BY_CONNECTED_ROUTING; current audit plus physical dressing/strain-relief test required", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "previous_status": "OPEN \u2014 old adapter route discarded.", "baseline_treatment": "Measure available factory length and protected exit; reserve loose dressing/slack without load on pouch or connector.", "baseline_evidence": "Factory leads and plug must remain intact; prior 100 mm path was a placeholder to the now-removed adapter.", "current_treatment": "Superseded routes/restraints are retired. Current named J2/J3/J10/J9/J8/J5/J7 envelopes, open channels and harness instructions govern; electrical mapping corrected. Factory battery and RF cables remain intact." }, { "id": "FIT-09", "components": [ "J5", "P15", "P16" ], "location": "RF plug and full coax route", "failure_mechanism": "RF plug side-load, sharp coax bend, pinching or antenna loading.", "loading_situation": "Antenna installation and service.", "evidence": "The selected coax is 150 mm long. Old mated plug gauge and R5 route are unverified assumptions.", "treatment": "Measure plug/exit and retain full cable volume plus release access. Coordinate antenna location with all plugs.", "status": "REPLACED_BY_CONNECTED_ROUTING; current audit plus physical dressing/strain-relief test required", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "previous_status": "OPEN \u2014 legacy route is a reference only.", "baseline_treatment": "Measure plug/exit and retain full cable volume plus release access. Coordinate antenna location with all plugs.", "baseline_evidence": "The selected coax is 150 mm long. Old mated plug gauge and R5 route are unverified assumptions.", "current_treatment": "Superseded routes/restraints are retired. Current named J2/J3/J10/J9/J8/J5/J7 envelopes, open channels and harness instructions govern; electrical mapping corrected. Factory battery and RF cables remain intact." }, { "id": "FIT-10", "components": [ "J9", "P08", "P09", "P10" ], "location": "Switch terminals and stops", "failure_mechanism": "Wrong same-contact pair or stop geometry preloads/damages switch.", "loading_situation": "Harness build; centre/edge and simultaneous button operation.", "evidence": "The selected assortment lacks a component drawing; original nominal travel is not measured travel.", "treatment": "Continuity-map each switch; measure click/release and travel; make open seats for insulated prewired terminals.", "status": "REPLACED_BY_CONNECTED_ROUTING; current audit plus physical dressing/strain-relief test required", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "previous_status": "OPEN \u2014 must be verified before terminating harness and freezing stops.", "baseline_treatment": "Continuity-map each switch; measure click/release and travel; make open seats for insulated prewired terminals.", "baseline_evidence": "The selected assortment lacks a component drawing; original nominal travel is not measured travel.", "current_treatment": "Superseded routes/restraints are retired. Current named J2/J3/J10/J9/J8/J5/J7 envelopes, open channels and harness instructions govern; electrical mapping corrected. Factory battery and RF cables remain intact." }, { "id": "FIT-11", "components": [ "P01", "J9" ], "location": "Deleted closed wiring fixtures", "failure_mechanism": "New draft lacks final strain relief after eliminating difficult threading.", "loading_situation": "Installation/service/lead pull.", "evidence": "Two old J9 fixtures required terminal soldering after threading and a small taped common junction.", "treatment": "Remove obsolete fixtures, then design broad accessible strain relief around the accepted wiring space.", "status": "REPLACED_BY_CONNECTED_ROUTING; current audit plus physical dressing/strain-relief test required", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "previous_status": "WORKING REMOVAL ONLY \u2014 no complete assembly release.", "baseline_treatment": "Remove obsolete fixtures, then design broad accessible strain relief around the accepted wiring space.", "baseline_evidence": "Two old J9 fixtures required terminal soldering after threading and a small taped common junction.", "current_treatment": "Superseded routes/restraints are retired. Current named J2/J3/J10/J9/J8/J5/J7 envelopes, open channels and harness instructions govern; electrical mapping corrected. Factory battery and RF cables remain intact." }, { "id": "FIT-12", "components": [ "All" ], "location": "Practical slack, tolerance and tools", "failure_mechanism": "Nominal ideal cable path fits but ordinary assembly cannot reproduce it.", "loading_situation": "Case assembly/disassembly and screw tightening.", "evidence": "Earlier routes used tightly located wires and numerous separate pads; no complete physical connected fit passed.", "treatment": "Check defined dressing volumes, insertion/removal sweeps, tools, actual stock and one coherent tolerance budget.", "status": "REVIEWED; current nominal checks and physical qualification remain distinct", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "previous_status": "BLOCKED until full connected layout and critical dimensions are resolved.", "baseline_treatment": "Check defined dressing volumes, insertion/removal sweeps, tools, actual stock and one coherent tolerance budget.", "baseline_evidence": "Earlier routes used tightly located wires and numerous separate pads; no complete physical connected fit passed.", "current_treatment": "Functional stock/hardware retained only as named in assembly_index.json; obsolete stock retired there. Use installed thicknesses and current assembly sequence." }, { "id": "FIT-13", "components": [ "P01", "P02" ], "location": "Temporary supports versus permanent features", "failure_mechanism": "Support cleanup removes structural material or leaves interference.", "loading_situation": "De-supporting and loose-part handling.", "evidence": "Photos contain lattice structures not present in the permanent CAD. Thick battery supports and screw bosses are permanent.", "treatment": "Supply CAD comparison and process-specific support-removal diagram after final print orientation is known.", "status": "REVIEWED; current nominal checks and physical qualification remain distinct", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "previous_status": "OPEN \u2014 do not treat all internal material as removable.", "baseline_treatment": "Supply CAD comparison and process-specific support-removal diagram after final print orientation is known.", "baseline_evidence": "Photos contain lattice structures not present in the permanent CAD. Thick battery supports and screw bosses are permanent.", "current_treatment": "Original outer faces retained. Integrated three switch seats, broader PTT bearing and PCB stop, repositioned PCB supports, open cable channels, revised LED and speaker seats. Original outer faces/seam retained. Obsolete adapter/PCB stock removed; paired PCB pads and battery supports preserved around the connected cable routes. Battery slack belongs in the centre bay." }, { "id": "FIT-14", "components": [ "K01", "K02", "P17", "P18", "P11", "P12" ], "location": "Part consolidation spans", "failure_mechanism": "A lower part count produces longer flexible or fragile bridges.", "loading_situation": "Button edge loads, speaker fitting and screw tightening.", "evidence": "Candidate merges have not passed complete wire-space or insertion checks.", "treatment": "Only merge with broad supported load paths; retain separate pieces where service or material function requires them.", "status": "REVIEWED; current nominal checks and physical qualification remain distinct", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "previous_status": "PENDING \u2014 proposed merges excluded from claimed implemented savings.", "baseline_treatment": "Only merge with broad supported load paths; retain separate pieces where service or material function requires them.", "baseline_evidence": "Candidate merges have not passed complete wire-space or insertion checks.", "current_treatment": "One short radial keeper with one M2x5 pan screw.6.8x2.2mm section, hard seating boss, supported silicone contact on the frame. Second short removable keeper uses a recessed M2x4 pan screw with1.2mm bearing floor and0.35mm maximum-pouch head clearance; it permits straight speaker fitting/removal. A long bridge or permanent lip would obstruct service. Speaker frame rotates45deg about the unchanged acoustic centre. Short supported guide and two accessible screws. Keeping it separate preserves the LED/wiring corridor. Second short guide maintains local support and PTT end-press control; no unsupported joining bridge. Both stationary retainers become one shell-supported rail. Four original screws and independent travel stops retained; the joining span has a continuous rear bed. Now part of K01. No second loose rail." }, { "id": "FIT-15", "components": [ "J9", "K02", "P01", "P02" ], "location": "Five-wire button harness exit", "failure_mechanism": "A reasonable wire turn or normal dressing space collides with the lower volume capture and shell.", "loading_situation": "Board mating, wire placement, button actuation and closure.", "evidence": "The R3 immediate-turn study intersects K02, P01 and P02. A fused 0.5 mm radial dressing reservation also intersects all three. This is an engineering scenario, not a measured cable bend.", "treatment": "Reserve the full J9 exit before designing the combined volume rail; maintain independent slider motion and open strain relief.", "status": "REPLACED_BY_CONNECTED_ROUTING; current audit plus physical dressing/strain-relief test required", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "previous_status": "BLOCKED \u2014 final routed branch/slack volumes and capture redesign pending.", "baseline_treatment": "Reserve the full J9 exit before designing the combined volume rail; maintain independent slider motion and open strain relief.", "baseline_evidence": "The R3 immediate-turn study intersects K02, P01 and P02. A fused 0.5 mm radial dressing reservation also intersects all three. This is an engineering scenario, not a measured cable bend.", "current_treatment": "Superseded routes/restraints are retired. Current named J2/J3/J10/J9/J8/J5/J7 envelopes, open channels and harness instructions govern; electrical mapping corrected. Factory battery and RF cables remain intact." }, { "id": "FIT-16", "components": [ "J7", "P01" ], "location": "Existing internal USB tunnel obstruction", "failure_mechanism": "Plug shoulder contacts internal shell stock despite a nominally large external opening.", "loading_situation": "USB insertion/removal.", "evidence": "The old 12 x 8 mm reference shoulder intersects 0.5504 mm3 of P01 in both R3.4 and R3.6. This is not proof that the photographed cable collides.", "treatment": "Clear the obstruction inside the original 14 x 9.6 mm tunnel envelope. New candidate removes 2.9072 mm3; original PCB bearing seat and exterior band remain unchanged.", "status": "REVIEWED; current nominal checks and physical qualification remain distinct", "verification": "See Verification/ for frozen-geometry results; Documents/04_Assembly_and_Qualification.md for unperformed physical tests. Historical geometry/physical assumptions are not promoted to a new pass.", "previous_status": "REFERENCE GAUGE CLEARED; actual cable fit and final PCB pose remain unverified.", "baseline_treatment": "Clear the obstruction inside the original 14 x 9.6 mm tunnel envelope. New candidate removes 2.9072 mm3; original PCB bearing seat and exterior band remain unchanged.", "baseline_evidence": "The old 12 x 8 mm reference shoulder intersects 0.5504 mm3 of P01 in both R3.4 and R3.6. This is not proof that the photographed cable collides.", "current_treatment": "Original outer faces retained. Integrated three switch seats, broader PTT bearing and PCB stop, repositioned PCB supports, open cable channels, revised LED and speaker seats." }, { "id": "R37-STR-01", "components": [ "P01" ], "location": "USB right edge stop", "failure_mechanism": "Insertion force bends/slits a tall narrow stop.", "loading_situation": "USB insertion/removal.", "evidence": "Original candidate root5x8mm; final root8x10mm with supported taper and unchanged edge gap.", "current_treatment": "Broaden root within exterior; screen tapered section with stated load assumptions; physical cable-force test.", "status": "CAD_TREATMENT; inspect current verification results; physical qualification pending", "verification": "Matched CAD checks and the documented first-article tests." }, { "id": "R37-STR-02", "components": [ "P01" ], "location": "PTT inner seat and wired terminals", "failure_mechanism": "Wire pockets isolate the inner cradle rail.", "loading_situation": "Assembly, normal PTT press and service.", "evidence": "First channel screen isolated40.18mm3 of old cradle rail.", "current_treatment": "Replace with broad2.95x4.8mm bearing and direct5.1mm-wide front root; carry return across its front; verify one connected solid and motion.", "status": "CAD_TREATMENT; inspect current verification results; physical qualification pending", "verification": "Matched CAD checks and the documented first-article tests." }, { "id": "R37-STR-03", "components": [ "P02", "Battery" ], "location": "Right battery support and slack space", "failure_mechanism": "An oversized slack reservation undercuts the support roof.", "loading_situation": "Battery handling and case closure.", "evidence": "First candidate slack field isolated a support-roof fragment.", "current_treatment": "Move slack between supports; lower the rear lead crossings to preserve support thickness. No disconnected battery platform may remain.", "status": "CAD_TREATMENT; inspect current verification results; physical qualification pending", "verification": "Matched CAD checks and the documented first-article tests." }, { "id": "R37-ELEC-01", "components": [ "J8", "LED" ], "location": "Different PCB and LED pin numbering", "failure_mechanism": "Green/common-cathode misconnection.", "loading_situation": "Harness termination and power-up.", "evidence": "PCB J8 orderR,G,B,GND; Kingbright LED physical orderR,K,B,G.", "current_treatment": "Explicit mapping1->1,2->4,3->3,4->2 and continuity before power.", "status": "CAD_TREATMENT; inspect current verification results; physical qualification pending", "verification": "Matched CAD checks and the documented first-article tests." }, { "id": "R37-OPT-01", "components": [ "L02", "LED" ], "location": "Longer two-turn optical path", "failure_mechanism": "Insufficient RGB indicator brightness or adhesive loss.", "loading_situation": "Normal operation and service.", "evidence": "Original external lens unchanged; internal LED moved beside PCB.", "current_treatment": "Use clear optical material and finished45deg faces; test all colors and inspect bonds.", "status": "CAD_TREATMENT; inspect current verification results; physical qualification pending", "verification": "Matched CAD checks and the documented first-article tests." }, { "id": "R37-CAD-01", "components": [ "All" ], "location": "Wider dressing envelopes at tight bends", "failure_mechanism": "Self-intersecting swept clearance tool can corrupt solid subtraction.", "loading_situation": "CAD generation, not a physical failure mode.", "evidence": "Some dressing radii exceed the local bend radius; a topology-valid torus is insufficient.", "current_treatment": "Use unioned edge envelopes/chord capsules at tight turns, verify each final solid, material loss, exterior coincidence and native mesh topology.", "status": "CAD_TREATMENT; inspect current verification results; physical qualification pending", "verification": "Matched CAD checks and the documented first-article tests." }, { "id": "R37-ASM-01", "components": [ "All" ], "location": "Received hardware vs design envelopes", "failure_mechanism": "Ordinary actual wire dressing exceeds the modeled bound.", "loading_situation": "Fully connected assembly and service.", "evidence": "Photo/catalog-based dimensions are explicitly separated from engineering cable/stock assumptions.", "current_treatment": "Use the defined cable construction, dressing spaces and hand-seat first-article gate; do not enlarge the case or force closure.", "status": "CAD_TREATMENT; inspect current verification results; physical qualification pending", "verification": "Matched CAD checks and the documented first-article tests." } ]