Integrate DB9 mounting into enclosure lid

hardware/case/README.md

@@ -12,14 +12,13 @@ Open `enclosure.scad` in OpenSCAD (tested here with **2021.01**). Set `part` to:
 |---|---|
 | `assembly` / `exploded` | Assembled / exploded reference preview; **not printable combined parts** |
 | `base` | Floor, carrier insert bosses, daughterboard insert bosses, side assembly bosses |
-| `lid` | Roof, skirt, screw head wells, button guides, DB9 panel attachment hangers, raised labels |
-| `panel` | Separate externally installed DB9 retaining panel, oriented flat for printing |
+| `lid` | Roof, skirt, screw head wells, button guides, integral bottom-open DB9 retaining panel and ribs, raised labels |
 | `plunger` / `plungers` | One / three identical captive button actuators |
 
 | `labels` | Raised text alone for a second material or separately attached lettering |
 | `layout` | Spaced parts for inspection; orient/support each part separately in the slicer |
 
-`show_references` displays simplified hardware only in **F5 preview** (`$preview` and `%` background geometry); it is excluded from STL/F6 geometry. The reference boxes are not complete component models. Orange/brown stock DB9 post envelopes deliberately reveal the conflict with a panel fitted without replacing/reseating the posts. Gold dummies represent **two M3 and four M2 male/female brass standoffs above the carrier**, with lower studs and blind upper bores; their OD, stud length and bore depth are provisional. The red RF overlay and enclosure RF-reserve restriction have been removed at the user's request. Actual antenna geometry remains; no PCB reserve/copper/layout was changed and no Wi-Fi performance guarantee is implied.
+`show_references` displays simplified hardware only in **F5 preview** (`$preview` and `%` background geometry); it is excluded from STL/F6 geometry. The reference boxes are not complete component models. Orange/brown DB9 post-body envelopes are shown reseated **outside** the integral panel; they illustrate unverified hardware, not guaranteed stock-thread or cable fit. Gold dummies represent **two M3 and four M2 male/female brass standoffs above the carrier**, with lower studs and blind upper bores; their OD, stud length and bore depth are provisional. The red RF overlay and enclosure RF-reserve restriction have been removed at the user's request. Actual antenna geometry remains; no PCB reserve/copper/layout was changed and no Wi-Fi performance guarantee is implied.
 
 All dimensions are **mm**. Parameter/source coordinates are carrier-local, X right and Y down toward USB; add `(100,100)` for KiCad coordinates. The rendered model maps `Y_world = 80 - Y_carrier`, so the DB9 is above the USB end in top view. Text is separately transformed to remain readable from the USB end.
 
@@ -55,14 +54,14 @@ The user's intended/reported module elevation is **10 mm**. The descriptions “
 
 **Insert pockets are examples, not validated fits:** M3 Ø4.2 × 4 deep; M2 Ø3.2 × 3 deep, 0.3 entry flare. These numbers do not specify insert OD/length, thread engagement or thermal process. Choose the actual insert family and set diameter/depth/boss OD using its supplier recommendations and a material-specific test coupon first. Install inserts before electronics. Default carrier pockets leave 3.4 mm solid material to the outside bottom (1 mm boss web plus 2.4 floor).
 
-Default insert count with all options enabled: **12 M3** (4 carrier, 4 case, 2 RS-232, 2 panel hangers) and **4 M2** (OLED). The last two M3 pockets face outward horizontally in the lid; install with the lid removed. These M3s are **not** the connector cable-lock threads.
+Default insert count with all options enabled: **10 M3** (4 carrier, 4 case, 2 RS-232) and **4 M2** (OLED), all in the base. **No DB9 panel insert hangers, panel-to-lid screws or separate printable plate remain.** Connector screw posts use their own verified thread, not an inferred M3 designation.
 
 Screw-length selection is by measured engagement, not a fixed BOM promise:
 
 - Carrier screws: **1.6 mm** carrier thickness + washers + engagement into the base insert. Keep the head and shoulder clear of nearby components/copper.
 - Case screw under-head plane Z34.6 to insert mouth Z15 is **19.6**, plus chosen engagement (e.g. 3 gives 22.6); do not blindly use an overlong 25 mm screw in a 4 mm pocket.
 - Lower brass studs first traverse **1.6 mm carrier**, then engage the base inserts. `brass_m3_stud_l` / `brass_m2_stud_l` default to **4 mm reference lengths**, not measured hardware: tips at Z5.0 give **2.4 mm engagement**, leaving 1.6 mm to the M3 pocket bottom / 0.6 mm to the M2 pocket bottom. Actual insert usable threads may differ from pocket depth: measure before selecting. Upper daughterboard screws traverse **1.57 RS-232 / 1.6 OLED**, plus washers and chosen engagement into the **top female**, not the base. Preview female depths are 4/3 mm, also unknown. Verify studs/screws pass the nominal 3/2 mm holes without force; these are not generous M3/M2 clearance holes.
-- Panel-to-lid screws traverse **2 mm** panel plus selected M3 engagement. Round/pan head clearance is open from outside; use small heads/washers which do not foul cable hardware.
+- Connector posts traverse **2.4 mm** integral panel plus any washers/gap before engaging the connector flange. See the thread-reach and cable-mating gates below; these are not panel-to-lid screws.
 
 ## Cable interfaces
 
@@ -78,19 +77,25 @@ Signage says **USB**, not a guessed left/right native-USB vs USB-UART mapping. B
 
 ![DB9-side reference preview](db9-preview.png)
 
-The STEP source registers the flange front at **Y1.930**, stock lock mouths **Y−2.870**, shell nose **Y−3.870**, with module front at Y0. The flange is **30.8 × 12.55**. Shell maximum root/lip envelope is **16.878038 × 9.1**; the panel hole is an intentionally rectangular **18.078038 × 10.3** envelope with 0.6 margin per side, not a reconstructed D-profile.
+![Integral lid underside: closed post holes and bottom-open shell slot](lid-detail.png)
 
-The **separate 46 × 13.68 × 2 panel** sits at **Y−0.070…1.930**, above the module PCB at Z21.07…34.75. The module PCB extends under/forward of it; the panel must not be extended down through that PCB. A **48 mm wide** main-wall service recess is open at X33…81, Z18.4…35, making the connector and panel screws externally reachable. Shell nose remains 0.47 beyond the ordinary outer wall plane. Check your cable hood against this recess; no universal connector/cable compatibility is claimed.
+The STEP registers flange front **Y1.930**, original post mouths **Y−2.870**, shell nose **Y−3.870**, with module front Y0. Flange bounds are **X41.57…72.37**, Z20.57262024…33.12262024, thickness 0.4. Shell maximum root/lip envelope is **16.878038 × 9.1**; the design uses a conservative rectangular clearance, not a reconstructed D-profile.
 
-There are **three independent fastener systems**:
+**Integral cover mounting:** a **48 mm nominal wide × 2.4 mm axial-thickness** panel spans X33…81 (0.02 mm union overlap at each wall), Y−0.470…1.930, Z21.07…35 and joins the roof directly. Two **6 mm nominal wide full-height ribs**, X33…39 and X75…81 (outer union overlap 0.02 mm), run forward to the outer wall plane Y−3.4. They provide broad roof load paths rather than small insert posts, with 2.57/2.63 mm lateral clearance to the flange. The ribs are forward of the connector anchors (nearest anchor Y5.03; panel rear Y1.93 gives 3.10 mm separation). Panel bottom remains **0.5 mm above the module PCB top**; neither wings nor ribs extend through the PCB. Load/print strength still needs testing.
 
-1. **Connector flange/cable lock axes X44.47 / 69.47, spacing 25**, parallel to Y, Z26.84762024. Panel holes default to Ø3.6 clearance, adjustable with `external_fastener_clearance`. The source models Ø3 cylindrical bores/Ø3.4 mouth chamfers, **no threads**. This does not establish M3, 4-40, pitch, removable posts, or usable engagement.
-2. **Panel-to-lid M3 screws X38 / 76**, spacing 38, same height, into forward-facing insert hangers. These carry panel loads to the case and can be serviced externally.
-3. **Module-to-carrier M3 screws**, Z axes, **24.13 spacing**, as above. Connector anchor/prong holes are not used as mounting screws.
+The shell slot is **18.078038 mm wide**, X47.930981…66.009019, **open through the panel bottom**, with top Z31.99762024 (0.6 above shell top). There is no lower crossbar to trap the connector. The upper rail is **3.00238 mm high**, continuous with the roof. Two **closed Ø3.6 through holes** retain screw posts on **X44.47 / 69.47, Z26.84762024, 25 mm spacing**, parallel to Y. The minimum slot-to-hole ligament is **1.660981 mm**. `external_fastener_clearance` is clearance only, **not a thread designation**. The module mounting holes remain a separate **24.13 mm** Z-axis system; anchor/prong holes are not new mounting points.
 
-**Required unresolved hardware selection:** confirm the actual connector posts can be removed/reseated, determine their real thread and required engagement, and fit suitable panel-mount replacement jackscrews (or a verified equivalent) that sandwich this panel against the flange **while preserving the cable's mating screw receptacles and nose reach**. Stock 4.8 mm posts occupy the panel volume; simply passing ordinary screws into their front bores does not clamp the panel to the flange and consumes the cable locks. **Do not do that. Do not assume an M3 screw fits.** `panel_t`, `panel_flange_gap` and clearance are adjustable for verified hardware; keeping the replacement posts too far forward can prevent full cable mating even if threads engage.
+The outer-wall service recess is **X33…81**, open down to the lid seam (**Z15.25**) so no lid crossbar sweeps over the shell. The former 1 mm side slits are closed by extending the integral panel/ribs to join the wall boundaries. A **base-only stepped upstand** fills the lower opening: shoulders span X33.25…80.75 and rise from Z15 to **Z20.82**; the **17.578038 mm-wide central tongue** rises to **Z21.69762024**, leaving **0.6 mm below the STEP shell minimum Z22.29762024**. The steps interfit without an undercut, retaining **0.25 mm** horizontal edge/tongue seams and the vertical shoulder-to-panel seam. The upstand is **2.9 mm deep**, Y−3.4…−0.5: it stays **0.5 mm forward of the PCB edge Y0** and 5.53 mm forward of the nearest anchor Y5.03, rather than filling through the PCB/underside. This closes unwanted openings, not the required manufacturing/cable clearances, and is not a sealed enclosure. Forward ribs narrow the unobstructed central cable approach to **X39…75 (36 mm)**. Shell nose stays **0.47 mm beyond the ordinary outer wall** and **3.4 mm beyond the panel front**. Full cable-hood, tool and mating clearance must be checked against that recess, not assumed from nose protrusion alone.
 
-The detachable panel is intentional: an integral panel with closed shell hole could not be lowered vertically over the installed horizontal connector. Lower the lid first, then introduce the panel along the mating axis from outside and fasten it. `db_panel=false` removes lid hangers and assembled panel for a temporary access-only configuration — **not mechanically equivalent to external flange retention**. If the stock connector cannot accept suitable panel hardware, this retention concept must be revised, not declared validated.
+**Installation path, not a horizontal-slide claim:** remove both connector screw posts and unplug *all* cables. Hold the lid at its final XY registration and lower it straight down. The shell enters the bottom-open slot; the closed side holes sweep beside the shell, where the removed posts used to obstruct them. The panel remains forward of the flange and above the PCB for the entire descent. The USB shells end at Y77.705, inboard of the rear inner wall Y81 by **3.295 mm**, so a closed USB bay does not require a horizontal slide with cables removed. Downward button guides stay on their final XY axes, stop above switch tops, and case bosses approach their corresponding base bosses without a lateral move. The nominal continuous 60 mm sweep is tested in `validate.py --installation`, including a negative control that detects unremoved posts. This checks selected envelopes, not unmodeled components or manufacturing tolerances.
+
+**Hardware gate — do not skip:** remove stock posts only if the real connector permits it without damaging captive nuts/anchors. Screw their male studs **from outside through the cover holes into the connector**, leaving post bodies outside and female cable-lock receptacles available. Actual thread/pitch, removability, stud length, usable female depth and clamp torque are **unmeasured**; STEP Ø3 bores/Ø3.4 chamfers prove neither M3 nor 4-40. Ordinary screws inserted into the original front bores do not implement this clamp.
+
+For under-shoulder stud length `L`, washer thickness `w`, and flange gap `g`, available engagement is **`L − panel_t − w − g`**: default **`L − 2.4 − w`**. To retain the previous engagement, studs must provide **2.4 mm more reach** (plus any washer/gap). Reusing stock posts is conditional; verified longer-stud replacements or compatible extensions may be required, and must neither bottom nor interfere internally. Do not order a guessed thread. Default `panel_flange_gap=0` registers direct flange contact; any positive gap needs a measured, supported clamp stack, not tightening across air and bending the PCB.
+
+Reseating a same-length **4.8 mm** post body puts its mouth at **Y−5.270**, **1.4 mm forward of the shell nose**, instead of 1 mm behind it. This is a significant **full-mating risk**, not validated by thread engagement. A verified shorter shoulder/body, recessed cable hardware or another compatible panel-mount post geometry may be necessary; retaining the original mouth plane would require a **2.4 mm body length** at the default panel face, whose female thread depth is not established. Keep full shell mating and functional cable locks as acceptance limits. If no compatible hardware exists, revise the cover/hardware design rather than force it. `panel_t`, `panel_flange_gap`, `external_fastener_clearance` and `panel_rib_w` expose the relevant choices; do not thin structural webs just to make stock threads reach.
+
+`db_panel=false` omits the integral panel/ribs and base upstand for temporary access only, **not equivalent connector retention**. The obsolete `panel` export mode and `panel-default.stl` are removed; there is no duplicate printable plate.
 
 ## Display, buttons and antenna
 
@@ -104,13 +109,13 @@ The detachable panel is intentional: an integral panel with closed shell hole co
 
 1. Measure insert family, actual assembled stack and connector hardware before committing to a full print. Inspect the rendered assembly against physical parts. Print cutout/insert/guide coupons or slicer-cut samples first.
 2. Print the base floor down. Indicative starting point only: 0.4 mm nozzle, 0.2 mm layers, 4 perimeters, 4–5 top/bottom layers, 25–40% infill with local solid regions around inserts. PETG is a reasonable prototype option; PLA is for fit checks away from heat. Determine material/thermal suitability yourself. No sealing, flame or temperature rating is established.
-3. Lid can be printed roof-up with supports beneath the roof, guides, panel hangers and cable openings, avoiding supports in bores where practical. Alternatively print roof-down with `emboss=false`, attach separately printed text, or use a proper multi-material setup. **Integrated raised text prevents a flat roof-down first layer**; do not ignore this 0.6 mm offset. No support-free claim for the supplied embossed lid.
-4. Print panel flat in its supplied orientation. **No plastic spacers are printed**; the brass dummies are preview-only purchased hardware. Print plungers with brim and support under their low retaining flange, or choose a slicer orientation that yields smooth, strong shafts. Deburr guides without opening them so far that stems tilt/jam. Test all three independently.
-5. Heat-set inserts with a controlled tool to the selected supplier process. Panel hanger inserts install horizontally from the front. Remove strings/debris; inspect for splits, exposed insert metal and screw bottoming.
+3. Lid can be printed roof-up with supports beneath the roof, guides, integral panel/ribs and cable openings, avoiding supports in bores where practical. Alternatively print roof-down with `emboss=false`, attach separately printed text, or use a proper multi-material setup. **Integrated raised text prevents a flat roof-down first layer**; do not ignore this 0.6 mm offset. No support-free claim for the supplied embossed lid.
+4. There is **no separate DB9 plate** to print. **No plastic spacers are printed**; the brass dummies are preview-only purchased hardware. Print plungers with brim and support under their low retaining flange, or choose a slicer orientation that yields smooth, strong shafts. Deburr guides without opening them so far that stems tilt/jam. Test all three independently.
+5. Heat-set inserts with a controlled tool to the selected supplier process. All inserts are in the base; none are used for the DB9 panel. Remove strings/debris; inspect for splits, exposed insert metal and screw bottoming.
 6. Seat the carrier directly on all base support bosses and secure its four M3 mounting holes. Install the two M3 and four M2 **10 mm brass standoffs above the carrier**, with lower studs through the corresponding existing carrier holes into inserts. Seat the RS-232/OLED on them and fasten with short screws into the top females; seat the ESP32 on its headers. Check that brass body height matches the header's seated height, neither bending boards nor lifting connectors; check DB9 prongs and all underside solder joints against the 5 mm floor clearance.
-7. Insert plungers from under the lid. Lower lid onto the base with DB9 panel **off**. Verify actuation/return before fastening the four case screws. Check screw heads fit the wells and screws engage without bottoming.
-8. After validating/removing the stock connector posts as required, slide the panel in from outside. Fit verified replacement connector jackscrews to the flange and the two independent M3 panel-to-lid screws. Do not use assembly screws to pull a misaligned flange/PCB into position. Test full USB/DB9 mating and cable locks; perform a restrained cable-load test before trusting retention.
-9. To remove the lid, disconnect cables and remove panel/connector retention hardware first. The full electronics assembly should remain independently secured by carrier/daughterboard fasteners.
+7. Disconnect all cables and remove the two verified-removable DB9 screw posts **before lowering the lid**. Insert plungers from under the lid and hold with removable tape. Align the cover in its final XY position and lower vertically: shell enters the bottom-open slot, panel wings clear the PCB, guides align over buttons. Do not slide horizontally, tilt around the USB end or force the shell. Verify free seating and button return; start the four case screws loosely.
+8. Insert verified stock or replacement post studs from outside through the two closed cover holes into the connector. Check clamp contact, engagement and bottoming independently; do not use them to pull a misaligned flange/PCB into position. Tighten case/post hardware cautiously to verified values. Test full USB/DB9 mating and cable locks, particularly the changed post-mouth reach; perform a restrained cable-load test before trusting retention.
+9. To remove the cover, unplug every cable, unscrew both connector posts completely out of the cover holes and remove the four case screws; lift vertically, retaining the plungers. The electronics remain secured by their independent carrier/daughterboard fasteners.
 
 Raised labels are positive **0.6 mm emboss**, not engraving. Single-colour is the default; roof-up printing allows a filament change just above the roof for contrasting text (check actual sliced layers). For a separate material export `labels`, and export the lid with `emboss=false`. In a multi-object slicer, preserve XY origin and translate the flat text object up **22.13 mm** relative to the default lid export (its initial 0.02 overlaps the roof). Do not auto-centre individual letters; STL carries neither colour nor assembly transforms. Changes to stack require recalculating that offset: `top_z - eps - split_z - seam_clearance`.
 
@@ -121,18 +126,19 @@ Run from `hardware/case`; no network or added dependencies are needed. Shell com
 ```sh
 QT_QPA_PLATFORM=offscreen openscad -o base-default.stl -D 'part="base"' enclosure.scad
 QT_QPA_PLATFORM=offscreen openscad -o lid-default.stl -D 'part="lid"' enclosure.scad
-QT_QPA_PLATFORM=offscreen openscad -o panel-default.stl -D 'part="panel"' enclosure.scad
+
 QT_QPA_PLATFORM=offscreen openscad -o plungers-default.stl -D 'part="plungers"' enclosure.scad
 
 python3 validate.py
-/usr/bin/python3 validate.py --source
+/usr/bin/python3 -B validate.py --source --installation --variants
 QT_QPA_PLATFORM=offscreen openscad -o assembly-preview.png --imgsize=1200,1000 --viewall --autocenter --projection=o --camera=0,0,0,55,0,25,200 -D 'part="exploded"' enclosure.scad
 QT_QPA_PLATFORM=offscreen openscad -o db9-preview.png --imgsize=1200,900 --viewall --autocenter --projection=o --camera=0,0,0,80,0,180,200 -D 'part="assembly"' enclosure.scad
+QT_QPA_PLATFORM=offscreen openscad -o lid-detail.png --render --imgsize=1200,900 --viewall --autocenter --projection=o --camera=0,0,0,100,0,155,200 -D 'part="lid"' enclosure.scad
 ```
 
-`validate.py` uses Python's standard library and installed OpenSCAD for evaluated datum, stud-engagement and nozzle-web fixtures, plus ASCII STL checks; `--source` additionally uses the **already installed system KiCad `pcbnew` binding**, read-only. It verifies current outline/holes/placements, measured U1 USB mouth graphics and STEP-derived lock/shell data against case constants. It is a drift tripwire, not a full source parser for every SCAD expression. It checks each STL has two oppositely directed uses of every triangle edge, nonzero triangle area, the expected connected component count (1 base, 1 lid, 1 panel, 3 plungers), positive total signed volume and minimum Z≈0. It does **not** prove vertex-manifoldness, absence of self-intersections, full component collision clearance or physical fit.
+`validate.py` uses Python's standard library and installed OpenSCAD for evaluated datum, stud-engagement and nozzle-web fixtures, plus ASCII STL checks; `--source` additionally uses the **already installed system KiCad `pcbnew` binding**, read-only. It verifies current outline/holes/placements, measured U1 USB mouth graphics and STEP-derived lock/shell data against case constants. It is a drift tripwire, not a full source parser for every SCAD expression. It checks each STL has two oppositely directed uses of every triangle edge, nonzero triangle area, the expected connected component count (1 base, 1 lid, 3 plungers), positive total signed volume and minimum Z≈0. It does **not** prove vertex-manifoldness, absence of self-intersections, full component collision clearance or physical fit.
 
-Executed for this corrected design: all four default CGAL exports completed with `Simple: yes`; native-source registration, evaluated geometry fixtures and the mesh checks passed; exploded and connector-side PNGs rendered and were visually inspected. `spacers-default.stl` and the `spacers` mode/layout objects were removed. The base is 10 mm shorter; lid/panel/plunger print-local dimensions stay unchanged because their assembly datums all descend together. All four exports were regenerated. KiCad printed its existing enum-property assertions but completed the read-only checks. No slicer, physical print, screw-fit, cable-load, hardware/firmware, thermal or RF tests were performed. Additional geometry regression results, if any, are recorded in [checks.md](checks.md).
+Validation results and bounded parameter/sweep tests are recorded in [checks.md](checks.md). The remaining exports are base, integral lid and three plungers; the corrected 37.4 mm shell / 7.4–9–19 mm stack is unchanged. No slicer, physical print, screw-fit, cable-load, hardware/firmware, thermal or RF acceptance is implied.
 
 ## Evidence and remaining measurements