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docs(plans): validate external wing/nacelle proposal; federate into nav-wire and power-routing plans - #192

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Aug 29, 2026
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docs(plans): validate external wing/nacelle proposal; federate into nav-wire and power-routing plans#192
Stab-Rabbit-coding merged 5 commits into
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claude/serenity-wing-nacelle-validation-kvux9w

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@Stab-Rabbit-coding Stab-Rabbit-coding commented Aug 29, 2026

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Summary

  • Validates an external (Gemini) conversation proposing wing/nacelle changes — a "16 mm Unified Spar" with an 11 mm bore for 4× 10 AWG ESC power leads, a static AS5600 Hall encoder on the wingtip, and a removable wingtip "garage" service hatch — against this repo's own analysis and as-built geometry.
  • AS5600 and the wingtip hatch are rejected on solid grounds: AS5600 was already datasheet-rejected (on-axis-only, incompatible with the off-axis through-shaft mechanism — the selected part is AK7455); no wingtip hatch exists, and one would conflict with the already-adopted nacelle-off-spar service architecture.
  • The power-wire claims turned out to be correct, and my first pass here got that wrong. I initially concluded the wing's existing Ø7 mm double-D conduit was "already a dedicated, sized, working path" for the 4× 10 AWG ESC feeds — that never checked real wire OD against bore area. Verified properly (and independently corroborated by docs/plans/2026-08-27-nacelle-wiring-plan.md, the repo owner's own draft, found merged onto this branch mid-review): even 2 wires at any realistic 10 AWG silicone OD (4.5–5.5 mm) cannot fit one Ø7 mm bore (need ≥2× OD ≈ 9–11 mm at zero clearance). Separately, the nacelle's harness_exit_port() is a rigid slot offset 17.65 mm from the tilt pivot, sweeping a ~29–45 mm arc across the tilt range with no service loop or disconnect modeled anywhere. Both are real, open problems — and the owner's own proposed fix (16 mm OD / 11 mm bore, on-axis) is itself undersized against the same packing math (4 wires need ≥13.3 mm at zero clearance).
  • The nav-light wiring finding from the first pass stands: nav_wire_channel() still routes the WS2812C signal wire into the ESC/harness bundle at harness_exit_port() (built 2026-07-04), never updated to match the later (2026-07-18) decision to route it through the spar's hollow bore instead.

Result — three federated plan docs, split by concern:

  1. docs/plans/2026-08-29-001-nacelle-nav-wire-hall-reconciliation-plan.md — corrected and narrowed to its still-valid scope: nav-light wire routing + finishing the AK7455 Hall-sensor wing-side geometry (unaffected by how power routing resolves).
  2. docs/plans/2026-08-29-002-nacelle-esc-power-routing-plan.md — new. Decision-support plan (same posture as docs/TILT_SPAR_ANALYSIS.md) laying out three candidate architectures for the confirmed power-wire/tilt-articulation problem: (A) keep the torque spar, fix the wire path with a real service loop; (B) enlarge the spar to carry torque+wire on-axis (re-derived, and still undersized even corrected, plus reopens the CF-keyway/bearing/duct-blockage gates TILT_SPAR_ANALYSIS.md already closed); (C) decouple torque transfer from wire routing via a belt/sprocket drive (the owner's stated preference, and the only option that resolves the sizing conflict rather than trading it for a different one). Gated on pinning real wire product data and an owner decision (U4) before any SCAD geometry changes. Also formally closes the long-open U6 item in docs/plans/2026-08-26-001-nacelle-esc-intake-integration-plan.md.
  3. docs/plans/2026-08-27-nacelle-wiring-plan.md — the owner's original draft, annotated in place (not rewritten/deleted) pointing to ...002 as the plan of record, per the repo's existing supersession convention.

This PR is docs-only; no SCAD/geometry changes are made here — those are gated behind the owner decision in ...002's U4.

Test plan

  • N/A — documentation-only change (no geometry/code touched)
  • Follow-up work: pin real WIRE-10AWG product OD/flex rating (...002 U1), owner decision among Options A/B/C (U4), then implement + run the listed verification-contract gates in whichever plan(s) apply

claude and others added 5 commits August 29, 2026 11:29
…7455 reconciliation plan

Cross-checked a Gemini-conversation proposal (16 mm unified spar with an
11 mm power bore, static AS5600 encoder, wingtip "garage" hatch) against
docs/TILT_SPAR_ANALYSIS.md, docs/TILT_ENCODER_WIRING_EMI_SPEC.md, and the
as-built nacelle/wing SCAD. All four concrete geometry changes are rejected
with citations: the 8 mm/5 mm-ID spar is already load-verified and
nav-wire-only, the 4x 10 AWG ESC feeds already have a dedicated Ø7 mm double-D
wing conduit, AS5600 was already datasheet-rejected as on-axis-only for this
through-shaft mechanism, and a wingtip hatch conflicts with the already-
adopted nacelle-off-spar service architecture.

Auditing the underlying EMI concern surfaced a real, separate gap: the
nacelle's nav_wire_channel() still routes the WS2812C signal wire into the
ESC/harness bundle at harness_exit_port() (built 2026-07-04), never updated
to match the later (2026-07-18) decision to route it through the spar's
hollow bore instead, specifically to avoid that co-location. Added a plan to
fix the routing and close the already-open WBS AK7455 wing-pocket item while
touching the same geometry.
…lan file

tools/precommit_index.py wasn't run on the previous commit (pre-commit hook
not enabled in this clone). Regenerates the two indexes to pick up
docs/plans/2026-08-29-001-nacelle-nav-wire-hall-reconciliation-plan.md.
…ated plan

The owner's own docs/plans/2026-08-27-nacelle-wiring-plan.md landed on this
branch (via the airframe-planning merge) after the first pass of
2026-08-29-001 had already (wrongly) concluded the 4x 10AWG ESC power wiring
"already has a dedicated, sized, working path" in the wing's Ø7mm double-D
conduit. That conclusion never checked real wire OD against bore area.

Verified properly: even 2 wires at any realistic 10AWG silicone OD
(4.5-5.5mm) cannot fit one Ø7mm bore (need 2x OD per the standard 2-circle
packing bound, i.e. 9-11mm at zero clearance). Separately, the nacelle's
harness_exit_port() is a rigid slot offset 17.65mm from the tilt pivot,
sweeping a ~29-45mm arc across the operational/stale-test tilt range with no
service loop, flex boot, or disconnect modeled anywhere. Both are real,
open problems -- and the owner's own proposed fix (16mm OD / 11mm bore,
on-axis) is itself undersized against the same packing math (4 wires need
>=13.3mm at zero clearance).

Corrects 2026-08-29-001's validation table and narrows it back to its still-
valid scope (nav-light + AK7455 Hall-sensor signal wiring, unaffected by how
power routing resolves). Adds 2026-08-29-002 as a decision-support plan
(matching TILT_SPAR_ANALYSIS.md's own posture) laying out three candidate
architectures -- keep the torque spar and fix the wire path with a real
service loop, enlarge the spar to carry both torque and wire on-axis
(re-checked and still too small even corrected), or decouple torque transfer
from wire routing via a belt/sprocket drive (the owner's stated preference,
and the only option that resolves the underlying wire-vs-torque sizing
conflict instead of trading it for a different one) -- gated on pinning real
wire product data and an owner decision before any SCAD geometry changes.
Annotates the original 2026-08-27 draft in place as superseded/formalized by
the new plan, per the repo's existing supersession convention, rather than
rewriting or deleting the owner's file.
@Stab-Rabbit-coding Stab-Rabbit-coding changed the title docs(plans): validate external wing/nacelle proposal; add nav-wire/AK7455 reconciliation plan docs(plans): validate external wing/nacelle proposal; federate into nav-wire and power-routing plans Aug 29, 2026
@Stab-Rabbit-coding
Stab-Rabbit-coding marked this pull request as ready for review August 29, 2026 13:56
@Stab-Rabbit-coding
Stab-Rabbit-coding merged commit 03fe30e into main Aug 29, 2026
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