#!/usr/bin/env python3 """Generate the HR-30 whole-body first-energization cell P0.1. The cell is a static, no-motion development enclosure. It places the real neutral-pose HR-30 CAD on a supported platform, locates a rigid pelvis cradle, clear guards, secondary position-only tethers, an exclusion zone, and external operator/instrument stations. It is not a walking gantry or rated fall-arrest system and grants no work authority. """ from __future__ import annotations import csv import hashlib import html import json import re import shutil import subprocess from pathlib import Path import cadquery as cq ROOT = Path(__file__).resolve().parents[1] WHOLE = ROOT / "hr30" / "whole-body-p0.1" OUT = WHOLE / "first-energization-cell-p0.1" RELEASE = ROOT / "release" / "hr30" / "whole-body-p0.1" / "first-energization-cell-p0.1" ROBOT_STEP = WHOLE / "HR-30_p00_neutral_stand_candidate.step" CAD_PYTHON = ROOT.parent / ".venvs" / "hr-v0-cad" / "Scripts" / "python.exe" IDENTIFIER = "HR30-FIRST-ENERGIZATION-CELL-P0.1" DATE = "2026-08-18" WARNING = ( "PRELIMINARY - UNBUILT STATIC FIRST-ENERGIZATION CELL CANDIDATE - " "NOT A WALKING GANTRY OR RATED FALL-ARREST SYSTEM - NOT APPROVED FOR " "PROCUREMENT, FABRICATION, ASSEMBLY, CONNECTION, POWERED TESTING, MOTION, " "WALKING OR ENERGIZATION" ) AUTHORITY = "NO PROCUREMENT, FABRICATION, ASSEMBLY, CONNECTION, POWERED-TEST, MOTION, WALKING OR ENERGIZATION AUTHORITY" def sha(path: Path) -> str: return hashlib.sha256(path.read_bytes()).hexdigest() def clean_step(path: Path) -> None: path.write_bytes(re.sub(rb"[ \t]+(?=\r?\n)", b"", path.read_bytes())) def write_csv(path: Path, rows: list[dict]) -> None: if not rows: raise RuntimeError(f"refusing empty table: {path}") fields: list[str] = [] for row in rows: for field in row: if field not in fields: fields.append(field) with path.open("w", encoding="utf-8", newline="") as handle: writer = csv.DictWriter(handle, fieldnames=fields, lineterminator="\n") writer.writeheader() writer.writerows(rows) def box(x: float, y: float, z: float, sx: float, sy: float, sz: float) -> cq.Shape: return cq.Workplane("XY").box(sx, sy, sz).translate((x, y, z)).val() def rod(a: tuple[float, float, float], b: tuple[float, float, float], radius: float) -> cq.Shape: start = cq.Vector(*a) vector = cq.Vector(b[0] - a[0], b[1] - a[1], b[2] - a[2]) return cq.Solid.makeCylinder(radius, vector.Length, start, vector.normalized()) def frame_geometry() -> tuple[list[dict], dict[str, cq.Shape]]: rows: list[dict] = [] shapes: dict[str, cq.Shape] = {} def add(member_id: str, role: str, center: tuple[float, float, float], size: tuple[float, float, float], cut_length: float) -> None: rows.append({ "member_id": member_id, "role": role, "candidate_profile": "80/20 40-4040-Lite 40 x 40 mm", "center_x_mm": center[0], "center_y_mm": center[1], "center_z_mm": center[2], "size_x_mm": size[0], "size_y_mm": size[1], "size_z_mm": size[2], "candidate_cut_length_mm": cut_length, "end_preparation": "SQUARE CUT CANDIDATE; DFM REQUIRED", "structural_release": "NO", "warning": WARNING, }) shapes[member_id] = box(*center, *size) # 1200 x 1000 x 1400 mm outside envelope. add("FR-BX-01", "BASE FRONT", (0, -480, 20), (1200, 40, 40), 1200) add("FR-BX-02", "BASE REAR", (0, 480, 20), (1200, 40, 40), 1200) add("FR-BY-01", "BASE LEFT", (-580, 0, 20), (40, 920, 40), 920) add("FR-BY-02", "BASE RIGHT", (580, 0, 20), (40, 920, 40), 920) for index, (x, y) in enumerate(((-580, -480), (580, -480), (-580, 480), (580, 480)), 1): add(f"FR-U-{index:02d}", "VERTICAL UPRIGHT", (x, y, 700), (40, 40, 1360), 1360) add("FR-TX-01", "TOP FRONT", (0, -480, 1380), (1200, 40, 40), 1200) add("FR-TX-02", "TOP REAR", (0, 480, 1380), (1200, 40, 40), 1200) add("FR-TY-01", "TOP LEFT", (-580, 0, 1380), (40, 920, 40), 920) add("FR-TY-02", "TOP RIGHT", (580, 0, 1380), (40, 920, 40), 920) add("FR-TC-01", "POSITION-ONLY TETHER CROSSBAR", (0, 0, 1360), (1120, 40, 40), 1120) return rows, shapes def guard_geometry() -> tuple[list[dict], dict[str, cq.Shape]]: panels = [ ("GP-LEFT", "FIXED LEFT", (-557, 0, 720), (6, 880, 1280), "FIXED"), ("GP-RIGHT", "FIXED RIGHT", (557, 0, 720), (6, 880, 1280), "FIXED"), ("GP-REAR", "FIXED REAR", (0, 457, 720), (1090, 6, 1280), "FIXED"), ("GP-FRONT-L", "FRONT LEFT DOOR", (-287, -457, 720), (540, 6, 1280), "HINGED OUTWARD"), ("GP-FRONT-R", "FRONT RIGHT DOOR", (287, -457, 720), (540, 6, 1280), "HINGED OUTWARD"), ("GP-ROOF", "TOP INFILL", (0, 0, 1357), (1090, 880, 6), "FIXED"), ] rows = [{ "panel_id": pid, "role": role, "center_x_mm": c[0], "center_y_mm": c[1], "center_z_mm": c[2], "width_x_mm": s[0], "depth_y_mm": s[1], "height_z_mm": s[2], "candidate_material": "6 mm SABIC LEXAN 9030 OR 9034 POLYCARBONATE - EXACT GRADE SELECTION REQUIRED", "mounting": mounting, "impact_containment_credit": "NONE", "door_interlock_credit": "NONE", "state": "DIMENSIONED CAD CANDIDATE; GUARD ANALYSIS/TEST OPEN", "warning": WARNING, } for pid, role, c, s, mounting in panels] return rows, {pid: box(*c, *s) for pid, _, c, s, _ in panels} def support_geometry() -> tuple[list[dict], dict[str, cq.Shape]]: items: list[tuple[str, str, tuple[float, float, float], tuple[float, float, float], str]] = [ ("SP-PLATFORM", "ROBOT FOOT PLATFORM", (0, 0, 81), (700, 700, 18), "BOTH FEET FULLY SUPPORTED; NO WALKING"), ("SP-POST-L", "LEFT CRADLE POST", (-95, 185, 290), (60, 60, 400), "CUSTOM STRUCTURE; CAPACITY OPEN"), ("SP-POST-R", "RIGHT CRADLE POST", (95, 185, 290), (60, 60, 400), "CUSTOM STRUCTURE; CAPACITY OPEN"), ("SP-BEAM-L", "LEFT CRADLE ARM", (-70, 112, 497), (50, 190, 28), "TERMINATES AT P01 RESTRAINT RESERVATION"), ("SP-BEAM-R", "RIGHT CRADLE ARM", (70, 112, 497), (50, 190, 28), "TERMINATES AT P01 RESTRAINT RESERVATION"), ("SP-PAD-L", "LEFT PELVIS PAD", (-43, 32, 506), (34, 26, 40), "COMPLIANT PAD MATERIAL SELECTION REQUIRED"), ("SP-PAD-R", "RIGHT PELVIS PAD", (43, 32, 506), (34, 26, 40), "COMPLIANT PAD MATERIAL SELECTION REQUIRED"), ("SP-REAR-BRACE", "POST CROSS-BRACE", (0, 185, 450), (250, 36, 40), "CUSTOM STRUCTURE; CAPACITY OPEN"), ] rows = [{ "support_id": pid, "role": role, "center_x_mm": c[0], "center_y_mm": c[1], "center_z_mm": c[2], "size_x_mm": s[0], "size_y_mm": s[1], "size_z_mm": s[2], "interface_basis": basis, "rated_load_n": "SELECTION REQUIRED", "proof_load_n": "NOT EXECUTED", "walking_credit": "NONE", "state": "DIMENSIONED CANDIDATE; STRUCTURAL REVIEW/PROOF OPEN", "warning": WARNING, } for pid, role, c, s, basis in items] return rows, {pid: box(*c, *s) for pid, _, c, s, _ in items} def build_cad() -> dict: frame_rows, frame = frame_geometry() guard_rows, guards = guard_geometry() support_rows, supports = support_geometry() robot_raw = cq.importers.importStep(str(ROBOT_STEP)).val() robot_shift_z = 92.5 robot = robot_raw.translate((0, 0, robot_shift_z)) tether_points = [ ("TR-01", (-210, 0, 1335), (-45, 42, 535)), ("TR-02", (210, 0, 1335), (45, 42, 535)), ] tethers = {pid: rod(a, b, 4.0) for pid, a, b in tether_points} tether_rows = [{ "support_id": pid, "tether_id": pid, "top_anchor_xyz_mm": json.dumps(a), "robot_anchor_xyz_mm": json.dumps(b), "candidate_diameter_mm": 8, "role": "SECONDARY POSITION/RETENTION CANDIDATE ONLY", "rated_load_n": "SELECTION REQUIRED", "proof_load_n": "NOT EXECUTED", "fall_arrest_credit": "NONE", "walking_credit": "NONE", "state": "VISUAL ROUTE ONLY; HARDWARE/ANCHORS/CAPACITY OPEN", "warning": WARNING, } for pid, a, b in tether_points] exclusion = { "EZ-FRONT": box(0, -900, 2, 2000, 24, 4), "EZ-REAR": box(0, 900, 2, 2000, 24, 4), "EZ-LEFT": box(-988, 0, 2, 24, 1776, 4), "EZ-RIGHT": box(988, 0, 2, 24, 1776, 4), } stations = { "ST-ESTOP": cq.Compound.makeCompound([box(-880, -700, 420, 110, 110, 800), box(-880, -700, 845, 160, 160, 50)]), "ST-INSTRUMENT": box(860, -650, 500, 500, 360, 1000), "ST-FIRE": cq.Compound.makeCompound([box(865, 680, 140, 220, 220, 280), rod((865, 680, 280), (865, 680, 620), 45)]), } station_rows = [ {"station_id":"ST-ESTOP","role":"REMOTE E-STOP PEDESTAL","center_xyz_mm":"[-880,-700,845]","minimum_clearance_mm":300,"installed":"NO","calibrated_or_verified":"NO","state":"LOCATION CANDIDATE; DEVICE/REACH/RESPONSE VALIDATION OPEN","warning":WARNING}, {"station_id":"ST-INSTRUMENT","role":"ISOLATED INSTRUMENT CART ENVELOPE","center_xyz_mm":"[860,-650,500]","minimum_clearance_mm":300,"installed":"NO","calibrated_or_verified":"NO","state":"LOCATION CANDIDATE; INSTRUMENT SELECTION/CALIBRATION OPEN","warning":WARNING}, {"station_id":"ST-FIRE","role":"FIRE-RESPONSE EQUIPMENT STAGING","center_xyz_mm":"[865,680,280]","minimum_clearance_mm":300,"installed":"NO","calibrated_or_verified":"NO","state":"LOCATION CANDIDATE; DEVICE/TRAINING/SITE APPROVAL OPEN","warning":WARNING}, ] structure_assembly = cq.Assembly(name="HR30_FIRST_ENERGIZATION_CELL_STRUCTURE_P01_NOT_RELEASED") for key, shape in frame.items(): structure_assembly.add(shape, name=key, color=cq.Color(0.08, 0.25, 0.48, 1)) for key, shape in guards.items(): structure_assembly.add(shape, name=key, color=cq.Color(0.42, 0.82, 1.0, 0.25)) for key, shape in supports.items(): structure_assembly.add(shape, name=key, color=cq.Color(0.92, 0.68, 0.08, 1)) for key, shape in tethers.items(): structure_assembly.add(shape, name=key, color=cq.Color(0.93, 0.55, 0.07, 1)) for key, shape in exclusion.items(): structure_assembly.add(shape, name=key, color=cq.Color(1.0, 0.68, 0.0, 1)) for key, shape in stations.items(): color = cq.Color(0.78, 0.10, 0.08, 1) if key == "ST-ESTOP" else cq.Color(0.10, 0.45, 0.72, 0.22) structure_assembly.add(shape, name=key, color=color) structure_parts = [*frame.values(), *guards.values(), *supports.values(), *tethers.values(), *exclusion.values(), *stations.values()] structure = cq.Compound.makeCompound(structure_parts) structure_step = OUT / "HR30_first_energization_cell_structure_candidate.step" cq.exporters.export(structure, str(structure_step)); clean_step(structure_step) structure_assembly.save(str(OUT / "HR30_first_energization_cell_structure_candidate.glb"), tolerance=0.75, angularTolerance=0.20) whole = cq.Compound.makeCompound([structure, robot]) whole_step = OUT / "HR30_first_energization_cell_with_robot_candidate.step" cq.exporters.export(whole, str(whole_step)); clean_step(whole_step) structure_assembly.add(robot, name="HR30_P00_NEUTRAL_ROBOT_SHA_BOUND", color=cq.Color(0.78, 0.80, 0.83, 1)) structure_assembly.save(str(OUT / "HR30_first_energization_cell_with_robot_candidate.glb"), tolerance=0.75, angularTolerance=0.20) write_csv(OUT / "frame-member-register.csv", frame_rows) write_csv(OUT / "guard-panel-register.csv", guard_rows) write_csv(OUT / "restraint-interface-register.csv", support_rows + tether_rows) write_csv(OUT / "operator-and-instrument-location-register.csv", station_rows) bounds = whole.BoundingBox() return { "frame_member_count": len(frame_rows), "guard_panel_count": len(guard_rows), "support_component_count": len(support_rows), "secondary_tether_count": len(tether_rows), "external_station_count": len(station_rows), "robot_translation_z_mm": robot_shift_z, "assembly_extent_mm": [round(bounds.xlen, 3), round(bounds.ylen, 3), round(bounds.zlen, 3)], "robot_step_sha256": sha(ROBOT_STEP), } def publish(geometry: dict) -> None: dimensions = [ ("CELL-OUTER", "GUARD FRAME OUTSIDE", 1200, 1000, 1400, "robot-centered world frame; floor Z=0"), ("CELL-INNER", "CLEAR GUARDED VOLUME APPROXIMATE", 1114, 914, 1314, "between panels and base/top members"), ("EXCLUSION", "FLOOR EXCLUSION ZONE", 2000, 1800, 0, "gold perimeter; access control procedure open"), ("PLATFORM", "FOOT SUPPORT PLATFORM", 700, 700, 18, "top Z=90 mm"), ("ROBOT", "SHA-BOUND P00 ROBOT IN CELL", 330, 152.5, 764.5, "translated +92.5 mm so foot bottom rests at Z=90 mm"), ("PELVIS-RESERVATION", "P01 RESTRAINT INTERFACE AFTER CELL TRANSLATION", 80, 52, 20, "X +/-40; Y 6..58; Z 496.5..516.5 mm"), ] write_csv(OUT / "cell-dimension-register.csv", [{ "dimension_id": a, "description": b, "x_mm": c, "y_mm": d, "z_mm": e, "datum_or_basis": f, "validation_state": "CAD DEFINED; PHYSICAL VALIDATION OPEN", "warning": WARNING, } for a,b,c,d,e,f in dimensions]) stages = [ ("FER-E0", "UNPOWERED INSPECTION", "CELL OPTIONAL; ROBOT MAY BE IN CELL ONLY IF MECHANICALLY STABLE", "NO MOTION"), ("FER-E1", "UNPOWERED ELECTRICAL MEASUREMENTS", "USE SEPARATE E1 FIXTURE; WHOLE ROBOT REMAINS DISCONNECTED", "NO MOTION"), ("FER-E2", "COMPUTE/CONTROLLER BOOT", "USE CONTROLS-ONLY FIXTURE; NO ACTUATOR INTERFACES", "NO MOTION"), ("FER-E3", "SAFETY-LOGIC OBSERVATION", "USE CONTROLS-ONLY FIXTURE; CONTACTOR LOAD SIDE DE-ENERGIZED", "NO MOTION"), ("FER-E4", "ONE-ACTUATOR IDENTITY", "SEPARATE GUARDED BENCH FIXTURE; NOT THIS WHOLE-BODY CELL", "NO MOTION"), ("FER-E5", "ONE-BRANCH LOAD", "SEPARATE ISOLATED LOAD FIXTURE; NO ACTUATORS", "NO MOTION"), ("FER-E6", "WHOLE HARNESS POLARITY", "ROBOT IN CELL MAY BE USED ONLY AFTER G02/G10/G11 AND ALL REQUIRED GATES", "NO ACTUATORS CONNECTED"), ("FER-E7", "FIRST WHOLE-BODY STATIC RAIL OBSERVATION", "ROBOT RIGIDLY SUPPORTED AT PELVIS AND FEET; DOORS CLOSED; EXCLUSION ZONE ACTIVE", "TORQUE DISABLED; ZERO MOTION REQUEST"), ] write_csv(OUT / "stage-use-register.csv", [{ "stage_id": a, "stage": b, "cell_use": c, "motion_boundary": d, "execution_state": "OPEN - NOT EXECUTED", "cell_authorizes_stage": "NO", "required_release": "ALL APPLICABLE FER GATES PLUS QUALIFIED SIGNOFF", "warning": WARNING, } for a,b,c,d in stages]) bom = [ ("CELL-B01", "40 x 40 mm T-slot frame members", "80/20", "40-4040-Lite", 13, "CUT LENGTHS IN FRAME REGISTER; WRITTEN QUOTE/DFM REQUIRED"), ("CELL-B02", "8-hole gusseted inside corner brackets", "80/20", "40-4338", 16, "CANDIDATE QUANTITY; JOINT CALCULATION/FASTENERS REQUIRED"), ("CELL-B03", "40-series leveling-caster base plates", "80/20", "40-2407", 4, "CANDIDATE ONLY; FOOTING/ANCHORAGE DESIGN OPEN"), ("CELL-B04", "leveling casters", "80/20", "2715", 4, "CANDIDATE ONLY; CATALOG LOAD IS NOT CELL/FALL RATING"), ("CELL-B05", "panel hinges for 6 mm panels", "80/20", "40-2080", 6, "CANDIDATE ONLY; DOOR DESIGN/RETENTION OPEN"), ("CELL-B06", "6 mm clear polycarbonate panels", "SABIC", "LEXAN 9030 OR 9034 - SELECTION REQUIRED", 6, "DIMENSIONS IN GUARD REGISTER; IMPACT CONTAINMENT UNVALIDATED"), ("CELL-B07", "panel retainers and door latches", "SELECTION REQUIRED", "SELECTION REQUIRED", 1, "COMPLETE SET; EXACT HARDWARE/RETENTION OPEN"), ("CELL-B08", "robot platform and pelvis cradle parts", "CUSTOM", "SELECTION REQUIRED", 8, "MATERIAL/WELD OR FASTENER DESIGN/CAPACITY/PROOF OPEN"), ("CELL-B09", "secondary tether assemblies", "SELECTION REQUIRED", "SELECTION REQUIRED", 2, "POSITION ONLY; ZERO FALL-ARREST CREDIT"), ("CELL-B10", "remote E-stop pedestal/device", "SELECTION REQUIRED", "SELECTION REQUIRED", 1, "LOCATION ENVELOPE ONLY; SAFETY CIRCUIT SELECTION/VALIDATION OPEN"), ] write_csv(OUT / "candidate-bom.csv", [{ "item_id": a, "item": b, "manufacturer": c, "candidate_part_or_family": d, "quantity": e, "selection_state": f, "procurement_released": "NO", "warning": WARNING, } for a,b,c,d,e,f in bom]) sources = [ ("CELL-S01", "80/20", "40-4040-Lite product page", "live official page; accessed 2026-08-18", "https://8020.net/40-4040-lite.html", "40 x 40 mm 6063-T6 four-slot profile; machine guards/enclosures/work benches"), ("CELL-S02", "80/20", "40-4338 product page", "live official page; accessed 2026-08-18", "https://8020.net/fasteningmethods/externalfasteners/bracketsgussetscorners/standardgussetedbrackets/8holegussetedinsidecornerbracket/40-series.html", "40-series 8-hole gusseted inside corner bracket candidate"), ("CELL-S03", "80/20", "40-2407 product page", "live official page; accessed 2026-08-18", "https://8020.net/40-2407.html", "40-series leveling-caster base plate candidate"), ("CELL-S04", "80/20", "2715 product page", "live official page; accessed 2026-08-18", "https://8020.net/2715.html", "leveling-caster candidate; published product load is not credited as system rating"), ("CELL-S05", "80/20", "40-2080 product page", "live official page; accessed 2026-08-18", "https://8020.net/40-2080.html", "panel hinge candidate for plastic panels up to 6 mm"), ("CELL-S06", "SABIC", "LEXAN sheet portfolio brochure", "official Americas portfolio; accessed 2026-08-18", "https://www.sabic.com/en/images/sabic-lexan-sheet-portfolio-brochure-english-americas_tcm1010-5016.pdf", "9030/9034 general-purpose polycarbonate sheet; available gauge includes 6 mm"), ] write_csv(OUT / "primary-source-register.csv", [{ "source_id": a, "manufacturer": b, "document": c, "revision_date": d, "url": e, "verified_scope": f, "not_verified": "WHOLE-CELL CAPACITY, GUARD IMPACT, RESTRAINT, FALL ARREST, SITE ACCEPTANCE", "warning": WARNING, } for a,b,c,d,e,f in sources]) instruments = [ ("IN-01", "ISOLATED CURRENT-LIMITED SOURCE", "ST-INSTRUMENT", "OUTPUT LIMIT/POLARITY/ISOLATION", "SELECTION/CALIBRATION REQUIRED"), ("IN-02", "VOLTAGE PROBES / DMM", "ST-INSTRUMENT", "ALL OBSERVED RAILS AND DC REFERENCE", "SELECTION/CALIBRATION REQUIRED"), ("IN-03", "CURRENT SHUNT / CLAMP", "ST-INSTRUMENT", "SOURCE AND SELECTED BRANCH", "SELECTION/CALIBRATION REQUIRED"), ("IN-04", "THERMAL CAMERA", "OUTSIDE RIGHT GUARD", "CONNECTORS, PDU, CONTROLLERS, ACTUATORS", "SELECTION/CALIBRATION REQUIRED"), ("IN-05", "E-STOP RESPONSE LOGGER", "ST-INSTRUMENT", "PERMIT/CONTACTOR/RAIL STATE", "SELECTION/CALIBRATION REQUIRED"), ("IN-06", "VIDEO RECORD", "OUTSIDE REAR/RIGHT GUARD", "ROBOT, OPERATORS, INDICATORS", "SELECTION/TIMESTAMP CORRELATION REQUIRED"), ] write_csv(OUT / "instrument-location-register.csv", [{ "instrument_id": a, "instrument": b, "location": c, "measurement_scope": d, "selection_and_calibration": e, "installed": "NO", "abort_limits_frozen": "NO", "warning": WARNING, } for a,b,c,d,e in instruments]) checks = [ ("CELL-T01", "frame identity/dimensions", "every member and joint matches the frozen as-built register"), ("CELL-T02", "base anchorage and leveling", "cell cannot roll, rack, lift or tip under reviewed static/proof cases"), ("CELL-T03", "guard panel retention", "all panels/doors/retainers pass the approved inspection and proof procedure"), ("CELL-T04", "door state", "doors latch closed; any selected interlock is separately validated"), ("CELL-T05", "platform support", "both complete soles contact the level platform with no rocking"), ("CELL-T06", "pelvis cradle fit", "pads engage the P01 reservation without harness, cover or mechanism interference"), ("CELL-T07", "restraint proof", "reviewed cradle and anchors pass defined proof load with recorded deflection"), ("CELL-T08", "secondary tether fit", "tethers are slack/position-only and cannot create hidden primary restraint credit"), ("CELL-T09", "whole-body clearance", "robot and support remain inside guards in the approved static envelope"), ("CELL-T10", "exclusion zone", "floor boundary, access control and observer positions are physically established"), ("CELL-T11", "E-stop access", "operator can reach remote E-stop from the assigned station without entering zone"), ("CELL-T12", "instrumentation", "all selected instruments have valid calibration and frozen limits"), ("CELL-T13", "fire response", "site-specific equipment, evacuation and trained roles are approved"), ("CELL-T14", "dry rehearsal", "test lead, observer and stop operator complete an unpowered abort rehearsal"), ("CELL-T15", "configuration signoff", "G02, G10, G11 and all other applicable FER gates close on one frozen configuration"), ] write_csv(OUT / "inspection-traveler.csv", [{ "check_id": a, "inspection": b, "acceptance": c, "result": "NOT EXECUTED", "evidence": "REQUIRED", "responsible_role": "QUALIFIED ROLE SELECTION REQUIRED", "warning": WARNING, } for a,b,c in checks]) holds = [ ("CELL-H01", "frame joints/base anchorage", "structural calculation, exact fasteners, floor/base condition, proof plan and qualified acceptance"), ("CELL-H02", "pelvis cradle capacity", "load cases, material/joints, pad forces, proof load and received as-built inspection"), ("CELL-H03", "guard containment", "hazard analysis, panel grade/thickness, retention, impact/deflection test and qualified acceptance"), ("CELL-H04", "secondary tethers", "exact anchors/hardware and load evidence; no fall-arrest credit until separately released"), ("CELL-H05", "door/access control", "latch/interlock selection, defeat prevention, safety allocation and validation"), ("CELL-H06", "test-site commissioning", "floor, clearance, egress, fire response, observer and stop-role signoff"), ("CELL-H07", "instrumentation/limits", "selected calibrated instruments and frozen voltage/current/temperature/time abort limits"), ("CELL-H08", "whole-body fit", "physical robot/platform/cradle/guard/envelope inspection with measured clearances"), ("CELL-H09", "FER gate closure", "FER-G01 through G12 closed with traceable evidence on the same configuration"), ("CELL-H10", "future walking restraint", "separate rated dynamic gantry and walking test architecture; explicitly outside this cell"), ] write_csv(OUT / "open-holds.csv", [{ "hold_id": a, "unresolved_item": b, "closure_evidence": c, "state": "OPEN", "authority": AUTHORITY, "warning": WARNING, } for a,b,c in holds]) source_binding = { "identifier": IDENTIFIER, "date": DATE, "warning": WARNING, "robot_source": ROBOT_STEP.relative_to(ROOT).as_posix(), "robot_source_sha256": sha(ROBOT_STEP), "robot_source_extent_mm": [330.0000002, 152.5000002, 764.5000002], "robot_translation_z_mm": geometry["robot_translation_z_mm"], "pelvis_reservation_source": "component-envelope-schedule.csv PELVIS_RESTRAINT_INTERFACE_ENVELOPE", "pelvis_reservation_cell_xyz_mm": {"x": [-40, 40], "y": [6, 58], "z": [496.5, 516.5]}, } (OUT / "source-binding.json").write_text(json.dumps(source_binding, indent=2) + "\n", encoding="utf-8") status = { "identifier": IDENTIFIER, "date": DATE, "warning": WARNING, **geometry, "whole_robot_cad_bound": True, "complete_humanoid_visible": True, "static_first_energization_use_only": True, "walking_gantry": False, "structure_calculated": False, "restraint_rated": False, "guard_impact_validated": False, "fabricated": False, "site_commissioned": False, "instrumentation_calibrated": False, "fire_response_approved": False, "fer_g02_state": "OPEN - NOT EXECUTED", "fer_g10_state": "OPEN - NOT EXECUTED", "fer_g11_state": "OPEN - NOT EXECUTED", "fall_arrest_credit": False, "walking_credit": False, "functional_safety_credit": False, "procurement_authority": False, "fabrication_authority": False, "assembly_authority": False, "connection_authority": False, "powered_test_authority": False, "motion_authority": False, "walking_authority": False, "energization_authority": False, } (OUT / "cell-status.json").write_text(json.dumps(status, indent=2) + "\n", encoding="utf-8") (OUT / "README.md").write_text( f"# HR-30 first-energization cell P0.1\n\n**{WARNING}**\n\n" "This package places the SHA-bound complete neutral-pose HR-30 assembly inside a dimensioned " "1200 x 1000 x 1400 mm guarded cell. Both feet rest on a fixed platform and the pelvis is held by " "a rigid cradle located at the reserved P01 interface. Two overhead lines are position-only secondary " "tether candidates with zero fall-arrest credit. The static cell does not authorize or support walking.\n\n" "Editable source, STEP, GLB, dimensions, frame members, guards, restraint interfaces, stage use, " "instrument locations, BOM, sources, inspection traveler and open holds are included. The cell is unbuilt; " "FER-G02, G10 and G11 remain open, as do all other readiness gates and every work authority.\n", encoding="utf-8", ) stage_cards = "".join( f'' for a,b,c,_ in stages ) (OUT / "index.html").write_text(f'''HR-30 first-energization cell
{html.escape(WARNING)}

The complete robot now has a physical static test cell.

A dimensioned enclosure, clear guards, supported feet, rigid pelvis cradle, exclusion zone and external test stations surround the actual HR-30 CAD.

Whole cell + robot STEP · cell-only STEP · dimensions · inspection traveler.

1200 × 1000 × 1400

mm guarded frame envelope.

6

dimensioned clear polycarbonate panels.

2 + 2

supported feet and pelvis contact pads.

0

motion, walking, fall-arrest or energization authority.

What physically restrains the robot

Feet stay planted

Both full soles rest on a 700 × 700 mm rigid platform. The cell is not a suspended walking rig.

Pelvis carries the restraint

Twin posts and arms terminate in two pads at the P01 pelvis reservation. Exact load capacity and proof remain open.

Tethers are secondary only

Two visible overhead routes locate future hardware but carry zero rated-load or fall-arrest credit.

Stage-by-stage boundary

Select a stage to highlight its planned use. Every stage remains open and unexecuted.

{stage_cards}
Choose a stage. No selection authorizes work.

Three external readiness stations

What this does not solve

The frame and cradle are not structurally released; guards have no impact-containment credit; tethers are not fall arrest; the site is not commissioned; instruments and abort limits are not selected; FER-G02, G10 and G11 remain open. E7 and all powered work remain prohibited.

Engineering package

editable source · frame · guards · restraint · stations · instrumentation · BOM · manufacturer sources · open holds.

''', encoding="utf-8") def integrate() -> None: status_path = WHOLE / "package-status.json" status = json.loads(status_path.read_text(encoding="utf-8")) status.update({ "first_energization_cell_present": True, "first_energization_cell_whole_robot_bound": True, "first_energization_cell_static_use_only": True, "first_energization_cell_walking_gantry": False, "first_energization_cell_structure_calculated": False, "first_energization_cell_restraint_rated": False, "first_energization_cell_guard_impact_validated": False, "first_energization_cell_fabricated": False, "first_energization_cell_site_commissioned": False, "first_energization_cell_instrumentation_calibrated": False, "fer_g02_closed": False, "fer_g10_closed": False, "fer_g11_closed": False, }) status_path.write_text(json.dumps(status, indent=2) + "\n", encoding="utf-8") start, end = "", "" readme = WHOLE / "README.md" text = readme.read_text(encoding="utf-8") if start in text and end in text: text = text.split(start, 1)[0] + text.split(end, 1)[1] block = f'''{start}\n## Whole-body first-energization cell\n\nThe [interactive first-energization-cell guide](first-energization-cell-p0.1/index.html) places the SHA-bound complete neutral-pose robot inside a dimensioned **1200 x 1000 x 1400 mm** guarded frame. Both feet are supported and a rigid cradle locates the reserved pelvis interface. The two overhead routes are secondary position-only tether candidates, not fall arrest. The cell is unbuilt, FER-G02/G10/G11 remain open, and it grants no powered-test, motion, walking or energization authority.\n{end}\n''' readme.write_text(text.rstrip() + "\n\n" + block, encoding="utf-8") page = WHOLE / "index.html" text = page.read_text(encoding="utf-8") if start in text and end in text: text = text.split(start, 1)[0] + text.split(end, 1)[1] section = f'''{start}

The complete robot now has a physical static first-energization cell

1200 × 1000 × 1400

mm dimensioned guarded frame around the SHA-bound whole robot.

Supported, not suspended

Both feet rest on a platform and a rigid pelvis cradle carries the primary restraint intent.

Not a walking gantry

Structure, guards, restraint, site, instruments and all FER gates remain unvalidated and open.

Open the interactive cell guide.

{end}''' text = text.replace("", section + "", 1) page.write_text(text, encoding="utf-8") def manifest_release() -> None: shutil.copy2(Path(__file__), OUT / "first-energization-cell-source.py") files = [p for p in OUT.rglob("*") if p.is_file() and p.name != "file-manifest.csv"] write_csv(OUT / "file-manifest.csv", [{ "path": p.relative_to(OUT).as_posix(), "bytes": p.stat().st_size, "sha256": sha(p), "warning": WARNING, } for p in sorted(files)]) if RELEASE.exists(): shutil.rmtree(RELEASE) shutil.copytree(OUT, RELEASE) code = "import sys;sys.path.insert(0,'tools');import generate_hr30_system_package_p01 as s;s.refresh_manifest_and_release()" result = subprocess.run([str(CAD_PYTHON), "-c", code], cwd=ROOT) if result.returncode: raise RuntimeError("whole-body manifest/release refresh failed") def main() -> int: if OUT.exists(): shutil.rmtree(OUT) OUT.mkdir(parents=True) print("first-energization cell: CAD", flush=True) geometry = build_cad() print("first-energization cell: registers and guide", flush=True) publish(geometry) integrate() manifest_release() print(json.dumps({"identifier": IDENTIFIER, **geometry, "authorities": 0}, indent=2)) return 0 if __name__ == "__main__": raise SystemExit(main())