PRELIMINARY - UNBUILT CABLE COUPON PLAN - NOT APPROVED FOR PROCUREMENT, PRODUCTION CUTTING, FABRICATION, CONNECTION, POWERED TESTING, MOTION OR ENERGIZATION

HR-30 whole-body P0.1

Build and break coupons before cutting robot cables.

The 24 AWG predecessor is no longer treated as an actuator-power candidate. The package now separates a 22 AWG static suspended-commissioning lead from a 22 AWG dynamic cable candidate, and requires construction-specific destructive evidence for both.

4

candidate tooling paths and operations

11

controlled coupon specimen families

25

axis routes requiring as-built measurement

0

built coupons, executed tests, or released cut lengths

Evidence flow

Cable coupon validation and robot route measurement workflow

Test the complete transition, not a direct CF130-to-JST crimp

Moving side

CF130.03.02.UL terminates only into Molex 430250200 / 430300001. Its individual-core OD must be measured against the 1.85 mm terminal limit.

Fixed panel side

Molex 430200200 / 430310001 mounts to the dimensioned bracket candidate; 25 nominal module placements are configuration-bound. Restrained Alpha Wire 3051 continues to JST EH.

Isolation test

Cycle the moving cable while measuring panel motion and confirming that the JST pigtail sees no cyclic bend or pull.

CF9.UL.02.02 is 24 AWG. It remains a data/flex investigation candidate only and receives no actuator-power credit. Official cutout, received fit, material/fasteners, clamp force, pigtail lengths and tolerance-aware integration remain open.

Inspect the dimensioned transition-bracket candidate.

Prototype tooling path

Loose-piece trial: JST BEH-001T-P0.6 contact, YC-260R hand tool, EHR-3/EHR-4 housings and EJ-PH extraction tool. The alternative strip path is SEH-001T-P0.6 + YRS-260. These are manufacturer-linked candidates—not a released process for either wire construction.

Production lengths remain deliberately blank

The existing geometry values are planning lengths, not cable cut lengths. Each axis must be measured on the assembled robot with pull string through its complete joint range. Connector termination allowance, service slack, clamps, bend radius and collision clearance must then be frozen.

AxisGeometry planning lengthCommanded rangeFinal cut lengthAction
WAIST_YAW74.615 mmspeed <=15 deg/s in HR-30ASELECTION REQUIRED - MEASURE ON ASSEMBLED ROBOTDO NOT CUT PRODUCTION CABLE
HEAD_PAN74.325 mmSELECTION REQUIREDSELECTION REQUIRED - MEASURE ON ASSEMBLED ROBOTDO NOT CUT PRODUCTION CABLE
HEAD_TILT142.325 mmSELECTION REQUIREDSELECTION REQUIRED - MEASURE ON ASSEMBLED ROBOTDO NOT CUT PRODUCTION CABLE
L_SHOULDER_PITCH114.724 mmSELECTION REQUIREDSELECTION REQUIRED - MEASURE ON ASSEMBLED ROBOTDO NOT CUT PRODUCTION CABLE
L_SHOULDER_ROLL142.724 mmSELECTION REQUIREDSELECTION REQUIRED - MEASURE ON ASSEMBLED ROBOTDO NOT CUT PRODUCTION CABLE
L_ELBOW_PITCH320.724 mmSELECTION REQUIREDSELECTION REQUIRED - MEASURE ON ASSEMBLED ROBOTDO NOT CUT PRODUCTION CABLE
L_WRIST_ROTATION490.672 mmSELECTION REQUIREDSELECTION REQUIRED - MEASURE ON ASSEMBLED ROBOTDO NOT CUT PRODUCTION CABLE
L_GRIPPER561.672 mmSELECTION REQUIREDSELECTION REQUIRED - MEASURE ON ASSEMBLED ROBOTDO NOT CUT PRODUCTION CABLE
L_HIP_YAW145.546 mm+/-30 degSELECTION REQUIRED - MEASURE ON ASSEMBLED ROBOTDO NOT CUT PRODUCTION CABLE
L_HIP_ROLL193.546 mm+/-25 degSELECTION REQUIRED - MEASURE ON ASSEMBLED ROBOTDO NOT CUT PRODUCTION CABLE
L_HIP_PITCH241.546 mm-35..+45 degSELECTION REQUIRED - MEASURE ON ASSEMBLED ROBOTDO NOT CUT PRODUCTION CABLE
L_KNEE_PITCH429.546 mm0..120 degSELECTION REQUIRED - MEASURE ON ASSEMBLED ROBOTDO NOT CUT PRODUCTION CABLE
L_ANKLE_PITCH612.546 mm-35..+30 degSELECTION REQUIRED - MEASURE ON ASSEMBLED ROBOTDO NOT CUT PRODUCTION CABLE
L_ANKLE_ROLL660.546 mm+/-20 degSELECTION REQUIRED - MEASURE ON ASSEMBLED ROBOTDO NOT CUT PRODUCTION CABLE
R_SHOULDER_PITCH114.724 mmSELECTION REQUIREDSELECTION REQUIRED - MEASURE ON ASSEMBLED ROBOTDO NOT CUT PRODUCTION CABLE
R_SHOULDER_ROLL142.724 mmSELECTION REQUIREDSELECTION REQUIRED - MEASURE ON ASSEMBLED ROBOTDO NOT CUT PRODUCTION CABLE
R_ELBOW_PITCH320.724 mmSELECTION REQUIREDSELECTION REQUIRED - MEASURE ON ASSEMBLED ROBOTDO NOT CUT PRODUCTION CABLE
R_WRIST_ROTATION490.672 mmSELECTION REQUIREDSELECTION REQUIRED - MEASURE ON ASSEMBLED ROBOTDO NOT CUT PRODUCTION CABLE
R_GRIPPER561.672 mmSELECTION REQUIREDSELECTION REQUIRED - MEASURE ON ASSEMBLED ROBOTDO NOT CUT PRODUCTION CABLE
R_HIP_YAW145.546 mm+/-30 degSELECTION REQUIRED - MEASURE ON ASSEMBLED ROBOTDO NOT CUT PRODUCTION CABLE
R_HIP_ROLL193.546 mm+/-25 degSELECTION REQUIRED - MEASURE ON ASSEMBLED ROBOTDO NOT CUT PRODUCTION CABLE
R_HIP_PITCH241.546 mm-35..+45 degSELECTION REQUIRED - MEASURE ON ASSEMBLED ROBOTDO NOT CUT PRODUCTION CABLE
R_KNEE_PITCH429.546 mm0..120 degSELECTION REQUIRED - MEASURE ON ASSEMBLED ROBOTDO NOT CUT PRODUCTION CABLE
R_ANKLE_PITCH612.546 mm-35..+30 degSELECTION REQUIRED - MEASURE ON ASSEMBLED ROBOTDO NOT CUT PRODUCTION CABLE
R_ANKLE_ROLL660.546 mm+/-20 degSELECTION REQUIRED - MEASURE ON ASSEMBLED ROBOTDO NOT CUT PRODUCTION CABLE

Controlled records

Tooling | Coupon BOM | Specimens | Build traveler | Measurements | 25 route measurements | Open holds | Primary sources

No acceptance limit has been invented. Unresolved values are explicitly SELECTION REQUIRED.