ASR Production-Reference Digital Assembly

Engineering visualization and layout-study application for the Autonomous Security Robot, companion to ASR-ENG-001 Rev B and the Rev B expanded BOM.

The application uses strict TypeScript, Three.js, and Vite. It preserves a small dependency footprint while providing detailed mechanical reference assemblies, named manufacturing subparts, engineering metadata, collision and service checks, editable cable routes, and CAD handoff hooks.

Engineering status: Rev B is a design-review baseline, not a manufacturing release. Every placement or value marked PROVISIONAL / ASSUMED is a layout seed only. Vendor-reference meshes are not a substitute for vendor STEP files. Do not release a part for procurement or fabrication from this viewer.

Run

npm install
npm run dev
npm run build
npm run preview

Coordinate conventions

• Robot frame: +X forward, +Y left, +Z up (ROS convention).
• Data and exported STL coordinates: millimetres.
• Three.js scene: metres.
• Origin: ground level under the chassis centre.
• Component parentId values are logical hierarchy only; all component poses remain in the robot world frame.

Engineering feature map

Feature	Location
Perspective and six orthographic engineering views	Toolbar / core/SceneManager.ts
Orbit, pan, zoom and fit	Three.js controls
Component hierarchy, selection and visibility	Left panel
Solid, transparent and hidden enclosure modes	Toolbar
Internal layout preset	Toolbar
Adjustable exploded view	Right panel
Dimensions, mass, power, cooling, service and provenance	Component inspector
Move/rotate tools with 1 mm / 5 degree snapping	Toolbar
Component AABB collision and red highlighting	features/CollisionManager.ts
Service and connector keep-out volumes	keepOuts[]
X/Y/Z section clipping	Right panel
Two-point measurement with delta XYZ	Measure tool
Battery, compute, power, drive and sensor zones	Zone controls
Editable Catmull-Rom cable routes	Cable tool
Centre-of-mass estimate	COM control
Save/load configuration JSON	Toolbar
Local GLB CAD import with mm/m and Y-up/Z-up handling	Inspector
Named manufacturing parts and datum-preserving STL export	Inspector

Keyboard: S select, G move, R rotate, M measure, C cables, F fit, Esc cancel/deselect. Double-click sets the orbit target.

Production-reference assemblies

The default MFG layer preserves the 19 canonical engineering components while building each component as stable, named local subparts. Fasteners, panels, brackets and purchased references therefore stay attached to their component without corrupting COM, cable endpoints, collision rules, configurations, or exploded-view behavior.

The upgraded model includes:

• A removable lower skid, drilled floor pan, boxed longitudinal rails, crossmembers, four replaceable axle/torque plates, battery cradle, four structure-cleared equipment trays, and six matched enclosure isolation interfaces.
• A hollow, low and wide faceted enclosure with a vertical graphite lower tub, outward shoulder break, inward upper slope, angular partial wheel covers, joined front and rear fascia returns, rear service door, separate bumpers, recessed RealSense through-frame, and a collared perimeter rail.
• Four photo-matched wheel references with rounded pneumatic carcasses, mirrored chevron/shoulder tread, large machined annuli, six-lobed hub spiders, axle hardware, cable strain relief, and outboard-only red/yellow/blue sidewall arcs.
• A deck-integrated PTZ pedestal, positively seated reinforced mast, broad rear yoke, sealed pan adapter, closed helmet camera shell, opaque lower optical visor, recessed lens/IR module, cap-free Livox MID-360 dome, D435i carrier, and one installed antenna hardpoint.
• Named bases, housings, heatsinks, connector faces, covers, terminals, disconnects and carriers for compute, battery, PDU, controller, converter, and modem packaging.

The large black louvered top-deck "air window" in the concept renders has been removed completely. The top deck is a single continuous sealed panel with no slots or grille. Compute and power equipment remain inside sealed bays.

Components can render in three representations:

1. Named MFG assemblies (default) - production-style parametric subparts with part number, material/process intent, make/buy status and interface notes.
2. Dimensional primitives (MFG off) - the conservative JSON box, cylinder and sphere basis.
3. Imported GLB - a per-component vendor/released CAD replacement that takes precedence over both parametric representations.

STL and SolidWorks handoff

Select a component and open Manufacturing reference in the inspector:

• Export assembly STL writes the complete selected component.
• Every named subpart has an individual STL export.
• Export parts manifest writes part numbers, material/process intent, make/buy status, mating-interface notes, local bounds and triangle counts.

STL is unitless. Exported numeric coordinates are deliberately millimetres. Every subpart preserves the shared component-local datum so separate files retain their assembly relationship when imported into SolidWorks. A slicer can use "drop to bed" when preparing one prototype-printable part.

The model audit in scripts/audit-models.ts builds every styled component without a browser and checks:

• The canonical 19-component and cable-endpoint dataset.
• Finite model bounds and nonzero triangle counts.
• Stable, nonduplicated part IDs.
• Closed-edge topology for every part marked prototype-printable.
• Current assembly collisions and service/connector keep-outs.
• Absence of the deleted top air-window geometry.

Manufacturing boundary: the STL outputs are tessellated engineering references, not released feature-history CAD. Purchased parts are marked PURCHASED / REF and must be replaced by measured or vendor STEP models. Every provisional alloy, wall section, fastener, insert, gasket compression, tolerance, print orientation, load case and safety interface still needs formal engineering verification and drawing release.

Data model

src/data/components.json remains the canonical engineering source. Each record contains:

• geometry.primitives: conservative dimensions.
• geometry.styled: production-reference assembly builder and parameters.
• geometry.glbUrl, glbUnits, glbUpAxis: released/vendor CAD hooks.
• physical, power, cooling, service: engineering metadata with provisional flags and provenance.
• keepOuts: service and connector volumes.
• status: vendor-datasheet, provisional, or assumed.

zones.json defines planning volumes. cables.json contains the provisional harness routes and BOM cable references. Every route is authored below the sealed deck or terminates at an internal bulkhead; cable tubes are hidden by default and are exposed only through the cable engineering controls.

scripts/audit-interfaces.mjs runs as part of every production build. It checks wheel track, battery/deck clearance, PDU/crossmember clearance, sensor-to-hardpoint datums, internal cable height, the single default antenna, the hollow wall construction, and removal of loose wheel pigtails and the LiDAR top cap.

Pair collision checks exclude the structural chassis and enclosure because internal equipment legitimately sits within them. Keep-out intrusion checks include the structure and use separate local mechanical meshes so sparse rails, crossmembers and isolators do not create one false union box.

Replacing a reference with released CAD

1. Keep the SolidWorks/STEP part origin on the component reference datum.
2. Convert the STEP model to GLB for the viewer.
3. Set glbUnits to mm for a typical CAD export, or m for native glTF.
4. Set glbUpAxis to y for standard glTF, or z for a Z-up export.
5. Use Inspector -> Import GLB. Placement, selection, clipping, COM, collision, explode behavior, and engineering metadata stay intact.
6. Revert to primitives restores the parametric reference assembly.

Verified seeds and unresolved release gates

• Wheel/tyre: nominal 10 x 2.5 in (254 x 63.5 mm). Vendor, inflated envelope, axle flat/thread, torque reaction and cable exit remain unverified.
• Jetson AGX Orin developer kit: 110 x 110 x 71.65 mm. It is a prototype compute platform, not released production compute.
• Livox MID-360: 65 x 65 x 60 mm, approximately 265 g, four M3 mounting holes. The 40 mm custom riser remains provisional.
• Intel RealSense D435i: 90 x 25 x 25 mm, USB-C, one 1/4-20 and two M3 mounting interfaces. Its weather carrier remains custom.
• Amcrest IP8M-2899EW-AI-V2: 160 mm diameter x 270.5 mm high and 2.60 kg. The supplied wall-arm revision must be measured before mast-hole release.
• The Master BOM names Roboteq FBLG2360T (140 x 140 x 25 mm) while the References sheet says SBLG2360TS. The viewer uses the Master BOM envelope but keeps the selection provisional until that conflict is closed.
• Mean Well SDR-960-48 is bench/dock equipment only and is intentionally not represented as an onboard traction supply.

The concept renders are styling references, not mutually consistent orthographic drawings. Overall released chassis dimensions, motor/axle data, gross mass/CG, battery packaging, controller selection, safety architecture, ingress target, and thermal design remain release-gated by ASR-ENG-001 Rev B.

Known approximations

• Collision uses transformed world-axis-aligned boxes.
• COM treats each canonical component as a point mass at its geometric centre.
• Explode offsets are display-only; collisions and COM use the base layout.
• Transparent enclosure geometry is excluded from picking.
• Cable routes are schematic and are not a cable-schedule length release.