hardware-kit

Living spec for the All Systems Go camera body. In-flight deltas: openspec/changes/*/specs/hardware-kit/.

Purpose

CAD and buys use envelopes and URLs from docs/references/, not folklore. The kit crib (SKUs, BOM lines, quotes) is sister repo daBOM. Preferred production kit is SKU kit-prod (Cart T). Lab brick is kit-lab. Hybrid 1+2 plant is kit-hybrid-plant. Explode with GET /api/v1/items/{sku}/bom?explode=true. This markdown is capability SHALLs, not the parts list.

Requirements

Requirement: Kit crib

The preferred production kit SHALL be the daBOM item kit-prod (Cart T — T4000 + Rogue-T5). Lab bring-up SHALL be kit-lab. The 1 body + 2 sat plant SHALL be kit-hybrid-plant. SKUs, BOM lines, and quotes SHALL be read from daBOM, not copied into this spec.

Scenario: explode production kit

GIVEN daBOM is running
WHEN GET /api/v1/items/kit-prod/bom?explode=true
THEN the tree includes the T4000 SOM, Rogue-T5, and satellite encode mules, not a handwritten parts list in this file

Requirement: Datasheet manifest

Every steered SKU SHALL have a PDF or URL, fetch date, and mechanical envelope listed under docs/references/.

Scenario: Thor SOM

GIVEN DS-11945-001 v1.4 in docs/references/
WHEN CAD or power work starts
THEN envelopes come from T4000.md, not memory

Requirement: Cooke /i–class lens sidecar

Each camera, body and satellite, SHALL produce frame-accurate lens metadata in Cooke /i (or ARRI LDS, ZEISS XD, or EF electronic mapped into the same fields). Thor SHALL write it as a JSONL sidecar 1:1 with that camera’s HEVC timecode. RAW lens maps (/i3 distortion, shading) SHALL be files on the NAS keyed by lens identity, not per-frame blobs.

Scenario: body and two sats

GIVEN three cameras recording
WHEN a take is written to the NAS
THEN each HEVC file has a sibling JSONL with at least make, serial, true focal length, T-stop, and focus distance locked to timecode

Requirement: First-article enclosure

The first printable enclosure SHALL fit the AGX Thor Developer Kit envelope and provide a body-camera mount plus TTP ventilation.

Scenario: Anycubic fit-check

GIVEN the AGX kit dimensions 243.19 × 112.40 × 56.88 mm
WHEN an STL is printed in resin
THEN the kit seats, the body cam has a mount, and vents do not cover the TTP

Requirement: Split power tree

Thor module power and satellite PoE SHALL be separate supplies. PoE SHALL NOT backfeed the AGX kit or SOM.

Scenario: sag

GIVEN thermal or power headroom is gone
WHEN the kit must shed load
THEN AI (MIG slice 1) is dropped and record (slice 0) continues

Requirement: T4000 thermal ceiling

A T4000 body SHALL be designed for 70 W default and 90 W TMP, TTP ≤ 75 °C.

Scenario: enclosure

GIVEN a resin lid over the SOM or AGX kit
WHEN the GPU is at default power
THEN the TTP is vented or heat-sunk; resin is not the thermal path

Requirement: Body-mounted camera

One camera SHALL be mounted to the Thor enclosure and ingested over CSI-2 or GMSL into Thor NVENC. It SHALL be 4K30 class. HSB or USB on the AGX kit is a bring-up fallback only and SHALL NOT be the production body path.

Scenario: body record

GIVEN the body camera is mounted and powered on the production enclosure
WHEN capture starts
THEN Thor encodes H.265 from that CSI/GMSL sensor without a PoE hop and without using HSB/USB as the ingest

Requirement: PoE satellites

Bring-up SHALL include two satellite cameras on PoE that emit H.265 at 4K30. The shipped satellite class SHALL support electronic iris and/or focus, a Cooke /i–class metadata path (barrel port to Ethernet), and a UART 1D ToF sensor whose range is written into the same JSONL sidecar as picture. A sealed P-iris turret MAY be an encode mule for bring-up and SHALL NOT be the shipped satellite class.

Scenario: satellite record

GIVEN two PoE satellites of the shipped class and a PoE switch
WHEN capture starts
THEN each satellite delivers camera-side H.265 that Thor remuxes to the NAS, plus Cooke-class lens metadata and 1D ToF in the sidecar, without a RAW Ethernet payload

Requirement: Lab brick

Bring-up SHALL use the NVIDIA Jetson AGX Thor Developer Kit (T5000 module).

Scenario: first power-on

GIVEN no custom carrier yet
WHEN the lab kit is used
THEN I/O is the kit’s 5GbE, QSFP28 (independent MGBE lanes), USB-C, and HSB/USB cameras

Requirement: Production ceiling

Production body design SHALL fit the T4000 SOM: 87 × 100 × 15.29 mm, 699-pin B2B, default 70 W, throttle at 90 W TMP, 1× NVENC, 3× 25GbE, no CAN. The carrier SHALL supply SYS_VIN_HV 7–20 V and SYS_VIN_MV 5 V. It SHALL NOT require SYS_VIN_SV (a T5000-only rail). T4000 is the default production module. T5000 is permitted only when the required satellite encode load cannot remain camera-side or otherwise exceeds the validated T4000 hybrid budget.

Scenario: drop to T4000

GIVEN hybrid HEVC satellites
WHEN the body is a T4000 SOM
THEN Thor encodes the body camera only and satellites remain camera-side H.265

Scenario: rails

GIVEN a production carrier for T4000
WHEN the SOM is seated
THEN HV 7–20 V and MV 5 V are present and SYS_VIN_SV is absent at the module

Scenario: T5000 escape

GIVEN satellite count or encode demand that will not stay camera-side within the T4000 hybrid budget (1× NVENC, HQ 2× 4Kp30)
WHEN the body module is chosen
THEN T5000 may be used; otherwise the body stays T4000

Requirement: Hybrid camera fabric

The camera body SHALL ingest the body camera over CSI-2 or GMSL on the Thor module, and SHALL ingest satellite cameras over Power-over-Ethernet. USB-C SHALL NOT be the satellite trunk.

Scenario: bring-up plant

GIVEN one body camera and two satellites
WHEN the kit is powered
THEN the body path is native CSI/GMSL into Thor and each satellite is a PoE endpoint

Requirement: HEVC record path

The kit SHALL record 4K picture as H.265. RAW SHALL NOT be required on the satellite or truck uplink. CSI RAW is permitted only as the body sensor hop into Thor NVENC. Satellite H.265 SHALL be written to the NAS by Thor (remux, no re-encode) alongside the body master.

Scenario: bring-up bit rate

GIVEN 1 body + 2 satellites at 4K30 HEVC
WHEN streams are recorded
THEN aggregate payload is on the order of 0.24 Gbps and fits in 5 GbE

Requirement: Satellite-side encode for T4000 bring-up

On the T4000 production ceiling (1× NVENC, HQ 2× 4Kp30), each satellite SHALL encode its own H.265. Thor NVENC SHALL own the body master only. The kit SHALL NOT require Thor to HQ-encode the 1 body + 2 satellite bring-up trio.

Scenario: T4000 HQ ceiling

GIVEN T4000 HQ NVENC is 2× 4Kp30
WHEN 1 body + 2 satellites record 4K30
THEN the body is Thor NVENC and each satellite ships camera-side H.265

Requirement: PoE power vs data boundary

PoE SHALL power satellites. The satellite Ethernet PHY SHALL carry H.265. Thor SHALL NOT supply PoE. An external PoE switch is a kit item. PoE class and switch uplink capacity SHALL be evaluated as separate criteria; PoE does not name link bitrate.

Scenario: switch is in the kit

GIVEN Thor has no PoE
WHEN two satellites are on set
THEN each sat is a PoE endpoint on an external switch, and that switch’s data uplink is sized for the HEVC payload plus overhead, not by PoE class

Requirement: Independent MGBE lanes

QSFP/MGBE lanes on Thor SHALL be treated as independent controllers. The kit SHALL NOT present QSFP28 as one aggregated 100GbE video trunk.

Scenario: QSFP is not 100G

GIVEN QSFP28 is three (T4000) or four (T5000 / AGX kit) independent MGBE controllers (DS-11945-001 4.10.1)
WHEN the truck uplink is planned
THEN each lane is budgeted on its own; the plant is not a 100G pipe

Requirement: Clock and sidecar alignment

Body hardware timing, satellite PTP, picture timecode, and Cooke /i–class JSONL SHALL be reconcilable per frame. The exact product clock master MAY remain unspecified.

Scenario: sidecar locks to picture

GIVEN a take written to the NAS
WHEN a HEVC file and its JSONL sidecar are opened
THEN timecode on the sidecar matches picture; satellite PTP and body hardware clocks are named well enough to reconcile them

Requirement: Record-first under AI drop

HEVC recording, the NVMe ring, satellite remux to storage, and metadata sidecars SHALL continue when AI decode or overlay is dropped. Mode switch drops AI, never record. Remux is record, not AI.

Scenario: thermal sag

GIVEN 1 body + 2 satellites recording
WHEN slice-1 AI is killed or thermal sag drops overlay/AD
THEN body HEVC, sat remux to the NAS, and JSONL sidecars keep writing

Requirement: Four compute envelopes

The kit SHALL name four compute envelopes: Thor T4000 (production body), fractal1 RTX 3090 (local FP16 pipe), RunPod RTX PRO 6000 Blackwell Server 96 GB (30 fps perception lab), and the truck 6000 (quality). The AGX Thor Developer Kit (T5000 module) SHALL share envelope id t4000 until measured apart: bandwidth-bound reads ~1× T4000, TPC-bound ×0.6, NVENC count 2 not 1. The 3090 SHALL NOT be treated as a T4000 TOPS proxy. Derates SHALL live in docs/3090-SIM.md. Hardware envelope id (derate and log attribution) and pack id (SMALL or LARGE weights) SHALL be separate fields. Pack and residency default by envelope and SHALL be overridable. RunPod 6000 and truck 6000 share the 6000 quality-class column until measured apart.

Scenario: cartridge costs

GIVEN the cartridge catalog
WHEN costs are recorded per envelope id
THEN the ids t4000, 3090, and 6000 match this four-box list (RunPod 6000 and truck 6000 share the 6000 quality-class column until measured apart; the AGX kit logs as t4000 with the partial derate above)

Requirement: Resident 30 fps design target

The live perception pipeline SHALL be designed as named slots kept resident at 30 fps on Thor T4000 and on an RTX PRO 6000. fractal1’s 3090 SHALL emulate that pipeline by loading one slot at a time and unloading it, and SHALL NOT be a 30 fps host. The same software SHALL select residency (resident or swap) and pack (SMALL or LARGE) as independent fields that default by envelope id and MAY be overridden. A PRO 6000 LARGE-pack stream SHALL NOT be logged as a T4000 FACT; no derate from 6000 fps to T4000 exists. T4000 30 fps SHALL remain SPEC until measured on Thor silicon. Swap-mode logs SHALL split load/unload time from per-frame time before docs/3090-SIM.md derates apply.

Scenario: rent or local body

GIVEN the live mix is running
WHEN the envelope is a rented PRO 6000 96 GB
THEN every live slot stays resident, pack is LARGE, and the stream is a lab result with no derate to T4000
WHEN the envelope is a local T4000
THEN every live slot stays resident, pack is SMALL, and 30 fps is SPEC
WHEN the envelope is fractal1 3090
THEN slots swap, pack is SMALL, and the log splits load/unload from per-frame time then applies docs/3090-SIM.md derates

Requirement: Envelope-sized packs

T4000 SHALL pack SMALL live weights (VDA-S / oVDA, YOLOE, SAM2-tiny or EdgeTAM, RVM-MN3 on talent, Maxine AR). The 30 fps lab 6000 SHALL pack LARGE live weights (VDA-L or DA3METRIC-L, SAM 3.1, SAM2Matting). The 3090 SHALL load SMALL weights only. SAM 3.1 + VDA-L SHALL NOT be packed on T4000.

Scenario: MODELS quant rows

GIVEN MODELS.md
WHEN a live perception job is listed
THEN it names SMALL and LARGE packs and which envelope runs each