20261024-2230-air-hub-pcb-layout-and-appearance Air Hub / Air Hub Pro: PCB layout, appearance design and handover update

• status: completed
• priority: P2
• owner: worker/session-20261015-1500
• createdAt: 2026-10-24 22:30

Description

On 2026-10-24 the owner kept both radios on the Air Hub ("保留现状") and asked for the next step on the revision D carrier: "开始做pcb和外观设计，然后更新handover".

Scope (approved 2026-10-24: "1，可以，当前没有外壳 2，可以工业风"):

1. PCB layout (Linux carrier, revision D): after the part reduction, the board is placed again with the enclosure in mind. The board outline shrinks where the removed parts leave space. Connectors, the key, the LEDs and the two antenna ends go where the enclosure needs them. The EMC pre-check errors that the layout can fix are fixed: the RJ45 pin-field reference-plane gaps and the RMII fan-out return vias. The board is rerouted to DRC 0.
2. Appearance design: an appearance package for the Air Hub / Air Hub Pro enclosure built like the Key Box 36 package (CadQuery base and lid, the board in place, coloured STEP and ray-traced renders): IP54 PC/ABS housing, side-wall RJ45 / RP-SMA / USB-C / M8, two light pipes and the silicone PAIR key in the lid, wall mounting. The Air Hub variant gets blanked RJ45 and RP-SMA openings.
3. Handover update: refresh the air-hub/ and air-hub-pro/ product directories (exports, renders, cost sheets, enclosure, README) and fix the stale handover/air-hub-2026-10-13/ references in the docs.

Acceptance criteria:

1. ERC 0 and net verification clean; PCB DRC 0 unconnected, 0 errors, 0 schematic-parity issues.
2. Fewer EMC pre-check errors than revision D's 24, with the remaining ones explained.
3. Enclosure STEP and renders exist in air-hub-pro/enclosure/, and the board fits the enclosure (no collisions).
4. Product directories and docs describe the new board and enclosure; bun run docs:lint && bun run docs:build && git diff --check passes.

ActiveForm

Laying out the Air Hub carrier and designing the enclosure

Dependencies

• blocked by: (none)
• blocks: (none)

Notes

The Air Hub Mini is handled in a separate session and is out of scope. No commit until the owner asks.

• complete: Board 104 x 90 mm (was 110 x 102), MG24 module on the right edge, key / LEDs / pads in the lower right corner, RMII TXD0 / REFCLK / CLK50 on L1. ERC 0, net verification clean; DRC 0 unconnected, 0 errors, 0 parity issues; SPICE 22/22. EMC pre-check 58 findings, 23 errors (was 24); the remaining 11 RP-001 are RMII / PHY-control vias from L1 to L3 that share the L2 GND plane as reference, the 8 GP-001 are the RJ45 pin field. Enclosure appearance model tools/enclosure/air_hub_3d.py + tools/render_air_hub.sh (STEP in air-hub-pro/3d/, renders and assembly STEP in air-hub-pro/enclosure/), interference check 0 overlaps (VRML-only parts not checked). Product READMEs, reference board R1.15, guide R1.11 and the EMC evaluation updated; stale handover references removed.