{"id":"interface-bench-01","status":"Proposed experiment — not performed","objective":"Determine whether one exact-constraint datum can make repeated robotic/manual carrier replacement practical without coupling fluid sealing to precision location.","proposedDimensions":{"baseM":[0.62,0.05,0.52],"ballRadiusM":0.025,"grooveRodRadiusM":0.012,"railHalfSeparationM":0.018},"bom":[{"item":"Machined reference and carrier plates","quantity":2,"material":"Aluminum alloy selected for stiffness/corrosion requirements"},{"item":"Replaceable spherical contacts","quantity":3,"material":"Hardened steel, surface quality to be specified"},{"item":"Radial groove contact rails","quantity":6,"material":"Hardened round steel inserts"},{"item":"Adjustable retention clamps","quantity":3,"material":"Rated industrial clamps, not precision locators"},{"item":"Media-specific connector pair","quantity":1,"material":"Select after fluid/pressure/sanitation review; not a universal plug"},{"item":"Seat sensor and independent displacement measurement","quantity":2,"material":"Local switch plus dial indicator or calibrated displacement sensor"}],"planningCost":{"currency":"USD","range":[400,1500],"basis":"Authored bench planning allowance, not supplier quotes","excludes":["machining labor if outsourced","robot","certification","safety review","water-quality testing","engineering labor"]},"tests":[{"test":"Clean re-seating","method":"Fifty manual remove/reseat cycles at a fixed declared preload; measure position in multiple axes and record distribution, not only the best result","target":"Proposed screening target: 95th percentile error below 0.10 mm under the declared payload. Not a demonstrated rating."},{"test":"Debris and wrong-part rejection","method":"Introduce known dust/debris and an incorrect module revision; detect or reject ambiguous states","target":"No process enable when identity or physical engagement is uncertain"},{"test":"Retention and stiffness","method":"Apply a controlled representative disturbance load, with protective enclosure and engineering review","target":"No unintended separation; report force/deflection and permanent offsets"},{"test":"Isolated wet exchange","method":"Use a separately qualified low-risk water test loop and measure actual residual release, pressure drop and leaks after exchange","target":"Freeze connector-specific limits before test; datum accuracy alone is not acceptance"}],"stopCondition":"Change the contact protection or station reference if dust, payload deformation or service connection forces consume the allowable robot positioning error."}