From 313aa7dd265bafb70f184c0333ad9c2d57717212 Mon Sep 17 00:00:00 2001 From: jaseg Date: Mon, 16 Oct 2023 14:34:06 +0200 Subject: Make coil test board more amenable to our favorite fab --- coil_test_board.py | 163 ++++++++++++++++++++++++++++++++++++++++++----------- 1 file changed, 129 insertions(+), 34 deletions(-) diff --git a/coil_test_board.py b/coil_test_board.py index eaafbd2..df55a69 100644 --- a/coil_test_board.py +++ b/coil_test_board.py @@ -1,6 +1,7 @@ #!/usr/bin/env python3 import math +import hashlib import re import itertools import datetime @@ -8,6 +9,7 @@ import tempfile import subprocess import sqlite3 import json +from pathlib import Path import tqdm @@ -50,14 +52,16 @@ coil_specs = [ {'n': 25, 's': False, 't': 13, 'c': 0.15, 'w': 0.50, 'd': 0.30, 'v': 0.60}, ] +cachedir = Path('/tmp/coil_test_cache') version_string = 'v1.0' coil_border = 7 # mm cut_gap = 3 # mm tooling_border = 10 # mm vscore_extra = 10 # mm mouse_bite_width = 8 # mm +mouse_bite_yoff = -0.00 mouse_bite_hole_dia = 0.5 -mouse_bite_hole_spacing = 0.3 +mouse_bite_hole_spacing = 0.35 hole_offset = 5 hole_dia = 3.2 coil_dia = 35 # mm @@ -68,8 +72,10 @@ pad_dia = 2.0 # mm pad_length = 3.5 # mm pad_drill = 1.1 # mm pad_pitch = 2.54 # mm +vrail_width = 10 # mm +join_trace_w = 0.35 # mm v_cuts = False # FIXME DEBUG -mouse_bites = False # FIXME DEBUG +mouse_bites = True # FIXME DEBUG db = sqlite3.connect('coil_parameters.sqlite3') db.execute('CREATE TABLE IF NOT EXISTS runs (run_id INTEGER PRIMARY KEY, timestamp TEXT, version TEXT)') @@ -80,10 +86,11 @@ cur.execute('INSERT INTO runs(timestamp, version) VALUES (datetime("now"), ?)', run_id = cur.lastrowid db.commit() -coil_pitch = coil_dia + coil_border*2 + cut_gap +coil_pitch_v = coil_dia + coil_border*2 + cut_gap +coil_pitch_h = coil_dia + coil_border*2 + 2*cut_gap + vrail_width -total_width = coil_pitch*cols + 2*tooling_border + cut_gap -total_height = coil_pitch*rows + 2*tooling_border + cut_gap +total_width = coil_pitch_h*cols + 2*tooling_border - vrail_width +total_height = coil_pitch_v*rows + 2*tooling_border + cut_gap tile_width = tile_height = coil_dia + 2*coil_border drawing_text_size = 2.0 @@ -106,7 +113,7 @@ def do_line(x0, y0, x1, y1, off_x=0, off_y=0): if v_cuts: for y in range(rows): for off_y in [0, tile_height]: - y_pos = y0 + tooling_border + cut_gap + off_y + y*coil_pitch + y_pos = y0 + tooling_border + cut_gap + off_y + y*coil_pitch_v do_line(x0 - vscore_extra, y_pos, x0 + total_width + vscore_extra, y_pos) b.add(kc_gr.Text(text='V-score', at=pcb.AtPos(x0 + total_width + vscore_extra + drawing_text_size/2, y_pos, 0), @@ -119,7 +126,7 @@ if v_cuts: for x in range(cols): for off_x in [0, tile_width]: - x_pos = x0 + tooling_border + cut_gap + off_x + x*coil_pitch + x_pos = x0 + tooling_border + cut_gap + off_x + x*coil_pitch_h do_line(x_pos, y0 - vscore_extra, x_pos, y0 + total_height + vscore_extra) b.add(kc_gr.Text(text='V-score', at=pcb.AtPos(x_pos, y0 + total_height + vscore_extra + drawing_text_size/2, 90), @@ -243,37 +250,42 @@ draw_corner(corner_x0, corner_y1, 'YYNN') draw_corner(corner_x1, corner_y0, 'NNYY') draw_corner(corner_x1, corner_y1, 'NYYN') -# T junctions +# Top / bottom V rail L junctions for x in range(1, cols): - draw_corner(corner_x0 + x*coil_pitch, corner_y0, 'YNYY') - draw_corner(corner_x0 + x*coil_pitch, corner_y1, 'YYYN') + draw_corner(corner_x0 + x*coil_pitch_h - cut_gap - vrail_width, corner_y0, 'NNYY') + draw_corner(corner_x0 + x*coil_pitch_h, corner_y0, 'YNNY') + draw_corner(corner_x0 + x*coil_pitch_h - cut_gap - vrail_width, corner_y1, 'NYYN') + draw_corner(corner_x0 + x*coil_pitch_h, corner_y1, 'YYNN') + +# Left / right T junctions for y in range(1, rows): - draw_corner(corner_x0, corner_y0 + y*coil_pitch, 'YYNY') - draw_corner(corner_x1, corner_y0 + y*coil_pitch, 'NYYY') + draw_corner(corner_x0, corner_y0 + y*coil_pitch_v, 'YYNY') + draw_corner(corner_x1, corner_y0 + y*coil_pitch_v, 'NYYY') -# X Junctions -for x in range(1, cols): - for y in range(1, rows): - draw_corner(corner_x0 + x*coil_pitch, corner_y0 + y*coil_pitch, 'YYYY') +# Middle T junctions +for y in range(1, rows): + for x in range(1, cols): + draw_corner(corner_x0 + x*coil_pitch_h - cut_gap - vrail_width, corner_y0 + y*coil_pitch_v, 'NYYY') + draw_corner(corner_x0 + x*coil_pitch_h, corner_y0 + y*coil_pitch_v, 'YYNY') # Mouse bites if mouse_bites: for x in range(0, cols): for y in range(0, rows): - tile_x0 = x0 + tooling_border + cut_gap + x*coil_pitch - tile_y0 = y0 + tooling_border + cut_gap + y*coil_pitch + tile_x0 = x0 + tooling_border + cut_gap + x*coil_pitch_h + tile_y0 = y0 + tooling_border + cut_gap + y*coil_pitch_v - b.add(make_mouse_bite(tile_x0 + tile_width/2, tile_y0, 0)) - b.add(make_mouse_bite(tile_x0 + tile_width/2, tile_y0 + tile_height, 0)) - b.add(make_mouse_bite(tile_x0, tile_y0 + tile_height/2, 90)) - b.add(make_mouse_bite(tile_x0 + tile_width, tile_y0 + tile_height/2, 90)) + b.add(make_mouse_bite(tile_x0 + tile_width/2, tile_y0 - mouse_bite_hole_dia/2, 0)) + b.add(make_mouse_bite(tile_x0 + tile_width/2, tile_y0 + tile_height + mouse_bite_hole_dia/2, 0)) + b.add(make_mouse_bite(tile_x0 - mouse_bite_hole_dia/2, tile_y0 + tile_height/2, 90)) + b.add(make_mouse_bite(tile_x0 + tile_width + mouse_bite_hole_dia/2, tile_y0 + tile_height/2 + mouse_bite_yoff, 90)) # Mounting holes for x in range(0, cols): for y in range(0, rows): - tile_x0 = x0 + tooling_border + cut_gap + x*coil_pitch + tile_width/2 - tile_y0 = y0 + tooling_border + cut_gap + y*coil_pitch + tile_height/2 + tile_x0 = x0 + tooling_border + cut_gap + x*coil_pitch_h + tile_width/2 + tile_y0 = y0 + tooling_border + cut_gap + y*coil_pitch_v + tile_height/2 dx = tile_width/2 - hole_offset dy = tile_height/2 - hole_offset @@ -307,8 +319,8 @@ b.add(kc_gr.Text(text=f'Planar inductor test panel {version_string} {timestamp} for index, ((y, x), spec) in tqdm.tqdm(enumerate(zip(itertools.product(range(rows), range(cols)), coil_specs), start=1)): pass with tempfile.NamedTemporaryFile(suffix='.kicad_mod') as f: - tile_x0 = x0 + tooling_border + cut_gap + x*coil_pitch + tile_width/2 - tile_y0 = y0 + tooling_border + cut_gap + y*coil_pitch + tile_height/2 + tile_x0 = x0 + tooling_border + cut_gap + x*coil_pitch_h + tile_width/2 + tile_y0 = y0 + tooling_border + cut_gap + y*coil_pitch_v + tile_height/2 for key, alias in { 'gen.inner_diameter': 'id', @@ -339,10 +351,22 @@ for index, ((y, x), spec) in tqdm.tqdm(enumerate(zip(itertools.product(range(row args.append('--' + k.replace('_', '-')) if v is not True: args.append(str(v)) - args.append(f.name) - res = subprocess.run(args, check=True, capture_output=True, text=True) - coil = fp.Footprint.open_mod(f.name) + arg_digest = hashlib.sha3_256(' / '.join(map(str, args)).encode()).hexdigest() + cachedir.mkdir(exist_ok=True) + cache_file = cachedir / f'C-{arg_digest}.kicad_mod' + log_file = cachedir / f'Q-{arg_digest}.kicad_mod' + if not cache_file.is_file(): + args.append(cache_file) + try: + res = subprocess.run(args, check=True, capture_output=True, text=True) + log_file.write_text(res.stdout + res.stderr) + except subprocess.CalledProcessError as e: + print(f'Error generating coil with command line {args}, rc={e.returncode}') + print(e.stdout) + print(e.stderr) + + coil = fp.Footprint.open_mod(cache_file) coil.at = fp.AtPos(tile_x0, tile_y0, 0) b.add(coil) @@ -361,7 +385,7 @@ for index, ((y, x), spec) in tqdm.tqdm(enumerate(zip(itertools.product(range(row value = str(value) db.execute('INSERT INTO results(coil_id, key, value) VALUES (?, ?, ?)', (coil_id, key, value)) - for l in res.stderr.splitlines(): + for l in log_file.read_text().splitlines(): if (m := re.fullmatch(r'Approximate inductance:\s*([-+.0-9eE]+)\s*µH', l.strip())): val = float(m.group(1)) * 1e-6 db.execute('INSERT INTO results(coil_id, key, value) VALUES (?, "calculated_approximate_inductance", ?)', (coil_id, val)) @@ -406,16 +430,87 @@ for index, ((y, x), spec) in tqdm.tqdm(enumerate(zip(itertools.product(range(row b.add(pads) w = min(spec.get('gen.trace_width', pad_dia), pad_dia) - x, y, _r, _f = pads.pad(2).abs_pos - w2 = (x - pad_length/2, y) - x, y, _r, _f = pads.pad(1).abs_pos - w1 = (x - pad_length/2, y) + wx, wy, _r, _f = pads.pad(2).abs_pos + w2 = (wx - pad_length/2, wy) + wx, wy, _r, _f = pads.pad(1).abs_pos + w1 = (wx - pad_length/2, wy) b.add(cad_pr.Trace(w, coil.pad(1), pads.pad(1), waypoints=[w1], orientation=['ccw'], side='top')) b.add(cad_pr.Trace(w, coil.pad(2), pads.pad(2), waypoints=[w2], orientation=['cw'], side='bottom')) + p = cut_gap + 5 + q = 3 + if y == 0: + if x > 0 and x % 2 == 1: + wx, wy, _r, _f = pads.pad(1).abs_pos + w1 = (wx + p), (wy - q) + w2 = (tile_x0 + tile_width/2 + cut_gap), (tile_y0 - tile_height/2 - cut_gap - q) + w3 = (tile_x0 - coil_pitch_h + tile_width/2 + cut_gap + 2*q), (tile_y0 - tile_height/2 - cut_gap - q) + w4 = (wx + p - coil_pitch_h), (wy - q) + w5 = (wx - coil_pitch_h), (wy) + b.add(cad_pr.Trace(join_trace_w, pads.pad(1), w5, waypoints=[w1, w2, w3, w4], orientation=['cw', 'cw', 'cw', 'cw'], side='top')) + + else: + wx, wy, _r, _f = pads.pad(1).abs_pos + w1 = (wx + p), (wy - q) + w2 = (wx + p), (wy - coil_pitch_v + pad_pitch + q) + w3 = wx, (wy - coil_pitch_v + pad_pitch) + b.add(cad_pr.Trace(join_trace_w, pads.pad(1), w3, waypoints=[w1, w2], orientation=['cw', 'cw', 'cw'], side='bottom')) + + if y == rows-1: + if x > 0 and x % 2 == 0: + wx, wy, _r, _f = pads.pad(2).abs_pos + w1 = (wx + p), (wy + q) + w2 = (tile_x0 + tile_width/2 + cut_gap), (tile_y0 + tile_height/2 + cut_gap + q) + w3 = (tile_x0 - coil_pitch_h + tile_width/2 + cut_gap + 2*q), (tile_y0 + tile_height/2 + cut_gap + q) + w4 = (wx + p - coil_pitch_h), (wy + q) + w5 = (wx - coil_pitch_h), (wy) + b.add(cad_pr.Trace(join_trace_w, pads.pad(2), w5, waypoints=[w1, w2, w3, w4], orientation=['ccw', 'ccw', 'ccw', 'ccw', 'cw'], side='top')) + + elif x == 0: + wx, wy, _r, _f = pads.pad(2).abs_pos + w1 = (wx + p), (wy + q) + w2 = (wx + p + q), (tile_y0 + tile_height/2 + cut_gap + q) + w5 = (x0 + total_width/2 - pad_pitch/2), (w2[1]) + b.add(cad_pr.Trace(join_trace_w, pads.pad(2), w5, waypoints=[w1, w2], orientation=['ccw', 'cw', 'ccw'], side='bottom')) + elif x == cols-1: + wx, wy, _r, _f = pads.pad(2).abs_pos + w1 = (wx + p), (wy + q) + w2 = (wx + p - q), (tile_y0 + tile_height/2 + cut_gap + q) + w5 = (x0 + total_width/2 + pad_pitch/2), (w2[1]) + b.add(cad_pr.Trace(join_trace_w, pads.pad(2), w5, waypoints=[w1, w2], orientation=['ccw', 'ccw', 'ccw'], side='bottom')) + pads = make_pads(x0 + total_width/2, w5[1], 0, 2, pad_dia, pad_length, pad_drill, pad_pitch) + b.add(pads) + k = 3 for layer in ['F.SilkS', 'B.SilkS']: b.add(kc_gr.Rectangle(start=xy(x-k/2, y-pad_pitch-k/2), end=xy(x+k/2, y-pad_pitch), layer=layer, stroke=pcb.Stroke(width=0), fill=kc_gr.FillMode(pcb.Atom.solid))) +b.add(pcb.Zone(layers=['F.Cu', 'B.Cu'], hatch=pcb.Hatch(), + min_thickness=0.25, filled_areas_thickness=False, + fill=pcb.ZoneFill(island_removal_mode=1, island_area_min=10), + polygon=pcb.ZonePolygon(pts=pcb.PointList(xy=[ + pcb.XYCoord(x0, y0), + pcb.XYCoord(x0, y0+total_height), + pcb.XYCoord(x0+total_width, y0+total_height), + pcb.XYCoord(x0+total_width, y0)])))) + +for x in range(0, cols): + tile_x0 = x0 + tooling_border + cut_gap + x*coil_pitch_h + tile_y0 = y0 + tooling_border + cut_gap + + w = coil_dia + coil_border*2 + y1 = y0 + total_height - tooling_border - cut_gap + + b.add(pcb.Zone(layers=['F.Cu', 'B.Cu'], hatch=pcb.Hatch(), + min_thickness=0.25, filled_areas_thickness=False, + fill=pcb.ZoneFill(island_removal_mode=1, island_area_min=10), + keepout=pcb.ZoneKeepout(copperpour_allowed=False), + polygon=pcb.ZonePolygon(pts=pcb.PointList(xy=[ + pcb.XYCoord(tile_x0, tile_y0), + pcb.XYCoord(tile_x0, y1), + pcb.XYCoord(tile_x0+w, y1), + pcb.XYCoord(tile_x0+w, tile_y0)])))) + b.write('coil_test_board.kicad_pcb') + -- cgit