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Make coil test board more amenable to our favorite fab

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This commit is contained in:
jaseg 2023-10-16 14:34:06 +02:00
parent 1ce02a9d25
commit 313aa7dd26
1 changed files with 129 additions and 34 deletions
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163
coil_test_board.py
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@ -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')