Export wide coil specimens

make_wide_coils.py

@@ -0,0 +1,100 @@
+#!/bin/sh
+
+import math
+import subprocess
+import tempfile
+
+from gerbonara import utils
+from gerbonara.cad.kicad import pcb as kicad_pcb
+from gerbonara.cad.kicad import graphical_primitives as kicad_gr
+from gerbonara.cad.kicad import footprints as kicad_fp
+
+outer_dias = [40, 65, 90]
+
+nks = [[(1, 150),
+        (1, 300),
+        (1, 480)],
+       [(53, 50),
+        (53, 100),
+        (53, 160)],
+       [(53, 100),
+        (53, 200),
+        (53, 320)],
+       [(53, 150),
+        (53, 300),
+        (53, 480)],
+       [(53, 1),
+        (53, 1),
+        (53, 1)]]
+
+def make_pad(x, y, side, w, h, **kwargs):
+    f = kicad_fp.Footprint(name=f'conn_gen_01x{n}', _version=None, generator=None, at=kicad_fp.AtPos(x, y, 0), **kwargs)
+
+    for i in range(n):
+        f.pads.append(kicad_fp.Pad(
+            layers=['F.Mask', 'F.Cu'] if side == 'top' else ['B.Mask', 'B.Cu'],
+            number=str(i+1),
+            type=kicad_fp.Atom.smd,
+            shape=kicad_fp.Atom.rect,
+            at=kicad_fp.AtPos(0, 0, 0),
+            size=kicad_fp.XYCoord(w, h),
+            footprint=f))
+
+    return f
+
+for case_num, nk in enumerate(nks, start=1):
+    board_out = kicad_pcb.Board.empty_board()
+
+    for (i, d2), (n, k) in zip(enumerate(outer_dias), nk):
+        d1 = d2 - 15
+
+        with tempfile.NamedTemporaryFile(suffix='.kicad_pcb') as f:
+            args = 'python twisted_coil_gen_twolayer.py --circle-segments 331 --trace-width 0.13 --via-drill 0.3 --via-diameter 0.6 --via-offset 0.3'.split() + [
+                '--pcb', f.name,
+                '--turns', str(n), '--twists', str(k),
+                '--inner-diameter', str(d1), '--outer-diameter', str(d2),
+                ]
+
+            if k > 100:
+                args += ['--stagger-inner-vias', '--stagger-outer-vias', '--via-offset', '0.4']
+
+            subprocess.run(args, check=True)
+
+            for obj in kicad_pcb.Board.open(f.name).objects():
+                board_out.add(obj)
+
+        board_out.add(kicad_gr.Text(text=f'case {case_num} n={n} k={k}\\nd={d1:.1f}-{d2:.2f}mm\\nt=0.15mm',
+                                at=kicad_gr.AtPos(0, (d1+d2)/2/2), layer=kicad_gr.TextLayer('F.SilkS')))
+
+        # Slots
+        if i < len(outer_dias)-1:
+            na = 8
+            r2 = d2/2
+            r = r2 + 2.5
+            aw = 2*math.asin(3 / 2 / r)
+            for j in range(na):
+                start = utils.rotate_point(r, 0, (j+1)*2*math.pi/na - aw/2)
+                end = utils.rotate_point(r, 0, j*2*math.pi/na + aw/2)
+                arc = kicad_gr.Arc(end=end, center=(0, 0), start=start, stroke=kicad_gr.Stroke(width=1.2), layer='Edge.Cuts')
+                board_out.add(arc)
+
+        # Connecting pads
+        board_out.add(make_pad(d2/2+1, 0, 'top', 2, 0.7))
+        board_out.add(make_pad(d2/2+1, 0, 'bottom', 2, 0.7))
+        board_out.add(kicad_pcb.TrackSegment(start=kicad_pcb.XYCoord(d2/2, 0), end=kicad_pcb.XYCoord(d2/2+1, 0), width=0.15, layer='F.Cu'))
+        board_out.add(kicad_pcb.TrackSegment(start=kicad_pcb.XYCoord(d2/2, 0), end=kicad_pcb.XYCoord(d2/2+1, 0), width=0.15, layer='B.Cu'))
+
+    # Circular board outline
+    board_out.add(kicad_gr.Circle(center=kicad_gr.XYCoord(0, 0), end=kicad_gr.XYCoord(d2/2+5, 0), layer='Edge.Cuts'))
+
+    # Silk crosshairs
+    r = d2/2 * math.sin(math.pi/4)
+    board_out.add(kicad_gr.Line(start=kicad_gr.XYCoord(-r, -r), end=kicad_gr.XYCoord(r, r), layer='F.SilkS'))
+    board_out.add(kicad_gr.Line(start=kicad_gr.XYCoord(r, -r), end=kicad_gr.XYCoord(-r, r), layer='F.SilkS'))
+    board_out.add(kicad_gr.Line(start=kicad_gr.XYCoord(-r, -r), end=kicad_gr.XYCoord(r, r), layer='B.SilkS'))
+    board_out.add(kicad_gr.Line(start=kicad_gr.XYCoord(r, -r), end=kicad_gr.XYCoord(-r, r), layer='B.SilkS'))
+    r = d2/2
+    board_out.add(kicad_gr.Line(start=kicad_gr.XYCoord(0, r), end=kicad_gr.XYCoord(0, -r), layer='B.SilkS'))
+    board_out.add(kicad_gr.Line(start=kicad_gr.XYCoord(r, 0), end=kicad_gr.XYCoord(-r, 0), layer='B.SilkS'))
+
+    board_out.write(f'wide_coil_{case_num}.kicad_pcb')

twisted_coil_gen_twolayer.py

@@ -1,5 +1,6 @@
 #!/usr/bin/env python3
 
+import warnings
 import subprocess
 import sys
 import math
@@ -714,7 +715,7 @@ def generate(outfile, turns, outer_diameter, inner_diameter, via_diameter, via_d
     # Check if the vias of the inner ring are so large that they would overlap
     if inner_via_angle*twists > (4*pi if stagger_inner_vias else 2*pi):
         min_dia = 2*((via_diameter + clearance) / (2*sin(pi / twists * (2 if stagger_inner_vias else 1))) + via_offset)
-        raise click.ClickException(f'Error: Overlapping vias in inner via ring. Calculated minimum inner diameter is {min_dia:.2f} mm.')
+        warnings.warn(f'Overlapping vias in inner via ring. Calculated minimum inner diameter is {min_dia:.2f} mm.')
 
     pitch = clearance + trace_width
     t, _, b = layer_pair.partition(',')
@@ -866,7 +867,7 @@ def generate(outfile, turns, outer_diameter, inner_diameter, via_diameter, via_d
         x = inverse[i]*floor(2*sweeping_angle / (2*pi)) * 2*pi
         (x0, y0), (xn, yn), clen = do_spiral(0, outer_radius, inner_radius, start_angle, fold_angle, (x + start_angle)/total_angle, (x + fold_angle)/total_angle, circle_segments)
         if two_layer:
-            do_spiral(1, inner_radius, outer_radius, fold_angle, end_angle, (x + fold_angle)/total_angle, (x + end_angle)/total_angle)
+            do_spiral(1, inner_radius, outer_radius, fold_angle, end_angle, (x + fold_angle)/total_angle, (x + end_angle)/total_angle, circle_segments)
         else:
             dr = outer_radius - inner_radius
             xq = xn + cos(fold_angle) * dr