gerber_drill.py

'''
    A python script example to create plot files to build a board:
    Gerber files
    Drill files
    Map dril files
    This file is forked from "https://github.com/blairbonnett-mirrors/kicad/blob/master/demos/python_scripts_examples/gen_gerber_and_drill_files_board.py"
    Important note:
        this python script does not plot frame references (page layout).
        the reason is it is not yet possible from a python script because plotting
        plot frame references needs loading the corresponding page layout file
        (.wks file) or the default template.

        This info (the page layout template) is not stored in the board, and therefore
        not available.

        Do not try to change SetPlotFrameRef(False) to SetPlotFrameRef(true)
        the result is the pcbnew lib will crash if you try to plot
        the unknown frame references template.

        Anyway, in gerber and drill files the page layout is not plot
'''

import sys
import os
import re
import math
import zipfile as zf

from pcbnew import *
def def_logger(*args):
    r = ""
    for t in args:
        r = r + str(t) + " "
    print r
def GenGerberDrill(board = None, split_G85 = 0.2, plotDir = "plot/", plotReference = True, logger = def_logger):
	if not board:
		board = GetBoard()

	plotFiles = []

	pctl = PLOT_CONTROLLER(board)

	popt = pctl.GetPlotOptions()

	popt.SetOutputDirectory(plotDir)

	# Set some important plot options:
	popt.SetPlotFrameRef(False)     #do not change it
	popt.SetLineWidth(FromMM(0.35))

	popt.SetAutoScale(False)        #do not change it
	popt.SetScale(1)                #do not change it
	popt.SetMirror(False)
	popt.SetUseGerberAttributes(True)
	popt.SetUseGerberProtelExtensions(False)
	popt.SetExcludeEdgeLayer(True);
	popt.SetScale(1)
	popt.SetUseAuxOrigin(False)
	popt.SetPlotReference(plotReference)

	# This by gerbers only (also the name is truly horrid!)
	popt.SetSubtractMaskFromSilk(False)

	# Once the defaults are set it become pretty easy...
	# I have a Turing-complete programming language here: I'll use it...
	# param 0 is a string added to the file base name to identify the drawing
	# param 1 is the layer ID
	# param 2 is a comment
	plot_plan = [
		( "Top_Cu", F_Cu, "Top layer" ),
		( "Bottom_Cu", B_Cu, "Bottom layer" ),
		( "Bottom_Paste", B_Paste, "Paste Bottom" ),
		( "Top_Paste", F_Paste, "Paste top" ),
		( "Top_Silk", F_SilkS, "Silk top" ),
		( "Bottom_Silk", B_SilkS, "Silk top" ),
		( "Bottom_Mask", B_Mask, "Mask bottom" ),
		( "Top_Mask", F_Mask, "Mask top" ),
		( "EdgeCuts", Edge_Cuts, "Edges" ),
	]


	for layer_info in plot_plan:
		pctl.SetLayer(layer_info[1])
		pctl.OpenPlotfile(layer_info[0], PLOT_FORMAT_GERBER, layer_info[2])
		logger('plot %s' % pctl.GetPlotFileName())
		if pctl.PlotLayer() == False:
			logger("plot error")

	#generate internal copper layers, if any
	lyrcnt = board.GetCopperLayerCount();

	for innerlyr in range ( 1, lyrcnt-1 ):
		pctl.SetLayer(innerlyr)
		lyrname = 'inner%s' % innerlyr
		pctl.OpenPlotfile(lyrname, PLOT_FORMAT_GERBER, "inner")
		logger('plot %s' % pctl.GetPlotFileName())
		if pctl.PlotLayer() == False:
			logger("plot error")


	# At the end you have to close the last plot, otherwise you don't know when
	# the object will be recycled!
	pctl.ClosePlot()

	# Fabricators need drill files.
	# sometimes a drill map file is asked (for verification purpose)
	drlwriter = EXCELLON_WRITER( board )
	drlwriter.SetMapFileFormat( PLOT_FORMAT_PDF )

	mirror = False
	minimalHeader = False
	offset = wxPoint(0,0)
	# False to generate 2 separate drill files (one for plated holes, one for non plated holes)
	# True to generate only one drill file
	mergeNPTH = False
	drlwriter.SetOptions( mirror, minimalHeader, offset, mergeNPTH )

	metricFmt = True
	drlwriter.SetFormat( metricFmt )

	genDrl = True
	genMap = False
	logger('create drill and map files in %s' % pctl.GetPlotDirName())
	drlwriter.CreateDrillandMapFilesSet( pctl.GetPlotDirName(), genDrl, genMap )

	# One can create a text file to report drill statistics
	#rptfn = pctl.GetPlotDirName() + 'drill_report.rpt'
	#print 'report: %s' % rptfn
	#drlwriter.GenDrillReportFile( rptfn );
	
	if split_G85:
		logger("Split the slot into holes")
		SplitSlotInDrill(pctl.GetPlotDirName(), False, split_G85)

	files = [f for f in os.listdir(pctl.GetPlotDirName()) if f.endswith('.gbr')]
	for f in files:
		plotFiles.append( pctl.GetPlotDirName() + f )

	files = [f for f in os.listdir(pctl.GetPlotDirName()) if f.endswith('.drl')]
	for f in files:
		plotFiles.append( pctl.GetPlotDirName() + f )

	brdName = board.GetFileName()
	s = os.path.split(brdName)
	brdName = s[1]
	brdName = brdName[0:brdName.rfind('.')]
	logger("Board Name:", brdName)
	zipName = pctl.GetPlotDirName() + brdName + "_gerber.zip"
	logger("Zip them into " + zipName)

	azip = zf.ZipFile(zipName, 'w')
	for f in plotFiles:
		azip.write(filename=f, arcname = os.path.split(f)[1] , compress_type=zf.ZIP_DEFLATED)
	azip.close()

	return pctl.GetPlotDirName()

def FromGerberPosition(position_str):
	s1 = position_str.find('X')
	s2 = position_str.find('Y')
	if (s1 != -1) and (s2 != -1):
		x = float(position_str[s1+1:s2])
		y = float(position_str[s2+1:])
	return [x,y]

def same(p1,p2,diff = 0.0001):
	return (abs(p1[0]-p2[0])<diff) and (abs(p1[1]-p2[1])<diff)

def SplitSlot(p1, p2, step = 0.2):
	r = []
	dx = p2[0] - p1[0]
	dy = p2[1] - p1[1]
	dist = sqrt(dx*dx+dy*dy)
	td = 0
	pt = [p1[0],p1[1]]
	count = 0
	while not same(pt,p2):
		r.append('X%sY%s\n' %(str(float('%.3f'%pt[0])),str(float('%.3f'%pt[1]))))
		pt[0] = pt[0] + step*dx/dist
		pt[1] = pt[1] + step*dy/dist
		if dist - td < (step*1.5):
			pt[0] = p2[0]
			pt[1] = p2[1]
		else:
			td = td + step
		count = count + 1
		if count > 50:
			break
	r.append('X%sY%s\n' %(str(float('%.3f'%pt[0])),str(float('%.3f'%pt[1]))))
	return r

def SplitG85(G85Data,step = 0.2):
	t = G85Data.split('G85')
	r = []
	if len(t) == 2:
		p1 = FromGerberPosition(t[0])
		p2 = FromGerberPosition(t[1])
		dx = p2[0] - p1[0]
		dy = p2[1] - p1[1]
		dist = sqrt(dx*dx+dy*dy)
		td = 0
		pt = [p1[0],p1[1]]
		count = 0
		while not same(pt,p2):
			r.append('X%sY%s\n' %(str(float('%.3f'%pt[0])),str(float('%.3f'%pt[1]))))
			pt[0] = pt[0] + step*dx/dist
			pt[1] = pt[1] + step*dy/dist
			if dist - td < (step*1.5):
				pt[0] = p2[0]
				pt[1] = p2[1]
			else:
				td = td + step
			count = count + 1
			if count > 50:
				break
		r.append('X%sY%s\n' %(str(float('%.3f'%pt[0])),str(float('%.3f'%pt[1]))))
		return r
	else:
		return None

def HoleSize(line):
	r = re.compile('(T[0-9]+)C([-0-9.]+)')
	m = r.match(line)
	if m:
		t = m.groups()
		return t[0], float(t[1])
	return None, None

def round(value, round = 0.1):
	if value < round:
		return round
	t = value / round
	t = math.ceil(t)
	return t * round

def isG05(line):
	return line.find('G05') == 0

def isG00(line):
	return line.find('G00') == 0
def isG01(line):
	return line.find('G01') == 0
def isM15(line):
	return line.find('M15') == 0
def isM16(line):
	return line.find('M16') == 0



def SplitSlotInDrill(drillPath, newfilename = True,step = 0.2):
	files = [f for f in os.listdir(drillPath) if f.endswith('.drl')]
	for fn in files:
		infn = drillPath + fn
		outfn = infn
		if not fn.endswith('_no_slot.drl'):
			with open(infn, "r") as ins:
				outline = []
				skip_G05 = False
				holes = {}
				curHolesSize = None
				slot_mode = False
				hole_begin = None
				hole_end = None
				for line in ins:
					hn,hs = HoleSize(line)
					if hn and hs:
						holes[hn+'\n'] = hs
					if holes.has_key(line):
						curHolesSize = holes[line]
					step = 0.2
					if curHolesSize:
						step = round(curHolesSize/3)
					r = SplitG85(line, step)
					if not r:
						if isG00(line):
							slot_mode = True
							hole_begin = FromGerberPosition(line)
					if not slot_mode:
						if r:
							skip_G05 = True
							for l in r:
								outline.append(l)
						else:
							if skip_G05 and isG05(line):
								skip_G05 = False
							else:
								outline.append(line)
					else:
						if isG01(line):
							hole_end = FromGerberPosition(line)
						if isG05(line):
							slot_mode = False
							if hole_begin and hole_end:
								r = SplitSlot(hole_begin, hole_end, step)
								for l in r:
									outline.append(l)
							else:
								logger("Slot hole format error")
							hole_begin = None
							hole_end = None
				ins.close()
				if newfilename:
					outfn = infn.replace(".drl", "_no_slot.drl")
				fo = open(outfn, "w+")
				fo.writelines(outline)
				fo.close()