From 649e00b28e3fc2c6531871f1eab16f6c5574eda8 Mon Sep 17 00:00:00 2001
From: Werner Almesberger <werner@openmoko.org>
Date: Sat, 27 Nov 2010 22:41:45 -0300
Subject: [PATCH] vialtray: ready for first test run (on-going)

- doit (GEN): corrected name of toolpath generator
- doit (rdata): fixed typo ("rdate" vs. "rdata")
- doit (Z): set Z depth here, to avoid manual depth adjustment
- doit: don't use cameo - we compensate for the tool size in tray.pl
- doit: increased feed rate from 2 mm/s to 4 mm/s
- doit: clearance is above top layer, so 5 mm are more than enough
- tray.pl (zf): increase floor depth from very conservative 15 mm to
  17 mm
- tray.pl (zs): increase depth step from 2 mm to 2.5 mm to accelerate
  milling
- tray.pl (mw): increase wall thickness from 2 mm to 2.5 mm in order to
  enlarge gap between sides (was smaller than tool diameter)
- tray.pl (r1): stop 2 steps before the edge, since we have the outline
  as another radius-like step
- tray.pl (do_col): account for tool radius
- tray.pl (do_circles): lift the tool after each disc, not only after
  each column
- tray.pl (do_cols, do_circles): temporarily skip 1st column
- tray.pl (main): do circles before the outline, to reduce chatter when
  cutting the outline
- tray.pl (main): since we're no longer using "cameo" here, don't print
  directives for it
---
 vialtray/doit    | 14 +++++---------
 vialtray/tray.pl | 33 +++++++++++++++++++--------------
 2 files changed, 24 insertions(+), 23 deletions(-)
 mode change 100644 => 100755 vialtray/doit

diff --git a/vialtray/doit b/vialtray/doit
old mode 100644
new mode 100755
index 815203b..0bbd492
--- a/vialtray/doit
+++ b/vialtray/doit
@@ -6,12 +6,10 @@ ZMAP=$DIR/zmap/zmap
 GP2RML=$DIR/gp2rml/gp2rml
 CAMEO=../../../cae-tools/cameo/cameo
 
-GEN=${1:-./pcb.pl}
+GEN=${1:-./tray.pl}
 
-# manual tool positioning !!
-rdate="0 0 0  150 0 0  0 100 0"
-# lower Z by 0.5 mm relative to highest point (-56.8)
-Z=0
+rdata="0 0 0  150 0 0  0 100 0"
+Z=-27.6
 
 rect=`$RECT $rdata | awk '{$3 = ""; print}'`
 
@@ -19,10 +17,8 @@ rect=`$RECT $rdata | awk '{$3 = ""; print}'`
 
 $GEN |
   awk '{ if ($3 != "") $3 += '$Z'; print $0; }' |
-  $CAMEO -d 0 |
   $ALIGN 0 1 $rect |
         # angle, reference (lower left corner), rect
-  $GP2RML 20 2 2
+  tee check |
+  $GP2RML 5 4 4
         # clearance, xy speed, z speed
-# since everything is in the same plane, z clearance must be thickness plus
-# real clearance !
diff --git a/vialtray/tray.pl b/vialtray/tray.pl
index 9890b1f..b23da47 100755
--- a/vialtray/tray.pl
+++ b/vialtray/tray.pl
@@ -111,10 +111,10 @@ sub circ
 $z0 = -0.5;
 
 # floor depth
-$zf = -15;
+$zf = -17;
 
 # maximum depth step
-$zs = 2;
+$zs = 2.5;
 
 # distance between columns
 $xs = 24;
@@ -126,7 +126,7 @@ $ys = 20;
 $vd = 18.6;
 
 # minimum wall thickness
-$mw = 2;
+$mw = 2.5;
 
 $nc = 6;
 $nr = 4;
@@ -140,7 +140,7 @@ $vr = $vd/2;
 
 # circle radii: first, last, increment
 $r0 = $r/2;
-$r1 = $vr-$r*0.75;
+$r1 = $vr-$r*1.5;
 $rs = $r*0.75;
 
 #
@@ -187,12 +187,12 @@ sub do_col
 		if ($rw) {
 			$end = $rw == $nr-1 ? $vr : ($ys-$mw)/2;
 			&yarc($x0-$bx, $y0-$ys/2,
-			    1, -$mw/2, $mw/2, $br, @m_ccw);
+			    1, -$mw/2-$r, $mw/2+$r, $br+$r, @m_ccw);
 			&yarc($x0, $y0,
-			    -1, -($ys-$mw)/2, $end, $vr, @m_cw);
+			    -1, -($ys-$mw)/2+$r, $end-$r, $vr-$r, @m_cw);
 		} else {
 			&yarc($x0, $y0,
-			    1, -$vr, ($ys-$mw)/2, $vr, @m_cw);
+			    1, -$vr+$r, ($ys-$mw)/2-$r, $vr-$r, @m_cw);
 		}
 		$y0 += $ys;
 	}
@@ -201,12 +201,12 @@ sub do_col
 		if ($rw) {
 			$end = $rw == $nr-1 ? $vr : ($ys-$mw)/2;
 			&yarc($x0+$bx, $y0+$ys/2,
-			    -1, $mw/2, -$mw/2, $br, @m_ccw);
+			    -1, $mw/2+$r, -$mw/2-$r, $br+$r, @m_ccw);
 			&yarc($x0, $y0,
-			    1, ($ys-$mw)/2, -$end, $vr, @m_cw);
+			    1, ($ys-$mw)/2-$r, -$end+$r, $vr-$r, @m_cw);
 		} else {
 			&yarc($x0, $y0,
-			    1, $vr, -($ys-$mw)/2, $vr, @m_cw);
+			    1, $vr-$r, -($ys-$mw)/2+$r, $vr-$r, @m_cw);
 		}
 	}
 }
@@ -218,7 +218,9 @@ sub do_cols
 
 	$x = $x0;
 	for ($c = 0; $c != $nc; $c++) {
+if ($c) {
 		&do_col($x);
+}
 		$x += $xs;
 		print "\n";
 	}
@@ -235,12 +237,14 @@ sub do_circles
 		$y = $y0;
 		for ($rw = 0; $rw != $nr; $rw++) {
 			for ($rr = $r0; $rr <= $r1; $rr += $rs) {
+if ($c) {
 				&circ($x, $y, $rr, 180);
+}
 			}
+			print "\n";
 			$y += $ys;
 		}
 		$x += $xs;
-		print "\n";
 	}
 }
 
@@ -249,10 +253,11 @@ sub do_circles
 
 $z = $z0;
 for ($i = 0; $i != $nz; $i++) {
-	print "#%%r_tool=", $r, "\n";
+#	print "#%%r_tool=0\n";
+	&do_circles;
+
+#	print "#%%r_tool=", $r, "\n";
 	&do_cols;
 
-	print "#%%r_tool=0\n";
-	&do_circles;
 	$z -= $zs;
 }