Integrate A1 carrier PCB CAD updates

- Add pinned STEP-derived DE-9 mechanical measurements and provenance - Refresh placement, routing, silkscreen, and nominal CAD envelopes - Document provisional dimensions, assumptions, and validation status
2026-09-21 12:31:24 +02:00
parent 06df47c934
commit c0f7a1ad51
13 changed files with 5825 additions and 3966 deletions
@@ -0,0 +1,93 @@
+#!/usr/bin/env python3
+"""Add nominal STEP-derived metal bounding projections on Dwgs.User only.
+
+Not silkscreen, a courtyard, or a case cutout. See db9-mechanical-notes.md for
+source attribution, selected face subsets and the user-confirmed male/female
+external-geometry equivalence. No module height or case-wall thickness assumed.
+"""
+import json
+from pathlib import Path
+import uuid
+import pcbnew as p
+
+ROOT=Path(__file__).resolve().parent
+PCB=ROOT/"serial-carrier.kicad_pcb"
+NS=uuid.UUID("ba7274a8-c35d-46bc-908d-cd86708fc6c4")
+
+
+def main():
+    lock=ROOT/"~serial-carrier.kicad_pcb.lck"
+    if lock.exists():
+        raise SystemExit("Close PCB Editor before refreshing the CAD envelopes")
+    before=PCB.read_bytes()
+    project=ROOT/"serial-carrier.kicad_pro"
+    project_before=project.read_bytes()
+    board=p.LoadBoard(str(PCB))
+    u2=next(f for f in board.GetFootprints() if f.GetReference()=="U2")
+    assert u2.GetOrientationDegrees()==0, "Review transform for rotated module"
+    x0,y0=p.ToMM(u2.GetPosition().x),p.ToMM(u2.GetPosition().y)
+    data=json.loads((ROOT/"reference/db9-cad/measurements.json").read_text())
+    owned={str(uuid.uuid5(NS,str(i))) for i in range(64)}
+    for drawing in list(board.GetDrawings()):
+        if drawing.m_Uuid.AsString() in owned:
+            board.Delete(drawing)
+    count=0
+
+    def point(x,y):
+        # STEP/Eagle axes +Y toward connector; KiCad local Y is downward.
+        return p.VECTOR2I(p.FromMM(x0+x-1.905),p.FromMM(y0+2.667-y))
+
+    def add(item):
+        nonlocal count
+        assert count<64
+        item.SetLayer(p.Dwgs_User)
+        item.SetUuid(p.KIID(str(uuid.uuid5(NS,str(count)))))
+        board.Add(item)
+        count+=1
+
+    for feature in ("front_flange_exposed_faces", "shell_outer_including_root_and_lip",
+                    "left_front_hex_post", "right_front_hex_post"):
+        xmin,ymin,_,xmax,ymax,_=data[feature]["bounds"]
+        rect=p.PCB_SHAPE(board)
+        rect.SetShape(p.SHAPE_T_RECT)
+        rect.SetStart(point(xmin,ymax)); rect.SetEnd(point(xmax,ymin))
+        rect.SetWidth(p.FromMM(0.1))
+        add(rect)
+    for axis in data["front_lock_axes"]:
+        x=axis["location"][0]
+        # These mark front-facing Y axes, not holes through the carrier PCB.
+        line=p.PCB_SHAPE(board)
+        line.SetShape(p.SHAPE_T_SEGMENT)
+        line.SetStart(point(x,26.907)); line.SetEnd(point(x,32.707))
+        line.SetWidth(p.FromMM(0.08))
+        add(line)
+    label=p.PCB_TEXT(board)
+    label.SetText("CAD METAL ENVELOPES - NOT CASE CUTOUT")
+    label.SetPosition(p.VECTOR2I(p.FromMM(x0+13.97),p.FromMM(y0-17.67)))
+    label.SetTextSize(p.VECTOR2I(p.FromMM(0.65),p.FromMM(0.65)))
+    label.SetTextThickness(p.FromMM(0.1))
+    add(label)
+    for drawing in board.GetDrawings():
+        if not isinstance(drawing,p.PCB_TEXT):
+            continue
+        value=drawing.GetText()
+        if value.startswith("DE-9 OUT /"):
+            drawing.SetPosition(p.VECTOR2I(p.FromMM(x0+13.97),p.FromMM(y0-20.67)))
+        elif value=="82 x 80 mm / 2 copper layers":
+            drawing.SetPosition(p.VECTOR2I(p.FromMM(141),p.FromMM(91)))
+        elif value.startswith("Nominal RS-232 metal verified;"):
+            drawing.SetPosition(p.VECTOR2I(p.FromMM(141),p.FromMM(93.5)))
+    temp=ROOT/"serial-carrier-envelope-tmp.kicad_pcb"
+    try:
+        assert p.SaveBoard(str(temp),board,True)
+        if lock.exists() or PCB.read_bytes()!=before:
+            raise RuntimeError("PCB changed or reopened; refusing overwrite")
+        assert project.read_bytes()==project_before
+        temp.replace(PCB)
+    finally:
+        temp.unlink(missing_ok=True)
+    print(f"Added {count} nominal CAD projection graphics on Dwgs.User; no copper/project changes")
+
+
+if __name__=="__main__":
+    main()