pcb-stator-coil-generator/coil_generator-12.ipynb

{
 "cells": [
  {
   "cell_type": "code",
   "execution_count": null,
   "metadata": {},
   "outputs": [],
   "source": [
    "import pandas as pd\n",
    "import numpy as np\n",
    "\n",
    "import matplotlib.pyplot as plt\n",
    "from skspatial.objects import LineSegment, Line, Vector\n",
    "\n",
    "# some helper functions\n",
    "from helpers import (\n",
    "    get_arc_point,\n",
    "    draw_arc,\n",
    "    rotate,\n",
    "    translate,\n",
    "    flip_y,\n",
    "    flip_x,\n",
    "    optimize_points,\n",
    "    chaikin,\n",
    "    rotate_point,\n",
    "    scale,\n",
    ")\n",
    "from pcb_json import (\n",
    "    dump_json,\n",
    "    plot_json,\n",
    "    create_via,\n",
    "    create_pad,\n",
    "    create_pin,\n",
    "    create_track,\n",
    "    create_silk,\n",
    "    create_silk,\n",
    "    create_mounting_hole,\n",
    ")\n",
    "\n",
    "from enum import Enum\n",
    "\n",
    "Layer = Enum(\"Layer\", \"FRONT BACK\")"
   ]
  },
  {
   "cell_type": "code",
   "execution_count": null,
   "metadata": {},
   "outputs": [],
   "source": [
    "# Track width and spacing\n",
    "TRACK_WIDTH = 0.127\n",
    "TRACK_SPACING = 0.127\n",
    "\n",
    "# via defaults\n",
    "VIA_DIAM = 0.8\n",
    "VIA_DRILL = 0.4\n",
    "\n",
    "# this is for a 1.27mm pitch pin\n",
    "PIN_DIAM = 1.0\n",
    "PIN_DRILL = 0.65\n",
    "\n",
    "# this is for the PCB connector - see https://www.farnell.com/datasheets/2003059.pdf\n",
    "PAD_WIDTH = 3\n",
    "PAD_HEIGHT = 2\n",
    "PAD_PITCH = 2.5\n",
    "\n",
    "STATOR_HOLE_RADIUS = 5.5"
   ]
  },
  {
   "cell_type": "code",
   "execution_count": null,
   "metadata": {},
   "outputs": [],
   "source": [
    "# Standard 25 mm version\n",
    "\n",
    "# PCB Edge size\n",
    "STATOR_RADIUS = 25\n",
    "STATOR_HOLE_RADIUS = 5.5\n",
    "\n",
    "# where to puth the mounting pins\n",
    "SCREW_HOLE_DRILL_DIAM = 2.3  # 2.3mm drill for a 2mm screw\n",
    "SCREW_HOLE_RADIUS = STATOR_RADIUS\n",
    "\n",
    "# Coil params\n",
    "TURNS = 12\n",
    "COIL_CENTER_RADIUS = 16\n",
    "COIL_VIA_RADIUS = 17"
   ]
  },
  {
   "cell_type": "code",
   "execution_count": null,
   "metadata": {},
   "outputs": [],
   "source": [
    "# Large 30 mm version\n",
    "\n",
    "# PCB Edge size\n",
    "STATOR_RADIUS = 30\n",
    "\n",
    "# where to puth the mounting pins\n",
    "SCREW_HOLE_DRILL_DIAM = 2.3  # 2.3mm drill for a 2mm screw\n",
    "SCREW_HOLE_RADIUS = STATOR_RADIUS\n",
    "\n",
    "# Coil params\n",
    "# for custom shape\n",
    "TURNS = 16\n",
    "# for spiral\n",
    "# TURNS = 17\n",
    "COIL_CENTER_RADIUS = 19.95\n",
    "COIL_VIA_RADIUS = 20.95"
   ]
  },
  {
   "cell_type": "code",
   "execution_count": null,
   "metadata": {},
   "outputs": [],
   "source": [
    "# where to put the input pads\n",
    "INPUT_PAD_RADIUS = STATOR_RADIUS - (PAD_WIDTH / 2 + VIA_DIAM + TRACK_SPACING)\n",
    "\n",
    "USE_SPIRAL = True\n",
    "\n",
    "if USE_SPIRAL:\n",
    "    TURNS = 18\n",
    "    COIL_VIA_RADIUS = 20.5\n",
    "    COIL_CENTER_RADIUS = 20.5\n",
    "\n",
    "LAYERS = 4"
   ]
  },
  {
   "cell_type": "markdown",
   "metadata": {},
   "source": [
    "# Arbitrary Coil Generation"
   ]
  },
  {
   "cell_type": "code",
   "execution_count": null,
   "metadata": {},
   "outputs": [],
   "source": [
    "# templates must be simetric around the X axis and must include the center points on both size (e.g. (X1, 0).... (X2, 0) )\n",
    "# template must also be convex\n",
    "template = [\n",
    "    (-3.5, 0),\n",
    "    (-3.5, -0.01),\n",
    "    (1.9, -1.45),\n",
    "    (1.9, 0.0),\n",
    "    (1.9, 1.45),\n",
    "    (-3.5, 0.01),\n",
    "]"
   ]
  },
  {
   "cell_type": "code",
   "execution_count": null,
   "metadata": {},
   "outputs": [],
   "source": [
    "# plot the template shape wrapping around to the first point\n",
    "df = pd.DataFrame(template + [template[0]], columns=[\"x\", \"y\"])\n",
    "ax = df.plot.line(x=\"x\", y=\"y\", color=\"blue\")\n",
    "ax.axis(\"equal\")"
   ]
  },
  {
   "cell_type": "code",
   "execution_count": null,
   "metadata": {},
   "outputs": [],
   "source": [
    "def calculate_point(point, point1, point2, spacing, turn):\n",
    "    reference_vector = Vector([-100, 0])\n",
    "    angle = np.rad2deg(Vector(point).angle_between(reference_vector))\n",
    "    if point[1] > 0:\n",
    "        angle = 360 - angle\n",
    "    vector = Vector(point1) - Vector(point2)\n",
    "    normal = vector / np.linalg.norm(vector)\n",
    "    # rotate the vector 90 degrees\n",
    "    normal = np.array([-normal[1], normal[0]])\n",
    "    # move the  point along the normal vector by the spacing\n",
    "    offset = spacing * (turn * 360 + angle) / 360\n",
    "    coil_point = point + normal * offset\n",
    "    return (coil_point[0], coil_point[1])\n",
    "\n",
    "\n",
    "def get_points(template, turns, spacing):\n",
    "    coil_points = []\n",
    "    reference_vector = Vector([-100, 0])\n",
    "    template_index = 0\n",
    "    template_length = len(template)\n",
    "    for turn in range(turns * template_length):\n",
    "        point1 = template[template_index % template_length]\n",
    "        point2 = template[(template_index + 1) % template_length]\n",
    "\n",
    "        # calculate the new positions of the points\n",
    "        coil_point1 = calculate_point(\n",
    "            point1, point1, point2, spacing, template_index // template_length\n",
    "        )\n",
    "        coil_point2 = calculate_point(\n",
    "            point2, point1, point2, spacing, (template_index + 1) // template_length\n",
    "        )\n",
    "        # adjust the previous point so that the previous line intersects with this new line\n",
    "        # this prevents any cutting of corners\n",
    "        if len(coil_points) >= 2:\n",
    "            # create a line from the previous two points\n",
    "            line1 = Line(\n",
    "                coil_points[len(coil_points) - 2],\n",
    "                np.array(coil_points[len(coil_points) - 1])\n",
    "                - np.array(coil_points[len(coil_points) - 2]),\n",
    "            )\n",
    "            # create a line from the two new points\n",
    "            line2 = Line(\n",
    "                np.array(coil_point1),\n",
    "                np.array(np.array(coil_point1) - np.array(coil_point2)),\n",
    "            )\n",
    "            # find the intersection of the two lines\n",
    "            try:\n",
    "                intersection = line1.intersect_line(line2)\n",
    "                # replace the previous point with the intersection\n",
    "                coil_points[len(coil_points) - 1] = intersection\n",
    "                # add the new point\n",
    "                coil_points.append(coil_point2)\n",
    "            except:\n",
    "                # the lines did not intersect so just add the points\n",
    "                coil_points.append(coil_point1)\n",
    "                coil_points.append(coil_point2)\n",
    "        else:\n",
    "            coil_points.append(coil_point1)\n",
    "            coil_points.append(coil_point2)\n",
    "\n",
    "        template_index = template_index + 1\n",
    "    return coil_points"
   ]
  },
  {
   "cell_type": "code",
   "execution_count": null,
   "metadata": {},
   "outputs": [],
   "source": [
    "def get_spiral(turns, start_radius, thickness, layer=Layer.FRONT):\n",
    "    points = []\n",
    "    # create a starting point in the center\n",
    "    for angle in np.arange(0, turns * 360, 1):\n",
    "        radius = start_radius + thickness * angle / 360\n",
    "        if layer == Layer.BACK:\n",
    "            x = radius * np.cos(np.deg2rad(angle + 180))\n",
    "            y = radius * np.sin(np.deg2rad(angle + 180))\n",
    "            points.append((x, -y))\n",
    "        else:\n",
    "            x = radius * np.cos(np.deg2rad(angle))\n",
    "            y = radius * np.sin(np.deg2rad(angle))\n",
    "            points.append((x, y))\n",
    "    return points"
   ]
  },
  {
   "cell_type": "code",
   "execution_count": null,
   "metadata": {},
   "outputs": [],
   "source": [
    "if not USE_SPIRAL:\n",
    "    print(\"Not using spiral\")\n",
    "    template_f = []\n",
    "    for i in range(len(template)):\n",
    "        template_f.append(template[len(template) - i - len(template) // 2])\n",
    "    template_f = flip_x(template_f)\n",
    "    points_f = chaikin(\n",
    "        optimize_points(\n",
    "            flip_x(get_points(template_f, TURNS, TRACK_SPACING + TRACK_WIDTH))\n",
    "        ),\n",
    "        2,\n",
    "    )\n",
    "    points_b = chaikin(\n",
    "        optimize_points(get_points(template, TURNS, TRACK_SPACING + TRACK_WIDTH)), 2\n",
    "    )\n",
    "else:\n",
    "    print(\"Using spiral\")\n",
    "    points_f = get_spiral(\n",
    "        TURNS, VIA_DIAM / 2 + TRACK_SPACING, TRACK_SPACING + TRACK_WIDTH, Layer.FRONT\n",
    "    )\n",
    "    points_b = get_spiral(\n",
    "        TURNS, VIA_DIAM / 2 + TRACK_SPACING, TRACK_SPACING + TRACK_WIDTH, Layer.BACK\n",
    "    )\n",
    "\n",
    "    points_f = [(0, 0)] + points_f\n",
    "    points_b = [(0, 0)] + points_b\n",
    "    print(\"Track points\", len(points_f), len(points_b))"
   ]
  },
  {
   "cell_type": "code",
   "execution_count": null,
   "metadata": {},
   "outputs": [],
   "source": [
    "points_f = [(COIL_VIA_RADIUS - COIL_CENTER_RADIUS, 0)] + points_f\n",
    "points_b = [(COIL_VIA_RADIUS - COIL_CENTER_RADIUS, 0)] + points_b\n",
    "\n",
    "df = pd.DataFrame(points_f, columns=[\"x\", \"y\"])\n",
    "ax = df.plot.line(x=\"x\", y=\"y\", color=\"blue\")\n",
    "ax.axis(\"equal\")\n",
    "df = pd.DataFrame(points_b, columns=[\"x\", \"y\"])\n",
    "ax = df.plot.line(x=\"x\", y=\"y\", color=\"red\", ax=ax)\n",
    "\n",
    "print(\"Track points\", len(points_f), len(points_b))"
   ]
  },
  {
   "cell_type": "code",
   "execution_count": null,
   "metadata": {},
   "outputs": [],
   "source": [
    "# write the coil out in a format that can be simulated\n",
    "# rotate the points by 90 degrees so that the x axis is horizontal\n",
    "pf = rotate(points_f, 90)\n",
    "pb = rotate(points_b, 90)\n",
    "fname = \"simulations/coils/coil_12_custom\"\n",
    "if USE_SPIRAL:\n",
    "    fname = \"simulations/coils/coil_12_spiral\"\n",
    "\n",
    "# write the coil out in a format that can be simulated\n",
    "p_f = rotate(points_f, 90)\n",
    "p_b = rotate(points_b, 90)\n",
    "\n",
    "with open(fname + \".csv\", \"w\") as f:\n",
    "    for point in p_f[::-1]:\n",
    "        f.write(f\"{point[0]},{point[1]},0,0.5\\n\")\n",
    "\n",
    "# two layer board\n",
    "with open(fname + \"-2-layer.csv\", \"wt\") as f:\n",
    "    for point in p_f[::-1]:\n",
    "        f.write(f\"{point[0]},{point[1]},0,0.5\\n\")\n",
    "    for point in p_b:\n",
    "        f.write(f\"{point[0]},{point[1]},0-0.062,0.5\\n\")\n",
    "\n",
    "# all four layer board\n",
    "with open(fname + \"-4-layer.csv\", \"wt\") as f:\n",
    "    for point in p_f[::-1]:\n",
    "        f.write(f\"{point[0]},{point[1]},0,0.5\\n\")\n",
    "    for point in p_b:\n",
    "        f.write(f\"{point[0]},{point[1]},0-0.011,0.5\\n\")\n",
    "    for point in p_f[::-1]:\n",
    "        f.write(f\"{point[0]},{point[1]},0-(0.011+0.04),0.5\\n\")\n",
    "    for point in p_b:\n",
    "        f.write(f\"{point[0]},{point[1]},0-(0.011+0.011+0.04),0.5\\n\")"
   ]
  },
  {
   "cell_type": "code",
   "execution_count": null,
   "metadata": {},
   "outputs": [],
   "source": [
    "# write the coil out in a format that can be simulated\n",
    "# shift the coils aronnd to make connections a bit easier\n",
    "pf = rotate(points_f, 90)\n",
    "pb = rotate(points_b, 90)\n",
    "fname = \"simulations/coils/coil_12_custom\"\n",
    "if USE_SPIRAL:\n",
    "    fname = \"simulations/coils/coil_12_spiral\"\n",
    "\n",
    "with open(fname + \".csv\", \"w\") as f:\n",
    "    for point in pf:\n",
    "        f.write(f\"{point[0]/10},{point[1]/10},0,0.5\\n\")\n",
    "\n",
    "# two layer board\n",
    "with open(fname + \"-2-layer.csv\", \"wt\") as f:\n",
    "    for point in pf[::-1]:\n",
    "        f.write(f\"{point[0]/10},{point[1]/10},0,0.5\\n\")\n",
    "    for point in pb:\n",
    "        f.write(f\"{point[0]/10},{point[1]/10},0-0.062,0.5\\n\")\n",
    "\n",
    "# all four layer board\n",
    "with open(fname + \"-4-layer.csv\", \"wt\") as f:\n",
    "    for point in pf[::-1]:\n",
    "        f.write(f\"{point[0]/10},{point[1]/10},0,0.5\\n\")\n",
    "    for point in pb:\n",
    "        f.write(f\"{point[0]/10},{point[1]/10},0-0.011,0.5\\n\")\n",
    "    for point in pf[::-1]:\n",
    "        f.write(f\"{point[0]/10},{point[1]/10},0-(0.011+0.04),0.5\\n\")\n",
    "    for point in pb:\n",
    "        f.write(f\"{point[0]/10},{point[1]/10},0-(0.011+0.011+0.04),0.5\\n\")"
   ]
  },
  {
   "cell_type": "markdown",
   "metadata": {},
   "source": [
    "# Generate PCB Layout"
   ]
  },
  {
   "cell_type": "code",
   "execution_count": null,
   "metadata": {},
   "outputs": [],
   "source": [
    "# calculat the total length of the track to compute the resistance\n",
    "total_length_front = 0\n",
    "for i in range(len(points_f) - 1):\n",
    "    total_length_front += np.linalg.norm(\n",
    "        np.array(points_f[i + 1]) - np.array(points_f[i])\n",
    "    )\n",
    "print(\"Total length front\", total_length_front)\n",
    "\n",
    "total_length_back = 0\n",
    "for i in range(len(points_b) - 1):\n",
    "    total_length_back += np.linalg.norm(\n",
    "        np.array(points_b[i + 1]) - np.array(points_b[i])\n",
    "    )\n",
    "print(\"Total length back\", total_length_back)"
   ]
  },
  {
   "cell_type": "code",
   "execution_count": null,
   "metadata": {},
   "outputs": [],
   "source": [
    "vias = []\n",
    "tracks_f = []\n",
    "tracks_b = []\n",
    "pads = []\n",
    "pins = []\n",
    "mounting_holes = []\n",
    "silk = []\n",
    "\n",
    "\n",
    "# shift the coils aronnd to make connections a bit easier\n",
    "COIL_ROTATION = -360 / 12\n",
    "\n",
    "coil_angles = []\n",
    "for i in range(12):\n",
    "    angle = i * 360 / 12 + COIL_ROTATION\n",
    "    coil_angles.append(angle)\n",
    "\n",
    "# the main coils\n",
    "coil_labels = [\"A\", \"B\", \"C\"]\n",
    "coils_f = []\n",
    "coils_b = []\n",
    "for i in range(12):\n",
    "    angle = coil_angles[i]\n",
    "    if (i // 3) % 2 == 0:\n",
    "        coil_A_f = translate(rotate(points_f, angle), COIL_CENTER_RADIUS, angle)\n",
    "        coil_A_b = translate(rotate(points_b, angle), COIL_CENTER_RADIUS, angle)\n",
    "    else:\n",
    "        # slightly nudge the coils so that they don't overlap when flipped\n",
    "        coil_A_f = translate(rotate(flip_y(points_f), angle), COIL_CENTER_RADIUS, angle)\n",
    "        coil_A_b = translate(rotate(flip_y(points_b), angle), COIL_CENTER_RADIUS, angle)\n",
    "    # keep track of the coils\n",
    "    coils_f.append(coil_A_f)\n",
    "    coils_b.append(coil_A_b)\n",
    "\n",
    "    tracks_f.append(coil_A_f)\n",
    "    tracks_b.append(coil_A_b)\n",
    "    vias.append(create_via(get_arc_point(angle, COIL_VIA_RADIUS)))\n",
    "    silk.append(\n",
    "        create_silk(get_arc_point(angle, COIL_CENTER_RADIUS), coil_labels[i % 3])\n",
    "    )\n",
    "\n",
    "# raidus for connecting the bottoms of the coils together\n",
    "connection_radius1 = STATOR_HOLE_RADIUS + 3 * TRACK_SPACING\n",
    "\n",
    "# create tracks to link the A coils around the center\n",
    "connection_via_radius_A = connection_radius1 + 3 * TRACK_SPACING + VIA_DIAM / 2\n",
    "coil_A1_A2_inner = (\n",
    "    [get_arc_point(coil_angles[0], connection_via_radius_A)]\n",
    "    + draw_arc(COIL_ROTATION, coil_angles[3], connection_radius1)\n",
    "    + [get_arc_point(coil_angles[3], connection_via_radius_A)]\n",
    ")\n",
    "tracks_f.append(coil_A1_A2_inner)\n",
    "coil_A3_A4_inner = (\n",
    "    [get_arc_point(coil_angles[6], connection_via_radius_A)]\n",
    "    + draw_arc(coil_angles[6], coil_angles[9], connection_radius1)\n",
    "    + [get_arc_point(coil_angles[9], connection_via_radius_A)]\n",
    ")\n",
    "tracks_f.append(coil_A3_A4_inner)\n",
    "# connect up the bottoms of the A coils\n",
    "coils_b[0].append(coil_A1_A2_inner[0])\n",
    "coils_b[3].append(coil_A1_A2_inner[-1])\n",
    "coils_b[6].append(coil_A3_A4_inner[0])\n",
    "coils_b[9].append(coil_A3_A4_inner[-1])\n",
    "# add the vias to stitch them together\n",
    "vias.append(create_via(coil_A1_A2_inner[0]))\n",
    "vias.append(create_via(coil_A1_A2_inner[-1]))\n",
    "vias.append(create_via(coil_A3_A4_inner[0]))\n",
    "vias.append(create_via(coil_A3_A4_inner[-1]))\n",
    "\n",
    "# create tracks to link the B coils around the center - this can all be done on the bottom layer\n",
    "coil_B1_B2_inner = draw_arc(coil_angles[1], coil_angles[4], connection_radius1)\n",
    "tracks_b.append(coil_B1_B2_inner)\n",
    "coil_B3_B4_inner = draw_arc(coil_angles[7], coil_angles[10], connection_radius1)\n",
    "tracks_b.append(coil_B3_B4_inner)\n",
    "# connect up the bottoms of the A coils\n",
    "coils_b[1].append(coil_B1_B2_inner[0])\n",
    "coils_b[4].append(coil_B1_B2_inner[-1])\n",
    "coils_b[7].append(coil_B3_B4_inner[0])\n",
    "coils_b[10].append(coil_B3_B4_inner[-1])\n",
    "\n",
    "# create tracks to link the C coils around the center\n",
    "connection_via_radius_C = connection_via_radius_A + 3 * TRACK_SPACING + VIA_DIAM / 2\n",
    "coil_C1_C2_inner = draw_arc(coil_angles[2], coil_angles[5], connection_via_radius_C)\n",
    "tracks_f.append(coil_C1_C2_inner)\n",
    "coil_C3_C4_inner = draw_arc(coil_angles[8], coil_angles[11], connection_via_radius_C)\n",
    "tracks_f.append(coil_C3_C4_inner)\n",
    "# connect up the bottoms of the B coils\n",
    "coils_b[2].append(coil_C1_C2_inner[0])\n",
    "coils_b[5].append(coil_C1_C2_inner[-1])\n",
    "coils_b[8].append(coil_C3_C4_inner[0])\n",
    "coils_b[11].append(coil_C3_C4_inner[-1])\n",
    "# add the vias to stitch them together\n",
    "vias.append(create_via(coil_C1_C2_inner[0]))\n",
    "vias.append(create_via(coil_C1_C2_inner[-1]))\n",
    "vias.append(create_via(coil_C3_C4_inner[0]))\n",
    "vias.append(create_via(coil_C3_C4_inner[-1]))\n",
    "\n",
    "# connect the last three coils together\n",
    "common_connection_radius = SCREW_HOLE_RADIUS - (SCREW_HOLE_DRILL_DIAM / 2 + 0.5)\n",
    "tracks_f.append(draw_arc(coil_angles[9], coil_angles[11], common_connection_radius))\n",
    "coils_f[9].append(get_arc_point(coil_angles[9], common_connection_radius))\n",
    "coils_f[10].append(get_arc_point(coil_angles[10], common_connection_radius))\n",
    "coils_f[11].append(get_arc_point(coil_angles[11], common_connection_radius))\n",
    "\n",
    "# connect the outer A coils together\n",
    "outer_connection_radius_A = SCREW_HOLE_RADIUS - (SCREW_HOLE_DRILL_DIAM / 2 + 0.5)\n",
    "tracks_f.append(draw_arc(coil_angles[3], coil_angles[6], outer_connection_radius_A))\n",
    "coils_f[3].append(get_arc_point(coil_angles[3], outer_connection_radius_A))\n",
    "coils_f[6].append(get_arc_point(coil_angles[6], outer_connection_radius_A))\n",
    "\n",
    "# connect the outer B coils together\n",
    "outer_connection_radius_B = outer_connection_radius_A - TRACK_SPACING - VIA_DIAM / 2\n",
    "tracks_b.append(\n",
    "    [get_arc_point(coil_angles[4], outer_connection_radius_B)]\n",
    "    + draw_arc(coil_angles[4], coil_angles[7], outer_connection_radius_A)\n",
    "    + [get_arc_point(coil_angles[7], outer_connection_radius_B)]\n",
    ")\n",
    "coils_f[4].append(get_arc_point(coil_angles[4], outer_connection_radius_B))\n",
    "coils_f[7].append(get_arc_point(coil_angles[7], outer_connection_radius_B))\n",
    "vias.append(\n",
    "    create_via(get_arc_point(4 * 360 / 12 + COIL_ROTATION, outer_connection_radius_B))\n",
    ")\n",
    "vias.append(\n",
    "    create_via(get_arc_point(7 * 360 / 12 + COIL_ROTATION, outer_connection_radius_B))\n",
    ")\n",
    "\n",
    "# connect the outer C coilds together\n",
    "outer_connection_radius_C = outer_connection_radius_B - TRACK_SPACING - VIA_DIAM / 2\n",
    "tracks_b.append(\n",
    "    draw_arc(\n",
    "        5 * 360 / 12 + COIL_ROTATION,\n",
    "        8 * 360 / 12 + COIL_ROTATION,\n",
    "        outer_connection_radius_C,\n",
    "    )\n",
    ")\n",
    "coils_f[5].append(\n",
    "    get_arc_point(5 * 360 / 12 + COIL_ROTATION, outer_connection_radius_C)\n",
    ")\n",
    "coils_f[8].append(\n",
    "    get_arc_point(8 * 360 / 12 + COIL_ROTATION, outer_connection_radius_C)\n",
    ")\n",
    "vias.append(\n",
    "    create_via(get_arc_point(5 * 360 / 12 + COIL_ROTATION, outer_connection_radius_C))\n",
    ")\n",
    "vias.append(\n",
    "    create_via(get_arc_point(8 * 360 / 12 + COIL_ROTATION, outer_connection_radius_C))\n",
    ")\n",
    "\n",
    "#  create the pads for connecting the inputs to the coils\n",
    "silk.append(\n",
    "    create_silk((INPUT_PAD_RADIUS - PAD_HEIGHT - 2.5, PAD_PITCH), \"C\", \"b\", 2.5, -900)\n",
    ")\n",
    "silk.append(create_silk((INPUT_PAD_RADIUS - PAD_HEIGHT - 2.5, 0), \"B\", \"b\", 2.5, -900))\n",
    "silk.append(\n",
    "    create_silk((INPUT_PAD_RADIUS - PAD_HEIGHT - 2.5, -PAD_PITCH), \"A\", \"b\", 2.5, -900)\n",
    ")\n",
    "\n",
    "pads.append(create_pad((INPUT_PAD_RADIUS, -PAD_PITCH), PAD_WIDTH, PAD_HEIGHT, \"b\"))\n",
    "pads.append(create_pad((INPUT_PAD_RADIUS, 0), PAD_WIDTH, PAD_HEIGHT, \"b\"))\n",
    "pads.append(create_pad((INPUT_PAD_RADIUS, PAD_PITCH), PAD_WIDTH, PAD_HEIGHT, \"b\"))\n",
    "\n",
    "# connect coil A to the top pad\n",
    "pad_connection_point_x = INPUT_PAD_RADIUS\n",
    "pad_angle = np.rad2deg(np.arcsin(PAD_PITCH / pad_connection_point_x))\n",
    "coils_f[0].append(get_arc_point(coil_angles[0], pad_connection_point_x))\n",
    "vias.append(create_via(get_arc_point(coil_angles[0], pad_connection_point_x)))\n",
    "# connect coil B to the middle pad\n",
    "coils_f[1].append((pad_connection_point_x + PAD_WIDTH / 2 + VIA_DIAM / 2, 0))\n",
    "vias.append(create_via(((pad_connection_point_x + PAD_WIDTH / 2 + VIA_DIAM / 2, 0))))\n",
    "# connect coil C to the bottom pad\n",
    "coils_f[2].append(get_arc_point(coil_angles[2], pad_connection_point_x))\n",
    "vias.append(create_via(get_arc_point(coil_angles[2], pad_connection_point_x)))"
   ]
  },
  {
   "cell_type": "code",
   "execution_count": null,
   "metadata": {},
   "outputs": [],
   "source": [
    "# if we are doing four layers then duplicate the front and back layers on (front and inner1), (inner2 and back)\n",
    "tracks_in1 = []\n",
    "tracks_in2 = []\n",
    "if LAYERS == 4:\n",
    "    tracks_in1 = tracks_b.copy()\n",
    "    tracks_in2 = tracks_f.copy()\n",
    "\n",
    "# these final bits of wiring up to the input pads don't need to be duplicated\n",
    "tracks_b.append(\n",
    "    [(pad_connection_point_x + PAD_WIDTH / 2, 0), (pad_connection_point_x, 0)]\n",
    ")\n",
    "tracks_b.append(draw_arc(coil_angles[0], -pad_angle, pad_connection_point_x, 1))\n",
    "tracks_b.append(draw_arc(coil_angles[2], pad_angle, pad_connection_point_x, 1))\n",
    "\n",
    "nibble_angle_size = 360 * SCREW_HOLE_DRILL_DIAM / (2 * np.pi * STATOR_RADIUS)\n",
    "\n",
    "outer_cuts = (\n",
    "    draw_arc(-45 + nibble_angle_size / 2, 45 - nibble_angle_size / 2, STATOR_RADIUS, 5)\n",
    "    + translate(\n",
    "        rotate(draw_arc(5, 175, SCREW_HOLE_DRILL_DIAM / 2, 5)[::-1], 135),\n",
    "        STATOR_RADIUS,\n",
    "        45,\n",
    "    )\n",
    "    + draw_arc(\n",
    "        45 + nibble_angle_size / 2, 135 - nibble_angle_size / 2, STATOR_RADIUS, 5\n",
    "    )\n",
    "    + translate(\n",
    "        rotate(draw_arc(5, 175, SCREW_HOLE_DRILL_DIAM / 2, 5), 225)[::-1],\n",
    "        STATOR_RADIUS,\n",
    "        135,\n",
    "    )\n",
    "    + draw_arc(\n",
    "        135 + nibble_angle_size / 2, 225 - nibble_angle_size / 2, STATOR_RADIUS, 5\n",
    "    )\n",
    "    + translate(\n",
    "        rotate(draw_arc(5, 175, SCREW_HOLE_DRILL_DIAM / 2, 5), 315)[::-1],\n",
    "        STATOR_RADIUS,\n",
    "        225,\n",
    "    )\n",
    "    + draw_arc(\n",
    "        225 + nibble_angle_size / 2, 315 - nibble_angle_size / 2, STATOR_RADIUS, 5\n",
    "    )\n",
    "    + translate(\n",
    "        rotate(draw_arc(5, 175, SCREW_HOLE_DRILL_DIAM / 2, 5), 45)[::-1],\n",
    "        STATOR_RADIUS,\n",
    "        315,\n",
    "    )\n",
    ")\n",
    "\n",
    "edge_cuts = [\n",
    "    outer_cuts,\n",
    "    draw_arc(0, 360, STATOR_HOLE_RADIUS, 1),\n",
    "]\n",
    "\n",
    "# dump out the json version\n",
    "json_result = dump_json(\n",
    "    filename=f\"coils_12_{STATOR_RADIUS}mm.json\",\n",
    "    track_width=TRACK_WIDTH,\n",
    "    pin_diam=PIN_DIAM,\n",
    "    pin_drill=PIN_DRILL,\n",
    "    via_diam=VIA_DIAM,\n",
    "    via_drill=VIA_DRILL,\n",
    "    vias=vias,\n",
    "    pins=pins,\n",
    "    pads=pads,\n",
    "    silk=silk,\n",
    "    tracks_f=tracks_f,\n",
    "    tracks_in1=tracks_in1,\n",
    "    tracks_in2=tracks_in2,\n",
    "    tracks_b=tracks_b,\n",
    "    mounting_holes=mounting_holes,\n",
    "    edge_cuts=edge_cuts,\n",
    ")"
   ]
  },
  {
   "cell_type": "code",
   "execution_count": null,
   "metadata": {},
   "outputs": [],
   "source": [
    "# plot the json\n",
    "plot_json(json_result)"
   ]
  }
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