export_to_pcbnew.cpp

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/*
 * This program source code file is part of KiCad, a free EDA CAD application.
 *
 * Copyright (C) 2007-2014 Jean-Pierre Charras jp.charras at wanadoo.fr
 * Copyright (C) 1992-2022 KiCad Developers, see AUTHORS.txt for contributors.
 *
 * This program is free software; you can redistribute it and/or
 * modify it under the terms of the GNU General Public License
 * as published by the Free Software Foundation; either version 2
 * of the License, or (at your option) any later version.
 *
 * This program is distributed in the hope that it will be useful,
 * but WITHOUT ANY WARRANTY; without even the implied warranty of
 * MERCHANTABILITY or FITNESS FOR A PARTICULAR PURPOSE. See the
 * GNU General Public License for more details.
 *
 * You should have received a copy of the GNU General Public License
 * along with this program; if not, you may find one here:
 * http://www.gnu.org/licenses/old-licenses/gpl-2.0.html
 * or you may search the http://www.gnu.org website for the version 2 license,
 * or you may write to the Free Software Foundation, Inc.,
 * 51 Franklin Street, Fifth Floor, Boston, MA 02110-1301, USA
 */
 
#include <vector>
 
#include <export_to_pcbnew.h>
 
#include <confirm.h>
#include <string_utils.h>
#include <locale_io.h>
#include <macros.h>
#include <trigo.h>
#include <gerbview_frame.h>
#include <gerber_file_image.h>
#include <gerber_file_image_list.h>
#include <build_version.h>
#include <wildcards_and_files_ext.h>
#include "excellon_image.h"
 
// Imported function
extern const wxString GetPCBDefaultLayerName( int aLayerNumber );
 
 
GBR_TO_PCB_EXPORTER::GBR_TO_PCB_EXPORTER( GERBVIEW_FRAME* aFrame, const wxString& aFileName )
{
 m_gerbview_frame = aFrame;
 m_pcb_file_name = aFileName;
 m_fp = nullptr;
 m_pcbCopperLayersCount = 2;
}
 
 
GBR_TO_PCB_EXPORTER::~GBR_TO_PCB_EXPORTER()
{
}
 
 
bool GBR_TO_PCB_EXPORTER::ExportPcb( const int* aLayerLookUpTable, int aCopperLayers )
{
 LOCALE_IO toggle; // toggles on, then off, the C locale.
 
 m_fp = wxFopen( m_pcb_file_name, wxT( "wt" ) );
 
 if( m_fp == nullptr )
 {
 wxString msg;
 msg.Printf( _( "Failed to create file '%s'." ), m_pcb_file_name );
 DisplayError( m_gerbview_frame, msg );
 return false;
 }
 
 m_pcbCopperLayersCount = aCopperLayers;
 
 writePcbHeader( aLayerLookUpTable );
 
 // create an image of gerber data
 const int pcbCopperLayerMax = 31;
 GERBER_FILE_IMAGE_LIST* images = m_gerbview_frame->GetGerberLayout()->GetImagesList();
 
 // First collect all the holes. We'll use these to generate pads, vias, etc.
 for( unsigned layer = 0; layer < images->ImagesMaxCount(); ++layer )
 {
 int pcb_layer_number = aLayerLookUpTable[layer];
 EXCELLON_IMAGE* excellon = dynamic_cast<EXCELLON_IMAGE*>( images->GetGbrImage( layer ) );
 GERBER_FILE_IMAGE* gerb = dynamic_cast<GERBER_FILE_IMAGE*>( images->GetGbrImage( layer ) );
 if( excellon )
 {
 for( GERBER_DRAW_ITEM* gerb_item : excellon->GetItems() )
 collect_hole( gerb_item );
 }
 else if( gerb && pcb_layer_number == UNDEFINED_LAYER ) // PCB_LAYER_ID doesn't have an entry for Hole Data,
 // but the dialog returns UNDEFINED_LAYER for it
 {
 for( GERBER_DRAW_ITEM* gerb_item : gerb->GetItems() )
 collect_hole( gerb_item );
 }
 else
 {
 continue;
 }
 }
 
 // Next: non copper layers:
 for( unsigned layer = 0; layer < images->ImagesMaxCount(); ++layer )
 {
 GERBER_FILE_IMAGE* gerber = images->GetGbrImage( layer );
 
 if( gerber == nullptr ) // Graphic layer not yet used
 continue;
 
 int pcb_layer_number = aLayerLookUpTable[layer];
 
 if( !IsPcbLayer( pcb_layer_number ) )
 continue;
 
 if( pcb_layer_number <= pcbCopperLayerMax ) // copper layer
 continue;
 
 for( GERBER_DRAW_ITEM* gerb_item : gerber->GetItems() )
 export_non_copper_item( gerb_item, pcb_layer_number );
 }
 
 // Copper layers
 for( unsigned layer = 0; layer < images->ImagesMaxCount(); ++layer )
 {
 GERBER_FILE_IMAGE* gerber = images->GetGbrImage( layer );
 
 if( gerber == nullptr ) // Graphic layer not yet used
 continue;
 
 int pcb_layer_number = aLayerLookUpTable[layer];
 
 if( pcb_layer_number < 0 || pcb_layer_number > pcbCopperLayerMax )
 continue;
 
 for( GERBER_DRAW_ITEM* gerb_item : gerber->GetItems() )
 export_copper_item( gerb_item, pcb_layer_number );
 }
 
 // Now write out the holes we collected earlier as vias
 for( const EXPORT_VIA& via : m_vias )
 export_via( via );
 
 fprintf( m_fp, ")\n" );
 
 fclose( m_fp );
 m_fp = nullptr;
 return true;
}
 
 
void GBR_TO_PCB_EXPORTER::export_non_copper_item( const GERBER_DRAW_ITEM* aGbrItem, int aLayer )
{
 // used when a D_CODE is not found. default D_CODE to draw a flashed item
 static D_CODE dummyD_CODE( 0 );
 
 VECTOR2I seg_start = aGbrItem->m_Start;
 VECTOR2I seg_end = aGbrItem->m_End;
 D_CODE* d_codeDescr = aGbrItem->GetDcodeDescr();
 SHAPE_POLY_SET polygon;
 
 if( d_codeDescr == nullptr )
 d_codeDescr = &dummyD_CODE;
 
 switch( aGbrItem->m_Shape )
 {
 case GBR_POLYGON:
 writePcbPolygon( aGbrItem->m_Polygon, aLayer );
 break;
 
 case GBR_SPOT_CIRCLE:
 {
 VECTOR2I center = aGbrItem->GetABPosition( seg_start );
 int radius = d_codeDescr->m_Size.x / 2;
 writePcbFilledCircle( center, radius, aLayer );
 }
 break;
 
 case GBR_SPOT_RECT:
 case GBR_SPOT_OVAL:
 case GBR_SPOT_POLY:
 case GBR_SPOT_MACRO:
 d_codeDescr->ConvertShapeToPolygon( aGbrItem );
 writePcbPolygon( d_codeDescr->m_Polygon, aLayer, aGbrItem->GetABPosition( seg_start ) );
 break;
 
 case GBR_ARC:
 {
 double a = atan2( (double) ( aGbrItem->m_Start.y - aGbrItem->m_ArcCentre.y ),
 (double) ( aGbrItem->m_Start.x - aGbrItem->m_ArcCentre.x ) );
 double b = atan2( (double) ( aGbrItem->m_End.y - aGbrItem->m_ArcCentre.y ),
 (double) ( aGbrItem->m_End.x - aGbrItem->m_ArcCentre.x ) );
 
 double angle = RAD2DEG(b - a);
 seg_start = aGbrItem->m_ArcCentre;
 
 // Ensure arc orientation is CCW
 if( angle < 0 )
 angle += 360.0;
 
 // Reverse Y axis:
 seg_start.y = -seg_start.y;
 seg_end.y = -seg_end.y;
 
 if( angle == 360.0 || angle == 0 )
 {
 fprintf( m_fp, "(gr_circle (center %s %s) (end %s %s) (layer %s) (width %s))\n",
 FormatDouble2Str( MapToPcbUnits( seg_start.x ) ).c_str(),
 FormatDouble2Str( MapToPcbUnits( seg_start.y ) ).c_str(),
 FormatDouble2Str( MapToPcbUnits( seg_end.x ) ).c_str(),
 FormatDouble2Str( MapToPcbUnits( seg_end.y ) ).c_str(),
 TO_UTF8( GetPCBDefaultLayerName( aLayer ) ),
 FormatDouble2Str( MapToPcbUnits( aGbrItem->m_Size.x ) ).c_str() );
 }
 else
 {
 fprintf( m_fp, "(gr_arc (start %s %s) (end %s %s) (angle %s) (layer %s) (width %s))\n",
 FormatDouble2Str( MapToPcbUnits( seg_start.x ) ).c_str(),
 FormatDouble2Str( MapToPcbUnits( seg_start.y ) ).c_str(),
 FormatDouble2Str( MapToPcbUnits( seg_end.x ) ).c_str(),
 FormatDouble2Str( MapToPcbUnits( seg_end.y ) ).c_str(),
 FormatDouble2Str( angle ).c_str(),
 TO_UTF8( GetPCBDefaultLayerName( aLayer ) ),
 FormatDouble2Str( MapToPcbUnits( aGbrItem->m_Size.x ) ).c_str() );
 }
 }
 break;
 
 case GBR_CIRCLE:
 // Reverse Y axis:
 seg_start.y = -seg_start.y;
 seg_end.y = -seg_end.y;
 
 fprintf( m_fp, "(gr_circle (start %s %s) (end %s %s) (layer %s) (width %s))\n",
 FormatDouble2Str( MapToPcbUnits( seg_start.x ) ).c_str(),
 FormatDouble2Str( MapToPcbUnits( seg_start.y ) ).c_str(),
 FormatDouble2Str( MapToPcbUnits( seg_end.x ) ).c_str(),
 FormatDouble2Str( MapToPcbUnits( seg_end.y ) ).c_str(),
 TO_UTF8( GetPCBDefaultLayerName( aLayer ) ),
 FormatDouble2Str( MapToPcbUnits( aGbrItem->m_Size.x ) ).c_str() );
 break;
 
 case GBR_SEGMENT:
 // Reverse Y axis:
 seg_start.y = -seg_start.y;
 seg_end.y = -seg_end.y;
 
 fprintf( m_fp, "(gr_line (start %s %s) (end %s %s) (layer %s) (width %s))\n",
 FormatDouble2Str( MapToPcbUnits( seg_start.x ) ).c_str(),
 FormatDouble2Str( MapToPcbUnits( seg_start.y ) ).c_str(),
 FormatDouble2Str( MapToPcbUnits( seg_end.x ) ).c_str(),
 FormatDouble2Str( MapToPcbUnits( seg_end.y ) ).c_str(),
 TO_UTF8( GetPCBDefaultLayerName( aLayer ) ),
 FormatDouble2Str( MapToPcbUnits( aGbrItem->m_Size.x ) ).c_str() );
 break;
 }
}
 
 
void GBR_TO_PCB_EXPORTER::collect_hole( const GERBER_DRAW_ITEM* aGbrItem )
{
 int size = std::min( aGbrItem->m_Size.x, aGbrItem->m_Size.y );
 m_vias.emplace_back( aGbrItem->m_Start, size + 1, size );
}
 
 
void GBR_TO_PCB_EXPORTER::export_via( const EXPORT_VIA& aVia )
{
 VECTOR2I via_pos = aVia.m_Pos;
 
 // Reverse Y axis:
 via_pos.y = -via_pos.y;
 
 // Layers are Front to Back
 fprintf( m_fp, " (via (at %s %s) (size %s) (drill %s)",
 FormatDouble2Str( MapToPcbUnits( via_pos.x ) ).c_str(),
 FormatDouble2Str( MapToPcbUnits( via_pos.y ) ).c_str(),
 FormatDouble2Str( MapToPcbUnits( aVia.m_Size ) ).c_str(),
 FormatDouble2Str( MapToPcbUnits( aVia.m_Drill ) ).c_str() );
 
 fprintf( m_fp, " (layers %s %s))\n",
 TO_UTF8( GetPCBDefaultLayerName( F_Cu ) ),
 TO_UTF8( GetPCBDefaultLayerName( B_Cu ) ) );
}
 
 
void GBR_TO_PCB_EXPORTER::export_copper_item( const GERBER_DRAW_ITEM* aGbrItem, int aLayer )
{
 switch( aGbrItem->m_Shape )
 {
 case GBR_SPOT_CIRCLE:
 case GBR_SPOT_RECT:
 case GBR_SPOT_OVAL:
 case GBR_SPOT_POLY:
 case GBR_SPOT_MACRO:
 export_flashed_copper_item( aGbrItem, aLayer );
 break;
 
 case GBR_ARC:
 export_segarc_copper_item( aGbrItem, aLayer );
 break;
 
 case GBR_POLYGON:
 // One can use a polygon or a zone to output a Gerber region.
 // none are perfect.
 // The current way is use a polygon, as the zone export
 // is experimental and only for tests.
#if 1
 writePcbPolygon( aGbrItem->m_Polygon, aLayer );
#else
 // Only for tests:
 writePcbZoneItem( aGbrItem, aLayer );
#endif
 break;
 
 default:
 export_segline_copper_item( aGbrItem, aLayer );
 break;
 }
}
 
 
void GBR_TO_PCB_EXPORTER::export_segline_copper_item( const GERBER_DRAW_ITEM* aGbrItem, int aLayer )
{
 VECTOR2I seg_start, seg_end;
 
 seg_start = aGbrItem->m_Start;
 seg_end = aGbrItem->m_End;
 
 // Reverse Y axis:
 seg_start.y = -seg_start.y;
 seg_end.y = -seg_end.y;
 
 writeCopperLineItem( seg_start, seg_end, aGbrItem->m_Size.x, aLayer );
}
 
 
void GBR_TO_PCB_EXPORTER::writeCopperLineItem( const VECTOR2I& aStart, const VECTOR2I& aEnd,
 int aWidth, int aLayer )
{
 fprintf( m_fp, "(segment (start %s %s) (end %s %s) (width %s) (layer %s) (net 0))\n",
 FormatDouble2Str( MapToPcbUnits(aStart.x) ).c_str(),
 FormatDouble2Str( MapToPcbUnits(aStart.y) ).c_str(),
 FormatDouble2Str( MapToPcbUnits(aEnd.x) ).c_str(),
 FormatDouble2Str( MapToPcbUnits(aEnd.y) ).c_str(),
  FormatDouble2Str( MapToPcbUnits( aWidth ) ).c_str(),
 TO_UTF8( GetPCBDefaultLayerName( aLayer ) ) );
}
 
 
void GBR_TO_PCB_EXPORTER::export_segarc_copper_item( const GERBER_DRAW_ITEM* aGbrItem, int aLayer )
{
 double a = atan2( (double) ( aGbrItem->m_Start.y - aGbrItem->m_ArcCentre.y ),
 (double) ( aGbrItem->m_Start.x - aGbrItem->m_ArcCentre.x ) );
 double b = atan2( (double) ( aGbrItem->m_End.y - aGbrItem->m_ArcCentre.y ),
 (double) ( aGbrItem->m_End.x - aGbrItem->m_ArcCentre.x ) );
 
 VECTOR2I start = aGbrItem->m_Start;
 VECTOR2I end = aGbrItem->m_End;
 
 /* Because Pcbnew does not know arcs in tracks,
 * approximate arc by segments (SEG_COUNT__CIRCLE segment per 360 deg)
 * The arc is drawn anticlockwise from the start point to the end point.
 */
 #define SEG_COUNT_CIRCLE 16
 #define DELTA_ANGLE 2 * M_PI / SEG_COUNT_CIRCLE
 
 // calculate the number of segments from a to b.
 // we want CNT_PER_360 segments fo a circle
 if( a > b )
 b += 2 * M_PI;
 
 VECTOR2I curr_start = start;
 VECTOR2I seg_start, seg_end;
 
 int ii = 1;
 
 for( double rot = a; rot < (b - DELTA_ANGLE); rot += DELTA_ANGLE, ii++ )
 {
 seg_start = curr_start;
 VECTOR2I curr_end = start;
 RotatePoint( curr_end, aGbrItem->m_ArcCentre, -EDA_ANGLE( DELTA_ANGLE, RADIANS_T ) * ii );
 seg_end = curr_end;
 
 // Reverse Y axis:
 seg_start.y = -seg_start.y;
 seg_end.y = -seg_end.y;
 writeCopperLineItem( seg_start, seg_end, aGbrItem->m_Size.x, aLayer );
 curr_start = curr_end;
 }
 
 if( end != curr_start )
 {
 seg_start = curr_start;
 seg_end = end;
 
 // Reverse Y axis:
 seg_start.y = -seg_start.y;
 seg_end.y = -seg_end.y;
 writeCopperLineItem( seg_start, seg_end, aGbrItem->m_Size.x, aLayer );
 }
}
 
#include <wx/log.h>
void GBR_TO_PCB_EXPORTER::export_flashed_copper_item( const GERBER_DRAW_ITEM* aGbrItem, int aLayer )
{
 static D_CODE flashed_item_D_CODE( 0 );
 
 D_CODE* d_codeDescr = aGbrItem->GetDcodeDescr();
 
 if( d_codeDescr == nullptr )
 d_codeDescr = &flashed_item_D_CODE;
 
 if( aGbrItem->m_Shape == GBR_SPOT_CIRCLE )
 {
 // See if there's a via that we can enlarge to fit this flashed item
 for( EXPORT_VIA& via : m_vias )
 {
 if( via.m_Pos == aGbrItem->m_Start )
 {
 via.m_Size = std::max( via.m_Size, aGbrItem->m_Size.x );
 return;
 }
 }
 }
 
 VECTOR2I offset = aGbrItem->GetABPosition( aGbrItem->m_Start );
 
 if( aGbrItem->m_Shape == GBR_SPOT_CIRCLE ||
 ( aGbrItem->m_Shape == GBR_SPOT_OVAL && d_codeDescr->m_Size.x == d_codeDescr->m_Size.y ) )
 {
 // export it as filled circle
 VECTOR2I center = offset;
 int radius = d_codeDescr->m_Size.x / 2;
 writePcbFilledCircle( center, radius, aLayer );
 return;
 }
 
 APERTURE_MACRO* macro = d_codeDescr->GetMacro();
 
 if( macro ) // export a GBR_SPOT_MACRO
 {
 SHAPE_POLY_SET macroShape;
 macroShape = *macro->GetApertureMacroShape( aGbrItem, VECTOR2I( 0, 0 ) );
 
 // Compensate the Y axis orientation ( writePcbPolygon invert the Y coordinate )
 macroShape.Outline( 0 ).Mirror( false, true );
 
 writePcbPolygon( macroShape, aLayer, offset );
 }
 else
 {
 // Should cover primitives: GBR_SPOT_RECT, GBR_SPOT_OVAL, GBR_SPOT_POLY
 d_codeDescr->ConvertShapeToPolygon( aGbrItem );
 writePcbPolygon( d_codeDescr->m_Polygon, aLayer, offset );
 }
}
 
 
void GBR_TO_PCB_EXPORTER::writePcbFilledCircle( const VECTOR2I& aCenterPosition, int aRadius,
 int aLayer )
{
 
 fprintf( m_fp, "(gr_circle (center %s %s) (end %s %s)",
 FormatDouble2Str( MapToPcbUnits( aCenterPosition.x ) ).c_str(),
 FormatDouble2Str( MapToPcbUnits( aCenterPosition.y ) ).c_str(),
 FormatDouble2Str( MapToPcbUnits( aCenterPosition.x + aRadius ) ).c_str(),
 FormatDouble2Str( MapToPcbUnits( aCenterPosition.y ) ).c_str() );
 
 
 fprintf( m_fp, "(layer %s) (width 0) (fill solid) )\n",
 TO_UTF8( GetPCBDefaultLayerName( aLayer ) ) );
}
 
 
void GBR_TO_PCB_EXPORTER::writePcbHeader( const int* aLayerLookUpTable )
{
 fprintf( m_fp, "(kicad_pcb (version 4) (generator gerbview)\n\n" );
 
 // Write layers section
 fprintf( m_fp, " (layers \n" );
 
 for( int ii = 0; ii < m_pcbCopperLayersCount; ii++ )
 {
 int id = ii;
 
 if( ii == m_pcbCopperLayersCount-1)
 id = B_Cu;
 
 fprintf( m_fp, " (%d %s signal)\n", id, TO_UTF8( GetPCBDefaultLayerName( id ) ) );
 }
 
 for( int ii = B_Adhes; ii < PCB_LAYER_ID_COUNT; ii++ )
 {
 if( GetPCBDefaultLayerName( ii ).IsEmpty() ) // Layer not available for export
 continue;
 
 fprintf( m_fp, " (%d %s user)\n", ii, TO_UTF8( GetPCBDefaultLayerName( ii ) ) );
 }
 
 fprintf( m_fp, " )\n\n" );
}
 
 
void GBR_TO_PCB_EXPORTER::writePcbPolygon( const SHAPE_POLY_SET& aPolys, int aLayer,
 const VECTOR2I& aOffset )
{
 // Ensure the polygon is valid:
 if( aPolys.OutlineCount() < 1 )
 return;
 
 // aPolys is expected having only one outline and no hole
 // (because it comes from a gerber file or is built from a aperture )
 const SHAPE_LINE_CHAIN& poly = aPolys.COutline( 0 );
 
 fprintf( m_fp, "(gr_poly (pts " );
 
 #define MAX_COORD_CNT 4
 int jj = MAX_COORD_CNT;
 int cnt_max = poly.PointCount() -1;
 
 // Do not generate last corner, if it is the same point as the first point:
 if( poly.CPoint( 0 ) == poly.CPoint( cnt_max ) )
 cnt_max--;
 
 for( int ii = 0; ii <= cnt_max; ii++ )
 {
 if( --jj == 0 )
 {
 jj = MAX_COORD_CNT;
 fprintf( m_fp, "\n" );
 }
 
 fprintf( m_fp, " (xy %s %s)",
 FormatDouble2Str( MapToPcbUnits( poly.CPoint( ii ).x + aOffset.x ) ).c_str(),
 FormatDouble2Str( MapToPcbUnits( -poly.CPoint( ii ).y + aOffset.y ) ).c_str() );
 }
 
 fprintf( m_fp, ")" );
 
 if( jj != MAX_COORD_CNT )
 fprintf( m_fp, "\n" );
 
 fprintf( m_fp, "(layer %s) (width 0) )\n", TO_UTF8( GetPCBDefaultLayerName( aLayer ) ) );
}
 
 
void GBR_TO_PCB_EXPORTER::writePcbZoneItem( const GERBER_DRAW_ITEM* aGbrItem, int aLayer )
{
 SHAPE_POLY_SET polys = aGbrItem->m_Polygon.CloneDropTriangulation();
 polys.Simplify( SHAPE_POLY_SET::PM_FAST );
 
 if( polys.OutlineCount() == 0 )
 return;
 
 fprintf( m_fp, "(zone (net 0) (net_name \"\") (layer %s) (tstamp 0000000) (hatch edge 0.508)\n",
 TO_UTF8( GetPCBDefaultLayerName( aLayer ) ) );
 
 fprintf( m_fp, " (connect_pads (clearance 0.0))\n" );
 
 fprintf( m_fp, " (min_thickness 0.1) (filled_areas_thickness no)\n"
 " (fill (thermal_gap 0.3) (thermal_bridge_width 0.3))\n" );
 
 // Now, write the zone outlines with holes.
 // first polygon is the main outline, next are holes
 // One cannot know the initial zone outline.
 // However most of (if not all) holes are just items with clearance,
 // not really a hole in the initial zone outline.
 // So we build a zone outline only with no hole.
 fprintf( m_fp, " (polygon\n (pts" );
 
 SHAPE_LINE_CHAIN& poly = polys.Outline( 0 );
 
 #define MAX_COORD_CNT 4
 int jj = MAX_COORD_CNT;
 int cnt_max = poly.PointCount() -1;
 
 // Do not generate last corner, if it is the same point as the first point:
 if( poly.CPoint( 0 ) == poly.CPoint( cnt_max ) )
 cnt_max--;
 
 for( int ii = 0; ii <= cnt_max; ii++ )
 {
 if( --jj == 0 )
 {
 jj = MAX_COORD_CNT;
 fprintf( m_fp, "\n " );
 }
 
 fprintf( m_fp, " (xy %s %s)", FormatDouble2Str( MapToPcbUnits( poly.CPoint( ii ).x ) ).c_str(),
 FormatDouble2Str( MapToPcbUnits( -poly.CPoint( ii ).y ) ).c_str() );
 }
 
 fprintf( m_fp, ")\n" );
 
 fprintf( m_fp, " )\n)\n" );
}