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Extension cable checks March 2011
How: 
Unzip Dyconex files from here:

Extension Cable Design Files From Dyconex February 22, 2011
to www/phenix/fvtx/construction/cabes/feb11/, this makes subdirs 
380437-440 through 380449-452, and single-cable subdirs 380437a-380452a 
below that.

Use the gerbv Gerber viewer, turn on the surface pad and outline layers,
export as 3201-3504.pdf. This is done at 400 dpi, or 157.48 px/cm.
 
Open Hytec cable drawings, from
Release Drawing Packages of Extension Cables (10-September-2010) 
Unzip to www/phenix/fvtx/construction/cables/feb11/hytec/

This makes many files per cables, I use
'111-PHX-02-3xxx - Check Plots - 6 To 1 Scale.pdf', sheet #8, and import 
at 400 dpi.

Overlay top left, check perimeter, and go to bottom right.
Overlay the plots. In this image, the gerber background is orange, the connecter pads are yellow, and the outline is in light gray. The Hitec overlay has black outline, and green pads.

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The images are matched on the top right. Here I cut away a corner from the Hytec overlay. You can see the perfect alignment of the gray and black outlines, and the way the pads line up. This is the HDI end. The HDI's connectors are male, and have a narrow width (4mm) footprint. The matching female connectors on the extension cable are wider (5 mm). These wide footprints appear on both the Gerber and the Hytec versions.

Bigger →

On the bottom right, you can see that the mechanical outlines match up perfectly, but the Hytec drawing has the wide (female, green) connector footprint drawn, whereas the Gerber (yellow) has the male (narrow footprint), which is correct.

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The connector pairs are either on the same side or opposite side of the cable, and when the cable makes the 90° turn onto the ROC surface, it makes a jog to the left or the right. There is the possibility of a mirror-image error. Here I check for that.

Type (1A-2B) is how the cables can be identified in the 3D model. Gerber is the gerber files directory, e.g. 437 = 380437a. Disk is position on the disk. Opp/same is whether the connector pairs are on the same or opposite side of the cable. Orientation checks for mirror image problems. Outline overlays Gerber with Hytec.

# typegerberdiskopp/same orientation outline
3201 1A 437 front neutral->ok ok ok
3202 2A 438 back same ok ok ok
3203 1B 439 front neutral->ok ok ok
3204 2B 440 back same ok ok ok
3301 1A 441 front opp. ok ok ok
3302 2A 442 back same ok ok ok
3303 1B 443 front opp. ok ok [1 px long]
3304 2B 444 back same ok ok [2 px long]
3401 1A 445 front opp. ok ok OK
3402 2A 446 back same ok ok [1 px short]
3403 1B 447 front opp. ok ok [1 px long]
3404 2B 448 back same ok ok [1 px long]
3501 1A 449 front opp. ok ok ok
3502 2A 450 back same ok ok [2 px short]
3503 1B 451 front opp. ok ok ok
3504 2B 452 back same ok ok ok


The Gerber file for 3401 will not produce a pdf that contains the outline. However, the connector pads line up OK with those of the Hytec drawing.
1 pixel is 1/400th" or 0.063 mm, and we ignore 1-2 pixels. So all cables are OK now, mechanically.
Hubert van Hecke
Last modified: Mon Mar 7 10:51:10 MST 2011