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sorry to get in on this thread so late (i did try dave's tiler, it works great, but the version i have only allows for tiling to 6 zoom levels), I've been using tilecache with manifold wms, and after following all the optimizing performance tips to the letter, I've got a workable system, although there still appears to be a problem with manifold and/or iis. for my sites, i take a two fold approach (i will be posting a permanent demo site soon), i pre-seed the cache with tiles ( are people who are using tilecache (which is great by the way!) aware that there is already a script to do this?) for the first couple of zoom levels, then let manifold handle the image production as people zoom in. this works great because the tiles with lots of data take longer to render, and thankfully, for me, they're also usually the tiles you see when zoomed out, so there arent that many to generate. generating a complete tile set beforehand would take too long, so this way, i can handle the majority of requests before hand, then let manifold file in tiles slowly for the zoom levels that have tons of tiles. and now to the problem, when iis is fresh, or right after an app pool recycle, the worker processes and manifold seem to be able to handle all of the concurrent wms requests, but as time goes by, sometimes the processes go "bad" somehow, because some of the requests will be successful, and others will return the error i mention here (can't create mapserver) (http://forum.manifold.net/forum/t74325.10) to get around this, i wrote the app i mentioned at the bottom of the page, it tests if the worker processes are behaving, otherwise, recycles them. anyways, I generally don't have a problem using the tilecache seed script, perhaps because it never makes concurrent requests, but in any case, you can use to create a tileset for google maps, etc- I'm not sure where this leaves dave's tiler, i imagine his probably goes much faster than making wms requests...
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