Initial import: KiCad zone resistance plugin
DC/AC resistance, power dissipation, and via/injection-area currents of copper zone fills. KiCad 10 IPC-API plugin (kicad-python/kipy): multi-layer via-coupled FDM solver, multi-part terminals via User.1/User.2 marker layers, pads as contacts, uniform-injection and equipotential contact models, per-foil skin effect, optional solder/copper buildup on mask openings. 54-case test suite incl. exact analytic references. Co-Authored-By: Claude Fable 5 <noreply@anthropic.com>
This commit is contained in:
janik
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"""Figures: per-layer rasterized maps, potential, current density, power
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density, and the error figure. PNGs are saved BEFORE any window opens.
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Backend: interactive if a GUI toolkit exists (tkinter, else Qt), else Agg
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with os.startfile on the saved PNGs so results are never silent.
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"""
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from __future__ import annotations
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import os
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import textwrap
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from pathlib import Path
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import matplotlib
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import numpy as np
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def _pick_backend():
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"""matplotlib.use() is lazy and 'succeeds' for backends whose GUI
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toolkit is missing (KiCad's Python has no tkinter), so probe the
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toolkits explicitly."""
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try:
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import tkinter # noqa: F401
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return "TkAgg"
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except Exception:
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pass
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for qt in ("PySide6", "PyQt6", "PyQt5", "PySide2"):
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try:
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__import__(qt)
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return "QtAgg" if qt in ("PySide6", "PyQt6") else "Qt5Agg"
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except Exception:
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continue
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return None
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INTERACTIVE_BACKEND = _pick_backend()
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matplotlib.use(INTERACTIVE_BACKEND or "Agg")
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import matplotlib.pyplot as plt # noqa: E402 (after backend selection)
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from matplotlib.colors import ListedColormap, LogNorm # noqa: E402
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from matplotlib.patches import Patch # noqa: E402
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from . import config # noqa: E402
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_BG = "#f5f3f0"
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_COPPER = "#c98b4e"
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_E1_COLOR = "#c8385a"
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_E2_COLOR = "#2f6fb0"
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_VIA_COLOR = "#2d6b45"
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_SOLDER = "#9aa3ad" # tin-gray: solder buildup areas
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_INK = "#3a3a3a"
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_GRID_INK = "#b8b4ae"
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def _fmt_si(value: float, unit: str) -> str:
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for scale, prefix in ((1.0, ""), (1e-3, "m"), (1e-6, "µ")):
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if abs(value) >= scale:
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return f"{value / scale:.4g} {prefix}{unit}"
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return f"{value:.3g} {unit}"
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def _suptitle(problem, stack, result=None) -> str:
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ny, nx = stack.shape2d
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parts = []
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if result is not None:
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parts.append(f"R = {result.R_ohm * 1000:.4g} mΩ")
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parts.append(f"P = {_fmt_si(result.P_total, 'W')} @ "
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f"{result.i_test:g} A")
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if result.freq_hz > 0:
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parts.append(f"f = {result.freq_hz / 1e3:g} kHz "
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f"(δ={result.skin_depth_um:.0f} µm, lower bound)")
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parts.append(problem.net_name)
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parts.append(f"{nx}×{ny}×{stack.nlayers} @ {stack.h_nm / 1000:.0f} µm")
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return " | ".join(parts)
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def _layer_fig(stack, window_title: str):
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L = stack.nlayers
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ny, nx = stack.shape2d
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aspect = ny / nx
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w = 9.5
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row_h = min(max(w * aspect * 0.9 + 0.6, 1.8), 8.5 / L)
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fig, axes = plt.subplots(L, 1, figsize=(w, row_h * L + 1.4),
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sharex=True, sharey=True, squeeze=False)
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axes = axes[:, 0]
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if INTERACTIVE_BACKEND:
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fig.canvas.manager.set_window_title(window_title)
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for ax, name in zip(axes, stack.layer_names):
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ax.set_ylabel(f"{name}\ny [mm]", fontsize=8)
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ax.tick_params(colors=_INK, labelsize=8)
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for s in ax.spines.values():
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s.set_color(_GRID_INK)
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axes[-1].set_xlabel("x [mm]")
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return fig, axes
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def _electrode_labels(ax, stack, e1_l, e2_l):
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"""Label each connected contact part (multi-part terminals get one
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label per island, largest first, up to 4)."""
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from scipy import ndimage
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for e, label, color in ((e1_l, "V+", _E1_COLOR), (e2_l, "V−", _E2_COLOR)):
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if not e.any():
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continue
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labels, n = ndimage.label(e)
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sizes = ndimage.sum_labels(np.ones_like(labels), labels,
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range(1, n + 1))
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order = np.argsort(sizes)[::-1][:4] + 1
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for comp in order:
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ii, jj = np.nonzero(labels == comp)
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cx = (stack.x0_nm + (jj.mean() + 0.5) * stack.h_nm) * 1e-6
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cy = (stack.y0_nm + (ii.mean() + 0.5) * stack.h_nm) * 1e-6
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ax.annotate(label, (cx, cy), xytext=(0, 0),
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textcoords="offset points", color="white",
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fontsize=9, fontweight="bold", ha="center",
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va="center",
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bbox=dict(boxstyle="round,pad=0.2", fc=color,
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ec="none", alpha=0.9))
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def _via_markers(ax, problem, layer):
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xs = [v.x * 1e-6 for v in problem.vias if v.spans(layer.z_nm)]
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ys = [v.y * 1e-6 for v in problem.vias if v.spans(layer.z_nm)]
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if xs:
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ax.plot(xs, ys, ".", ms=2.5, color=_VIA_COLOR, alpha=0.7)
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def area_tag(sign: str, index: int) -> str:
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"""Short injection-area tag: P1, P2, ... for V+; N1, N2, ... for V-."""
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return f"{'P' if sign == '+' else 'N'}{index + 1}"
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def _injection_area_labels(ax, li, layer_name, problem, result):
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"""Mark every injection area with its short tag (currents live in
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the legend)."""
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groups = ((problem.electrodes1, "+", _E1_COLOR),
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(problem.electrodes2, "-", _E2_COLOR))
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for parts, sign, color in groups:
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for i, el in enumerate(parts):
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if el.contact != "all" and el.contact != layer_name:
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continue
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cx = (el.rect.x0 + el.rect.x1) / 2e6
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cy = (el.rect.y0 + el.rect.y1) / 2e6
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ax.annotate(area_tag(sign, i), (cx, cy), xytext=(0, 0),
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textcoords="offset points", color="white",
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fontsize=8, fontweight="bold", ha="center",
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va="center",
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bbox=dict(boxstyle="round,pad=0.15", fc=color,
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ec="none", alpha=0.9))
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def fig_raster(stack, e1, e2, problem, result=None):
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fig, axes = _layer_fig(stack, "Fill Resistance - rasterized map")
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cmap = ListedColormap([_BG, _COPPER, _E1_COLOR, _E2_COLOR, _SOLDER])
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has_buildup = stack.buildup is not None and stack.buildup.any()
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for li, ax in enumerate(axes):
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codes = np.zeros(stack.shape2d, dtype=np.uint8)
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codes[stack.masks[li]] = 1
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if has_buildup:
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codes[stack.buildup[li]] = 4
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codes[e1[li]] = 2
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codes[e2[li]] = 3
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ax.imshow(codes, cmap=cmap, vmin=0, vmax=4, origin="upper",
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extent=stack.extent_mm(), interpolation="nearest")
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_via_markers(ax, problem, problem.layers[li])
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if result is not None and (result.part_currents1
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or result.part_currents2):
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_injection_area_labels(ax, li, stack.layer_names[li], problem,
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result)
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else:
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_electrode_labels(ax, stack, e1[li], e2[li])
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handles = [Patch(fc=_COPPER, label="copper"),
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Patch(fc=_VIA_COLOR, label="vias")]
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if has_buildup:
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handles.append(Patch(
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fc=_SOLDER,
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label=f"solder buildup "
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f"({problem.solder_thickness_nm / 1000:.0f} µm"
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+ (f" + {problem.extra_cu_nm / 1000:.0f} µm Cu"
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if problem.extra_cu_nm else "") + ")"))
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if result is not None and (result.part_currents1
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or result.part_currents2):
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entries = ([("+", _E1_COLOR, i, amps)
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for i, (_, amps) in enumerate(result.part_currents1)]
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+ [("-", _E2_COLOR, i, amps)
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for i, (_, amps) in enumerate(result.part_currents2)])
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shown = entries[:14]
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for sign, color, i, amps in shown:
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handles.append(Patch(
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fc=color,
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label=f"{area_tag(sign, i)}: {amps:.3g} A "
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f"({100 * amps / result.i_test:.0f}%)"))
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if len(entries) > len(shown):
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handles.append(Patch(fc="#00000000",
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label=f"... +{len(entries) - len(shown)} "
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f"more in summary.txt"))
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else:
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handles += [Patch(fc=_E1_COLOR, label="V+"),
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Patch(fc=_E2_COLOR, label="V−")]
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axes[0].legend(handles=handles, loc="upper right", fontsize=7,
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framealpha=0.9)
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fig.suptitle("Rasterized fill + electrodes | "
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+ _suptitle(problem, stack, result), fontsize=10, color=_INK)
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fig.tight_layout()
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return fig
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def fig_potential(result, stack, e1, e2, problem):
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fig, axes = _layer_fig(stack, "Fill Resistance - potential")
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vmax = float(np.nanmax(result.V))
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unit, scale = ("mV", 1e3) if vmax < 0.1 else ("V", 1.0)
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cmap = matplotlib.colormaps[config.CMAP_POTENTIAL].copy()
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cmap.set_bad(_BG)
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im = None
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for li, ax in enumerate(axes):
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vs = result.V[li] * scale
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im = ax.imshow(vs, cmap=cmap, vmin=0, vmax=vmax * scale,
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origin="upper", extent=stack.extent_mm(),
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interpolation="nearest")
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if np.isfinite(vs).sum() > 4:
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ext = stack.extent_mm()
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ny, nx = stack.shape2d
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xs = np.linspace(ext[0], ext[1], nx, endpoint=False)
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xs += (xs[1] - xs[0]) / 2
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ys = np.linspace(ext[3], ext[2], ny, endpoint=False)
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ys += (ys[1] - ys[0]) / 2
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with np.errstate(invalid="ignore"):
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ax.contour(xs, ys, vs, levels=15, colors="white",
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linewidths=0.4, alpha=0.5)
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_electrode_labels(ax, stack, e1[li], e2[li])
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cb = fig.colorbar(im, ax=axes, shrink=0.85)
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cb.set_label(f"potential [{unit}] @ {result.i_test:g} A", fontsize=9)
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fig.suptitle("Potential | " + _suptitle(problem, stack, result),
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fontsize=10, color=_INK)
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return fig
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def _field_fig(result, stack, e1, e2, problem, data3, cmap_name, dyn_range,
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label, title, window):
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"""Shared per-layer LogNorm field figure (current, power)."""
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fig, axes = _layer_fig(stack, window)
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vmax = float(np.nanmax(data3))
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cmap = matplotlib.colormaps[cmap_name].copy()
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cmap.set_bad(_BG)
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if config.LOG_CURRENT_SCALE and vmax > 0:
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norm = LogNorm(vmin=vmax / dyn_range, vmax=vmax)
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else:
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norm = None
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im = None
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for li, ax in enumerate(axes):
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d = data3[li]
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shown = np.clip(d, vmax / dyn_range, None) if norm is not None else d
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im = ax.imshow(shown, cmap=cmap, norm=norm, origin="upper",
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extent=stack.extent_mm(), interpolation="nearest")
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_electrode_labels(ax, stack, e1[li], e2[li])
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if vmax > 0:
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li, i, j = np.unravel_index(np.nanargmax(data3), data3.shape)
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mx = (stack.x0_nm + (j + 0.5) * stack.h_nm) * 1e-6
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my = (stack.y0_nm + (i + 0.5) * stack.h_nm) * 1e-6
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axes[li].plot(mx, my, "o", ms=9, mfc="none", mec="white", mew=1.4)
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axes[li].annotate(f"max {vmax:.3g}", (mx, my), xytext=(10, -10),
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textcoords="offset points", color="white",
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fontsize=8,
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bbox=dict(boxstyle="round,pad=0.2", fc="#00000088",
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ec="none"))
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cb = fig.colorbar(im, ax=axes, shrink=0.85)
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cb.set_label(label, fontsize=9)
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fig.suptitle(title + " | " + _suptitle(problem, stack, result),
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fontsize=10, color=_INK)
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return fig, axes
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def fig_current(result, stack, e1, e2, problem):
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fig, axes = _field_fig(
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result, stack, e1, e2, problem, result.Jmag * 1e-6,
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config.CMAP_CURRENT, config.CURRENT_DYNAMIC_RANGE,
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f"|J| [A/mm²] @ {result.i_test:g} A",
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"Current density (log)", "Fill Resistance - current density")
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# mark the hottest via
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if result.via_reports:
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v = result.via_reports[0]
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for ax in axes:
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ax.plot(v.x_mm, v.y_mm, "s", ms=7, mfc="none", mec="#7fe0a8",
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mew=1.2)
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axes[0].annotate(
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f"hottest via {v.current_a:.3g} A", (v.x_mm, v.y_mm),
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xytext=(10, 10), textcoords="offset points", color="white",
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fontsize=8,
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bbox=dict(boxstyle="round,pad=0.2", fc="#2d6b45", ec="none"))
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return fig
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def fig_power(result, stack, e1, e2, problem):
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# W/m^2 -> W/mm^2
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fig, axes = _field_fig(
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result, stack, e1, e2, problem, result.Parea * 1e-6,
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config.CMAP_POWER, config.POWER_DYNAMIC_RANGE,
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f"p [W/mm²] @ {result.i_test:g} A",
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"Power density (log)", "Fill Resistance - power density")
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for li, ax in enumerate(axes):
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ax.set_title(f"P({stack.layer_names[li]}) = "
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f"{_fmt_si(result.P_layers[li], 'W')}",
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fontsize=8, color=_INK, loc="right", pad=2)
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return fig
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def fig_error(message: str):
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fig, ax = plt.subplots(figsize=(9, 4.5))
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ax.axis("off")
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ax.set_title("Fill Resistance — ERROR", color="#b02a2a",
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fontsize=14, fontweight="bold", loc="left")
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wrapped = "\n".join(
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textwrap.fill(line, width=90) for line in message.splitlines()
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)
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ax.text(0.0, 0.95, wrapped, family="monospace", fontsize=9,
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va="top", ha="left", color=_INK, transform=ax.transAxes)
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fig.tight_layout()
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return fig
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def _resolve_label_overlaps(fig):
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"""Measure every annotation's rendered box and greedily push
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overlapping labels upward until nothing collides. Runs on the real
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renderer, so it handles any font/DPI."""
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from matplotlib.text import Annotation
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try:
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fig.canvas.draw()
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renderer = fig.canvas.get_renderer()
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except Exception:
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return
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for ax in fig.axes:
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anns = [c for c in ax.get_children() if isinstance(c, Annotation)]
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placed = []
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for a in sorted(anns, key=lambda t: t.get_window_extent(renderer).x0):
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try:
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bb = a.get_window_extent(renderer)
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except Exception:
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continue
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guard = 50
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while guard > 0:
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hit = next((p for p in placed if bb.overlaps(p)), None)
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if hit is None:
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break
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push_px = (hit.y1 - bb.y0) + 3.0
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dx, dy = a.xyann
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a.xyann = (dx, dy + push_px * 72.0 / fig.dpi)
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bb = a.get_window_extent(renderer)
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guard -= 1
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placed.append(bb)
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def _raise_windows():
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"""Best effort: bring plot windows in front of KiCad (windows spawned
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by a background process tend to open behind)."""
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for num in plt.get_fignums():
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try:
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win = plt.figure(num).canvas.manager.window
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if hasattr(win, "attributes"): # Tk
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win.attributes("-topmost", True)
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win.after(300, lambda w=win: w.attributes("-topmost", False))
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else: # Qt
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win.raise_()
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win.activateWindow()
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except Exception:
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pass
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def save_and_show(figs_named: list[tuple], outdir: Path | None,
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show: bool = True) -> list[Path]:
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"""figs_named: [(figure, basename), ...]. Saves first, then shows."""
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saved = []
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for fig, _ in figs_named:
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_resolve_label_overlaps(fig)
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if outdir is not None:
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outdir.mkdir(parents=True, exist_ok=True)
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for fig, name in figs_named:
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p = outdir / f"{name}.png"
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fig.savefig(p, dpi=config.DPI, facecolor="white",
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bbox_inches="tight")
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saved.append(p)
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print(f"saved {p}")
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if show and config.INTERACTIVE:
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if INTERACTIVE_BACKEND:
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_raise_windows()
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plt.show()
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else:
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for p in saved:
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try:
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os.startfile(p) # windows: open in default viewer
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except Exception:
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pass
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plt.close("all")
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return saved
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Reference in New Issue
Block a user