Include the net's traces as conductors alongside zone fills
Straight tracks become capsule outline polygons (rectangle + semicircular caps), arc tracks annular bands with end caps, both tessellated to the same sagitta tolerance as zone-fill arcs; they merge into the per-layer copper next to the fills, so rasterization, via stitching, the solver and the plots handle them unchanged. Trace-only layers and trace-only nets now qualify as candidates. Dialog checkbox (on by default, INCLUDE_TRACKS) toggles them per run. Hole-less polygons (every track outline) now paint the layer mask directly instead of allocating a full-frame temporary each. Tests: exact N-cell chain on a rasterized capsule, analytic annular- sector convergence for an arc trace, capsule/arc-band outline geometry invariants, collinear-arc degradation, and fill+trace union solve. Co-Authored-By: Claude Fable 5 <noreply@anthropic.com>
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janik
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"""Track (trace) conductor tests: capsule / arc-band outline generation
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and solves on rasterized traces. The 1-cell-wide capsule chain is exact;
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the arc band is checked against the analytic annular-sector resistance."""
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import math
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import numpy as np
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import pytest
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from fill_resistance import raster, solver
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from fill_resistance.geometry import (Electrode, LayerFill, Polygon, Problem,
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arc_band_ring, capsule_ring)
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from tests.util import NM, rect_mm, sigma_s
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TOL_NM = 10_000
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def _track_problem(rings, rect1, rect2, t_um=70.0):
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return Problem(
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board_path="synthetic", net_name="TEST", rho_ohm_m=1.68e-8,
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plating_nm=18_000,
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layers=[LayerFill(layer_name="F.Cu", thickness_nm=int(t_um * 1000),
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z_nm=0,
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polygons=[Polygon(outline=r) for r in rings])],
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vias=[],
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electrodes1=[Electrode(rect=rect_mm(rect1))],
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electrodes2=[Electrode(rect=rect_mm(rect2))],
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)
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def _solve(problem, h_mm):
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stack = raster.rasterize_stack(problem, h_mm * NM)
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e1, e2 = raster.electrode_masks(stack, problem)
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return solver.run_solve(problem, stack, e1, e2, 1.0,
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contact_model="equipotential"), stack
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def test_straight_track_exact_chain():
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"""A 1.2 mm wide capsule at h = 1 mm rasterizes to a single-cell-high
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row (the grid origin floats with the polygon bbox, so the count is
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taken from the mask): an N-cell chain solves to exactly (N-1) faces."""
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ring = capsule_ring(1 * NM, NM // 2, 9 * NM, NM // 2,
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int(1.2 * NM), TOL_NM)
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p = _track_problem([ring], (0, 0, 1.5, 1), (8.5, 0, 10, 1))
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res, stack = _solve(p, 1.0)
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m = stack.masks[0]
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rows = np.flatnonzero(m.any(axis=1))
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assert len(rows) == 1 # one 1-cell-high chain
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n = int(m.sum())
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assert n >= 8
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assert res.R_ohm == pytest.approx((n - 1) / sigma_s(), rel=1e-9)
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def test_capsule_zero_length_is_circle():
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ring = capsule_ring(5 * NM, 5 * NM, 5 * NM, 5 * NM, 2 * NM, TOL_NM)
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d = np.hypot(ring[:, 0] - 5 * NM, ring[:, 1] - 5 * NM)
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assert np.allclose(d, NM, atol=TOL_NM + 2)
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assert len(ring) >= 8
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def test_capsule_ring_geometry():
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"""Every outline point lies on the capsule boundary: at half-width
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from the centerline segment."""
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ring = capsule_ring(2 * NM, 3 * NM, 17 * NM, 11 * NM,
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int(1.5 * NM), TOL_NM)
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a = np.array([2 * NM, 3 * NM], dtype=float)
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b = np.array([17 * NM, 11 * NM], dtype=float)
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ab = b - a
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t = np.clip(((ring - a) @ ab) / (ab @ ab), 0.0, 1.0)
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d = np.hypot(*(ring - (a + t[:, None] * ab)).T)
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assert np.allclose(d, 0.75 * NM, atol=TOL_NM + 2)
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def test_arc_band_ring_geometry():
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"""Arc-band points lie on the annulus walls or on the end caps."""
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start, mid, end = ((10 * NM, 0), (int(10 * NM / math.sqrt(2)),
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int(10 * NM / math.sqrt(2))),
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(0, 10 * NM))
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ring = arc_band_ring(start, mid, end, 1 * NM, TOL_NM).astype(float)
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r = np.hypot(ring[:, 0], ring[:, 1])
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on_annulus = (np.abs(r - 10.5 * NM) < TOL_NM + 2) \
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| (np.abs(r - 9.5 * NM) < TOL_NM + 2)
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d_start = np.hypot(ring[:, 0] - start[0], ring[:, 1] - start[1])
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d_end = np.hypot(ring[:, 0] - end[0], ring[:, 1] - end[1])
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on_caps = (d_start < 0.5 * NM + TOL_NM + 2) | (d_end < 0.5 * NM + TOL_NM + 2)
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assert (on_annulus | on_caps).all()
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def test_collinear_arc_degrades_to_capsule():
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cap = capsule_ring(0, 0, 10 * NM, 0, NM, TOL_NM)
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band = arc_band_ring((0, 0), (5 * NM, 0), (10 * NM, 0), NM, TOL_NM)
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assert np.array_equal(cap, band)
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def test_arc_track_matches_annular_sector():
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"""90 deg arc trace, r = 10 mm, w = 1 mm: R = theta / (sigma *
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ln(r_out/r_in)) between the radial end faces (electrodes cover the
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end caps). The staircase on the curved walls narrows the band, so R
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converges to the analytic value from above as h shrinks."""
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start = (10 * NM, 0)
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mid = (int(round(10 * NM / math.sqrt(2))),
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int(round(10 * NM / math.sqrt(2))))
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end = (0, 10 * NM)
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ring = arc_band_ring(start, mid, end, 1 * NM, TOL_NM)
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def solve_at(h_mm):
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p = _track_problem([ring], rect1=(9.3, -0.8, 10.7, 0.05),
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rect2=(-0.8, 9.3, 0.05, 10.7))
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res, _ = _solve(p, h_mm)
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return res.R_ohm
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r_exact = (math.pi / 2) / (sigma_s() * math.log(10.5 / 9.5))
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err_coarse = abs(solve_at(0.1) / r_exact - 1)
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err_fine = abs(solve_at(0.05) / r_exact - 1)
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assert err_fine < err_coarse # converges toward analytic
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assert err_fine < 0.04
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def test_track_unions_with_fill():
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"""A trace overlapping a plate merges into one conductor: the mask is
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the union, and R drops when the trace bridges a slot."""
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plate = [(0, 0), (20, 0), (20, 10), (0, 10)]
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slot = [(9, 2), (11, 2), (11, 10), (9, 10)] # slot open to the top
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plate_poly = Polygon(
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outline=np.array([(x * NM, y * NM) for x, y in plate]),
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holes=[np.array([(x * NM, y * NM) for x, y in slot])])
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bridge = capsule_ring(6 * NM, 6 * NM, 14 * NM, 6 * NM,
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int(1.2 * NM), TOL_NM)
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def problem(polys):
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return Problem(
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board_path="synthetic", net_name="TEST", rho_ohm_m=1.68e-8,
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plating_nm=18_000,
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layers=[LayerFill(layer_name="F.Cu", thickness_nm=70_000,
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z_nm=0, polygons=polys)],
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vias=[],
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electrodes1=[Electrode(rect=rect_mm((0, 0, 1, 10)))],
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electrodes2=[Electrode(rect=rect_mm((19, 0, 20, 10)))],
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)
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r_plate, s_plate = _solve(problem([plate_poly]), 0.25)
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r_both, s_both = _solve(problem([plate_poly,
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Polygon(outline=bridge)]), 0.25)
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assert int(s_both.masks.sum()) > int(s_plate.masks.sum())
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assert r_both.R_ohm < 0.75 * r_plate.R_ohm # bridge shortens the detour
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assert r_both.power_balance_rel < 1e-9
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