janik
e7627352c1
- Refuse the uniform contact model when the fills form multiple disconnected copper groups that each touch both terminals: the prescribed injection split is ill-posed and the grounded system was singular, silently returning garbage (e.g. negative gigaohms). connected_restrict now reports the component count; a power-balance backstop (SolverError) catches any other inconsistent solve. - Connect via/pad barrels to the nearest fill copper within the pad footprint (+1 cell) instead of only the exact center cell, so thermal-relief spokes still stitch layers; barrels that reach fill on fewer than two layers are warned about. ViaLink gains pad_nm (extracted from the padstack, JSON-roundtripped). - Validate dialog input on OK (layers, current > 0, cell > 0, parseable frequency, extra Cu >= 0) with an inline error instead of silently substituting defaults; parse_frequency raises on garbage; pipeline rejects i_test <= 0; choose_cell_size rejects non-positive overrides. - Warn when a contact part is dropped by the connectivity restriction; floor instead of truncate in cell_of; correct the uniform-model summary line; drop an unused variable; refresh plugin.json wording. Co-Authored-By: Claude Fable 5 <noreply@anthropic.com>
187 lines
7.7 KiB
Python
187 lines
7.7 KiB
Python
"""Multi-layer / via solver tests. The 1-cell-wide strip cases are pure
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series chains, so the discrete solution is exact and validates the via
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barrel model, layer coupling, and flux integration to solver precision."""
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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.errors import ConnectivityError, ElectrodeError
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from tests.util import NM, make_multilayer, sigma_s
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def _solve(problem, h_mm, i_test=1.0):
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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, i_test,
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contact_model="equipotential"), stack
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STRIP = [(0, 0), (10, 0), (10, 1), (0, 1)] # 10 x 1 mm; h=1 -> 1 row
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def _r_via(length_mm, drill_mm=0.3, plating_um=18.0, rho=1.68e-8):
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area = math.pi * (drill_mm * 1e-3) * (plating_um * 1e-6)
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return rho * (length_mm * 1e-3) / area
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def test_two_identical_layers_parallel():
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"""Both electrodes contact both layers, no vias needed: two identical
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independent sheets in parallel -> exactly half the single-layer R."""
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one = make_multilayer([[(STRIP, [])]], (0, 0, 1, 1), (9, 0, 10, 1))
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two = make_multilayer([[(STRIP, [])], [(STRIP, [])]],
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(0, 0, 1, 1), (9, 0, 10, 1))
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r1, _ = _solve(one, 1.0)
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r2, _ = _solve(two, 1.0)
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assert r2.R_ohm == pytest.approx(r1.R_ohm / 2, rel=1e-9)
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def test_via_chain_1d_exact():
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"""e1 on L0 left end, e2 on L1 right end, one through-via at x=5.5:
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R = faces_L0/sigma + R_via + faces_L1/sigma, exact."""
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p = make_multilayer(
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[[(STRIP, [])], [(STRIP, [])]],
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rect1_mm=(0, 0, 1, 1), rect2_mm=(9, 0, 10, 1),
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contact1="L0", contact2="L1",
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vias_mm=[(5.5, 0.5)], gap_mm=1.0)
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res, stack = _solve(p, 1.0)
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# cells at x centers 0.5..9.5 -> cols 0..9 (plus margins); electrode
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# cells: col of 0.5 (e1), col of 9.5 (e2); via cell: col of 5.5
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sig = sigma_s()
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faces_l0 = 5 # cols 0->5: faces between 0|1 .. 4|5
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faces_l1 = 4 # cols 5->9
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r_exact = (faces_l0 + faces_l1) / sig + _r_via(1.0)
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assert res.R_ohm == pytest.approx(r_exact, rel=1e-9)
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assert res.mismatch_rel < 1e-10
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assert len(res.via_reports) == 1
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# the single via carries the full test current
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assert res.via_reports[0].current_a == pytest.approx(1.0, rel=1e-9)
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assert res.via_reports[0].power_w == pytest.approx(_r_via(1.0), rel=1e-9)
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def test_parallel_vias_halve_barrel_resistance():
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base = dict(rect1_mm=(0, 0, 1, 1), rect2_mm=(9, 0, 10, 1),
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contact1="L0", contact2="L1", gap_mm=1.0)
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one = make_multilayer([[(STRIP, [])], [(STRIP, [])]],
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vias_mm=[(5.5, 0.5)], **base)
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two = make_multilayer([[(STRIP, [])], [(STRIP, [])]],
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vias_mm=[(5.5, 0.5), (5.5, 0.5)], **base)
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r_one, _ = _solve(one, 1.0)
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r_two, _ = _solve(two, 1.0)
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assert (r_one.R_ohm - r_two.R_ohm) == pytest.approx(_r_via(1.0) / 2,
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rel=1e-9)
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def test_antipad_bridging():
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"""3 layers; the middle layer has an antipad hole at the via, WIDER
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than the barrel connection search (pad footprint + 1 cell), so the
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barrel bridges L0 -> L2 directly with DOUBLE the length."""
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mid_with_hole = [(STRIP, [[(4, 0), (7, 0), (7, 1), (4, 1)]])]
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p = make_multilayer(
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[[(STRIP, [])], mid_with_hole, [(STRIP, [])]],
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rect1_mm=(0, 0, 1, 1), rect2_mm=(9, 0, 10, 1),
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contact1="L0", contact2="L2",
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vias_mm=[(5.5, 0.5)], gap_mm=1.0)
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res, _ = _solve(p, 1.0)
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sig = sigma_s()
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r_exact = (5 + 4) / sig + _r_via(2.0) # barrel length 2 mm
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assert res.R_ohm == pytest.approx(r_exact, rel=1e-9)
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def test_thermal_gap_via_connects_to_nearby_copper():
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"""The cell under the via is not copper (thermal-relief knockout),
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but fill copper within the pad footprint (+1 cell) still reaches the
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barrel: the link lands on the nearest copper cell instead of being
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silently dropped."""
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top_with_gap = [(STRIP, [[(5, 0), (7, 0), (7, 1), (5, 1)]])]
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p = make_multilayer(
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[top_with_gap, [(STRIP, [])]],
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rect1_mm=(0, 0, 1, 1), rect2_mm=(9, 0, 10, 1),
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contact1="L0", contact2="L1",
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vias_mm=[(5.5, 0.5)], gap_mm=1.0)
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res, _ = _solve(p, 1.0)
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sig = sigma_s()
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# L0 attaches at col 4 (nearest copper, 1.0 mm from the barrel),
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# L1 at col 5: 4 faces on L0, the barrel, 4 faces on L1 - exact
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r_exact = (4 + 4) / sig + _r_via(1.0)
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assert res.R_ohm == pytest.approx(r_exact, rel=1e-9)
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assert len(res.via_reports) == 1
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assert res.via_reports[0].current_a == pytest.approx(1.0, rel=1e-9)
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def test_dead_barrel_is_warned(capsys):
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"""A via isolated from the fill by an antipad wider than the search
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radius on all but one layer carries nothing and is reported."""
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bot_with_hole = [(STRIP, [[(3, 0), (8, 0), (8, 1), (3, 1)]])]
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p = make_multilayer(
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[[(STRIP, [])], bot_with_hole],
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rect1_mm=(0, 0, 1, 1), rect2_mm=(9, 0, 10, 1),
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contact1="L0", contact2="L0",
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vias_mm=[(5.5, 0.5)], gap_mm=1.0)
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res, _ = _solve(p, 1.0)
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sig = sigma_s()
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assert res.R_ohm == pytest.approx(9 / sig, rel=1e-9) # L0 alone
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assert res.via_reports == []
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assert "carry no current" in capsys.readouterr().out
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def test_via_short_between_electrodes_raises():
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"""Both electrodes over the SAME cell on different layers with a via
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there = direct short, no free copper -> error."""
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p = make_multilayer(
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[[(STRIP, [])], [(STRIP, [])]],
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rect1_mm=(5, 0, 6, 1), rect2_mm=(5, 0, 6, 1),
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contact1="L0", contact2="L1",
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vias_mm=[(5.5, 0.5)], gap_mm=1.0)
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stack = raster.rasterize_stack(p, 1.0 * NM)
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e1, e2 = raster.electrode_masks(stack, p)
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with pytest.raises(ElectrodeError, match="directly connected"):
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solver.run_solve(p, stack, e1, e2, 1.0,
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contact_model="equipotential")
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def test_layers_without_via_disconnected():
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p = make_multilayer(
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[[(STRIP, [])], [(STRIP, [])]],
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rect1_mm=(0, 0, 1, 1), rect2_mm=(9, 0, 10, 1),
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contact1="L0", contact2="L1", gap_mm=1.0) # no vias
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stack = raster.rasterize_stack(p, 1.0 * NM)
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e1, e2 = raster.electrode_masks(stack, p)
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with pytest.raises(ConnectivityError, match="not connected"):
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solver.run_solve(p, stack, e1, e2, 1.0,
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contact_model="equipotential")
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def test_power_split_layers_and_vias():
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"""Power accounting: layer + via powers sum to I^2 R."""
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p = make_multilayer(
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[[(STRIP, [])], [(STRIP, [])]],
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rect1_mm=(0, 0, 1, 1), rect2_mm=(9, 0, 10, 1),
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contact1="L0", contact2="L1",
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vias_mm=[(5.5, 0.5)], gap_mm=1.0)
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res, _ = _solve(p, 1.0, i_test=10.0)
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assert res.power_balance_rel < 1e-9
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assert res.P_vias == pytest.approx(100 * _r_via(1.0), rel=1e-9)
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sig = sigma_s()
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assert res.P_layers[0] == pytest.approx(100 * 5 / sig, rel=1e-9)
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assert res.P_layers[1] == pytest.approx(100 * 4 / sig, rel=1e-9)
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def test_pad_polygon_electrode():
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"""A polygon-shaped electrode (pad) restricted to one layer."""
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from fill_resistance.geometry import Electrode, Polygon
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from tests.util import rect_mm, ring_mm
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p = make_multilayer([[(STRIP, [])]], (0, 0, 1, 1), (9, 0, 10, 1))
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# replace terminal 1 with a small polygon pad covering the same cell
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p.electrodes1 = [Electrode(
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rect=rect_mm((0.2, 0.2, 0.8, 0.8)),
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contact="all",
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polygons=[Polygon(outline=ring_mm(
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[(0.2, 0.2), (0.8, 0.2), (0.8, 0.8), (0.2, 0.8)]))],
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label="pad TP1.1",
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)]
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res, _ = _solve(p, 1.0)
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sig = sigma_s()
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assert res.R_ohm == pytest.approx(9 / sig, rel=1e-9) # cols 0..9
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