janik
935cb2a959
The overlaid contour lines belonged on the potential plot the plugin already produces; demo-potential.png is that figure for the same demo solve. Co-Authored-By: Claude Fable 5 <noreply@anthropic.com>
318 lines
13 KiB
Python
318 lines
13 KiB
Python
"""Generate the README model figures in docs/img/.
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.venv\\Scripts\\python.exe tools\\gen_readme_figs.py
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Real solver output wherever possible: the demo-board maps (raster map
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with the adaptive mesh, current density) and the contact-model
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comparison come straight from the plugin's own pipeline on small
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synthetic boards; only the hole-anatomy cross-section is drawn by hand.
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"""
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import sys
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from pathlib import Path
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import numpy as np
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ROOT = Path(__file__).resolve().parents[1]
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sys.path.insert(0, str(ROOT))
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from fill_resistance import config # noqa: E402
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config.INTERACTIVE = False
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import matplotlib # noqa: E402
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matplotlib.use("Agg", force=True)
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from fill_resistance import plots, raster, solver # noqa: E402
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from fill_resistance.geometry import (Electrode, LayerFill, Polygon, # noqa: E402
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Problem, Rect, ViaLink,
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contact_solder_buildups)
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import matplotlib.pyplot as plt # noqa: E402
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plt.switch_backend("Agg")
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plots.INTERACTIVE_BACKEND = None # save-only: no window panels
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NM = 1_000_000
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OUT = ROOT / "docs" / "img"
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COPPER = plots._COPPER
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SOLDER = plots._SOLDER
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LEAD = "#5c6570"
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CORE = "#ccd6b3" # FR-4
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FILLER = "#eae5dc" # non-conductive via fill
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INK = plots._INK
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def _poly(pts_mm, holes_mm=()) -> Polygon:
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ring = lambda pts: np.asarray( # noqa: E731
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[[int(x * NM), int(y * NM)] for x, y in pts], dtype=np.int64)
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return Polygon(outline=ring(pts_mm),
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holes=[ring(h) for h in holes_mm])
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def _rect(x0, y0, x1, y1, layer="User.1") -> Rect:
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return Rect.normalized(int(x0 * NM), int(y0 * NM),
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int(x1 * NM), int(y1 * NM), layer)
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def _disc(x_mm, y_mm, r_mm, n=64) -> Polygon:
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ang = np.linspace(0, 2 * np.pi, n, endpoint=False)
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return _poly([(x_mm + r_mm * np.cos(a), y_mm + r_mm * np.sin(a))
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for a in ang])
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def _solve(problem, h_mm, i_test=10.0, model=None):
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stack = raster.rasterize_stack(problem, int(h_mm * NM))
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e1, e2 = raster.electrode_masks(stack, problem)
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p1, p2 = raster.electrode_partition(stack, problem)
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res = solver.run_solve(problem, stack, e1, e2, i_test,
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contact_model=model, parts1=p1, parts2=p2)
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return res, stack, e1, e2
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# --- demo board: 2 layers, notched F.Cu pour, half-size B.Cu pour, ----
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# --- a soldered THT-pad contact and a stitching-via field -------------
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def demo_problem() -> Problem:
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# F.Cu: full pour with a notch from the top edge down to y=6 - the
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# current from the left contact must squeeze through the channel
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top = _poly([(0, 0), (40, 0), (40, 22), (13, 22), (13, 6),
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(10, 6), (10, 22), (0, 22)])
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# B.Cu: pour on the right half only - vias must carry the transfer
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bot = _poly([(18, 0), (40, 0), (40, 22), (18, 22)])
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z_bot = int(1.6 * NM)
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vias = [ViaLink(x=int(x * NM), y=int(y * NM), drill_nm=300_000,
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z_top_nm=-1, z_bot_nm=z_bot + 1, pad_nm=600_000)
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for x in (20.5, 24.5, 28.5, 32.5, 36) for y in (3, 7, 11, 15, 19)]
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tht = Electrode(
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rect=_rect(3.4, 9.9, 5.6, 12.1), contact="F.Cu",
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label="THT pad (4.5, 11)", drill_nm=1_000_000,
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pad_nm=int(2.2 * NM), pad_min_nm=int(2.2 * NM),
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center=(int(4.5 * NM), int(11 * NM)), solder=True,
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protrusion_side="F.Cu", polygons=[_disc(4.5, 11, 1.1)])
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lug = Electrode(rect=_rect(37.5, 3, 39.5, 19, "User.2"),
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contact="B.Cu", label="lug")
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p = Problem(
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board_path="synthetic", net_name="DEMO",
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rho_ohm_m=1.68e-8, plating_nm=18_000,
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layers=[LayerFill("F.Cu", 70_000, 0, [top]),
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LayerFill("B.Cu", 70_000, z_bot, [bot])],
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vias=vias, electrodes1=[tht], electrodes2=[lug],
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thickness_source="override")
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contact_solder_buildups(p)
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return p
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def gen_demo_maps():
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p = demo_problem()
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res, stack, e1, e2 = _solve(p, 0.05)
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figs = [
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(plots.fig_raster(stack, e1, e2, p, res), "demo-raster"),
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(plots.fig_current(res, stack, e1, e2, p), "demo-current"),
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(plots.fig_potential(res, stack, e1, e2, p), "demo-potential"),
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]
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plots.save_and_show(figs, OUT, show=False)
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# --- contact models: equipotential vs uniform injection ---------------
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def gen_contact_models():
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plate = [(0, 0), (24, 0), (24, 18), (0, 18)]
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r_ohm, zooms = {}, {}
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# uniform grid: the coarse adaptive leaves would pixelate the |J| zoom
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config.ADAPTIVE_CELLS = False
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for model in ("equipotential", "uniform"):
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p = Problem(
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board_path="synthetic", net_name="DEMO",
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rho_ohm_m=1.68e-8, plating_nm=18_000,
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layers=[LayerFill("F.Cu", 70_000, 0, [_poly(plate)])],
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vias=[],
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electrodes1=[Electrode(rect=_rect(4.5, 7.5, 7.5, 10.5))],
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electrodes2=[Electrode(rect=_rect(22, 1, 23.5, 17, "User.2"))],
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thickness_source="override")
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res, stack, _, _ = _solve(p, 0.05, model=model)
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h_mm = stack.h_nm / NM
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j = res.Jmag[0] * 1e-6 # A/mm^2
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x0, y0 = stack.x0_nm / NM, stack.y0_nm / NM
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c0, c1 = int((2 - x0) / h_mm), int((13 - x0) / h_mm)
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r0, r1 = int((3 - y0) / h_mm), int((15 - y0) / h_mm)
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zooms[model] = (j[r0:r1, c0:c1],
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(x0 + c0 * h_mm, x0 + c1 * h_mm,
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y0 + r1 * h_mm, y0 + r0 * h_mm))
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r_ohm[model] = res.R_ohm
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config.ADAPTIVE_CELLS = True
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vmax = float(np.percentile(
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zooms["equipotential"][0][np.isfinite(zooms["equipotential"][0])],
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99.0))
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fig, axes = plt.subplots(1, 2, figsize=(9.5, 4.2), sharey=True,
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layout="constrained")
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titles = {"equipotential": "equipotential (ideal bonded lug):\n"
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"|J| crowds at the contact edges",
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"uniform": "uniform injection (pressed conductor):\n"
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"|J| ramps across the contact"}
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for ax, model in zip(axes, ("equipotential", "uniform")):
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data, extent = zooms[model]
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cmap = matplotlib.colormaps[config.CMAP_CURRENT].copy()
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cmap.set_bad(plots._BG)
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im = ax.imshow(data, cmap=cmap, vmin=0, vmax=vmax, origin="upper",
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extent=extent, interpolation="nearest")
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ax.add_patch(plt.Rectangle((4.5, 7.5), 3, 3, fill=False,
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ec="white", ls="--", lw=1.0))
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ax.set_title(f"{titles[model]}\nR = {r_ohm[model] * 1e3:.3f} mΩ",
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fontsize=9, color=INK)
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ax.set_xlabel("x [mm]", fontsize=8)
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ax.tick_params(labelsize=8, colors=INK)
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axes[0].set_ylabel("y [mm]", fontsize=8)
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cb = fig.colorbar(im, ax=axes, shrink=0.85)
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cb.set_label("|J| [A/mm²] @ 10 A", fontsize=9)
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fig.suptitle("The two contact models bracket a real contact: "
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"R$_{equipotential}$ ≤ R$_{real}$ ≤ R$_{uniform}$",
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fontsize=10, color=INK)
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fig.savefig(OUT / "contact-models.png", dpi=config.DPI,
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facecolor="white", bbox_inches="tight")
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plt.close(fig)
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print(f"saved {OUT / 'contact-models.png'}")
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# --- hole anatomy: hand-drawn cross-section of the four hole types ----
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CORE_T = 1.6 # substrate thickness [drawing units ~ mm]
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FOIL_T = 0.18 # foil thickness, exaggerated
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PLATE_W = 0.12 # barrel plating, exaggerated
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CAP_T = 0.07 # via cap
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COAT_T = 0.1 # pad-face solder coat
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Y_TOP = CORE_T + FOIL_T
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def _board_segment(ax, x0, x1):
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ax.add_patch(plt.Rectangle((x0, 0), x1 - x0, CORE_T, fc=CORE, ec="none"))
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for y in (CORE_T, -FOIL_T):
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ax.add_patch(plt.Rectangle((x0, y), x1 - x0, FOIL_T,
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fc=COPPER, ec="none"))
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def _barrel(ax, xc, drill):
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for s in (-1, 1):
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x = xc + s * drill / 2 - (PLATE_W if s > 0 else 0)
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ax.add_patch(plt.Rectangle((x, -FOIL_T), PLATE_W,
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CORE_T + 2 * FOIL_T, fc=COPPER,
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ec="none"))
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def _label(ax, text, xy, xytext, ha="left"):
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ax.annotate(text, xy, xytext=xytext, fontsize=7.5, color=INK, ha=ha,
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va="center",
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arrowprops=dict(arrowstyle="-", color=INK, lw=0.7,
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shrinkA=2, shrinkB=1))
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def gen_hole_anatomy():
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fig, ax = plt.subplots(figsize=(12.5, 5.2), layout="constrained")
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holes = [(3.0, 0.7), (10.0, 1.6), (17.5, 1.6), (25.0, 1.6)]
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edges = [0.0]
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for xc, d in holes:
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edges += [xc - d / 2, xc + d / 2]
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edges.append(28.5)
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for x0, x1 in zip(edges[::2], edges[1::2]):
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_board_segment(ax, x0, x1)
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for xc, d in holes:
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_barrel(ax, xc, d)
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# 1: small via, filled + capped
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xc, d = holes[0]
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ax.add_patch(plt.Rectangle((xc - d / 2 + PLATE_W, -FOIL_T),
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d - 2 * PLATE_W, CORE_T + 2 * FOIL_T,
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fc=FILLER, ec="none"))
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for y in (Y_TOP, -FOIL_T - CAP_T):
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ax.add_patch(plt.Rectangle((xc - d / 2 - 0.12, y), d + 0.24, CAP_T,
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fc=COPPER, ec="none"))
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_label(ax, "cap, CAP_PLATING_UM (15 µm)\non both outer mouths",
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(xc, Y_TOP + CAP_T), (xc, 3.3), ha="center")
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_label(ax, "non-conductive fill", (xc, 0.8), (5.6, -0.9))
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# 2: big via, mouth open
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xc, d = holes[1]
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_label(ax, "open mouth: covered cells\nremoved, sub-cell mouths\n"
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"scale the sheet conductance",
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(xc, Y_TOP - FOIL_T / 2), (xc, 3.2), ha="center")
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# 3: populated THT pad - full solder joint
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xc, d = holes[2]
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lead_w = d - 0.5 # drill - clearance, exaggerated
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pad_r = 1.7
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prot = 1.5
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sn_edge = "#7d8791" # delineate solder sub-shapes
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# solder fill between plating and lead
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for s in (-1, 1):
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x0 = xc + s * lead_w / 2 if s > 0 else xc - d / 2 + PLATE_W
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ax.add_patch(plt.Rectangle((x0, -FOIL_T),
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d / 2 - PLATE_W - lead_w / 2,
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CORE_T + 2 * FOIL_T, fc=SOLDER,
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ec="none"))
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# pad-face coat, solder side only
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ax.add_patch(plt.Rectangle((xc - pad_r, Y_TOP), 2 * pad_r, COAT_T,
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fc=SOLDER, ec=sn_edge, lw=0.5))
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# solder cone: protrusion height at the wall -> 0 at the pad edge
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for s in (-1, 1):
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wall = xc + s * lead_w / 2
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ax.add_patch(plt.Polygon(
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[(wall, Y_TOP + prot), (wall, Y_TOP + COAT_T),
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(xc + s * pad_r, Y_TOP + COAT_T)],
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closed=True, fc=SOLDER, ec=sn_edge, lw=0.5))
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# lead: through the hole, protruding on top, component below
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ax.add_patch(plt.Rectangle((xc - lead_w / 2, -2.05), lead_w,
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2.05 + Y_TOP + prot, fc=LEAD, ec="none"))
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ax.add_patch(plt.Rectangle((xc - 1.5, -2.75), 3.0, 0.7,
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fc="#8a8f96", ec="none"))
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ax.text(xc, -2.4, "component", fontsize=7.5, color="white",
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ha="center", va="center")
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_label(ax, "clipped lead protrudes\nTHT_LEAD_PROTRUSION_MM (1.5 mm)",
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(xc + lead_w / 2, Y_TOP + prot - 0.2), (xc + 3.4, 4.15))
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_label(ax, "solder cone: full height at the\nwall, tapers to 0 at the "
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"pad edge", (xc - (lead_w / 2 + pad_r) / 2, Y_TOP + 0.7),
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(13.6, 4.2), ha="center")
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_label(ax, "pad-face solder coat (50 µm),\nSOLDER side only",
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(xc - pad_r + 0.2, Y_TOP + COAT_T / 2), (12.9, 2.35),
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ha="center")
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_label(ax, "solder-filled hole: lead ∥ solder ∥ plating\n"
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"lead ⌀ = drill − THT_LEAD_CLEARANCE_MM",
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(xc - d / 2 + PLATE_W + 0.07, 0.5), (12.3, -1.5), ha="center")
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_label(ax, "component side:\npad face stays bare",
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(xc + pad_r - 0.3, -FOIL_T), (xc + 4.0, -1.05))
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# 4: DNP THT pad
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xc, d = holes[3]
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_label(ax, "open hole on every layer,\nplating-only barrel, no joint",
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(xc, 0.8), (xc + 1.3, -2.45), ha="center")
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for (xc, _), title in zip(holes, (
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"via ≤ cap-drill\n(capped)", "via > cap-drill\n(open)",
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"THT pad, populated\n(read from KiCad)", "THT pad, DNP")):
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ax.text(xc, 5.6, title, fontsize=9, color=INK, ha="center",
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va="top", fontweight="bold")
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handles = [plt.Rectangle((0, 0), 1, 1, fc=c) for c in
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(COPPER, SOLDER, LEAD, CORE, FILLER)]
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fig.legend(handles, ("copper (foil / plating / pad)", "solder",
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"component lead", "FR-4", "non-conductive fill"),
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loc="outside right center", fontsize=8, framealpha=0.95)
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ax.set_title("How drilled holes are modeled — cross-section "
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"(vertical scale exaggerated)", fontsize=11, color=INK)
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ax.set_xlim(-0.3, 29.0)
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ax.set_ylim(-3.1, 5.7)
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ax.set_aspect("equal")
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ax.axis("off")
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fig.savefig(OUT / "hole-model.png", dpi=config.DPI,
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facecolor="white", bbox_inches="tight")
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plt.close(fig)
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print(f"saved {OUT / 'hole-model.png'}")
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if __name__ == "__main__":
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OUT.mkdir(parents=True, exist_ok=True)
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gen_hole_anatomy()
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gen_contact_models()
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gen_demo_maps()
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