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No size-threshold guessing: whether a hole is a via or a THT pad already comes from KiCad (board.get_vias vs drilled board.get_pads). Every populated THT pad of the net now carries the complete joint the contacts got: solder-filled barrel, average-thickness coat over a pad-diameter disc on the outer layers, and the protruding-lead cone on the side opposite its owning footprint. The footprint side and the Do-not-populate flag are read from KiCad (footprint pads store absolute positions, so owner lookup is an exact (x, y, number) map); DNP pads stay plating-only with no joint. Contact pads are deduplicated by barrel center so their cone/coat is never applied twice. Barrels are now gathered in single-layer runs too: via rings and drill mouths perforate a lone plane, THT joints stiffen it locally. ViaLink gains solder_filled + protrusion_side (legacy dumps load with the old every-THT-pad-filled semantics). Co-Authored-By: Claude Fable 5 <noreply@anthropic.com>
127 lines
5.4 KiB
Python
127 lines
5.4 KiB
Python
"""Via ring-copper and drill-mouth (capping) tests. THT pads (kind
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'pad') skip both, which doubles as the feature-off reference."""
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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
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from tests.util import NM, make_multilayer
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def _two_layer(width_mm=5.0, drill_mm=0.3, pad_mm=0.6, kind="via",
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capped=True, cap_um=15.0, hole_mm=None,
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cap_max_drill_mm=10.0):
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"""10 x width strip on both (outer-named) layers, e1 left on F.Cu,
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e2 right on B.Cu, one via mid-strip. Optionally a circular hole in
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the F.Cu fill around the via (ring-bridging scenario). The cap-drill
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threshold defaults to 10 mm here (= every drill capped) so the tests
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exercise the mouth treatment itself; the threshold has its own test."""
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y = width_mm / 2
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strip = [(0, 0), (10, 0), (10, width_mm), (0, width_mm)]
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holes = []
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if hole_mm is not None:
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ang = np.linspace(0, 2 * np.pi, 64, endpoint=False)
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holes = [[(5 + hole_mm * np.cos(a), y + hole_mm * np.sin(a))
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for a in ang]]
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p = make_multilayer(
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[[(strip, holes)], [(strip, [])]],
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rect1_mm=(0, 0, 1, width_mm), rect2_mm=(9, 0, 10, width_mm),
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contact1="F.Cu", contact2="B.Cu",
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vias_mm=[(5, y)], gap_mm=1.0, drill_mm=drill_mm)
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p.layers[0].layer_name = "F.Cu"
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p.layers[1].layer_name = "B.Cu"
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p.vias[0].kind = kind
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p.vias[0].pad_nm = int(pad_mm * NM)
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p.vias_capped = capped
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p.cap_plating_nm = int(cap_um * 1000)
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p.cap_max_drill_nm = int(cap_max_drill_mm * NM)
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return p
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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_cap_at_foil_thickness_is_identity():
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"""cap thickness == foil thickness makes every mouth scale exactly 1,
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so the result equals the feature-off reference (a 'pad'-kind barrel,
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which skips rings and mouths) with the mouth fully inside copper."""
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r_cap, _ = _solve(_two_layer(capped=True, cap_um=70.0), 0.1)
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# a bare 'pad' barrel (solder_filled defaults False) is plating-only,
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# exactly like the via's
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r_ref, _ = _solve(_two_layer(kind="pad"), 0.1)
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assert r_cap.R_ohm == pytest.approx(r_ref.R_ohm, rel=1e-9)
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def test_mouth_ordering_solid_capped_uncapped():
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"""A large mouth in the current path: R(solid) < R(15 um cap) <
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R(open hole), and the barrel stays connected through the ring."""
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kw = dict(drill_mm=2.0, pad_mm=2.6)
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r_solid, _ = _solve(_two_layer(capped=True, cap_um=70.0, **kw), 0.25)
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r_cap, s_cap = _solve(_two_layer(capped=True, cap_um=15.0, **kw), 0.25)
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r_open, s_open = _solve(_two_layer(capped=False, **kw), 0.25)
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assert r_solid.R_ohm < r_cap.R_ohm < r_open.R_ohm
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assert s_cap.thick_scale is not None
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# open mouths remove the fully covered cells from the copper
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assert int(s_open.masks.sum()) < int(s_cap.masks.sum())
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assert r_open.power_balance_rel < 1e-9
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def test_ring_bridges_fill_gap():
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"""F.Cu fill has a 1 mm-radius hole around the via; the 2.4 mm pad
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ring bridges it. A 'pad'-kind barrel (no ring) stays disconnected."""
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p = _two_layer(drill_mm=0.3, pad_mm=2.4, hole_mm=1.0)
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res, _ = _solve(p, 0.2)
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assert np.isfinite(res.R_ohm) and res.R_ohm > 0
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assert len(res.via_reports) == 1
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bare = _two_layer(drill_mm=0.3, pad_mm=0.0, kind="pad", hole_mm=1.0)
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stack = raster.rasterize_stack(bare, 0.2 * NM)
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e1, e2 = raster.electrode_masks(stack, bare)
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with pytest.raises(ConnectivityError):
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solver.run_solve(bare, stack, e1, e2, 1.0,
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contact_model="equipotential")
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def test_subcell_mouth_perturbs_gently():
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"""A 0.3 mm mouth at 0.5 mm cells must not knock out whole cells:
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the area-weighted scaling changes R only slightly."""
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r_solid, _ = _solve(_two_layer(capped=True, cap_um=70.0), 0.5)
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r_open, s = _solve(_two_layer(capped=False), 0.5)
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assert int(s.masks.sum()) == int(_solve(
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_two_layer(capped=True, cap_um=70.0), 0.5)[1].masks.sum())
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assert r_solid.R_ohm <= r_open.R_ohm <= 1.05 * r_solid.R_ohm
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def test_cap_drill_threshold():
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"""Drills above cap_max_drill_nm stay open even with capping on: a
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2 mm drill over a 0.5 mm threshold behaves exactly like uncapped,
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while a threshold above the drill restores the cap."""
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kw = dict(drill_mm=2.0, pad_mm=2.6)
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r_big, s_big = _solve(_two_layer(capped=True, cap_max_drill_mm=0.5,
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**kw), 0.25)
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r_open, s_open = _solve(_two_layer(capped=False, **kw), 0.25)
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assert r_big.R_ohm == pytest.approx(r_open.R_ohm, rel=1e-12)
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assert int(s_big.masks.sum()) == int(s_open.masks.sum())
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r_cap, _ = _solve(_two_layer(capped=True, cap_max_drill_mm=2.1,
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**kw), 0.25)
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assert r_cap.R_ohm < r_open.R_ohm
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def test_capping_json_roundtrip(tmp_path):
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from fill_resistance.geometry import load_problem, save_problem
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p = _two_layer(capped=False, cap_um=12.0, cap_max_drill_mm=0.8)
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f = tmp_path / "d.json"
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save_problem(p, f)
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q = load_problem(f)
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assert q.vias_capped is False
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assert q.cap_plating_nm == 12_000
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assert q.cap_max_drill_nm == 800_000
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r_p, _ = _solve(p, 0.25)
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r_q, _ = _solve(q, 0.25)
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assert r_q.R_ohm == pytest.approx(r_p.R_ohm, rel=1e-12)
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