grabowski
0afb55216b
- adaptive: skip layers with zero quadtree leaves in the connectivity restriction and mesh-boundary loops (IndexError on boards where a selected layer has no copper) - board_io: accept ZT_TEARDROP zones as conducting copper (KiCad types teardrop fills ZT_TEARDROP, never ZT_COPPER, so they were dropped) - geometry: copper_bbox uses the exact stroke bbox (centerline extrema + half width) instead of a 100 um chord tessellation that could undershoot arc/cap extrema past the raster guard margin - solver/adaptive: reference |J| to the conduction-equivalent thickness sigma*rho in every branch (the uniform branch used geometric t, so AC plots changed scale ~rs_ratio depending on unrelated per-cell maps) - solver/adaptive/raster: chain cells no longer show phantom sheet-face currents; store dl per chain link and overlay the true 1D density |dV|/(rho*dl) (exact at any frequency: AC scaling of link conductance and cross-section cancels) - test_quadtree: compare edge lists pair-for-pair (the independent column sort destroyed endpoint association)
469 lines
20 KiB
Python
469 lines
20 KiB
Python
"""Rasterization of the fill polygons onto a shared multi-layer grid, and
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electrode mask construction.
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Grid convention: layer l, row i, col j maps to the cell center
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x = x0_nm + (j + 0.5) * h_nm
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y = y0_nm + (i + 0.5) * h_nm
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in KiCad board coordinates (y grows down). Row 0 is the minimum-y row,
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the TOP of the board as drawn in the editor; plots use origin='upper'.
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All layers share the same frame, so cell (i, j) is vertically aligned
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across layers (via links connect equal (i, j) on different layers).
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Connectivity restriction lives in solver.py: it needs the via edges.
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"""
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from __future__ import annotations
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import math
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from dataclasses import dataclass
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import numpy as np
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from matplotlib.path import Path as MplPath
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from PIL import Image, ImageDraw
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from scipy import ndimage
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from . import config
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from .errors import ElectrodeError, GridSizeError
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from .geometry import Electrode, Problem, Rect
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# 4-connectivity: matches the in-plane 5-point stencil of the solver
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_STRUCT4 = ndimage.generate_binary_structure(2, 1)
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@dataclass
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class RasterStack:
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masks: np.ndarray # bool (L, ny, nx), True = copper
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x0_nm: float # grid origin (outer corner of cell [., 0, 0])
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y0_nm: float
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h_nm: float
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layer_names: list[str]
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buildup: np.ndarray | None = None # bool (L, ny, nx): solder buildup
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# (mask opening ∩ copper)
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chain: np.ndarray | None = None # bool (L, ny, nx): cells that are
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# copper only through a 1D trace chain
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chain_edges: tuple | None = None # (a, b, g_dc, layer, dl_m) arrays:
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# explicit DC conductances and link
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# lengths of the chain links
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thick_scale: np.ndarray | None = None # float (L, ny, nx): per-cell
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# copper-thickness factor (via
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# mouths: cap-thin or partially
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# drilled cells); None = all 1
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mesh: np.ndarray | None = None # bool (L, ny, nx): adaptive leaf
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# boundaries (drawn on the raster map)
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@property
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def nlayers(self) -> int:
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return self.masks.shape[0]
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@property
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def shape2d(self) -> tuple[int, int]:
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return self.masks.shape[1:]
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def cell_centers(self, i0: int, i1: int, j0: int, j1: int):
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xs = self.x0_nm + (np.arange(j0, j1) + 0.5) * self.h_nm
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ys = self.y0_nm + (np.arange(i0, i1) + 0.5) * self.h_nm
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return np.meshgrid(xs, ys)
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def cell_of(self, x_nm: float, y_nm: float) -> tuple[int, int] | None:
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"""(i, j) of the cell containing the point, or None if outside."""
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ny, nx = self.shape2d
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j = math.floor((x_nm - self.x0_nm) / self.h_nm)
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i = math.floor((y_nm - self.y0_nm) / self.h_nm)
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if 0 <= i < ny and 0 <= j < nx:
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return i, j
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return None
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def extent_mm(self) -> tuple[float, float, float, float]:
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"""imshow extent (left, right, bottom, top) for origin='upper',
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y axis in board orientation (increasing downward)."""
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ny, nx = self.shape2d
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return (
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self.x0_nm * 1e-6,
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(self.x0_nm + nx * self.h_nm) * 1e-6,
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(self.y0_nm + ny * self.h_nm) * 1e-6,
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self.y0_nm * 1e-6,
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)
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def choose_cell_size(bbox_nm: tuple[int, int, int, int], nlayers: int) -> float:
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"""Pick the cell size h [nm]; TARGET_CELLS counts TOTAL cells across
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all layers. Raise if the grid would exceed HARD_MAX_CELLS."""
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x0, y0, x1, y1 = bbox_nm
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w, ht = float(x1 - x0), float(y1 - y0)
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if w <= 0 or ht <= 0:
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raise GridSizeError("Copper geometry has a degenerate bounding box.")
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if config.CELL_UM_OVERRIDE is not None:
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if config.CELL_UM_OVERRIDE <= 0:
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raise GridSizeError(
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f"Cell size must be positive "
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f"(got {config.CELL_UM_OVERRIDE:g} um)."
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)
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h = config.CELL_UM_OVERRIDE * 1000.0
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else:
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# the adaptive grid decouples unknowns from the fine cell count,
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# so its auto sizing affords a larger fine-cell budget (finer h)
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target = (config.TARGET_CELLS_ADAPTIVE if config.ADAPTIVE_CELLS
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else config.TARGET_CELLS)
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h = math.sqrt(w * ht * nlayers / target)
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h = min(max(h, config.MIN_CELL_UM * 1000.0), config.MAX_CELL_UM * 1000.0)
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ncells = math.ceil(w / h) * math.ceil(ht / h) * nlayers
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if ncells > config.HARD_MAX_CELLS:
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raise GridSizeError(
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f"Grid would need ~{ncells / 1e6:.1f} M cells over {nlayers} "
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f"layer(s) at cell size {h / 1000:.0f} um (limit "
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f"{config.HARD_MAX_CELLS / 1e6:.0f} M). Raise MAX_CELL_UM / "
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f"CELL_UM_OVERRIDE in config.py, deselect layers, or measure a "
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f"smaller region."
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)
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return h
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def _paint_ring(stack: RasterStack, ring: np.ndarray, value: bool,
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target: np.ndarray) -> None:
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"""Set target (2D) cells whose center lies inside ring to `value`,
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working only within the ring's bbox. Hybrid rasterizer: PIL scanline
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fill for the bulk (fast, O(vertices + cells)), then the cells within
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a ~2 px band around the ring edge are re-tested exactly against the
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polygon, so the result is identical to a pure center-in-polygon pass."""
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ny, nx = stack.shape2d
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h = stack.h_nm
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j0 = max(0, int((ring[:, 0].min() - stack.x0_nm) / h) - 1)
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j1 = min(nx, int((ring[:, 0].max() - stack.x0_nm) / h) + 2)
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i0 = max(0, int((ring[:, 1].min() - stack.y0_nm) / h) - 1)
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i1 = min(ny, int((ring[:, 1].max() - stack.y0_nm) / h) + 2)
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if i0 >= i1 or j0 >= j1:
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return
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w, ht = j1 - j0, i1 - i0
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# cell (i, j) center <-> pixel (j - j0, i - i0)
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px = (ring[:, 0] - stack.x0_nm) / h - 0.5 - j0
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py = (ring[:, 1] - stack.y0_nm) / h - 0.5 - i0
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pts = list(zip(px.tolist(), py.tolist()))
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inside = np.zeros((ht, w), dtype=bool)
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band = np.ones((ht, w), dtype=bool)
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if len(pts) >= 3:
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fill_img = Image.new("1", (w, ht), 0)
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ImageDraw.Draw(fill_img).polygon(pts, fill=1)
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inside = np.array(fill_img, dtype=bool)
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band_img = Image.new("1", (w, ht), 0)
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ImageDraw.Draw(band_img).line(pts + pts[:1], fill=1, width=5,
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joint="curve")
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band = np.array(band_img, dtype=bool)
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bi, bj = np.nonzero(band)
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if len(bi):
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xs = stack.x0_nm + (bj + j0 + 0.5) * h
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ys = stack.y0_nm + (bi + i0 + 0.5) * h
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# Path(closed=True) treats the LAST vertex as the CLOSEPOLY dummy,
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# so the first vertex must be appended or the ring loses its last
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# corner
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verts = np.vstack([ring, ring[:1]])
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inside[bi, bj] = MplPath(verts, closed=True).contains_points(
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np.column_stack([xs, ys]))
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sub = target[i0:i1, j0:j1]
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sub[inside] = value
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def rasterize_stack(problem: Problem, h_nm: float) -> RasterStack:
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"""Rasterize every included layer onto one shared frame."""
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x0, y0, x1, y1 = problem.copper_bbox()
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m = config.MARGIN_CELLS
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nx = math.ceil((x1 - x0) / h_nm) + 2 * m
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ny = math.ceil((y1 - y0) / h_nm) + 2 * m
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stack = RasterStack(
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masks=np.zeros((len(problem.layers), ny, nx), dtype=bool),
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x0_nm=x0 - m * h_nm,
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y0_nm=y0 - m * h_nm,
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h_nm=h_nm,
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layer_names=problem.layer_names,
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)
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for li, layer in enumerate(problem.layers):
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for poly in layer.polygons:
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if poly.holes:
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pmask = np.zeros((ny, nx), dtype=bool)
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_paint_ring(stack, poly.outline, True, pmask)
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for hole in poly.holes:
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_paint_ring(stack, hole, False, pmask)
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stack.masks[li] |= pmask
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else:
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# hole-less (e.g. a track outline): paint the layer mask
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# directly, skipping the full-frame temp
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_paint_ring(stack, poly.outline, True, stack.masks[li])
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# via ring/pad copper BEFORE tracks, so 1D chains see it as regular
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# copper; drill mouths AFTER tracks, so drills go through trace copper
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_paint_via_rings(stack, problem)
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# traces: wide ones are rasterized from their outline, sub-resolution
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# ones become exact 1D resistor chains along their centerline
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index = {name: li for li, name in enumerate(stack.layer_names)}
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narrow = []
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for seg in problem.tracks:
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li = index.get(seg.layer_name)
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if li is None:
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continue
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if seg.width_nm >= config.TRACK_1D_FACTOR * h_nm:
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_paint_ring(stack, seg.outline(config.ARC_TOL_FRACTION * h_nm),
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True, stack.masks[li])
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else:
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narrow.append((li, seg))
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if narrow:
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n_links = _build_chains(stack, problem, narrow)
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print(f"{len(narrow)} trace(s) narrower than "
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f"{config.TRACK_1D_FACTOR:g} cells modeled as 1D resistor "
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f"chains ({n_links} links)")
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_apply_via_mouths(stack, problem)
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if problem.buildups:
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stack.buildup = np.zeros_like(stack.masks)
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index = {name: li for li, name in enumerate(stack.layer_names)}
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for b in problem.buildups:
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li = index.get(b.layer_name)
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if li is None:
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continue
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for poly in b.polygons:
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pmask = np.zeros((ny, nx), dtype=bool)
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_paint_ring(stack, poly.outline, True, pmask)
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for hole in poly.holes:
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_paint_ring(stack, hole, False, pmask)
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stack.buildup[li] |= pmask
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stack.buildup &= stack.masks # solder wets exposed copper only
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return stack
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def _via_span(problem: Problem, via) -> list[int]:
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return [li for li, layer in enumerate(problem.layers)
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if via.spans(layer.z_nm)]
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def _paint_via_rings(stack: RasterStack, problem: Problem) -> None:
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"""Annular-ring / via-pad copper: a full-thickness disc of the pad
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diameter on every layer the barrel spans (kind='via' only - THT pad
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copper stays outside the model). The drill mouth re-opens the disc
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center in _apply_via_mouths."""
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ny, nx = stack.shape2d
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h = stack.h_nm
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for via in problem.vias:
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if via.kind != "via" or via.pad_nm <= 0:
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continue
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r = via.pad_nm / 2.0
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j0 = max(0, math.floor((via.x - r - stack.x0_nm) / h))
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j1 = min(nx, math.floor((via.x + r - stack.x0_nm) / h) + 1)
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i0 = max(0, math.floor((via.y - r - stack.y0_nm) / h))
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i1 = min(ny, math.floor((via.y + r - stack.y0_nm) / h) + 1)
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if i0 >= i1 or j0 >= j1:
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continue
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xs = stack.x0_nm + (np.arange(j0, j1) + 0.5) * h - via.x
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ys = stack.y0_nm + (np.arange(i0, i1) + 0.5) * h - via.y
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disc = (ys[:, None] ** 2 + xs[None, :] ** 2) <= r * r
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for li in _via_span(problem, via):
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stack.masks[li, i0:i1, j0:j1] |= disc
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def _apply_via_mouths(stack: RasterStack, problem: Problem) -> None:
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"""Drill-mouth treatment, area-weighted per cell (4x4 supersampling):
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capped vias carry a cap_plating-thin copper cap over the mouth on the
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OUTER layers, uncapped vias (and inner layers either way) get an open
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hole. Fully swallowed cells leave the mask; partially covered cells
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keep a thickness-scaled sheet conductance via stack.thick_scale."""
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ny, nx = stack.shape2d
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h = stack.h_nm
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outer = {li for li, n in enumerate(stack.layer_names)
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if n in ("F.Cu", "B.Cu")}
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sub = (np.arange(4) + 0.5) / 4.0
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for via in problem.vias:
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if via.kind != "via" or via.drill_nm <= 0:
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continue
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r = via.drill_nm / 2.0
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j0 = max(0, math.floor((via.x - r - stack.x0_nm) / h))
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j1 = min(nx, math.floor((via.x + r - stack.x0_nm) / h) + 1)
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i0 = max(0, math.floor((via.y - r - stack.y0_nm) / h))
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i1 = min(ny, math.floor((via.y + r - stack.y0_nm) / h) + 1)
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if i0 >= i1 or j0 >= j1:
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continue
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xs = stack.x0_nm + (np.arange(j0, j1)[:, None] + sub[None, :]) * h \
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- via.x
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ys = stack.y0_nm + (np.arange(i0, i1)[:, None] + sub[None, :]) * h \
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- via.y
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cov = ((ys[:, None, :, None] ** 2 + xs[None, :, None, :] ** 2)
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<= r * r).mean(axis=(2, 3))
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if not (cov > 0).any():
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continue # mouth far smaller than h
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if stack.thick_scale is None:
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stack.thick_scale = np.ones(stack.masks.shape)
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for li in _via_span(problem, via):
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if problem.vias_capped and li in outer:
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ratio = min(problem.cap_plating_nm
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/ problem.layers[li].thickness_nm, 1.0)
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else:
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ratio = 0.0
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s = 1.0 - cov * (1.0 - ratio)
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gone = s <= 1e-9
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stack.masks[li, i0:i1, j0:j1] &= ~gone
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stack.thick_scale[li, i0:i1, j0:j1] *= np.where(gone, 1.0, s)
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def _build_chains(stack: RasterStack, problem: Problem,
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narrow: list) -> int:
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"""Sub-resolution traces as 1D resistor chains: mark the cells their
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centerline crosses as copper and record one explicit conductance per
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pair of consecutive cells, allocating the trace's TRUE arc length to
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each link (a diagonal trace is not staircase-inflated). Links whose
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cells are already regular copper AND face-adjacent are skipped there
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(the trace merges into the pour: union, not sum). Returns the number
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of links."""
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L, ny, nx = stack.masks.shape
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plane = ny * nx
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h = stack.h_nm
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regular = stack.masks.copy()
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chain = np.zeros_like(stack.masks)
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aa, bb, gg, ll, dd = [], [], [], [], []
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for li, seg in narrow:
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pts = seg.centerline(0.2 * h)
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d = np.hypot(*np.diff(pts, axis=0).T)
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s = np.concatenate([[0.0], np.cumsum(d)])
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length = float(s[-1])
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n_samp = max(2, int(math.ceil(length / (h / 3.0))) + 1)
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ss = np.linspace(0.0, length, n_samp)
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xs = np.interp(ss, s, pts[:, 0])
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ys = np.interp(ss, s, pts[:, 1])
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jj = np.floor((xs - stack.x0_nm) / h).astype(np.int64)
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ii = np.floor((ys - stack.y0_nm) / h).astype(np.int64)
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jj = np.clip(jj, 0, nx - 1) # bbox includes all tracks;
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ii = np.clip(ii, 0, ny - 1) # clip only guards rounding
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first = np.concatenate(
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[[True], (ii[1:] != ii[:-1]) | (jj[1:] != jj[:-1])])
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ci, cj, cs = ii[first], jj[first], ss[first]
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chain[li, ci, cj] = True
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g0 = (seg.width_nm * 1e-9
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* problem.layers[li].thickness_nm * 1e-9 / problem.rho_ohm_m)
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for k in range(len(ci) - 1):
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dl = (cs[k + 1] - cs[k]) * 1e-9
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if dl <= 0:
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continue
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adj4 = abs(int(ci[k + 1] - ci[k])) + abs(int(cj[k + 1] - cj[k])) == 1
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if adj4 and regular[li, ci[k], cj[k]] \
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and regular[li, ci[k + 1], cj[k + 1]]:
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continue # pour conducts here already
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aa.append(li * plane + int(ci[k]) * nx + int(cj[k]))
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bb.append(li * plane + int(ci[k + 1]) * nx + int(cj[k + 1]))
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gg.append(g0 / dl)
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ll.append(li)
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dd.append(dl)
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stack.chain = chain & ~regular
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stack.masks |= stack.chain
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stack.chain_edges = (np.asarray(aa, dtype=np.int64),
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np.asarray(bb, dtype=np.int64),
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np.asarray(gg, dtype=float),
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np.asarray(ll, dtype=np.int64),
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np.asarray(dd, dtype=float))
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return len(aa)
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def _rect_cells(stack: RasterStack, rect: Rect) -> np.ndarray:
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"""Bool (ny, nx) mask of cells whose center lies inside the rectangle."""
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ny, nx = stack.shape2d
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h = stack.h_nm
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out = np.zeros((ny, nx), dtype=bool)
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j0 = max(0, int(math.ceil((rect.x0 - stack.x0_nm) / h - 0.5)))
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j1 = min(nx, int(math.floor((rect.x1 - stack.x0_nm) / h - 0.5)) + 1)
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i0 = max(0, int(math.ceil((rect.y0 - stack.y0_nm) / h - 0.5)))
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i1 = min(ny, int(math.floor((rect.y1 - stack.y0_nm) / h - 0.5)) + 1)
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if i0 < i1 and j0 < j1:
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out[i0:i1, j0:j1] = True
|
|
return out
|
|
|
|
|
|
def _electrode_cells2d(stack: RasterStack, e: Electrode) -> np.ndarray:
|
|
"""2D footprint of the electrode shape (pad polygons or rectangle)."""
|
|
if e.polygons:
|
|
cells = np.zeros(stack.shape2d, dtype=bool)
|
|
for poly in e.polygons:
|
|
pm = np.zeros(stack.shape2d, dtype=bool)
|
|
_paint_ring(stack, poly.outline, True, pm)
|
|
for hole in poly.holes:
|
|
_paint_ring(stack, hole, False, pm)
|
|
cells |= pm
|
|
if not cells.any():
|
|
# shape smaller than one grid cell (small pad): use the cell
|
|
# containing its center
|
|
r = e.rect
|
|
c = stack.cell_of((r.x0 + r.x1) / 2, (r.y0 + r.y1) / 2)
|
|
if c is not None:
|
|
cells[c] = True
|
|
return cells
|
|
return _rect_cells(stack, e.rect)
|
|
|
|
|
|
def electrode_masks(stack: RasterStack, problem: Problem
|
|
) -> tuple[np.ndarray, np.ndarray]:
|
|
"""Terminal mask = OR over its parts; part = shape ∩ copper on the
|
|
part's contact layer(s). contact 'all' = every included layer (bolted
|
|
lug / through pad); a layer name = that layer only. Every part must
|
|
individually land on copper (clear feedback). V+/V- must not overlap;
|
|
touching is checked later, only for the equipotential contact model."""
|
|
def build(parts: list[Electrode], which: str) -> np.ndarray:
|
|
e = np.zeros_like(stack.masks)
|
|
for el in parts:
|
|
cells2d = _electrode_cells2d(stack, el)
|
|
part = np.zeros_like(stack.masks)
|
|
for li, name in enumerate(stack.layer_names):
|
|
if el.contact == "all" or el.contact == name:
|
|
part[li] = cells2d & stack.masks[li]
|
|
if not part.any():
|
|
raise ElectrodeError(
|
|
f"A {which} contact part ({el.label}) does not overlap "
|
|
f"any copper of the selected fill on contact layer(s) "
|
|
f"'{el.contact}' (or is smaller than one grid cell)."
|
|
)
|
|
e |= part
|
|
if not e.any():
|
|
raise ElectrodeError(f"The {which} terminal has no contact parts.")
|
|
return e
|
|
|
|
e1 = build(problem.electrodes1, "V+")
|
|
e2 = build(problem.electrodes2, "V-")
|
|
|
|
if (e1 & e2).any():
|
|
raise ElectrodeError(
|
|
"The V+ and V- contact areas overlap on the copper grid. "
|
|
"Move them apart."
|
|
)
|
|
return e1, e2
|
|
|
|
|
|
def electrode_partition(stack: RasterStack, problem: Problem
|
|
) -> tuple[list, list]:
|
|
"""Per-part cell masks for both terminals, as [(label, mask3d), ...].
|
|
Cells covered by several overlapping parts are attributed to the
|
|
FIRST part (first-wins partition), so part currents sum exactly to
|
|
the terminal current."""
|
|
def build(parts: list[Electrode]) -> list:
|
|
out = []
|
|
claimed = np.zeros_like(stack.masks)
|
|
for el in parts:
|
|
cells2d = _electrode_cells2d(stack, el)
|
|
m = np.zeros_like(stack.masks)
|
|
for li, name in enumerate(stack.layer_names):
|
|
if el.contact == "all" or el.contact == name:
|
|
m[li] = cells2d & stack.masks[li]
|
|
m &= ~claimed
|
|
claimed |= m
|
|
out.append((el.label, m))
|
|
return out
|
|
|
|
return build(problem.electrodes1), build(problem.electrodes2)
|
|
|
|
|
|
def electrodes_touch(stack: RasterStack, e1: np.ndarray,
|
|
e2: np.ndarray) -> str | None:
|
|
"""Layer name where the terminals are 4-adjacent, or None."""
|
|
for li in range(stack.nlayers):
|
|
if (ndimage.binary_dilation(e1[li], structure=_STRUCT4) & e2[li]).any():
|
|
return stack.layer_names[li]
|
|
return None
|