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Barrel contacts for vias/THT pads; configurable cap-drill threshold
- Selected vias and through-hole pads inject at the drill-wall ring on
  every spanned layer (both contact models), not the whole pad face,
  so the pad/pour spreading resistance is part of the result. Vias are
  now selectable as contacts.
- Soldered THT joints: the hole is modeled solder-filled (core in
  parallel with the plating, also for stitching THT barrels) and the
  pad face carries an average-thickness solder coat over the modeled
  copper (SOLDER_THICKNESS_UM).
- Vias with drills above a configurable threshold (dialog field,
  default CAP_MAX_DRILL_MM = 0.5) keep open mouths even with capping
  selected - the fab caps only small vias.
- Geometry dump schema v6: electrode barrel fields, cap_max_drill_nm.
- Verified against R = rho/(pi t)*acosh(d/2a) for two circular contacts
  on a sheet (+2.6% at h = 0.15 mm, a = 1 mm; uniform model above the
  equipotential one as required by the contact bracket).

Co-Authored-By: Claude Fable 5 <noreply@anthropic.com>
2026-07-16 18:28:47 +07:00

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"""Top-level orchestration for the KiCad-launched action.
Flow: connect -> read the two selected contacts (rectangles/pads) ->
gather fills -> selection dialog (net, layers, contacts, current, cell)
-> extract vias -> solve -> figures + report.
Every failure is reported twice: on stdout (lands in the KiCad status-bar
warning list) and as a matplotlib error figure, so it cannot be missed.
"""
from __future__ import annotations
import sys
import traceback
from . import config, pipeline, report
from .errors import CandidateError, UserFacingError
def _fail(message: str, outdir) -> None:
print(f"ERROR: {message}")
from . import plots
fig = plots.fig_error(message)
plots.save_and_show([(fig, "error")], outdir)
sys.exit(1)
def main() -> None:
outdir = None
try:
from kipy.errors import ApiError
from . import board_io, dialog
try:
kicad, board = board_io.connect()
stackup = board_io.get_stackup_info(board)
es1, es2, net_hint = board_io.get_electrodes(board, stackup)
if board_io.any_zone_unfilled(board) or config.ALWAYS_REFILL:
board_io.refill(board)
fills = board_io.gather_net_fills(board)
tracks = board_io.gather_net_tracks(board)
copper = board_io.merge_copper(
fills, board_io.tracks_as_polygons(tracks))
candidate_nets = board_io.nets_overlapping(copper, es1, es2)
buildups = board_io.gather_mask_buildups(board)
except ApiError as e:
raise UserFacingError(
f"KiCad API error: {e}\nIf KiCad is showing a dialog, close "
f"it and run again."
)
if not candidate_nets:
raise CandidateError(
"No copper (zone fill or trace) overlaps both contacts. "
"Check that both sit over copper of the same net and that "
"the fills are up to date (press B in the board editor)."
)
def group_label(parts):
names = [p.label for p in parts[:3]]
more = f" +{len(parts) - 3}" if len(parts) > 3 else ""
return f"{len(parts)}× " + ", ".join(names) + more
def group_contact(parts):
contacts = {p.contact for p in parts}
return contacts.pop() if len(contacts) == 1 else "auto"
default_net = (net_hint if net_hint in candidate_nets
else candidate_nets[0])
selection = dialog.ask(
candidates={n: list(copper[n].keys()) for n in candidate_nets},
layer_order=stackup.names,
default_net=default_net,
e1_label=group_label(es1), e2_label=group_label(es2),
contact1=group_contact(es1), contact2=group_contact(es2),
buildup_layers=sorted(buildups.keys()),
)
if selection is None:
print("cancelled")
return
if selection.contact1 != "auto":
for e in es1:
e.contact = selection.contact1
if selection.contact2 != "auto":
for e in es2:
e.contact = selection.contact2
if selection.cell_um is not None:
config.CELL_UM_OVERRIDE = selection.cell_um
config.ADAPTIVE_CELLS = selection.adaptive
try:
problem = board_io.build_problem(
board, selection.net, selection.layers, es1, es2, stackup,
fills,
buildups=(buildups if selection.include_buildup else None),
extra_cu_um=selection.extra_cu_um,
tracks=(tracks if selection.include_tracks else None),
vias_capped=selection.vias_capped,
cap_max_drill_mm=selection.cap_max_drill_mm)
outdir = report.make_output_dir(board_io.board_dir(board))
except ApiError as e:
raise UserFacingError(f"KiCad API error: {e}")
report.write_geometry_dump(outdir, problem)
pipeline.run(problem, outdir, show=True, i_test=selection.current_a,
freq_hz=selection.freq_hz,
contact_model=selection.contact_model)
except UserFacingError as e:
_fail(str(e), outdir)
except Exception:
_fail(traceback.format_exc(), outdir)
if __name__ == "__main__":
main()