drc: Add board outline and edge crossing

This adds a check for contiguous board outlines to the DRC.  It also
uses the calculated outline to ensure that traces are not crossing the
outlines.

Fixes: lp:1648055
* https://bugs.launchpad.net/kicad/+bug/1648055

common/geometry/seg.cpp

@@ -96,6 +96,39 @@ SEG::ecoord SEG::SquaredDistance( const SEG& aSeg ) const
 }
 
 
+const VECTOR2I SEG::NearestPoint( const SEG& aSeg ) const
+{
+    if( auto p = Intersect( aSeg ) )
+        return *p;
+
+    const VECTOR2I pts_origin[4] =
+    {
+            aSeg.NearestPoint( A ),
+            aSeg.NearestPoint( B ),
+            NearestPoint( aSeg.A ),
+            NearestPoint( aSeg.B )
+    };
+
+    const ecoord pts_dist[4] =
+    {
+            ( pts_origin[0] - A ).SquaredEuclideanNorm(),
+            ( pts_origin[1] - B ).SquaredEuclideanNorm(),
+            ( pts_origin[2] - aSeg.A ).SquaredEuclideanNorm(),
+            ( pts_origin[3] - aSeg.B ).SquaredEuclideanNorm()
+    };
+
+    int min_i = 0;
+
+    for( int i = 0; i < 4; i++ )
+    {
+        if( pts_dist[i] < pts_dist[min_i] )
+            min_i = i;
+    }
+
+    return pts_origin[min_i];
+}
+
+
 OPT_VECTOR2I SEG::Intersect( const SEG& aSeg, bool aIgnoreEndpoints, bool aLines ) const
 {
     const VECTOR2I  e( B - A );

include/geometry/seg.h

@@ -35,10 +35,8 @@ typedef OPT<VECTOR2I> OPT_VECTOR2I;
 
 class SEG
 {
-private:
-    typedef VECTOR2I::extended_type ecoord;
-
 public:
+    using ecoord = VECTOR2I::extended_type;
     friend inline std::ostream& operator<<( std::ostream& aStream, const SEG& aSeg );
 
     /* Start and the of the segment. Public, to make access simpler.
@@ -156,6 +154,12 @@ public:
       */
     const VECTOR2I NearestPoint( const VECTOR2I &aP ) const;
 
+    /**
+      * Computes a point on the segment (this) that is closest to any point on aSeg.
+      * @return the nearest point
+      */
+    const VECTOR2I NearestPoint( const SEG &aSeg ) const;
+
     /**
      * Function Intersect()
      *

pcbnew/class_board.cpp

@@ -171,8 +171,6 @@ void BOARD::BuildConnectivity()
 
 const wxPoint BOARD::GetPosition() const
 {
-    wxLogWarning( wxT( "This should not be called on the BOARD object") );
-
     return ZeroOffset;
 }
 
@@ -1021,6 +1019,12 @@ void BOARD::Remove( BOARD_ITEM* aBoardItem )
 }
 
 
+wxString BOARD::GetSelectMenuText( EDA_UNITS_T aUnits ) const
+{
+    return wxString::Format( _( "PCB" ) );
+}
+
+
 void BOARD::DeleteMARKERs()
 {
     // the vector does not know how to delete the MARKER_PCB, it holds pointers
@@ -2949,12 +2953,14 @@ BOARD_ITEM* BOARD::Duplicate( const BOARD_ITEM* aItem,
  * return true if success, false if a contour is not valid
  */
 extern bool BuildBoardPolygonOutlines( BOARD* aBoard, SHAPE_POLY_SET& aOutlines,
-                                wxString* aErrorText, unsigned int aTolerance );
+                                wxString* aErrorText, unsigned int aTolerance,
+                                wxPoint* aErrorLocation = nullptr );
 
 
-bool BOARD::GetBoardPolygonOutlines( SHAPE_POLY_SET& aOutlines, wxString* aErrorText )
+bool BOARD::GetBoardPolygonOutlines( SHAPE_POLY_SET& aOutlines, wxString* aErrorText, wxPoint* aErrorLocation )
 {
-    bool success = BuildBoardPolygonOutlines( this, aOutlines, aErrorText, Millimeter2iu( 0.05 ) );
+    bool success = BuildBoardPolygonOutlines( this, aOutlines, aErrorText,
+            Millimeter2iu( 0.05 ), aErrorLocation );
 
     // Make polygon strictly simple to avoid issues (especially in 3D viewer)
     aOutlines.Simplify( SHAPE_POLY_SET::PM_STRICTLY_SIMPLE );

pcbnew/class_board.h

@@ -562,6 +562,8 @@ public:
     const ZONE_SETTINGS& GetZoneSettings() const            { return m_zoneSettings; }
     void SetZoneSettings( const ZONE_SETTINGS& aSettings )  { m_zoneSettings = aSettings; }
 
+    wxString    GetSelectMenuText( EDA_UNITS_T aUnits ) const override;
+
     /**
      * Function GetColorSettings
      * @return the current COLORS_DESIGN_SETTINGS in use
@@ -585,11 +587,14 @@ public:
      * @param aOutlines The SHAPE_POLY_SET to fill in with outlines/holes.
      * @param aErrorText = a wxString reference to display an error message
      *          with the coordinate of the point which creates the error
-     *          (default = NULL , no message returned on error)
+     *          (default = nullptr , no message returned on error)
+     * @param aErrorLocation = a wxPoint giving the location of the Error message on the board
+     *          if left null (default), no location is returned
+     *
      * @return true if success, false if a contour is not valid
      */
     bool GetBoardPolygonOutlines( SHAPE_POLY_SET& aOutlines,
-                                  wxString* aErrorText = NULL );
+                                  wxString* aErrorText = nullptr, wxPoint* aErrorLocation = nullptr );
 
     /**
      * Function ConvertBrdLayerToPolygonalContours

pcbnew/class_module.cpp

@@ -1445,7 +1445,7 @@ double MODULE::CoverageRatio( const GENERAL_COLLECTOR& aCollector ) const
 
 // see convert_drawsegment_list_to_polygon.cpp:
 extern bool ConvertOutlineToPolygon( std::vector<DRAWSEGMENT*>& aSegList, SHAPE_POLY_SET& aPolygons,
-        wxString* aErrorText, unsigned int aTolerance );
+        wxString* aErrorText, unsigned int aTolerance, wxPoint* aErrorLocation = nullptr );
 
 bool MODULE::BuildPolyCourtyard()
 {

pcbnew/convert_drawsegment_list_to_polygon.cpp

@@ -177,9 +177,10 @@ static DRAWSEGMENT* findPoint( const wxPoint& aPoint, std::vector< DRAWSEGMENT*
  * @param aPolygons will contain the complex polygon.
  * @param aTolerance is the max distance between points that is still accepted as connected (internal units)
  * @param aErrorText is a wxString to return error message.
+ * @param aErrorLocation is the optional position of the error in the outline
  */
 bool ConvertOutlineToPolygon( std::vector<DRAWSEGMENT*>& aSegList, SHAPE_POLY_SET& aPolygons,
-                              wxString* aErrorText, unsigned int aTolerance )
+                              wxString* aErrorText, unsigned int aTolerance, wxPoint* aErrorLocation )
 {
     if( aSegList.size() == 0 )
         return true;
@@ -415,6 +416,9 @@ bool ConvertOutlineToPolygon( std::vector<DRAWSEGMENT*>& aSegList, SHAPE_POLY_SE
                     *aErrorText << msg << "\n";
                 }
 
+                if( aErrorLocation )
+                    *aErrorLocation = graphic->GetPosition();
+
                 return false;
             }
 
@@ -443,6 +447,9 @@ bool ConvertOutlineToPolygon( std::vector<DRAWSEGMENT*>& aSegList, SHAPE_POLY_SE
                         *aErrorText << msg << "\n";
                     }
 
+                    if( aErrorLocation )
+                        *aErrorLocation = prevPt;
+
                     return false;
                 }
                 break;
@@ -594,6 +601,9 @@ bool ConvertOutlineToPolygon( std::vector<DRAWSEGMENT*>& aSegList, SHAPE_POLY_SE
                         *aErrorText << msg << "\n";
                     }
 
+                    if( aErrorLocation )
+                        *aErrorLocation = graphic->GetPosition();
+
                     return false;
                 }
 
@@ -622,6 +632,9 @@ bool ConvertOutlineToPolygon( std::vector<DRAWSEGMENT*>& aSegList, SHAPE_POLY_SE
                             *aErrorText << msg << "\n";
                         }
 
+                        if( aErrorLocation )
+                            *aErrorLocation = prevPt;
+
                         return false;
                     }
                     break;
@@ -641,7 +654,7 @@ bool ConvertOutlineToPolygon( std::vector<DRAWSEGMENT*>& aSegList, SHAPE_POLY_SE
  * All contours should be closed, i.e. valid closed polygon vertices
  */
 bool BuildBoardPolygonOutlines( BOARD* aBoard, SHAPE_POLY_SET& aOutlines,
-        wxString* aErrorText, unsigned int aTolerance )
+        wxString* aErrorText, unsigned int aTolerance, wxPoint* aErrorLocation )
 {
     PCB_TYPE_COLLECTOR  items;
 
@@ -659,7 +672,7 @@ bool BuildBoardPolygonOutlines( BOARD* aBoard, SHAPE_POLY_SET& aOutlines,
             segList.push_back( static_cast< DRAWSEGMENT* >( items[ii] ) );
     }
 
-    bool success = ConvertOutlineToPolygon( segList, aOutlines, aErrorText, aTolerance );
+    bool success = ConvertOutlineToPolygon( segList, aOutlines, aErrorText, aTolerance, aErrorLocation );
 
     if( !success || !aOutlines.OutlineCount() )
     {

pcbnew/dialogs/dialog_export_step.cpp

@@ -221,7 +221,8 @@ void DIALOG_EXPORT_STEP::onUpdateYPos( wxUpdateUIEvent& aEvent )
 }
 
 extern bool BuildBoardPolygonOutlines( BOARD* aBoard, SHAPE_POLY_SET& aOutlines,
-                                wxString* aErrorText, unsigned int aTolerance );
+                                wxString* aErrorText, unsigned int aTolerance,
+                                wxPoint* aErrorLocation = nullptr );
 
 void DIALOG_EXPORT_STEP::onExportButton( wxCommandEvent& aEvent )
 {

pcbnew/drc.cpp

@@ -393,8 +393,15 @@ void DRC::RunTests( wxTextCtrl* aMessages )
     // ( the board can be reloaded )
     m_pcb = m_pcbEditorFrame->GetBoard();
 
-    // someone should have cleared the two lists before calling this.
+    if( aMessages )
+    {
+        aMessages->AppendText( _( "Board Outline...\n" ) );
+        wxSafeYield();
+    }
 
+    testOutline();
+
+    // someone should have cleared the two lists before calling this.
     if( !testNetClasses() )
     {
         // testing the netclasses is a special case because if the netclasses
@@ -1165,6 +1172,17 @@ void DRC::testCopperTextItem( BOARD_ITEM* aTextItem )
 }
 
 
+void DRC::testOutline()
+{
+    wxPoint error_loc( m_pcb->GetBoardEdgesBoundingBox().GetPosition() );
+    if( !m_pcb->GetBoardPolygonOutlines( m_board_outlines, nullptr, &error_loc ) )
+    {
+        addMarkerToPcb( newMarker( error_loc, m_pcb, DRCE_INVALID_OUTLINE ) );
+        return;
+    }
+}
+
+
 void DRC::testDisabledLayers()
 {
     BOARD* board = m_pcbEditorFrame->GetBoard();

pcbnew/drc.h

@@ -32,6 +32,7 @@
 #include <vector>
 #include <memory>
 #include <geometry/seg.h>
+#include <geometry/shape_poly_set.h>
 
 #define OK_DRC  0
 #define BAD_DRC 1
@@ -94,6 +95,8 @@
 #define DRCE_BURIED_VIA_NOT_ALLOWED            49   ///< buried vias are not allowed
 #define DRCE_DISABLED_LAYER_ITEM               50   ///< item on a disabled layer
 #define DRCE_DRILLED_HOLES_TOO_CLOSE           51   ///< overlapping drilled holes break drill bits
+#define DRCE_TRACK_NEAR_EDGE                   53   ///< track too close to board edge
+#define DRCE_INVALID_OUTLINE                   54   ///< invalid board outline
 
 
 class EDA_DRAW_PANEL;
@@ -220,6 +223,7 @@ private:
 
     PCB_EDIT_FRAME*     m_pcbEditorFrame;   ///< The pcb frame editor which owns the board
     BOARD*              m_pcb;
+    SHAPE_POLY_SET      m_board_outlines;   ///< The board outline including cutouts
     DIALOG_DRC_CONTROL* m_drcDialog;
 
     DRC_LIST            m_unconnected;      ///< list of unconnected pads, as DRC_ITEMs
@@ -314,6 +318,11 @@ private:
     ///> Tests for items placed on disabled layers (causing false connections).
     void testDisabledLayers();
 
+    /**
+     * Test that the board outline is contiguous and composed of valid elements
+     */
+    void testOutline();
+
     //-----<single "item" tests>-----------------------------------------
 
     bool doNetClass( const std::shared_ptr<NETCLASS>& aNetClass, wxString& msg );

pcbnew/drc_clearance_test_functions.cpp

@@ -704,6 +704,32 @@ bool DRC::doTrackDrc( TRACK* aRefSeg, TRACK* aStart, bool testPads )
             addMarkerToPcb( newMarker( aRefSeg, zone, DRCE_TRACK_NEAR_ZONE ) );
     }
 
+    /***********************************************/
+    /* Phase 4: test DRC with to board edge        */
+    /***********************************************/
+    {
+        SEG test_seg( aRefSeg->GetStart(), aRefSeg->GetEnd() );
+
+        // the minimum distance = clearance plus half the reference track
+        // width.  Board edges do not have width or clearance values, so we
+        // look for simple crossing.
+        SEG::ecoord w_dist = aRefSeg->GetClearance() + aRefSeg->GetWidth() / 2;
+        w_dist *= w_dist;
+
+        for( auto it = m_board_outlines.IterateSegmentsWithHoles(); it; it++ )
+        {
+            if( test_seg.SquaredDistance( *it ) < w_dist )
+            {
+                auto pt = test_seg.NearestPoint( *it );
+                markers.push_back( newMarker( wxPoint( pt.x, pt.y ), aRefSeg, DRCE_TRACK_NEAR_EDGE ) );
+
+                if( !handleNewMarker() )
+                    return false;
+            }
+        }
+    }
+
+
     if( markers.size() > 0 )
     {
         commitMarkers();

pcbnew/drc_item.cpp

@@ -101,6 +101,10 @@ wxString DRC_ITEM::GetErrorText() const
         return wxString( _( "Micro via drill too small" ) );
     case DRCE_DRILLED_HOLES_TOO_CLOSE:
         return wxString( _( "Drilled holes too close together" ) );
+    case DRCE_TRACK_NEAR_EDGE:
+        return wxString( _( "Track too close to board edge" ) );
+    case DRCE_INVALID_OUTLINE:
+        return wxString( _( "Board outline does not form a closed polygon" ) );
 
     // use < since this is text ultimately embedded in HTML
     case DRCE_NETCLASS_TRACKWIDTH: