Check for zone-zone overlap

Instead of just checking for the zone outline, we adjust to check the
full fill area of the zones for intersection and overlaps
This commit is contained in:
Seth Hillbrand 2023-07-06 19:23:28 -07:00
parent 2689037bde
commit 954b265839
6 changed files with 968 additions and 94 deletions

View File

@ -364,6 +364,14 @@ public:
return A + ( B - A ) / 2;
}
bool operator<( const SEG& aSeg ) const
{
if( A == aSeg.A )
return B < aSeg.B;
return A < aSeg.A;
}
private:
bool ccw( const VECTOR2I& aA, const VECTOR2I& aB, const VECTOR2I &aC ) const;

View File

@ -837,6 +837,11 @@ public:
return ( t1.m_Pos != t2.m_Pos || t1.m_Size != t2.m_Size );
}
const bool IsValid() const
{
return m_init;
}
private:
Vec m_Pos; // Rectangle Origin
Vec m_Size; // Rectangle Size

View File

@ -28,6 +28,7 @@
#include <pcb_shape.h>
#include <pad.h>
#include <pcb_track.h>
#include <thread_pool.h>
#include <zone.h>
#include <geometry/seg.h>
@ -41,6 +42,8 @@
#include <drc/drc_test_provider_clearance_base.h>
#include <pcb_dimension.h>
#include <future>
/*
Copper clearance test. Checks all copper items (pads, vias, tracks, drawings, zones) for their
electrical clearance.
@ -1028,19 +1031,81 @@ void DRC_TEST_PROVIDER_COPPER_CLEARANCE::testZonesToZones()
bool testClearance = !m_drcEngine->IsErrorLimitExceeded( DRCE_CLEARANCE );
bool testIntersects = !m_drcEngine->IsErrorLimitExceeded( DRCE_ZONES_INTERSECT );
SHAPE_POLY_SET buffer;
SHAPE_POLY_SET* boardOutline = nullptr;
DRC_CONSTRAINT constraint;
int zone2zoneClearance;
bool cancelled = false;
std::vector<std::map<PCB_LAYER_ID, std::vector<SEG>>> poly_segments;
if( m_board->GetBoardPolygonOutlines( buffer ) )
boardOutline = &buffer;
poly_segments.resize( m_board->m_DRCCopperZones.size() );
// Contains the index for zoneA, zoneB, the conflict point, the actual clearance, the required clearance, and the layer
using report_data = std::tuple<int, int, VECTOR2I, int, int, PCB_LAYER_ID>;
const int invalid_zone = -1;
std::vector<std::future<report_data>> futures;
thread_pool& tp = GetKiCadThreadPool();
auto checkZones = [testClearance, testIntersects, &poly_segments, &cancelled, invalid_zone]
( int zoneA, int zoneB,
int zone2zoneClearance, PCB_LAYER_ID layer ) -> report_data
{
// Iterate through all the segments of refSmoothedPoly
std::map<VECTOR2I, int> conflictPoints;
std::vector<SEG>& refSegments = poly_segments[zoneA][layer];
std::vector<SEG>& testSegments = poly_segments[zoneB][layer];
bool reported = false;
auto invalid_result = std::make_tuple( invalid_zone, invalid_zone, VECTOR2I(), 0, 0, F_Cu );
for( SEG& refSegment : refSegments )
{
int ax1 = refSegment.A.x;
int ay1 = refSegment.A.y;
int ax2 = refSegment.B.x;
int ay2 = refSegment.B.y;
// Iterate through all the segments in smoothed_polys[ia2]
for( SEG& testSegment : testSegments )
{
// Build test segment
VECTOR2I pt;
int bx1 = testSegment.A.x;
int by1 = testSegment.A.y;
int bx2 = testSegment.B.x;
int by2 = testSegment.B.y;
// We have ensured that the A segment starts before the B segment, so if the
// A segment ends before the B segment starts, we can skip to the next A
if( ax2 < bx1 )
break;
int d = GetClearanceBetweenSegments( bx1, by1, bx2, by2, 0,
ax1, ay1, ax2, ay2, 0,
zone2zoneClearance, &pt.x, &pt.y );
if( d < zone2zoneClearance )
{
if( d == 0 && testIntersects )
reported = true;
else if( testClearance )
reported = true;
if( reported )
return std::make_tuple( zoneA, zoneB, pt, d, zone2zoneClearance, layer );
}
if( cancelled )
return invalid_result;
}
}
return invalid_result;
};
for( int layer_id = F_Cu; layer_id <= B_Cu; ++layer_id )
{
PCB_LAYER_ID layer = static_cast<PCB_LAYER_ID>( layer_id );
std::vector<SHAPE_POLY_SET> smoothed_polys;
smoothed_polys.resize( m_board->m_DRCCopperZones.size() );
int zone2zoneClearance;
// Skip over layers not used on the current board
if( !m_board->IsLayerEnabled( layer ) )
@ -1050,12 +1115,30 @@ void DRC_TEST_PROVIDER_COPPER_CLEARANCE::testZonesToZones()
{
if( m_board->m_DRCCopperZones[ii]->IsOnLayer( layer ) )
{
m_board->m_DRCCopperZones[ii]->BuildSmoothedPoly( smoothed_polys[ii], layer,
boardOutline );
SHAPE_POLY_SET poly =
*m_board->m_DRCCopperZones[ii]->GetFilledPolysList( layer );
std::vector<SEG>& poly_segs = poly_segments[ii][layer];
poly.Fracture( SHAPE_POLY_SET::PM_FAST );
poly.BuildBBoxCaches();
poly_segs.reserve( poly.FullPointCount() );
for( auto it = poly.IterateSegmentsWithHoles(); it; it++ )
{
SEG seg = *it;
if( seg.A.x > seg.B.x )
seg.Reverse();
poly_segs.push_back( seg );
}
std::sort( poly_segs.begin(), poly_segs.end() );
}
}
// iterate through all areas
std::vector<std::pair<int, int>> zonePairs;
for( size_t ia = 0; ia < m_board->m_DRCCopperZones.size(); ia++ )
{
if( !reportProgress( layer_id * m_board->m_DRCCopperZones.size() + ia,
@ -1081,100 +1164,62 @@ void DRC_TEST_PROVIDER_COPPER_CLEARANCE::testZonesToZones()
if( zoneA->GetNetCode() == zoneB->GetNetCode() && zoneA->GetNetCode() >= 0 )
continue;
// test for different priorities
if( zoneA->GetAssignedPriority() != zoneB->GetAssignedPriority() )
continue;
// rule areas may overlap at will
if( zoneA->GetIsRuleArea() || zoneB->GetIsRuleArea() )
continue;
// Examine a candidate zone: compare zoneB to zoneA
SHAPE_POLY_SET* polyA = m_board->m_DRCCopperZones[ia]->GetFill( layer );
SHAPE_POLY_SET* polyB = m_board->m_DRCCopperZones[ia2]->GetFill( layer );
if( !polyA->BBoxFromCaches().Intersects( polyB->BBoxFromCaches() ) )
continue;
// Get clearance used in zone to zone test.
constraint = m_drcEngine->EvalRules( CLEARANCE_CONSTRAINT, zoneA, zoneB, layer );
zone2zoneClearance = constraint.GetValue().Min();
if( constraint.GetSeverity() == RPT_SEVERITY_IGNORE )
if( constraint.GetSeverity() == RPT_SEVERITY_IGNORE || zone2zoneClearance <= 0 )
continue;
if( testIntersects )
futures.push_back( tp.submit( checkZones, ia, ia2, zone2zoneClearance, layer ) );
}
}
}
for( auto& task : futures )
{
if( !task.valid() )
continue;
std::future_status result;
while( true )
{
result = task.wait_for( std::chrono::milliseconds( 200 ) );
if( m_drcEngine->IsCancelled() )
{
cancelled = true;
break;
}
if( result == std::future_status::ready )
{
report_data data = task.get();
int zoneA_id = std::get<0>( data );
int zoneB_id = std::get<1>( data );
VECTOR2I pt = std::get<2>( data );
int actual = std::get<3>( data );
int required = std::get<4>( data );
PCB_LAYER_ID layer = std::get<5>( data );
if( zoneA_id != invalid_zone )
{
// test for some corners of zoneA inside zoneB
for( auto it = smoothed_polys[ia].IterateWithHoles(); it; it++ )
{
VECTOR2I currentVertex = *it;
ZONE* zoneA = m_board->m_DRCCopperZones[zoneA_id];
ZONE* zoneB = m_board->m_DRCCopperZones[zoneB_id];
if( smoothed_polys[ia2].Contains( currentVertex ) )
{
std::shared_ptr<DRC_ITEM> drce = DRC_ITEM::Create( DRCE_ZONES_INTERSECT );
drce->SetItems( zoneA, zoneB );
drce->SetViolatingRule( constraint.GetParentRule() );
reportViolation( drce, currentVertex, layer );
}
}
// test for some corners of zoneB inside zoneA
for( auto it = smoothed_polys[ia2].IterateWithHoles(); it; it++ )
{
VECTOR2I currentVertex = *it;
if( smoothed_polys[ia].Contains( currentVertex ) )
{
std::shared_ptr<DRC_ITEM> drce = DRC_ITEM::Create( DRCE_ZONES_INTERSECT );
drce->SetItems( zoneB, zoneA );
drce->SetViolatingRule( constraint.GetParentRule() );
reportViolation( drce, currentVertex, layer );
}
}
}
// Iterate through all the segments of refSmoothedPoly
std::map<VECTOR2I, int> conflictPoints;
for( auto refIt = smoothed_polys[ia].IterateSegmentsWithHoles(); refIt; refIt++ )
{
// Build ref segment
SEG refSegment = *refIt;
// Iterate through all the segments in smoothed_polys[ia2]
for( auto it = smoothed_polys[ia2].IterateSegmentsWithHoles(); it; it++ )
{
// Build test segment
SEG testSegment = *it;
VECTOR2I pt;
int ax1, ay1, ax2, ay2;
ax1 = refSegment.A.x;
ay1 = refSegment.A.y;
ax2 = refSegment.B.x;
ay2 = refSegment.B.y;
int bx1, by1, bx2, by2;
bx1 = testSegment.A.x;
by1 = testSegment.A.y;
bx2 = testSegment.B.x;
by2 = testSegment.B.y;
int d = GetClearanceBetweenSegments( bx1, by1, bx2, by2, 0,
ax1, ay1, ax2, ay2, 0,
zone2zoneClearance, &pt.x, &pt.y );
if( d < zone2zoneClearance )
{
if( conflictPoints.count( pt ) )
conflictPoints[ pt ] = std::min( conflictPoints[ pt ], d );
else
conflictPoints[ pt ] = d;
}
}
}
for( const std::pair<const VECTOR2I, int>& conflict : conflictPoints )
{
int actual = conflict.second;
constraint = m_drcEngine->EvalRules( CLEARANCE_CONSTRAINT, zoneA, zoneB, layer );
std::shared_ptr<DRC_ITEM> drce;
if( actual <= 0 && testIntersects )
@ -1186,7 +1231,7 @@ void DRC_TEST_PROVIDER_COPPER_CLEARANCE::testZonesToZones()
drce = DRC_ITEM::Create( DRCE_CLEARANCE );
wxString msg = formatMsg( _( "(%s clearance %s; actual %s)" ),
constraint.GetName(),
zone2zoneClearance,
required,
std::max( actual, 0 ) );
drce->SetErrorMessage( drce->GetErrorText() + wxS( " " ) + msg );
@ -1197,13 +1242,13 @@ void DRC_TEST_PROVIDER_COPPER_CLEARANCE::testZonesToZones()
drce->SetItems( zoneA, zoneB );
drce->SetViolatingRule( constraint.GetParentRule() );
reportViolation( drce, conflict.first, layer );
reportViolation( drce, pt, layer );
}
}
if( m_drcEngine->IsCancelled() )
return;
break;
}
}
}
}

View File

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View File

@ -0,0 +1,232 @@
{
"board": {
"3dviewports": [],
"design_settings": {
"defaults": {
"board_outline_line_width": 0.049999999999999996,
"copper_line_width": 0.19999999999999998,
"copper_text_italic": false,
"copper_text_size_h": 1.5,
"copper_text_size_v": 1.5,
"copper_text_thickness": 0.3,
"copper_text_upright": false,
"courtyard_line_width": 0.049999999999999996,
"dimension_precision": 4,
"dimension_units": 3,
"dimensions": {
"arrow_length": 1270000,
"extension_offset": 500000,
"keep_text_aligned": true,
"suppress_zeroes": false,
"text_position": 0,
"units_format": 1
},
"fab_line_width": 0.09999999999999999,
"fab_text_italic": false,
"fab_text_size_h": 1.0,
"fab_text_size_v": 1.0,
"fab_text_thickness": 0.15,
"fab_text_upright": false,
"other_line_width": 0.09999999999999999,
"other_text_italic": false,
"other_text_size_h": 1.0,
"other_text_size_v": 1.0,
"other_text_thickness": 0.15,
"other_text_upright": false,
"pads": {
"drill": 0.0,
"height": 1.0,
"width": 1.0
},
"silk_line_width": 0.09999999999999999,
"silk_text_italic": false,
"silk_text_size_h": 1.0,
"silk_text_size_v": 1.0,
"silk_text_thickness": 0.09999999999999999,
"silk_text_upright": false,
"zones": {
"min_clearance": 0.5
}
},
"diff_pair_dimensions": [],
"drc_exclusions": [],
"meta": {
"version": 2
},
"rule_severities": {
"annular_width": "error",
"clearance": "error",
"connection_width": "warning",
"copper_edge_clearance": "error",
"copper_sliver": "warning",
"courtyards_overlap": "error",
"diff_pair_gap_out_of_range": "error",
"diff_pair_uncoupled_length_too_long": "error",
"drill_out_of_range": "error",
"duplicate_footprints": "warning",
"extra_footprint": "warning",
"footprint": "error",
"footprint_type_mismatch": "ignore",
"hole_clearance": "error",
"hole_near_hole": "error",
"invalid_outline": "error",
"isolated_copper": "warning",
"item_on_disabled_layer": "error",
"items_not_allowed": "error",
"length_out_of_range": "error",
"lib_footprint_issues": "warning",
"lib_footprint_mismatch": "warning",
"malformed_courtyard": "error",
"microvia_drill_out_of_range": "error",
"missing_courtyard": "ignore",
"missing_footprint": "warning",
"net_conflict": "warning",
"npth_inside_courtyard": "ignore",
"padstack": "warning",
"pth_inside_courtyard": "ignore",
"shorting_items": "error",
"silk_edge_clearance": "warning",
"silk_over_copper": "warning",
"silk_overlap": "warning",
"skew_out_of_range": "error",
"solder_mask_bridge": "error",
"starved_thermal": "error",
"text_height": "warning",
"text_thickness": "warning",
"through_hole_pad_without_hole": "error",
"too_many_vias": "error",
"track_dangling": "warning",
"track_width": "error",
"tracks_crossing": "error",
"unconnected_items": "error",
"unresolved_variable": "error",
"via_dangling": "warning",
"zones_intersect": "error"
},
"rules": {
"max_error": 0.005,
"min_clearance": 0.0,
"min_connection": 0.0,
"min_copper_edge_clearance": 0.5,
"min_hole_clearance": 0.25,
"min_hole_to_hole": 0.25,
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"min_microvia_drill": 0.09999999999999999,
"min_resolved_spokes": 2,
"min_silk_clearance": 0.0,
"min_text_height": 0.7999999999999999,
"min_text_thickness": 0.08,
"min_through_hole_diameter": 0.3,
"min_track_width": 0.0,
"min_via_annular_width": 0.09999999999999999,
"min_via_diameter": 0.5,
"solder_mask_to_copper_clearance": 0.0,
"use_height_for_length_calcs": true
},
"teardrop_options": [
{
"td_onpadsmd": true,
"td_onroundshapesonly": false,
"td_ontrackend": false,
"td_onviapad": true
}
],
"teardrop_parameters": [
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"td_curve_segcount": 0,
"td_height_ratio": 1.0,
"td_length_ratio": 0.5,
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"td_target_name": "td_round_shape",
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},
{
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"td_curve_segcount": 0,
"td_height_ratio": 1.0,
"td_length_ratio": 0.5,
"td_maxheight": 2.0,
"td_maxlen": 1.0,
"td_on_pad_in_zone": false,
"td_target_name": "td_rect_shape",
"td_width_to_size_filter_ratio": 0.9
},
{
"td_allow_use_two_tracks": true,
"td_curve_segcount": 0,
"td_height_ratio": 1.0,
"td_length_ratio": 0.5,
"td_maxheight": 2.0,
"td_maxlen": 1.0,
"td_on_pad_in_zone": false,
"td_target_name": "td_track_end",
"td_width_to_size_filter_ratio": 0.9
}
],
"track_widths": [],
"via_dimensions": [],
"zones_allow_external_fillets": false
},
"layer_presets": [],
"viewports": []
},
"boards": [],
"cvpcb": {
"equivalence_files": []
},
"libraries": {
"pinned_footprint_libs": [],
"pinned_symbol_libs": []
},
"meta": {
"filename": "intersectingzones.kicad_pro",
"version": 1
},
"net_settings": {
"classes": [
{
"bus_width": 12,
"clearance": 0.2,
"diff_pair_gap": 0.25,
"diff_pair_via_gap": 0.25,
"diff_pair_width": 0.2,
"line_style": 0,
"microvia_diameter": 0.3,
"microvia_drill": 0.1,
"name": "Default",
"pcb_color": "rgba(0, 0, 0, 0.000)",
"schematic_color": "rgba(0, 0, 0, 0.000)",
"track_width": 0.2,
"via_diameter": 0.6,
"via_drill": 0.3,
"wire_width": 6
}
],
"meta": {
"version": 3
},
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"netclass_assignments": null,
"netclass_patterns": []
},
"pcbnew": {
"last_paths": {
"gencad": "",
"idf": "",
"netlist": "",
"specctra_dsn": "",
"step": "",
"vrml": ""
},
"page_layout_descr_file": ""
},
"schematic": {
"legacy_lib_dir": "",
"legacy_lib_list": []
},
"sheets": [],
"text_variables": {}
}

View File

@ -187,3 +187,63 @@ BOOST_FIXTURE_TEST_CASE( DRCFalseNegativeRegressions, DRC_REGRESSION_TEST_FIXTUR
}
}
}
BOOST_FIXTURE_TEST_CASE( DRCFalseNegativeRegressionsNoFill, DRC_REGRESSION_TEST_FIXTURE )
{
// These documents at one time failed to catch DRC errors that they should have but only
// when the zones were filled. In other words, refilling the zone will fix the error, but
// DRC should have caught it regardless
std::vector< std::pair<wxString, int> > tests =
{
{ "intersectingzones", 1 } // zones are too close to each other
};
for( const std::pair<wxString, int>& entry : tests )
{
KI_TEST::LoadBoard( m_settingsManager, entry.first, m_board );
std::vector<DRC_ITEM> violations;
BOARD_DESIGN_SETTINGS& bds = m_board->GetDesignSettings();
// Disable DRC tests not useful in this testcase
bds.m_DRCSeverities[ DRCE_COPPER_SLIVER ] = SEVERITY::RPT_SEVERITY_IGNORE;
bds.m_DRCSeverities[ DRCE_LIB_FOOTPRINT_ISSUES ] = SEVERITY::RPT_SEVERITY_IGNORE;
bds.m_DRCSeverities[ DRCE_LIB_FOOTPRINT_MISMATCH ] = SEVERITY::RPT_SEVERITY_IGNORE;
bds.m_DRCEngine->SetViolationHandler(
[&]( const std::shared_ptr<DRC_ITEM>& aItem, VECTOR2I aPos, int aLayer )
{
PCB_MARKER temp( aItem, aPos );
if( bds.m_DrcExclusions.find( temp.Serialize() ) == bds.m_DrcExclusions.end() )
violations.push_back( *aItem );
} );
bds.m_DRCEngine->RunTests( EDA_UNITS::MILLIMETRES, true, false );
if( violations.size() == entry.second )
{
BOOST_CHECK_EQUAL( 1, 1 ); // quiet "did not check any assertions" warning
BOOST_TEST_MESSAGE( wxString::Format( "DRC regression: %s, passed", entry.first ) );
}
else
{
BOOST_CHECK_EQUAL( violations.size(), entry.second );
UNITS_PROVIDER unitsProvider( pcbIUScale, EDA_UNITS::INCHES );
std::map<KIID, EDA_ITEM*> itemMap;
m_board->FillItemMap( itemMap );
for( const DRC_ITEM& item : violations )
{
BOOST_TEST_MESSAGE( item.ShowReport( &unitsProvider, RPT_SEVERITY_ERROR,
itemMap ) );
}
BOOST_ERROR( wxString::Format( "DRC regression: %s, failed", entry.first ) );
}
}
}