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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

(cherry picked from commit 954b265839)
This commit is contained in:
Seth Hillbrand 2023-07-06 19:23:28 -07:00
parent 90d1695bbc
commit cadea90109
6 changed files with 968 additions and 96 deletions
Show Stats Download Patch File Download Diff File Expand all files Collapse all files

8
libs/kimath/include/geometry/seg.h
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;

5
libs/kimath/include/math/box2.h
View File

@ -836,6 +836,11 @@ 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

235
pcbnew/drc/drc_test_provider_copper_clearance.cpp
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.
@ -993,19 +996,81 @@ 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 ) )
@ -1015,12 +1080,30 @@ 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,
@ -1046,102 +1129,62 @@ 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;
wxPoint pt( currentVertex.x, currentVertex.y );
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, pt, layer );
}
}
// test for some corners of zoneB inside zoneA
for( auto it = smoothed_polys[ia2].IterateWithHoles(); it; it++ )
{
VECTOR2I currentVertex = *it;
wxPoint pt( currentVertex.x, currentVertex.y );
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, pt, 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 )
@ -1153,7 +1196,7 @@ 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 );
@ -1164,13 +1207,13 @@ 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;
}
}
}
}

524
qa/data/pcbnew/intersectingzones.kicad_pcb Normal file
View File

@ -0,0 +1,524 @@
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(41 "Cmts.User" user "User.Comments")
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232
qa/data/pcbnew/intersectingzones.kicad_pro Normal file
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,
"min_microvia_diameter": 0.19999999999999998,
"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": [
{
"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_round_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_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
},
"net_colors": null,
"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": {}
}

60
qa/unittests/pcbnew/drc/test_drc_regressions.cpp
View File

@ -191,3 +191,63 @@ 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 ) );
}
}
}