sandTable/pcb/tools/pour.py

"""Ground pour: raster fill on the router grid -> fractured polygons for KiCad.

Cells are squares of side G centred on grid points. A cell may be filled when no
foreign copper is within the pour clearance + half the cell diagonal; that radius
map already exists in the router (radius for a 0.2 mm track = 0.38 mm).
"""
from collections import deque

import router as R


def fill_mask(rt, net, layer, r_map, open_cells=2):
    k = rt.nid(net)
    nx, ny = rt.nx, rt.ny
    m = rt.maps[r_map][layer]
    mask = bytearray(nx * ny)
    for i in range(nx * ny):
        v = m[i]
        if v == -1 or v == k:
            mask[i] = 1
    # morphological opening (erode then dilate, 4-neighbourhood) removes slivers
    for _ in range(open_cells):
        mask = _erode(mask, nx, ny)
    for _ in range(open_cells):
        mask = _dilate(mask, nx, ny, limit=m, k=k)
    return mask


def _erode(mask, nx, ny):
    out = bytearray(len(mask))
    for iy in range(1, ny - 1):
        b = iy * nx
        for ix in range(1, nx - 1):
            i = b + ix
            if mask[i] and mask[i - 1] and mask[i + 1] and mask[i - nx] and mask[i + nx]:
                out[i] = 1
    return out


def _dilate(mask, nx, ny, limit, k):
    out = bytearray(mask)
    for iy in range(1, ny - 1):
        b = iy * nx
        for ix in range(1, nx - 1):
            i = b + ix
            if not mask[i] and (mask[i - 1] or mask[i + 1] or mask[i - nx] or mask[i + nx]):
                v = limit[i]
                if v == -1 or v == k:
                    out[i] = 1
    return out


def keep_connected(mask, nx, ny, anchors):
    """Keep only 4-connected components that contain an anchor cell index."""
    keep = bytearray(len(mask))
    q = deque(i for i in anchors if mask[i])
    for i in q:
        keep[i] = 1
    while q:
        i = q.popleft()
        for j in (i - 1, i + 1, i - nx, i + nx):
            if 0 <= j < len(mask) and mask[j] and not keep[j]:
                keep[j] = 1
                q.append(j)
    return keep


def contours(mask, nx, ny):
    """Boundary loops of the union of filled cells, in corner coordinates (cx, cy)
    where cell (ix, iy) spans corners (ix..ix+1, iy..iy+1). Filled area on the left."""
    edges = {}
    def add(a, b):
        edges.setdefault(a, []).append(b)
    for iy in range(ny):
        b = iy * nx
        for ix in range(nx):
            if not mask[b + ix]:
                continue
            # neighbours (outside = empty)
            up = iy > 0 and mask[b + ix - nx]
            dn = iy < ny - 1 and mask[b + ix + nx]
            lf = ix > 0 and mask[b + ix - 1]
            rt_ = ix < nx - 1 and mask[b + ix + 1]
            # traverse cell boundary counter-clockwise in screen coords (y down): filled on left
            if not up:
                add((ix + 1, iy), (ix, iy))
            if not lf:
                add((ix, iy), (ix, iy + 1))
            if not dn:
                add((ix, iy + 1), (ix + 1, iy + 1))
            if not rt_:
                add((ix + 1, iy + 1), (ix + 1, iy))
    loops = []
    while edges:
        start = next(iter(edges))
        loop = [start]
        cur = start
        prev_dir = None
        while True:
            outs = edges[cur]
            if len(outs) == 1:
                nxt = outs.pop()
            else:
                # pinch point: prefer the turn that keeps the filled region on the left (turn left first)
                best = None
                for cand in outs:
                    d = (cand[0] - cur[0], cand[1] - cur[1])
                    if prev_dir is None:
                        best = cand
                        break
                    # left turn in y-down coords: (dx,dy) -> (dy,-dx)
                    if d == (prev_dir[1], -prev_dir[0]):
                        best = cand
                        break
                if best is None:
                    best = outs[0]
                outs.remove(best)
                nxt = best
            if not outs:
                del edges[cur]
            prev_dir = (nxt[0] - cur[0], nxt[1] - cur[1])
            cur = nxt
            if cur == start:
                break
            loop.append(cur)
        loops.append(_simplify(loop))
    return loops


def _simplify(loop):
    out = []
    n = len(loop)
    for i in range(n):
        a, b, c = loop[i - 1], loop[i], loop[(i + 1) % n]
        if (b[0] - a[0]) * (c[1] - b[1]) - (b[1] - a[1]) * (c[0] - b[0]) != 0:
            out.append(b)
    return out


def area2(loop):
    s = 0
    for i in range(len(loop)):
        x1, y1 = loop[i - 1]
        x2, y2 = loop[i]
        s += x1 * y2 - x2 * y1
    return s


def point_in(loop, x, y):
    inside = False
    n = len(loop)
    for i in range(n):
        x1, y1 = loop[i - 1]
        x2, y2 = loop[i]
        if (y1 > y) != (y2 > y):
            xi = x1 + (y - y1) * (x2 - x1) / (y2 - y1)
            if xi > x:
                inside = not inside
    return inside


def fracture(outer, holes):
    """Merge holes into the outer ring with zero-width bridges (KiCad's fractured form).
    Rectilinear integer loops. Holes are bridged rightwards to the nearest vertical edge."""
    ring = list(outer)
    for hole in sorted(holes, key=lambda h: -max(p[0] for p in h)):
        xh = max(p[0] for p in hole)
        vi = min((i for i in range(len(hole)) if hole[i][0] == xh), key=lambda i: hole[i][1])
        V = hole[vi]
        best = None
        n = len(ring)
        for i in range(n):
            A, B = ring[i], ring[(i + 1) % n]
            if A[0] == B[0] and A[0] > V[0] and min(A[1], B[1]) <= V[1] <= max(A[1], B[1]):
                if best is None or A[0] < best[0]:
                    best = (A[0], i)
        if best is None:
            continue
        x, i = best
        P = (x, V[1])
        seq = hole[vi:] + hole[:vi]
        ring = ring[:i + 1] + [P] + seq + [V, P] + ring[i + 1:]
    out = []
    for p in ring:
        if not out or out[-1] != p:
            out.append(p)
    if len(out) > 1 and out[0] == out[-1]:
        out.pop()
    return out


def polygons(mask, nx, ny):
    loops = contours(mask, nx, ny)
    outers, holes = [], []
    for lp in loops:
        if len(lp) < 4:
            continue
        (outers if area2(lp) < 0 else holes).append(lp)
    result = []
    owner = {}
    for h in holes:
        x, y = h[0][0] + 1e-3, h[0][1] + 1e-3
        cands = [o for o in outers if point_in(o, x, y)]
        if cands:
            owner[id(h)] = min(cands, key=lambda o: abs(area2(o)))
    for o in outers:
        hs = [h for h in holes if owner.get(id(h)) is o]
        result.append(fracture(o, hs))
    return result


def to_mm(poly, G):
    return [((cx - 0.5) * G, (cy - 0.5) * G) for (cx, cy) in poly]