0hmX/am3352

scripts/plan-ddr-global-planes.ts

/** Isolated global PDN plane candidate. Does not mutate the frozen host capture.
 * Every conductor retains explicit schematic identity. All foreign through
 * barrels and planar copper are subtracted, including newly planned support.
 * Polygon boolean operations merge overlapping antipads; existing local voids
 * are retained except the eight explicitly rail-joined ground holes per plane.
 */
import {readFileSync,writeFileSync,mkdirSync} from 'node:fs'
import {resolve} from 'node:path'
import {createHash} from 'node:crypto'
import F from '@flatten-js/core'
import {verifyDdrCapture} from './ddr-capture-provenance'
import {verifyDdrSystemCopper} from './check-ddr-system-copper'
type P={x:number,y:number}
const hash=(v:any)=>createHash('sha256').update(JSON.stringify(v)).digest('hex')
const read=(p:string)=>JSON.parse(readFileSync(p,'utf8'))
class Union{p=new Map<string,string>();find(x:string):string{const p=this.p.get(x);if(!p){this.p.set(x,x);return x}if(p===x)return x;const r=this.find(p);this.p.set(x,r);return r}join(a:string,b:string){this.p.set(this.find(a),this.find(b))}}
function hull(points:P[]){const p=[...points].sort((a,b)=>a.x-b.x||a.y-b.y),cross=(a:P,b:P,c:P)=>(b.x-a.x)*(c.y-a.y)-(b.y-a.y)*(c.x-a.x),lo:P[]=[],hi:P[]=[];for(const a of p){while(lo.length>1&&cross(lo.at(-2)!,lo.at(-1)!,a)<=1e-12)lo.pop();lo.push(a)}for(const a of p.toReversed()){while(hi.length>1&&cross(hi.at(-2)!,hi.at(-1)!,a)<=1e-12)hi.pop();hi.push(a)}return [...lo.slice(0,-1),...hi.slice(0,-1)]}
const circle=(p:P,r:number)=>Array.from({length:32},(_,i)=>({x:p.x+r/Math.cos(Math.PI/32)*Math.cos(i*Math.PI/16),y:p.y+r/Math.cos(Math.PI/32)*Math.sin(i*Math.PI/16)}))
const poly=(points:P[])=>new F.Polygon(points.map(p=>[p.x,p.y]))
function ps(p:P,a:P,b:P){const dx=b.x-a.x,dy=b.y-a.y,t=Math.max(0,Math.min(1,((p.x-a.x)*dx+(p.y-a.y)*dy)/(dx*dx+dy*dy)||0));return Math.hypot(p.x-a.x-t*dx,p.y-a.y-t*dy)}
if(import.meta.main){
 const dir=resolve(process.argv[2]??'dist/ddr-system/host-taps-54af3e346b5e'),out=resolve(process.argv[3]??'dist/ddr-global-plane-plan'),{captureHash}=verifyDdrCapture(dir)
 const reuse=process.argv.includes('--reuse'),original=read(`${dir}/unrouted.circuit.json`),drop=read(`${dir}/${reuse?'power-via-reuse/candidate.json':'power-drop-exact-width/accepted-candidate.json'}`),host=read(`${dir}/data-d4-tuned/candidate.physical.json`),capRaw=read('dist/ddr-ram-decoupling-plan/candidate.circuit.json'),local=read(`${dir}/power-drop-exact-width/accepted-reference-planes.json`),connections=read(`${dir}/merged-routing-input.json`).connections
 if(drop.captureHash!==captureHash||host.captureHash!==captureHash||host.layerSpace!=='physical'||drop.replacements.length!==(reuse?28:24)||host.traces.length!==7)throw Error('Capture or expected candidate inventory mismatch')
 const ids=new Map(capRaw.filter((e:any)=>e[`${e.type}_id`]).map((e:any)=>[e[`${e.type}_id`],`power_plan_caps_${e[`${e.type}_id`]}`])),remap=(v:any):any=>Array.isArray(v)?v.map(remap):v&&typeof v==='object'?Object.fromEntries(Object.entries(v).map(([k,x])=>[k,remap(x)])):typeof v==='string'?ids.get(v)??v:v,caps=remap(capRaw).filter((e:any)=>!['pcb_board','source_board'].includes(e.type))
 const capRailConnections=caps.filter((e:any)=>e.type==='source_net').map((local:any)=>{
  const name=local.name==='DDR_1V5'?'VCC_DDR_1V5':local.name==='GND'?'GND':null
  if(!name)throw Error(`Unexpected cap rail ${local.name}`)
  const targets=original.filter((e:any)=>e.type==='source_net'&&e.name===name)
  if(targets.length!==1)throw Error(`Ambiguous global cap rail ${name}`)
  const ports=[...new Set(caps.filter((e:any)=>e.type==='source_trace'&&e.connected_source_net_ids?.includes(local.source_net_id)).flatMap((e:any)=>e.connected_source_port_ids??[]))]
  if(!ports.length)throw Error(`Cap rail has no actual source ports ${name}`)
  return {type:'source_trace',source_trace_id:`planned_capbank_${name}`,connected_source_port_ids:ports,connected_source_net_ids:[local.source_net_id,targets[0].source_net_id],name:`Cap bank connection to ${name}`}
 })
 const removed=new Set(drop.replacements.map((e:any)=>e.pcb_trace_id)),base=[...original.filter((e:any)=>e.type!=='pcb_copper_pour'&&!removed.has(e.pcb_trace_id)),...caps,...drop.supportConnections,...capRailConnections],all=[...base,...drop.replacements,...host.traces],aliases={...drop.aliases},electrical=new Union(),byId=new Map(all.map((e:any)=>[e[`${e.type}_id`],e]))
 for(const t of all.filter((e:any)=>e.type==='source_trace')){const ids=[t.source_trace_id,...t.connected_source_port_ids??[],...t.connected_source_net_ids??[]];for(const id of ids)electrical.join(ids[0],id)}
 for(const [a,b]of Object.entries(aliases))electrical.join(a,b as string)
 for(const c of connections)for(const id of [c.source_trace_id,...c.mergedConnectionNames??[],c.rootConnectionName].filter(Boolean))electrical.join(c.name,id)
 const net=(e:any):string=>{if(e.type==='pcb_via'&&e.pcb_trace_id){const owner=byId.get(e.pcb_trace_id)as any;if(!owner||owner.type!=='pcb_trace'||!owner.route.some((p:any)=>p.route_type==='via'&&Math.hypot(p.x-e.x,p.y-e.y)<1e-7&&Math.abs((p.via_diameter??.4572)-e.outer_diameter)<1e-7&&Math.abs((p.via_hole_diameter??.254)-e.hole_diameter)<1e-7))throw Error(`Unverified via owner ${e.pcb_via_id}`);const ownerNet=net(owner);for(const id of [e.source_net_id,e.source_trace_id].filter(Boolean))if(electrical.find(id)!==ownerNet)throw Error(`Conflicting via owner identity ${e.pcb_via_id}`);return ownerNet}const ids=[e.source_net_id,e.source_trace_id,e.source_port_id,e.pcb_port_id?(byId.get(e.pcb_port_id)as any)?.source_port_id:undefined,e.connection_name].filter(Boolean);if(!ids.length)throw Error(`Missing copper net identity ${e.type}:${e[`${e.type}_id`]}`);for(const id of ids)electrical.join(ids[0],id);return electrical.find(ids[0])}
 for(const e of [...all,...local].filter(e=>['pcb_trace','pcb_via','pcb_smtpad','pcb_copper_pour'].includes(e.type)))net(e)
 const rail=(name:string)=>{const es=original.filter((e:any)=>e.type==='source_net'&&e.name===name);if(es.length!==1)throw Error(`Ambiguous rail ${name}`);return es[0].source_net_id},gnd=rail('GND'),vdd=rail('VCC_DDR_1V5')
 type Copper={id:string,net:string,layers:string[],a:P,b:P,r:number,vertices?:P[]}
 const copper:Copper[]=[],layers=['top',...Array.from({length:8},(_,i)=>`inner${i+1}`),'bottom']
 for(const e of all){
  if(e.type==='pcb_via')copper.push({id:e.pcb_via_id,net:net(e),layers,a:e,b:e,r:e.outer_diameter/2})
  if(e.type==='pcb_trace')for(let i=0;i<e.route.length;i++){const p=e.route[i],q=e.route[i-1];if(p.route_type==='via')copper.push({id:`${e.pcb_trace_id}:via:${i}`,net:net(e),layers,a:p,b:p,r:(p.via_diameter??.4572)/2});else if(q?.route_type==='wire'&&q.layer===p.layer)copper.push({id:`${e.pcb_trace_id}:${i}`,net:net(e),layers:[p.layer],a:q,b:p,r:Math.max(p.width,q.width)/2})}
  if(e.type==='pcb_smtpad'&&['inner1','inner3','inner5'].includes(e.layer))throw Error('Unimplemented internal-layer pad offset; fail closed')
  if(['pcb_plated_hole','pcb_cutout'].includes(e.type))throw Error(`Unsupported copper ${e.type}`)
 }
 mkdirSync(out,{recursive:true});const planes:any[]=[],planeAudit:any[]=[]
 for(const [layer,source_net_id]of [['inner1',gnd],['inner3',vdd],['inner5',gnd]]){
  const target=electrical.find(source_net_id),foreign=copper.filter(c=>c.layers.includes(layer)&&c.net!==target),own=copper.filter(c=>c.layers.includes(layer)&&c.net===target),oldHoleRecords=local.filter((p:any)=>p.layer===layer).flatMap((p:any)=>p.brep_shape.inner_rings.map((r:any,i:number)=>({planeId:p.pcb_copper_pour_id,holeIndex:i,vertices:r.vertices}))),clearance=.105
  let region=poly([{x:-31,y:-20},{x:31,y:-20},{x:31,y:20},{x:-31,y:20}])
  const refillOwners=new Set(['3','5'].flatMap(group=>[16,49,51,53].map(index=>`saved_fanout_pcb_group_${group}_${index}:via:2`))),refillVias=own.filter(c=>refillOwners.has(c.id)),refilledHoles:any[]=[],oldHoles:P[][]=[]
  for(const h of oldHoleRecords){const matches=refillVias.filter(v=>poly(h.vertices).contains(new F.Point(v.a.x,v.a.y)));if(matches.length){if(matches.length!==1||target!==electrical.find(gnd))throw Error('Ambiguous authorized ground hole refill');refilledHoles.push({...h,viaId:matches[0].id,viaCenter:matches[0].a,reason:'Explicit support source_trace joins this previously independent VSS/VSSQ escape to CPU GND; remove obsolete ground antipad and revalidate all foreign conductors.'})}else oldHoles.push(h.vertices)}
  if(layer!=='inner3'&&refilledHoles.length!==8)throw Error(`Expected eight explicitly authorized obsolete ground holes on ${layer}, found ${refilledHoles.length}`)
  let count=0;for(const ring of oldHoles)region=F.BooleanOperations.subtract(region,poly(ring))
  for(const c of foreign){if(!(Number.isFinite(c.r)&&c.r>0))throw Error(`Invalid conductor radius ${c.id}`);region=F.BooleanOperations.subtract(region,poly(hull([...circle(c.a,c.r+clearance),...circle(c.b,c.r+clearance)])));if(++count%100===0)console.log(`${layer}: ${count}/${foreign.length} foreign conductors subtracted`)}
  const faces=[...region.faces],outers=faces.filter(f=>f.orientation()===-1),holes=faces.filter(f=>f.orientation()===1),vertices=(f:any)=>[...f.edges].map((e:any)=>({x:e.start.x,y:e.start.y}))
  if(outers.length!==1)throw Error(`Global plane fragmented into ${outers.length} islands on ${layer}`)
  const outer=vertices(outers[0]),rings=holes.map(vertices),edges=[outer,...rings].flatMap(r=>r.map((a,i)=>[a,r[(i+1)%r.length]]as[P,P]))
  const failures:any[]=[],contacts:any[]=[];let minGap=Infinity
  // Check all foreign copper independently against final boolean geometry.
  // Segment distanceTo accounts for an interior crossing, unlike endpoint-only sampling.
  for(const c of foreign){const seg=new F.Segment(new F.Point(c.a.x,c.a.y),new F.Point(c.b.x,c.b.y));const inside=region.contains(new F.Point(c.a.x,c.a.y))||region.contains(new F.Point(c.b.x,c.b.y));const distance=Math.hypot(c.b.x-c.a.x,c.b.y-c.a.y)<1e-12?Math.min(...edges.map(([a,b])=>ps(c.a,a,b))):seg.distanceTo(region)[0];const gap=(inside?0:distance)-c.r;minGap=Math.min(minGap,gap);if(gap<.1016-1e-7)failures.push({id:c.id,gap,a:c.a,b:c.b,r:c.r})}
  for(const c of own.filter(c=>c.a.x===c.b.x&&c.a.y===c.b.y)){const annulus=Array.from({length:32},(_,i)=>new F.Point(c.a.x+c.r*.9*Math.cos(i*Math.PI/16),c.a.y+c.r*.9*Math.sin(i*Math.PI/16))),n=annulus.filter(p=>region.contains(p)).length;contacts.push({id:c.id,x:c.a.x,y:c.a.y,annulusSamplesInPlane:n,total:32});}
  const missing=contacts.filter(c=>c.annulusSamplesInPlane!==32),unique=(xs:any[])=>[...new Map(xs.map(c=>[`${c.x.toFixed(7)},${c.y.toFixed(7)}`,c])).values()]
  const plane={type:'pcb_copper_pour',pcb_copper_pour_id:`planned_global_${layer}`,shape:'brep',layer,source_net_id,covered_with_solder_mask:true,brep_shape:{outer_ring:{vertices:outer},inner_rings:rings.map(vertices=>({vertices}))}}
  planes.push(plane);planeAudit.push({layer,source_net_id,outerComponents:outers.length,holes:rings.length,originalLocalHolesSubtracted:oldHoles.length,refilledHoles,foreignConductors:foreign.length,minForeignClearanceMm:minGap,failures,viaContacts:contacts,uniqueViaCount:unique(contacts).length,uniqueMissingFullAnnulusContacts:unique(missing),capViaContacts:contacts.filter(c=>c.id.startsWith('power_plan_caps_')),missingFullAnnulusContacts:missing,scope:'32 annulus samples plus full foreign-conductor distance; effective capacitance and complete PDN impedance unqualified.'})
  writeFileSync(`${out}/planes.partial.json`,JSON.stringify(planes,null,2));console.log(JSON.stringify({layer,holes:rings.length,failures:failures.length,contacts:contacts.length,missing:missing.length,minGap}))
 }
 const physical=verifyDdrSystemCopper([...base,...planes],[...host.traces,...drop.replacements],connections,aliases)
 const aliasFreePhysical=verifyDdrSystemCopper([...base,...planes],[...host.traces,...drop.replacements],connections,{})
 const candidate=[...all,...planes],report={captureHash,hostTracesSha256:hash(host.traces),dropReplacementsSha256:hash(drop.replacements),capCircuitSha256:hash(capRaw),localPlanesSha256:hash(local),aliases,capRailConnections,aliasFreePhysical,planeAudit,physical,retainedLocalPlanes:false,localVoidGeometryPreservedBySubtractionExceptExplicitGroundRefills:true,replacedOuterBoundary:'Global outline x +/-31mm, y +/-20mm; four local ground regions absorbed into two global ground planes.',scope:`Isolated partial PDN candidate, 28 caps, ${drop.replacements.length} early/reused drops and ${host.traces.length} immutable signal routes. ${38-drop.replacements.length} outer RAM power launches remain unresolved; no DDR signoff.`}
 writeFileSync(`${out}/candidate.circuit.json`,JSON.stringify(candidate,null,2));writeFileSync(`${out}/planes.json`,JSON.stringify(planes,null,2));writeFileSync(`${out}/report.json`,JSON.stringify(report,null,2));console.log(JSON.stringify({out,errors:physical.errors.length,violations:physical.violations.length,connected:physical.connectivity.filter(c=>c.connected).length}))
}