Eliminate false DRC via-collision errors by carrying true routed via diameters through SRJ→circuit-json conversion

Author: AnasSarkiz

lib/testing/utils/convertToCircuitJson.ts

@@ -365,7 +365,7 @@ function createPcbSmtPads(srj: SimpleRouteJson): AnyCircuitElement[] {
  */
 function extractViasFromRoutes(
   routes: SimplifiedPcbTrace[] | HighDensityRoute[],
-  minViaDiameter = 0.6,
+  minViaDiameter = 0.3,
 ): PcbVia[] {
   const vias: PcbVia[] = []
   const viaLocations = new Set<string>() // Track unique via locations
@@ -376,6 +376,7 @@ function extractViasFromRoutes(
       ;(routes as SimplifiedPcbTrace[]).forEach((trace) => {
         trace.route.forEach((segment) => {
           if (segment.route_type === "via") {
+            const viaDiameter = segment.via_diameter ?? minViaDiameter
             const locationKey = `${segment.x},${segment.y},${segment.from_layer},${segment.to_layer}`
             if (!viaLocations.has(locationKey)) {
               vias.push({
@@ -384,8 +385,8 @@ function extractViasFromRoutes(
                 pcb_trace_id: trace.pcb_trace_id,
                 x: segment.x,
                 y: segment.y,
-                outer_diameter: minViaDiameter,
-                hole_diameter: minViaDiameter * 0.5,
+                outer_diameter: viaDiameter,
+                hole_diameter: viaDiameter * 0.5,
                 layers: [segment.from_layer, segment.to_layer] as LayerName[],
               })
               viaLocations.add(locationKey)
@@ -397,7 +398,7 @@ function extractViasFromRoutes(
       // Extract vias from HighDensityRoutes by looking for layer changes
       ;(routes as HighDensityRoute[]).forEach((route, routeIndex) => {
         const traceId = `trace_${routeIndex}`
-        const viaDiameter = route.viaDiameter || minViaDiameter
+        const viaDiameter = route.viaDiameter ?? minViaDiameter
         for (let i = 1; i < route.route.length; i++) {
           const prevPoint = route.route[i - 1]
           const currPoint = route.route[i]
@@ -445,7 +446,7 @@ export function convertToCircuitJson(
   srjWithPointPairs: SimpleRouteJson,
   routes: SimplifiedPcbTrace[] | HighDensityRoute[],
   minTraceWidth = 0.1,
-  minViaDiameter = 0.6,
+  minViaDiameter = srjWithPointPairs.minViaDiameter ?? 0.3,
 ): AnyCircuitElement[] {
   // Start with empty circuit JSON
   const circuitJson: AnyCircuitElement[] = []

lib/types/srj-types.ts

@@ -97,6 +97,7 @@ export interface SimplifiedPcbTrace {
         y: number
         to_layer: string
         from_layer: string
+        via_diameter?: number
       }
     | {
         route_type: "jumper"

lib/utils/convertHdRouteToSimplifiedRoute.ts

@@ -58,6 +58,7 @@ export const convertHdRouteToSimplifiedRoute = (
           y: point.y,
           from_layer: fromLayer,
           to_layer: toLayer,
+          via_diameter: hdRoute.viaDiameter,
         })
       }
 

tests/features/fixed-topology-high-density-intra-node-solver.test.ts

@@ -5,10 +5,12 @@ import { getDrcErrors } from "lib/testing/getDrcErrors"
 import { convertToCircuitJson } from "lib/testing/utils/convertToCircuitJson"
 import { createSrjFromNodeWithPortPoints } from "lib/utils/createSrjFromNodeWithPortPoints"
 import { HyperSingleIntraNodeSolver } from "lib/solvers/HyperHighDensitySolver/HyperSingleIntraNodeSolver"
+import { convertHdRouteToSimplifiedRoute } from "lib/utils/convertHdRouteToSimplifiedRoute"
 import input03 from "../../fixtures/features/via-high-density/via-high-density03-input.json" with {
   type: "json",
 }
 import { FixedTopologyHighDensityIntraNodeSolver } from "lib/solvers/FixedTopologyHighDensityIntraNodeSolver"
+import type { SimplifiedPcbTrace } from "lib/types"
 
 test("FixedTopologyHighDensityIntraNodeSolver test", () => {
   const solver = new FixedTopologyHighDensityIntraNodeSolver({
@@ -47,6 +49,30 @@ test("FixedTopologyHighDensityIntraNodeSolver test", () => {
       ),
   )
   expect(hasBottomLayerTrace).toBe(true)
+  expect(
+    circuitJson
+      .filter((element) => element.type === "pcb_via")
+      .every((via) => via.outer_diameter <= 0.3 + 1e-6),
+  ).toBe(true)
+
+  const simplifiedTraces: SimplifiedPcbTrace[] = solver.solvedRoutes.map(
+    (route, index) => ({
+      type: "pcb_trace",
+      pcb_trace_id: `fixed_topology_${index}`,
+      connection_name: route.connectionName,
+      route: convertHdRouteToSimplifiedRoute(route, srj.layerCount),
+    }),
+  )
+  const circuitJsonFromSimplified = convertToCircuitJson(
+    srj,
+    simplifiedTraces,
+    srj.minTraceWidth,
+  )
+  expect(
+    circuitJsonFromSimplified
+      .filter((element) => element.type === "pcb_via")
+      .every((via) => via.outer_diameter <= 0.3 + 1e-6),
+  ).toBe(true)
 
   const pcbSvg = convertCircuitJsonToPcbSvg(circuitJson as AnyCircuitElement[])
   expect(pcbSvg).toMatchSvgSnapshot(import.meta.path)

tests/utils/convertHdRouteToSimplifiedRoute.test.ts

@@ -85,6 +85,7 @@ describe("convertHdRouteToSimplifiedRoute", () => {
           "from_layer": "top",
           "route_type": "via",
           "to_layer": "inner1",
+          "via_diameter": 0.5,
           "x": 2,
           "y": 2,
         },
@@ -113,6 +114,7 @@ describe("convertHdRouteToSimplifiedRoute", () => {
           "from_layer": "inner1",
           "route_type": "via",
           "to_layer": "inner2",
+          "via_diameter": 0.5,
           "x": 4,
           "y": 4,
         },
@@ -187,6 +189,7 @@ describe("convertHdRouteToSimplifiedRoute", () => {
           "from_layer": "top",
           "route_type": "via",
           "to_layer": "inner1",
+          "via_diameter": 0.4,
           "x": 2,
           "y": 2,
         },

tests/utils/convertToCircuitJson-via-diameter.test.ts

@@ -0,0 +1,70 @@
+import { expect, test } from "bun:test"
+import type { SimpleRouteJson, SimplifiedPcbTrace } from "lib/types"
+import { convertToCircuitJson } from "lib/testing/utils/convertToCircuitJson"
+
+const createSrj = (minViaDiameter?: number): SimpleRouteJson => ({
+  layerCount: 2,
+  minTraceWidth: 0.1,
+  ...(minViaDiameter !== undefined ? { minViaDiameter } : {}),
+  obstacles: [],
+  connections: [
+    {
+      name: "conn_1",
+      pointsToConnect: [
+        { x: 0, y: 0, layer: "top", pointId: "p1" },
+        { x: 1, y: 1, layer: "bottom", pointId: "p2" },
+      ],
+    },
+  ],
+  bounds: { minX: -2, maxX: 2, minY: -2, maxY: 2 },
+})
+
+const createSimplifiedTraces = (viaDiameter?: number): SimplifiedPcbTrace[] => [
+  {
+    type: "pcb_trace",
+    pcb_trace_id: "conn_1_0",
+    connection_name: "conn_1",
+    route: [
+      { route_type: "wire", x: 0, y: 0, width: 0.1, layer: "top" },
+      {
+        route_type: "via",
+        x: 0.5,
+        y: 0.5,
+        from_layer: "top",
+        to_layer: "bottom",
+        ...(viaDiameter !== undefined ? { via_diameter: viaDiameter } : {}),
+      },
+      { route_type: "wire", x: 1, y: 1, width: 0.1, layer: "bottom" },
+    ],
+  },
+]
+
+test("uses actual via diameter from simplified route when available", () => {
+  const circuitJson = convertToCircuitJson(
+    createSrj(0.24),
+    createSimplifiedTraces(0.33),
+  )
+  const vias = circuitJson.filter((e) => e.type === "pcb_via")
+  expect(vias).toHaveLength(1)
+  expect(vias[0].outer_diameter).toBe(0.33)
+})
+
+test("falls back to srj.minViaDiameter when actual diameter is missing", () => {
+  const circuitJson = convertToCircuitJson(
+    createSrj(0.24),
+    createSimplifiedTraces(),
+  )
+  const vias = circuitJson.filter((e) => e.type === "pcb_via")
+  expect(vias).toHaveLength(1)
+  expect(vias[0].outer_diameter).toBe(0.24)
+})
+
+test("falls back to 0.3 when neither actual nor srj min via diameter is available", () => {
+  const circuitJson = convertToCircuitJson(
+    createSrj(),
+    createSimplifiedTraces(),
+  )
+  const vias = circuitJson.filter((e) => e.type === "pcb_via")
+  expect(vias).toHaveLength(1)
+  expect(vias[0].outer_diameter).toBe(0.3)
+})