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- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -MAX3243 REF MAX3243 REF - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -U1 U1 - - - - - - - - - - - - - - -U2 U2 - - - - - - - - - - - - - - - - - - - - - + @@ -4024,7 +4584,7 @@ L72.7500 73.3700 - + @@ -4055,32 +4615,32 @@ L48.7500 73.3700 - + - - + + - - - - - - - - - - - + + - +Z" /> - +Z" /> @@ -4353,14 +4913,14 @@ L43.6600 34.0000 - +Z" /> @@ -4373,14 +4933,14 @@ L49.2500 73.2500 - +Z" /> @@ -4467,10 +5027,10 @@ L68.5000 56.6000 " /> - + - - + + + - -Carrier envelope only; module overhang and connector clearance not qualified -Carrier envelope only; module overhang and connector clearance not qualified - - + + + + - +CAD METAL ENVELOPES - NOT CASE CUTOUT +CAD METAL ENVELOPES - NOT CASE CUTOUT + - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - +Nominal RS-232 metal verified; ESP32 USB / antenna / assembly clearance pending +Nominal RS-232 metal verified; ESP32 USB / antenna / assembly clearance pending + - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 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- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -VERIFY ANTENNA VERIFY ANTENNA - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -DE-9 OUT / VERIFY MALE -DE-9 OUT / VERIFY MALE -DE-9 OUT / NOMINAL MALE +DE-9 OUT / NOMINAL MALE + - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - + + + + + + + +RF RESERVE RF RESERVE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -82 x 80 mm / 2 copper layers 82 x 80 mm / 2 copper layers - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 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b/hardware/PCB/validation/pcb-parity-drc.json @@ -1,7 +1,7 @@ { "$schema": "https://schemas.kicad.org/drc.v1.json", "coordinate_units": "mm", - "date": "2026-09-20T23:07:29", + "date": "2026-09-21T11:39:10", "ignored_checks": [ { "description": "Footprint has no courtyard defined", @@ -38,7 +38,7 @@ "description": "Footprint U2", "pos": { "x": 143.0, - "y": 130.0 + "y": 126.67 }, "uuid": "812387f6-6524-459e-8102-fe9c55122668" } diff --git a/hardware/PCB/validation/pcb-routing-a1-pass1.kicad_pcb b/hardware/PCB/validation/pcb-routing-a1-pass1.kicad_pcb new file mode 100644 index 0000000..b2a38bb --- /dev/null +++ b/hardware/PCB/validation/pcb-routing-a1-pass1.kicad_pcb @@ -0,0 +1,9655 @@ +(kicad_pcb + (version 20260206) + (generator "pcbnew") + (generator_version "10.0") + (general + (thickness 1.6) + (legacy_teardrops no) + ) + (paper "A4") + (title_block + (title "Serial Swiss Army Knife - 82x80 mm carrier draft") + (rev "A1 DRAFT") + (comment 1 "NOT FOR FABRICATION - USB / antenna 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+ (polygon + (pts + (xy 110 119) (xy 131 119) (xy 131 132) (xy 110 132) + ) + ) + ) + (embedded_fonts no) +) diff --git a/hardware/PCB/validation/pcb-routing-a1-pass1.log b/hardware/PCB/validation/pcb-routing-a1-pass1.log new file mode 100644 index 0000000..8bc00e1 --- /dev/null +++ b/hardware/PCB/validation/pcb-routing-a1-pass1.log @@ -0,0 +1,70 @@ +/builddir/build/BUILD/kicad-10.0.6-build/kicad-10.0.6/include/properties/property.h(607): assert "m_choices.GetCount() > 0" failed in PROPERTY_ENUM(): No enum choices defined +/builddir/build/BUILD/kicad-10.0.6-build/kicad-10.0.6/include/properties/property.h(607): assert "m_choices.GetCount() > 0" failed in PROPERTY_ENUM(): No enum choices defined +/builddir/build/BUILD/kicad-10.0.6-build/kicad-10.0.6/include/properties/property.h(607): assert "m_choices.GetCount() > 0" failed in PROPERTY_ENUM(): No enum choices defined +{"net": "/+3V3", "start": "U1.1", "end": "U1.2", "start_mm": [108.0, 123.0], "end_mm": [108.0, 125.54], "routed": true, "width_mm": 0.5, "power_fallback": false, "expansions": 52} +{"net": "/+3V3", "start": "R2.1", "end": "DS1.2", "start_mm": [154.0, 134.0], "end_mm": [154.73, 137.5], "routed": true, "width_mm": 0.5, "power_fallback": false, "expansions": 911} +{"net": "/BTN_NEXT", "start": "SW3.1", "end": "SW3.1", "start_mm": [167.0, 168.0], "end_mm": [173.5, 168.0], "routed": true, "width_mm": 0.25, "power_fallback": false, "expansions": 131} +{"net": "/BTN_PREVIOUS", "start": "SW1.1", "end": "SW1.1", "start_mm": [143.0, 168.0], "end_mm": [149.5, 168.0], "routed": true, "width_mm": 0.25, "power_fallback": false, "expansions": 131} +{"net": "/BTN_SELECT", "start": "SW2.1", "end": "SW2.1", "start_mm": [155.0, 168.0], "end_mm": [161.5, 168.0], "routed": true, "width_mm": 0.25, "power_fallback": false, "expansions": 131} +{"net": "/+3V3", "start": "U2.1", "end": "R1.1", "start_mm": [143.0, 126.67], "end_mm": [143.0, 134.0], "routed": true, "width_mm": 0.5, "power_fallback": false, "expansions": 148} 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"start_mm": [108.0, 125.54], "end_mm": [143.0, 126.67], "routed": true, "width_mm": 0.5, "power_fallback": false, "expansions": 297043} +{"net": "/BTN_PREVIOUS", "start": "U1.16", "end": "SW1.1", "start_mm": [108.0, 161.1], "end_mm": [143.0, 168.0], "routed": true, "width_mm": 0.25, "power_fallback": false, "expansions": 70393} +{"net": "/RS_DCD", "start": "U1.4", "end": "U2.3", "start_mm": [108.0, 130.62], "end_mm": [148.08, 126.67], "routed": true, "width_mm": 0.25, "power_fallback": false, "expansions": 54772} +{"net": "/BTN_SELECT", "start": "SW2.1", "end": "U1.19", "start_mm": [155.0, 168.0], "end_mm": [108.0, 168.72], "routed": true, "width_mm": 0.25, "power_fallback": false, "expansions": 36364} +{"net": "/RS_RX", "start": "U1.11", "end": "U2.4", "start_mm": [108.0, 148.4], "end_mm": [150.62, 126.67], "routed": true, "width_mm": 0.25, "power_fallback": false, "expansions": 119946} +{"net": "/RS_TX", "start": "U1.10", "end": "U2.5", "start_mm": [108.0, 145.86], "end_mm": [153.16, 126.67], "routed": true, "width_mm": 0.25, "power_fallback": false, "expansions": 297203} +{"net": "/RS_DTR", "start": "U1.7", "end": "U2.6", "start_mm": [108.0, 138.24], "end_mm": [155.7, 126.67], "routed": true, "width_mm": 0.25, "power_fallback": false, "expansions": 217446} +{"net": "/RS_DSR", "start": "U1.5", "end": "U2.7", "start_mm": [108.0, 133.16], "end_mm": [158.24, 126.67], "routed": true, "width_mm": 0.25, "power_fallback": false, "expansions": 177204} +{"net": "/RS_RTS", "start": "U1.8", "end": "U2.8", "start_mm": [108.0, 140.78], "end_mm": [160.78, 126.67], "routed": true, "width_mm": 0.25, "power_fallback": false, "expansions": 268999} +{"net": "/OLED_SCL", "start": "U1.18", "end": "DS1.3", "start_mm": [108.0, 166.18], "end_mm": [157.27, 137.5], "routed": true, "width_mm": 0.25, "power_fallback": false, "expansions": 453162} +{"net": "/RS_CTS", "start": "U1.9", "end": "U2.9", "start_mm": [108.0, 143.32], "end_mm": [163.32, 126.67], "routed": true, "width_mm": 0.25, "power_fallback": false, "expansions": 336768} +{"net": "/OLED_SDA", "start": "U1.17", "end": "DS1.4", "start_mm": [108.0, 163.64], "end_mm": [159.81, 137.5], "routed": true, "width_mm": 0.25, "power_fallback": false, "expansions": 574321} +{"net": "/RS_RI", "start": "U1.6", "end": "U2.10", "start_mm": [108.0, 135.7], "end_mm": [165.86, 126.67], "routed": true, "width_mm": 0.25, "power_fallback": false, "expansions": 221877} +{"net": "/BTN_NEXT", "start": "U1.20", "end": "SW3.1", "start_mm": [108.0, 171.26], "end_mm": [167.0, 168.0], "routed": true, "width_mm": 0.25, "power_fallback": false, "expansions": 69853} +{"net": "/RS_VALID", "start": "U1.12", "end": "U2.11", "start_mm": [108.0, 150.94], "end_mm": [168.4, 126.67], "routed": true, "width_mm": 0.25, "power_fallback": false, "expansions": 344679} +{"net": "/RS_OFF_N", "start": "U1.15", "end": "U2.12", "start_mm": [108.0, 158.56], "end_mm": [170.94, 126.67], "routed": true, "width_mm": 0.25, "power_fallback": false, "expansions": 690965} +{"net": "/GND", "start": "U1.43", "end": "U1.44", "start_mm": [133.4, 173.8], "end_mm": [133.4, 176.34], "routed": true, "width_mm": 0.5, "power_fallback": false, "expansions": 52} +{"net": "/GND", "start": "SW2.2", "end": "SW1.2", "start_mm": [155.0, 172.5], "end_mm": [149.5, 172.5], "routed": true, "width_mm": 0.5, "power_fallback": false, "expansions": 111} +{"net": "/GND", "start": "SW2.2", "end": "SW3.2", "start_mm": [161.5, 172.5], "end_mm": [167.0, 172.5], "routed": true, "width_mm": 0.5, "power_fallback": false, "expansions": 111} +{"net": "/GND", "start": "SW2.2", "end": "SW2.2", "start_mm": [155.0, 172.5], "end_mm": [161.5, 172.5], "routed": true, "width_mm": 0.5, "power_fallback": false, "expansions": 131} +{"net": "/GND", "start": "SW3.2", "end": "SW3.2", "start_mm": [167.0, 172.5], "end_mm": [173.5, 172.5], "routed": true, "width_mm": 0.5, "power_fallback": false, "expansions": 131} +{"net": "/GND", "start": "SW1.2", "end": "SW1.2", "start_mm": [149.5, 172.5], "end_mm": [143.0, 172.5], "routed": true, "width_mm": 0.5, "power_fallback": false, "expansions": 131} +{"net": "/GND", "start": "SW1.2", "end": "U1.43", "start_mm": [143.0, 172.5], "end_mm": [133.4, 173.8], "routed": true, "width_mm": 0.5, "power_fallback": false, "expansions": 2466} +{"net": "/GND", "start": "U2.2", "end": "U1.23", "start_mm": [145.54, 126.67], "end_mm": [133.4, 123.0], "routed": true, "width_mm": 0.5, "power_fallback": false, "expansions": 7318} +{"net": "/GND", "start": "DS1.1", "end": "U2.2", "start_mm": [152.19, 137.5], "end_mm": [145.54, 126.67], "routed": true, "width_mm": 0.25, "power_fallback": true, "expansions": 2378118} +{"net": "/GND", "start": "U1.44", "end": "U1.22", "start_mm": [133.4, 176.34], "end_mm": [108.0, 176.34], "routed": true, "width_mm": 0.5, "power_fallback": false, "expansions": 509} +{"net": "/GND", "start": "SW1.2", "end": "DS1.1", "start_mm": [149.5, 172.5], "end_mm": [152.19, 137.5], "routed": true, "width_mm": 0.5, "power_fallback": false, "expansions": 19033} +10:59:13: Debug: Adding duplicate image handler for 'PNG file' +10:59:13: Debug: Adding duplicate image handler for 'JPEG file' +10:59:13: Debug: Adding duplicate image handler for 'TIFF file' +10:59:13: Debug: Adding duplicate image handler for 'GIF file' +10:59:13: Debug: Adding duplicate image handler for 'PNM file' +10:59:13: Debug: Adding duplicate image handler for 'PCX file' +10:59:13: Debug: Adding duplicate image handler for 'IFF file' +10:59:13: Debug: Adding duplicate image handler for 'Windows icon file' +10:59:13: Debug: Adding duplicate image handler for 'Windows cursor file' +10:59:13: Debug: Adding duplicate image handler for 'Windows animated cursor file' +10:59:13: Debug: Adding duplicate image handler for 'TGA file' +10:59:13: Debug: Adding duplicate image handler for 'XPM file' +{ + "draft_only": true, + "saved": true, + "grid_mm": 0.05, + "clearance_mm": 0.25, + "safety_margin_mm": 0.02, + "via_diameter_mm": 0.7, + "via_drill_mm": 0.3, + "elapsed_seconds": 31.17737436400057, + "routed_tree_edges": 38, + "total_tree_edges": 38, + "tracks": 674, + "vias": 16, + "immutable_identity_sha256": "783ce7e212880e0836c93e1782d39bbfbc505fae856d9720ee6c50f5ba8f6275", + "input_sha256": "df62a5aeb64a6d871a477a8c9fe94c100210d5b239a0617558907d9d3d9a6007", + "validation": "KiCad DRC must be run separately; tree-edge counts are not DRC connectivity" +} diff --git a/hardware/PCB/validation/pcb-routing-a1-pass2.log b/hardware/PCB/validation/pcb-routing-a1-pass2.log new file mode 100644 index 0000000..30850af --- /dev/null +++ b/hardware/PCB/validation/pcb-routing-a1-pass2.log @@ -0,0 +1,70 @@ +/builddir/build/BUILD/kicad-10.0.6-build/kicad-10.0.6/include/properties/property.h(607): assert "m_choices.GetCount() > 0" failed in PROPERTY_ENUM(): No enum choices defined +/builddir/build/BUILD/kicad-10.0.6-build/kicad-10.0.6/include/properties/property.h(607): assert "m_choices.GetCount() > 0" failed in PROPERTY_ENUM(): No enum choices defined +/builddir/build/BUILD/kicad-10.0.6-build/kicad-10.0.6/include/properties/property.h(607): assert "m_choices.GetCount() > 0" failed in PROPERTY_ENUM(): No enum choices defined +{"net": "/GND", "start": "U1.43", "end": "U1.44", "start_mm": [133.4, 173.8], "end_mm": [133.4, 176.34], "routed": true, "width_mm": 0.5, "power_fallback": false, "expansions": 52} +{"net": "/+3V3", "start": "U1.1", "end": "U1.2", "start_mm": [108.0, 123.0], "end_mm": [108.0, 125.54], "routed": true, "width_mm": 0.5, "power_fallback": false, "expansions": 52} +{"net": "/+3V3", "start": "R2.1", "end": "DS1.2", "start_mm": [154.0, 134.0], "end_mm": [154.73, 137.5], "routed": true, "width_mm": 0.5, "power_fallback": false, "expansions": 911} +{"net": "/GND", "start": "SW2.2", "end": "SW1.2", "start_mm": [155.0, 172.5], "end_mm": [149.5, 172.5], "routed": true, "width_mm": 0.5, "power_fallback": false, "expansions": 111} +{"net": "/GND", "start": "SW2.2", "end": "SW3.2", "start_mm": [161.5, 172.5], "end_mm": [167.0, 172.5], "routed": true, "width_mm": 0.5, "power_fallback": false, "expansions": 111} +{"net": "/BTN_NEXT", "start": "SW3.1", "end": "SW3.1", "start_mm": [167.0, 168.0], "end_mm": [173.5, 168.0], "routed": true, "width_mm": 0.25, "power_fallback": false, "expansions": 131} +{"net": "/BTN_PREVIOUS", "start": "SW1.1", "end": "SW1.1", "start_mm": [143.0, 168.0], "end_mm": [149.5, 168.0], "routed": true, "width_mm": 0.25, "power_fallback": false, "expansions": 131} +{"net": "/BTN_SELECT", "start": "SW2.1", "end": "SW2.1", "start_mm": [155.0, 168.0], "end_mm": [161.5, 168.0], "routed": true, "width_mm": 0.25, "power_fallback": false, "expansions": 131} +{"net": "/GND", "start": "SW2.2", "end": "SW2.2", "start_mm": [155.0, 172.5], "end_mm": [161.5, 172.5], "routed": true, "width_mm": 0.5, "power_fallback": false, "expansions": 131} +{"net": "/GND", "start": "SW3.2", "end": "SW3.2", "start_mm": [167.0, 172.5], "end_mm": [173.5, 172.5], "routed": true, "width_mm": 0.5, "power_fallback": false, "expansions": 131} +{"net": "/GND", "start": "SW1.2", "end": "SW1.2", "start_mm": [149.5, 172.5], "end_mm": [143.0, 172.5], "routed": true, "width_mm": 0.5, "power_fallback": false, "expansions": 131} +{"net": "/+3V3", "start": "U2.1", "end": "R1.1", "start_mm": [143.0, 126.67], "end_mm": [143.0, 134.0], "routed": true, "width_mm": 0.5, "power_fallback": false, "expansions": 148} +{"net": "/GND", "start": "SW1.2", "end": "U1.43", "start_mm": [143.0, 172.5], "end_mm": [133.4, 173.8], "routed": true, "width_mm": 0.5, "power_fallback": false, "expansions": 4535} +{"net": "/+3V3", "start": "DS1.2", "end": "R3.1", "start_mm": [154.73, 137.5], "end_mm": [165.0, 134.0], "routed": true, "width_mm": 0.5, "power_fallback": false, "expansions": 5139} +{"net": "/+3V3", "start": "R1.1", "end": "R2.1", "start_mm": [143.0, 134.0], "end_mm": [154.0, 134.0], "routed": true, "width_mm": 0.5, "power_fallback": false, "expansions": 14153} +{"net": "/GND", "start": "U2.2", "end": "U1.23", "start_mm": [145.54, 126.67], "end_mm": [133.4, 123.0], "routed": true, "width_mm": 0.5, "power_fallback": false, "expansions": 9372} +{"net": "/GND", "start": "DS1.1", "end": "U2.2", "start_mm": [152.19, 137.5], "end_mm": [145.54, 126.67], "routed": true, "width_mm": 0.5, "power_fallback": false, "expansions": 8327} +{"net": "/BTN_SELECT", "start": "SW2.1", "end": "R2.2", "start_mm": [161.5, 168.0], "end_mm": [161.62, 134.0], "routed": true, "width_mm": 0.25, "power_fallback": false, "expansions": 2039} +{"net": "/BTN_NEXT", "start": "SW3.1", "end": "R3.2", "start_mm": [173.5, 168.0], "end_mm": [172.62, 134.0], "routed": true, "width_mm": 0.25, "power_fallback": false, "expansions": 12615} +{"net": "/BTN_PREVIOUS", "start": "SW1.1", "end": "R1.2", "start_mm": [149.5, 168.0], "end_mm": [150.62, 134.0], "routed": true, "width_mm": 0.25, "power_fallback": false, "expansions": 15179} +{"net": "/+3V3", "start": "U1.2", "end": "U2.1", "start_mm": [108.0, 125.54], "end_mm": [143.0, 126.67], "routed": true, "width_mm": 0.5, "power_fallback": false, "expansions": 332527} +{"net": "/BTN_PREVIOUS", "start": "U1.16", "end": "SW1.1", "start_mm": [108.0, 161.1], "end_mm": [143.0, 168.0], "routed": true, "width_mm": 0.25, "power_fallback": false, "expansions": 70393} +{"net": "/RS_DCD", "start": "U1.4", "end": "U2.3", "start_mm": [108.0, 130.62], "end_mm": [148.08, 126.67], "routed": true, "width_mm": 0.25, "power_fallback": false, "expansions": 21855} +{"net": "/BTN_SELECT", "start": "SW2.1", "end": "U1.19", "start_mm": [155.0, 168.0], "end_mm": [108.0, 168.72], "routed": true, "width_mm": 0.25, "power_fallback": false, "expansions": 36364} +{"net": "/RS_RX", "start": "U1.11", "end": "U2.4", "start_mm": [108.0, 148.4], "end_mm": [150.62, 126.67], "routed": true, "width_mm": 0.25, "power_fallback": false, "expansions": 123675} +{"net": "/RS_TX", "start": "U1.10", "end": "U2.5", "start_mm": [108.0, 145.86], "end_mm": [153.16, 126.67], "routed": true, "width_mm": 0.25, "power_fallback": false, "expansions": 397389} +{"net": "/RS_DTR", "start": "U1.7", "end": "U2.6", "start_mm": [108.0, 138.24], "end_mm": [155.7, 126.67], "routed": true, "width_mm": 0.25, "power_fallback": false, "expansions": 294174} +{"net": "/RS_DSR", "start": "U1.5", "end": "U2.7", "start_mm": [108.0, 133.16], "end_mm": [158.24, 126.67], "routed": true, "width_mm": 0.25, "power_fallback": false, "expansions": 294332} +{"net": "/RS_RTS", "start": "U1.8", "end": "U2.8", "start_mm": [108.0, 140.78], "end_mm": [160.78, 126.67], "routed": true, "width_mm": 0.25, "power_fallback": false, "expansions": 378833} +{"net": "/OLED_SCL", "start": "U1.18", "end": "DS1.3", "start_mm": [108.0, 166.18], "end_mm": [157.27, 137.5], "routed": true, "width_mm": 0.25, "power_fallback": false, "expansions": 442107} +{"net": "/RS_CTS", "start": "U1.9", "end": "U2.9", "start_mm": [108.0, 143.32], "end_mm": [163.32, 126.67], "routed": true, "width_mm": 0.25, "power_fallback": false, "expansions": 409990} +{"net": "/OLED_SDA", "start": "U1.17", "end": "DS1.4", "start_mm": [108.0, 163.64], "end_mm": [159.81, 137.5], "routed": true, "width_mm": 0.25, "power_fallback": false, "expansions": 567654} +{"net": "/RS_RI", "start": "U1.6", "end": "U2.10", "start_mm": [108.0, 135.7], "end_mm": [165.86, 126.67], "routed": true, "width_mm": 0.25, "power_fallback": false, "expansions": 436874} +{"net": "/BTN_NEXT", "start": "U1.20", "end": "SW3.1", "start_mm": [108.0, 171.26], "end_mm": [167.0, 168.0], "routed": true, "width_mm": 0.25, "power_fallback": false, "expansions": 273975} +{"net": "/RS_VALID", "start": "U1.12", "end": "U2.11", "start_mm": [108.0, 150.94], "end_mm": [168.4, 126.67], "routed": true, "width_mm": 0.25, "power_fallback": false, "expansions": 425742} +{"net": "/RS_OFF_N", "start": "U1.15", "end": "U2.12", "start_mm": [108.0, 158.56], "end_mm": [170.94, 126.67], "routed": true, "width_mm": 0.25, "power_fallback": false, "expansions": 645804} +{"net": "/GND", "start": "U1.44", "end": "U1.22", "start_mm": [133.4, 176.34], "end_mm": [108.0, 176.34], "routed": true, "width_mm": 0.5, "power_fallback": false, "expansions": 509} +{"net": "/GND", "start": "SW1.2", "end": "DS1.1", "start_mm": [149.5, 172.5], "end_mm": [152.19, 137.5], "routed": true, "width_mm": 0.5, "power_fallback": false, "expansions": 617019} +11:12:00: Debug: Adding duplicate image handler for 'PNG file' +11:12:00: Debug: Adding duplicate image handler for 'JPEG file' +11:12:00: Debug: Adding duplicate image handler for 'TIFF file' +11:12:00: Debug: Adding duplicate image handler for 'GIF file' +11:12:00: Debug: Adding duplicate image handler for 'PNM file' +11:12:00: Debug: Adding duplicate image handler for 'PCX file' +11:12:00: Debug: Adding duplicate image handler for 'IFF file' +11:12:00: Debug: Adding duplicate image handler for 'Windows icon file' +11:12:00: Debug: Adding duplicate image handler for 'Windows cursor file' +11:12:00: Debug: Adding duplicate image handler for 'Windows animated cursor file' +11:12:00: Debug: Adding duplicate image handler for 'TGA file' +11:12:00: Debug: Adding duplicate image handler for 'XPM file' +{ + "draft_only": true, + "saved": true, + "grid_mm": 0.05, + "clearance_mm": 0.25, + "safety_margin_mm": 0.02, + "via_diameter_mm": 0.7, + "via_drill_mm": 0.3, + "elapsed_seconds": 32.44472043699898, + "routed_tree_edges": 38, + "total_tree_edges": 38, + "tracks": 565, + "vias": 22, + "immutable_identity_sha256": "783ce7e212880e0836c93e1782d39bbfbc505fae856d9720ee6c50f5ba8f6275", + "input_sha256": "0ea7f0abff371eacc81262dc949f768cd42128f389ea4af9facee5034368d884", + "validation": "KiCad DRC must be run separately; tree-edge counts are not DRC connectivity" +} diff --git a/hardware/PCB/validation/pcb-routing-all-drc.json b/hardware/PCB/validation/pcb-routing-all-drc.json index 838eab3..ee339f6 100644 --- a/hardware/PCB/validation/pcb-routing-all-drc.json +++ b/hardware/PCB/validation/pcb-routing-all-drc.json @@ -1,7 +1,7 @@ { "$schema": "https://schemas.kicad.org/drc.v1.json", "coordinate_units": "mm", - "date": "2026-09-20T22:50:33", + "date": "2026-09-21T11:16:44", "ignored_checks": [ { "description": "Footprint has no courtyard defined", diff --git a/hardware/PCB/validation/pcb-routing-check.json b/hardware/PCB/validation/pcb-routing-check.json index 4717313..a0b91c5 100644 --- a/hardware/PCB/validation/pcb-routing-check.json +++ b/hardware/PCB/validation/pcb-routing-check.json @@ -1,39 +1,39 @@ { "immutable_geometry_nets_pads_linkage_preserved": true, - "board_sha256": "03b69c4084dba328b11e2373c219e8fe462bcb3add934cf9f527214b21bd9cb6", - "independent_min_different_net_or_npth_clearance_mm": 0.2749999999999886, + "board_sha256": "53e36538c0669604457b9e1a9ff1b1e20422970e8f9f356088c4581868ad5045", + "independent_min_different_net_or_npth_clearance_mm": 0.2705441169852849, "closest_items": [ - "R2.2:c118f27f-8ad4-4abe-b9c0-a30a22fe60c9", - "99fb402a-445b-4eba-aedf-76b7f0cad042" + "U1.38:4b8eabef-8493-437d-bd02-cb9ff4afd7cd", + "d95f45cb-7fa4-4203-a786-0a069425e2b8" ], - "min_copper_or_npth_edge_gap_mm": 0.5250000000000057, + "min_copper_or_npth_edge_gap_mm": 1.9, "min_rf_gap_mm": 0.025000000000005684, - "min_via_to_other_drilled_hole_gap_mm": 0.8401754250991242, + "min_via_to_other_drilled_hole_gap_mm": 0.8205441169852848, "track_width_counts": { - "0.25": 425, - "0.5": 144 + "0.25": 451, + "0.5": 114 }, "routed_length_mm_by_net": { - "/BTN_SELECT": 95.16152954766495, - "/GND": 152.2615364335217, - "/+3V3": 106.94219089103528, - "/RS_DCD": 47.76152984055992, - "/RS_DSR": 56.835284377834164, - "/RS_RI": 66.02000635033798, - "/RS_DTR": 52.162796381301995, - "/RS_RTS": 56.23655121147421, - "/RS_CTS": 58.073809511675655, - "/RS_TX": 47.51030692030297, - "/RS_RX": 43.90406233625865, - "/RS_VALID": 64.36573922778403, - "/RS_OFF_N": 67.05000417516253, - "/BTN_PREVIOUS": 86.95076506672746, - "/OLED_SDA": 54.781626385188304, - "/OLED_SCL": 53.30787155502609, - "/BTN_NEXT": 106.4266552277327 + "/BTN_SELECT": 88.94832552628598, + "/GND": 141.68412246223386, + "/+3V3": 90.29604731966161, + "/RS_DCD": 43.068490178879834, + "/RS_DSR": 55.09398706495997, + "/RS_RI": 67.91373841554615, + "/RS_DTR": 52.53487761643567, + "/RS_RTS": 60.056714985368814, + "/RS_CTS": 63.65082753507114, + "/RS_TX": 53.135260491559045, + "/RS_RX": 51.637429252872906, + "/RS_VALID": 72.10630197626116, + "/RS_OFF_N": 78.04100118378895, + "/BTN_PREVIOUS": 78.83370879187974, + "/OLED_SDA": 62.65168524184884, + "/OLED_SCL": 61.1779295330028, + "/BTN_NEXT": 101.24898628384834 }, - "tracks": 569, - "vias": 20, + "tracks": 565, + "vias": 22, "copper_zones": 0, "drc_freshly_run": true, "drc_violations": 0, diff --git a/hardware/PCB/validation/pcb-routing-check.py b/hardware/PCB/validation/pcb-routing-check.py index b904d8f..7375b46 100644 --- a/hardware/PCB/validation/pcb-routing-check.py +++ b/hardware/PCB/validation/pcb-routing-check.py @@ -70,8 +70,8 @@ for i, a in enumerate(items): if distance < min_clearance: min_clearance, closest = distance, (a[0], b[0]) assert min_clearance >= 0.25 - 1e-6, (min_clearance, closest) -outline = Polygon([(100,100),(182,100),(182,180),(136,180),(136,161),(100,161)]) -rf = box(110, 100, 131, 113) +outline = Polygon([(136,100),(182,100),(182,180),(100,180),(100,119),(136,119)]) +rf = box(110, 119, 131, 132) min_edge, min_rf = float('inf'), float('inf') for label, net, layers, geom, radius in items: assert outline.covers(geom), label diff --git a/hardware/PCB/validation/pcb-routing-drc.json b/hardware/PCB/validation/pcb-routing-drc.json index a989938..9c044cd 100644 --- a/hardware/PCB/validation/pcb-routing-drc.json +++ b/hardware/PCB/validation/pcb-routing-drc.json @@ -1,7 +1,7 @@ { "$schema": "https://schemas.kicad.org/drc.v1.json", "coordinate_units": "mm", - "date": "2026-09-20T23:07:33", + "date": "2026-09-21T11:39:13", "ignored_checks": [ { "description": "Footprint has no courtyard defined", diff --git a/hardware/PCB/validation/pcb-routing-input.kicad_pcb b/hardware/PCB/validation/pcb-routing-input.kicad_pcb index 9db8844..5f01ee2 100644 --- a/hardware/PCB/validation/pcb-routing-input.kicad_pcb +++ b/hardware/PCB/validation/pcb-routing-input.kicad_pcb @@ -9,8 +9,8 @@ (paper "A4") (title_block (title "Serial Swiss Army Knife - 82x80 mm carrier draft") - (rev "A0 DRAFT") - (comment 1 "NOT FOR FABRICATION - male module / USB / antenna geometry unverified") + (rev "A1 DRAFT") + (comment 1 "NOT FOR FABRICATION - USB / antenna geometry pending; verify module pinout / assembly") ) (layers (0 "F.Cu" signal) @@ -147,6 +147,54 @@ ) ) ) + (property "Manufacturer" "Omron" + (at 0 0 0) + (layer "F.SilkS") + (hide yes) + (uuid "ed0c853c-7bad-4223-ac1a-808d0fb64350") + (effects + (font + (size 1.27 1.27) + (thickness 0.15) + ) + ) + ) + (property "MPN" "B3F-1000" + (at 0 0 0) + (layer "F.SilkS") + (hide yes) + (uuid "9e5e1f5d-a99b-49ed-a322-375dd393a80c") + (effects + (font + (size 1.27 1.27) + (thickness 0.15) + ) + ) + ) + (property "Function" "Select / confirm" + (at 0 0 0) + (layer "F.SilkS") + (hide yes) + (uuid "769482c4-e8d8-4700-b7f3-899603f4f2b0") + (effects + (font + (size 1.27 1.27) + (thickness 0.15) + ) + ) + ) + (property "Procurement" "Live stock not verified" + (at 0 0 0) + (layer "F.SilkS") + (hide yes) + (uuid "5c19bcf2-9483-4cd5-bb8d-b4e61d5fceed") + (effects + (font + (size 1.27 1.27) + (thickness 0.15) + ) + ) + ) (path "/c86e0d56-4290-5f2b-b790-14926c8cdeea/c522a716-55a4-584d-a12e-ab135b4c08eb") (sheetname "serial-carrier") (sheetfile "serial-carrier.kicad_sch") @@ -340,7 +388,7 @@ (footprint "MountingHole:MountingHole_3.2mm_M3" (layer "F.Cu") (uuid "1a8b4cef-8dea-4172-b360-f297696eb7e7") - (at 103.5 103.5) + (at 103.5 122.5) (descr "Mounting Hole 3.2mm, M3, no annular, generated by kicad-footprint-generator mountinghole.py") (tags "mountinghole M3") (property "Reference" "H1" @@ -437,7 +485,7 @@ (footprint "Carrier:HW678_2x22_Provisional" (layer "F.Cu") (uuid "3b4d80e2-b60a-47c6-a06a-acd4c69d5a94") - (at 108 104) + (at 108 123) (descr "HW-678, component/top view antenna up USB down; origin pad 1; left top-bottom 1..22, right top-bottom 23..44; only header centres verified; no GPIO mapping, outline, courtyard or antenna keepout; PROVISIONAL connector fit: 1.70 mm pads / 1.00 mm drills from installed KiCad PinHeader_1x04_P2.54mm_Vertical, awaiting selected actual pin/socket datasheet") (tags "module provisional THT") (property "Reference" "U1" @@ -485,6 +533,30 @@ ) ) ) + (property "Status" "Header geometry nominal; outline/antenna clearance pending" + (at 0 0 0) + (layer "F.SilkS") + (hide yes) + (uuid "4191f9f5-6321-4688-8d4b-79bd6e331adb") + (effects + (font + (size 1.27 1.27) + (thickness 0.15) + ) + ) + ) + (property "Pin_numbering" "Left 1-22; right 23-44; both top-to-bottom, antenna up" + (at 0 0 0) + (layer "F.SilkS") + (hide yes) + (uuid "cb8b2cbb-0181-448d-b826-7aeaf767679f") + (effects + (font + (size 1.27 1.27) + (thickness 0.15) + ) + ) + ) (path "/c86e0d56-4290-5f2b-b790-14926c8cdeea/3ab265d0-7fd3-5891-94eb-d39426c6a8a3") (sheetname "serial-carrier") (sheetfile "serial-carrier.kicad_sch") @@ -1076,7 +1148,7 @@ (footprint "Carrier:MAX3243_Reference_Provisional" (layer "F.Cu") (uuid "812387f6-6524-459e-8102-fe9c55122668") - (at 143 130) + (at 143 126.67) (descr "PROVISIONAL female 5988 CAD reference / VERIFY MALE 6253 geometry and pad map. Top view DE9 toward -Y; origin JP2 pin 1. Female reference: 1 Vin, 2 GND, 3 DCD, 4 RX, 5 TX, 6 DTR, 7 DSR, 8 RTS, 9 CTS, 10 RI, 11 VLD, 12 OFF. PROVISIONAL connector fit: carrier pads 1.70 mm / drill 1.00 mm. No verified DE9 envelope or courtyard. CAD-derived outline: Limor Fried/Ladyada for Adafruit Industries, CC BY-SA 3.0; see rs232-footprint-notes.md") (tags "MAX3243 module female5988 reference male6253 provisional THT") (property "Reference" "U2" @@ -1124,6 +1196,30 @@ ) ) ) + (property "Status" "VERIFY male header numbering; footprint intentionally unassigned" + (at 0 0 0) + (layer "F.SilkS") + (hide yes) + (uuid "20d057b6-ffe5-4aae-a1a9-dd213e4abaae") + (effects + (font + (size 1.27 1.27) + (thickness 0.15) + ) + ) + ) + (property "Datasheet_source" "adafruit-research.md; reference female 5988 CAD" + (at 0 0 0) + (layer "F.SilkS") + (hide yes) + (uuid "4bfd59ab-ec6d-4656-918d-28d41109cf6c") + (effects + (font + (size 1.27 1.27) + (thickness 0.15) + ) + ) + ) (path "/c86e0d56-4290-5f2b-b790-14926c8cdeea/1127195e-e393-5d1d-9119-b25d10556144") (sheetname "serial-carrier") (sheetfile "serial-carrier.kicad_sch") @@ -1499,6 +1595,18 @@ ) ) ) + (property "Rating" "At least 0.125 W; exact resistor MPN pending" + (at 0 0 0) + (layer "F.SilkS") + (hide yes) + (uuid "1f5a2e3f-0e6c-46be-850e-aefedf55be1e") + (effects + (font + (size 1.27 1.27) + (thickness 0.15) + ) + ) + ) (path "/c86e0d56-4290-5f2b-b790-14926c8cdeea/405055c0-35ab-5334-ad4d-30d45c5ef6f2") (sheetname "serial-carrier") (sheetfile "serial-carrier.kicad_sch") @@ -1642,7 +1750,7 @@ (footprint "MountingHole:MountingHole_3.2mm_M3" (layer "F.Cu") (uuid "93345be0-a55c-48b6-ad01-af0edc524bba") - (at 103.5 156) + (at 103.5 175) (descr "Mounting Hole 3.2mm, M3, no annular, generated by kicad-footprint-generator mountinghole.py") (tags "mountinghole M3") (property "Reference" "H2" @@ -1799,6 +1907,18 @@ ) ) ) + (property "Rating" "At least 0.125 W; exact resistor MPN pending" + (at 0 0 0) + (layer "F.SilkS") + (hide yes) + (uuid "e18b9be7-cc36-4c84-97c3-98fc7ee4c32f") + (effects + (font + (size 1.27 1.27) + (thickness 0.15) + ) + ) + ) (path "/c86e0d56-4290-5f2b-b790-14926c8cdeea/78f9a74f-5d91-5687-b50e-68176333df23") (sheetname "serial-carrier") (sheetfile "serial-carrier.kicad_sch") @@ -1994,6 +2114,54 @@ ) ) ) + (property "Manufacturer" "Omron" + (at 0 0 0) + (layer "F.SilkS") + (hide yes) + (uuid "192dfc02-afc4-46d5-b9ca-54780213156f") + (effects + (font + (size 1.27 1.27) + (thickness 0.15) + ) + ) + ) + (property "MPN" "B3F-1000" + (at 0 0 0) + (layer "F.SilkS") + (hide yes) + (uuid "8734b77f-4d54-48c5-8647-9422ce526ee2") + (effects + (font + (size 1.27 1.27) + (thickness 0.15) + ) + ) + ) + (property "Function" "Next" + (at 0 0 0) + (layer "F.SilkS") + (hide yes) + (uuid "c31a095f-1890-4667-b888-c43d0e6eba27") + (effects + (font + (size 1.27 1.27) + (thickness 0.15) + ) + ) + ) + (property "Procurement" "Live stock not verified" + (at 0 0 0) + (layer "F.SilkS") + (hide yes) + (uuid "c1e4ac05-8087-4ac2-9a88-1b43478e3815") + (effects + (font + (size 1.27 1.27) + (thickness 0.15) + ) + ) + ) (path "/c86e0d56-4290-5f2b-b790-14926c8cdeea/35caa6bb-42a6-512c-848c-f1e4457aa97f") (sheetname "serial-carrier") (sheetfile "serial-carrier.kicad_sch") @@ -2247,6 +2415,18 @@ ) ) ) + (property "Rating" "At least 0.125 W; exact resistor MPN pending" + (at 0 0 0) + (layer "F.SilkS") + (hide yes) + (uuid "8747985b-43a4-4e66-970f-744e1b5e42b6") + (effects + (font + (size 1.27 1.27) + (thickness 0.15) + ) + ) + ) (path "/c86e0d56-4290-5f2b-b790-14926c8cdeea/defb78eb-632f-5f9d-a59d-dffbb1d31dec") (sheetname "serial-carrier") (sheetfile "serial-carrier.kicad_sch") @@ -2442,6 +2622,54 @@ ) ) ) + (property "Manufacturer" "Omron" + (at 0 0 0) + (layer "F.SilkS") + (hide yes) + (uuid "4b323911-93a0-4b21-a243-14ebc2f618d7") + (effects + (font + (size 1.27 1.27) + (thickness 0.15) + ) + ) + ) + (property "MPN" "B3F-1000" + (at 0 0 0) + (layer "F.SilkS") + (hide yes) + (uuid "b0bfc103-fdfe-41d2-90f7-40d09e860129") + (effects + (font + (size 1.27 1.27) + (thickness 0.15) + ) + ) + ) + (property "Function" "Previous / back" + (at 0 0 0) + (layer "F.SilkS") + (hide yes) + (uuid "2225dcee-db56-4b8d-b7e6-a331d3a5ee2c") + (effects + (font + (size 1.27 1.27) + (thickness 0.15) + ) + ) + ) + (property "Procurement" "Live stock not verified" + (at 0 0 0) + (layer "F.SilkS") + (hide yes) + (uuid "80cc3392-7ee9-4f40-9ab0-959d9528c918") + (effects + (font + (size 1.27 1.27) + (thickness 0.15) + ) + ) + ) (path "/c86e0d56-4290-5f2b-b790-14926c8cdeea/dd5f1f75-0093-55fc-9814-437ed26871eb") (sheetname "serial-carrier") (sheetfile "serial-carrier.kicad_sch") @@ -2683,6 +2911,18 @@ ) ) ) + (property "Status" "Module outline/header/display user fit-verified; pad/drill fit provisional" + (at 0 0 0) + (layer "F.SilkS") + (hide yes) + (uuid "06f7acd3-a6a6-4d04-9d60-cb6ed3f4c301") + (effects + (font + (size 1.27 1.27) + (thickness 0.15) + ) + ) + ) (path "/c86e0d56-4290-5f2b-b790-14926c8cdeea/0ae411c1-94cc-5551-9037-1d59c01a8ee5") (sheetname "serial-carrier") (sheetfile "serial-carrier.kicad_sch") @@ -2785,7 +3025,879 @@ (embedded_fonts no) ) (gr_line - (start 100 100) + (start 106.8 102.8) + (end 109.2 102.8) + (stroke 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default) + ) + (layer "F.SilkS") + (uuid "cf0840d6-e320-5738-912d-aac58ed27ccc") + ) + (gr_arc + (start 172.845 130.127) + (mid 172.526534 131.358416) + (end 171.650994 132.281042) + (stroke + (width 0.12) + (type default) + ) + (layer "F.SilkS") + (uuid "8f746121-d8e6-5a89-9328-da46f2da8ac0") + ) + (gr_line + (start 172.845 130.127) + (end 172.845 103.33) + (stroke + (width 0.12) + (type default) + ) + (layer "F.SilkS") + (uuid "c62b295c-ee54-5fb8-a84a-62d59f4f6f07") + ) + (gr_line + (start 100 119) + (end 136 119) + (stroke + (width 0.05) + (type default) + ) + (layer "Edge.Cuts") + (uuid "1dc7a9fd-03af-4394-8ed1-9a6edc5f15e6") + ) + (gr_line + (start 100 180) + (end 100 119) + (stroke + (width 0.05) + (type default) + ) + (layer "Edge.Cuts") + (uuid "f3fe1b44-d774-4285-b572-67c64ac82b95") + ) + (gr_line + (start 136 100) (end 182 100) (stroke (width 0.05) @@ -2795,8 +3907,8 @@ (uuid "c7599f57-6a67-4917-b673-436faff51ee4") ) (gr_line - (start 100 161) - (end 100 100) + (start 136 119) + (end 136 100) (stroke (width 0.05) (type default) @@ -2804,26 +3916,6 @@ (layer "Edge.Cuts") (uuid "390e3d7e-1ebd-4f8c-9ba4-0ebdd92195a1") ) - (gr_line - (start 136 161) - (end 100 161) - (stroke - (width 0.05) - (type default) - ) - (layer "Edge.Cuts") - (uuid "1dc7a9fd-03af-4394-8ed1-9a6edc5f15e6") - ) - (gr_line - (start 136 180) - (end 136 161) - (stroke - (width 0.05) - (type default) - ) - (layer "Edge.Cuts") - (uuid "f3fe1b44-d774-4285-b572-67c64ac82b95") - ) (gr_line (start 182 100) (end 182 180) @@ -2836,7 +3928,7 @@ ) (gr_line (start 182 180) - (end 136 180) + (end 100 180) (stroke (width 0.05) (type default) @@ -2844,6 +3936,17 @@ (layer "Edge.Cuts") (uuid "17ad1955-d7db-47eb-a736-baff736aac39") ) + (gr_text "HEADER GUIDES" + (at 120.7 132 0) + (layer "F.SilkS") + (uuid "2441022c-c903-5a57-a84c-86f0a5143cb5") + (effects + (font + (size 0.85 0.85) + (thickness 0.12) + ) + ) + ) (gr_text "BACK" (at 146.25 175 0) (layer "F.SilkS") @@ -2889,7 +3992,7 @@ ) ) (gr_text "ESP32 HW678" - (at 120.7 129 0) + (at 120.7 148 0) (layer "F.SilkS") (uuid "f45876c7-f270-4231-bfa4-b69ded09f3a4") (effects @@ -2911,7 +4014,7 @@ ) ) (gr_text "MAX3243 REF" - (at 156.97 121 0) + (at 156.97 117.67 0) (layer "F.SilkS") (uuid "fa700fde-d4f3-437c-9b51-4322d0fd68e0") (effects @@ -2921,7 +4024,7 @@ ) ) ) - (gr_text "Carrier envelope only; module overhang and connector clearance not qualified" + (gr_text "Nominal RS-232 metal verified; ESP32 USB / antenna / assembly clearance pending" (at 141 97.5 0) (layer "Dwgs.User") (uuid "de46e0e9-8a3a-42d0-b1c7-8915a9856836") @@ -2933,7 +4036,7 @@ ) ) (gr_text "USB ACCESS - VERIFY" - (at 118 164 0) + (at 118 183 0) (layer "Dwgs.User") (uuid "c695eb94-004e-4a56-801a-0ca6797a46b2") (effects @@ -2944,7 +4047,7 @@ ) ) (gr_text "VERIFY ANTENNA" - (at 120.5 110 0) + (at 120.5 129 0) (layer "Dwgs.User") (uuid "ce061da3-831a-4fb1-9676-9177435d649e") (effects @@ -2954,8 +4057,8 @@ ) ) ) - (gr_text "DE-9 OUT / VERIFY MALE" - (at 156.97 101.5 0) + (gr_text "DE-9 OUT / NOMINAL MALE" + (at 156.97 98.17 0) (layer "Dwgs.User") (uuid "94303a67-2a65-4a16-9499-2b409a657ba6") (effects @@ -2966,7 +4069,7 @@ ) ) (gr_text "RF RESERVE" - (at 120.5 107 0) + (at 120.5 126 0) (layer "Dwgs.User") (uuid "e8228b54-6114-48a6-80ef-7f0a68175b1d") (effects @@ -3014,7 +4117,7 @@ ) (polygon (pts - (xy 110 100) (xy 131 100) (xy 131 113) (xy 110 113) + (xy 110 119) (xy 131 119) (xy 131 132) (xy 110 132) ) ) ) diff --git a/hardware/PCB/validation/pcb-routing-preservation.json b/hardware/PCB/validation/pcb-routing-preservation.json new file mode 100644 index 0000000..afcc0f4 --- /dev/null +++ b/hardware/PCB/validation/pcb-routing-preservation.json @@ -0,0 +1,27 @@ +{ + "a0_snapshot_unchanged": true, + "a1_unrouted_snapshot_unchanged": true, + "protected_files_unchanged": [ + "serial-carrier.kicad_pro", + "serial-carrier.kicad_sch", + "serial-carrier.kicad_prl", + "fp-lib-table", + "sym-lib-table", + "Carrier.kicad_sym", + "Carrier.pretty/OLED_26mm_I2C_Provisional.kicad_mod", + "Carrier.pretty/HW678_2x22_Provisional.kicad_mod", + "Carrier.pretty/MAX3243_Reference_Provisional.kicad_mod" + ], + "intentional_documentation_updates": [ + "README.md", + "pcb-draft-notes.md" + ], + "cad_projection_graphics": 7, + "footprints_identical_except_authorized_placement": true, + "footprint_count": 13, + "unrelated_board_graphics_preserved": 5, + "non_owned_board_graphic_uuids_preserved": true, + "refreshed_device_silkscreen_items": 91, + "pcb_editor_lock_absent": true, + "final_board_sha256": "53e36538c0669604457b9e1a9ff1b1e20422970e8f9f356088c4581868ad5045" +} diff --git a/hardware/PCB/validation/pcb-routing-preservation.py b/hardware/PCB/validation/pcb-routing-preservation.py new file mode 100644 index 0000000..6991dc2 --- /dev/null +++ b/hardware/PCB/validation/pcb-routing-preservation.py @@ -0,0 +1,99 @@ +#!/usr/bin/python3 +"""Compare A1 against the untouched A0 snapshot, including unrelated graphics.""" +import hashlib +import json +from pathlib import Path +import re +import uuid + +ROOT=Path(__file__).resolve().parent.parent +OUT=ROOT/'validation' + + +def parse(path): + tokens=iter(re.findall(r'"(?:\\.|[^"\\])*"|[()]|[^\s()]+',path.read_text())) + def group(): + result=[] + for token in tokens: + if token==')': + return result + result.append(group() if token=='(' else token) + raise ValueError('unterminated S-expression') + assert next(tokens)=='(' + return group() + + +def child(item,key): + return next(v for v in item if isinstance(v,list) and v[0]==key) + + +def ident(item): + return child(item,'uuid')[1].strip('"') + + +def sha(path): + return hashlib.sha256(path.read_bytes()).hexdigest() + + +report=json.loads(OUT.joinpath('pcb-routing-reposition.json').read_text()) +a0=OUT/'pcb-a0-before-reposition.kicad_pcb' +a1=ROOT/'serial-carrier.kicad_pcb' +assert sha(a0)==report['a0_snapshot_sha256'], 'A0 snapshot changed' +assert sha(OUT/'pcb-routing-input.kicad_pcb')==report['a1_unrouted_sha256'], 'A1 routing input changed' +# These two handoff documents are intentionally updated during A1 integration. +protected={name:digest for name,digest in report['protected_file_sha256'].items() + if name not in ('README.md','pcb-draft-notes.md')} +for name,digest in protected.items(): + assert sha(ROOT/name)==digest, 'protected file changed: '+name +old,new=parse(a0),parse(a1) +old_fp={ident(x):x for x in old if isinstance(x,list) and x[0]=='footprint'} +new_fp={ident(x):x for x in new if isinstance(x,list) and x[0]=='footprint'} +assert set(old_fp)==set(new_fp) +for key,fp in old_fp.items(): + # Footprint geometry, fields, UUIDs and connectivity must be identical; + # only the top-level placement may differ, and only for the four moves. + ref=next(v[2].strip('"') for v in fp if isinstance(v,list) and v[:2]==['property','"Reference"']) + cleaned=lambda f:[v for v in f if not isinstance(v,list) or v[0]!='at'] + assert cleaned(fp)==cleaned(new_fp[key]), 'footprint content changed: '+ref + if ref not in report['moves_local_mm']: + assert child(fp,'at')==child(new_fp[key],'at'),ref + else: + expected=report['moves_local_mm'][ref][1] + assert [round(float(v)-100,6) for v in child(new_fp[key],'at')[1:3]]==expected,ref +ns=uuid.UUID('67964aa4-c3a5-45d8-9b54-250fb68e7c41') +owned={str(uuid.uuid5(ns,str(i))) for i in range(4096)} +cad_ns=uuid.UUID('ba7274a8-c35d-46bc-908d-cd86708fc6c4') +cad_owned={str(uuid.uuid5(cad_ns,str(i))) for i in range(7)} +changed_texts=set(report['changed_board_text_uuids']) +for item in old: + if isinstance(item,list) and item[0]=='gr_text': + value=json.loads(item[1]) + if value=='82 x 80 mm / 2 copper layers' or value.startswith('DE-9 OUT /'): + changed_texts.add(ident(item)) + +def drawings(tree): + return {ident(x):x for x in tree if isinstance(x,list) and + (x[0].startswith('gr_') or x[0] in ('dimension','target','image'))} + +old_gr,new_gr=drawings(old),drawings(new) +edge_ids={key for key,value in old_gr.items() if child(value,'layer')[1]=='"Edge.Cuts"'} +assert cad_owned <= set(new_gr), 'missing CAD projection graphics' +assert all(child(new_gr[key],'layer')[1]=='"Dwgs.User"' for key in cad_owned) +excluded=owned|cad_owned|changed_texts|edge_ids +unchanged_old={key:value for key,value in old_gr.items() if key not in excluded} +unchanged_new={key:value for key,value in new_gr.items() if key not in excluded} +assert unchanged_old==unchanged_new, 'unrelated board graphics changed' +assert set(old_gr)-owned==set(new_gr)-owned-cad_owned, 'non-owned board graphic UUID set changed' +assert [x for x in old if isinstance(x,list) and x[0]=='net']==[x for x in new if isinstance(x,list) and x[0]=='net'] +assert not (ROOT/'~serial-carrier.kicad_pcb.lck').exists(), 'PCB reopened before handoff' +result=dict(a0_snapshot_unchanged=True,a1_unrouted_snapshot_unchanged=True, + protected_files_unchanged=list(protected), + intentional_documentation_updates=['README.md','pcb-draft-notes.md'], + cad_projection_graphics=len(cad_owned), + footprints_identical_except_authorized_placement=True, + footprint_count=len(old_fp),unrelated_board_graphics_preserved=len(unchanged_old), + non_owned_board_graphic_uuids_preserved=True, + refreshed_device_silkscreen_items=len(set(new_gr)&owned), + pcb_editor_lock_absent=True,final_board_sha256=sha(a1)) +OUT.joinpath('pcb-routing-preservation.json').write_text(json.dumps(result,indent=2)+'\n') +print(json.dumps(result,indent=2)) diff --git a/hardware/PCB/validation/pcb-routing-reposition.json b/hardware/PCB/validation/pcb-routing-reposition.json new file mode 100644 index 0000000..5c3bd4a --- /dev/null +++ b/hardware/PCB/validation/pcb-routing-reposition.json @@ -0,0 +1,98 @@ +{ + "revision": "A1", + "a0_snapshot_sha256": "25669051086d6a5315650580ead8ce847f42ae07b8d08af5d76f0a813131ff18", + "a1_unrouted_sha256": "df62a5aeb64a6d871a477a8c9fe94c100210d5b239a0617558907d9d3d9a6007", + "outline_local_mm": [ + [ + 36, + 0 + ], + [ + 82, + 0 + ], + [ + 82, + 80 + ], + [ + 0, + 80 + ], + [ + 0, + 19 + ], + [ + 36, + 19 + ] + ], + "moves_local_mm": { + "U1": [ + [ + 8, + 4 + ], + [ + 8, + 23 + ] + ], + "U2": [ + [ + 43, + 30 + ], + [ + 43, + 26.67 + ] + ], + "H1": [ + [ + 3.5, + 3.5 + ], + [ + 3.5, + 22.5 + ] + ], + "H2": [ + [ + 3.5, + 56 + ], + [ + 3.5, + 75 + ] + ] + }, + "changed_board_text_uuids": [ + "e8228b54-6114-48a6-80ef-7f0a68175b1d", + "ce061da3-831a-4fb1-9676-9177435d649e", + "f45876c7-f270-4231-bfa4-b69ded09f3a4", + "c695eb94-004e-4a56-801a-0ca6797a46b2", + "94303a67-2a65-4a16-9499-2b409a657ba6", + "fa700fde-d4f3-437c-9b51-4322d0fd68e0", + "de46e0e9-8a3a-42d0-b1c7-8915a9856836" + ], + "normalized_footprints_preserved": true, + "nets_preserved": true, + "protected_file_sha256": { + "serial-carrier.kicad_pro": "9ad5b992785ebfe01fa7ea4e1aa391a2c7d7f1f2c3b1c13136173c301ecb6516", + "serial-carrier.kicad_sch": "1876ef30aae16d9eb4a421efea7c090c50cddd16a59a9bfe866ed5c802e2571c", + "serial-carrier.kicad_prl": "b448331403441aabec6e4718d3c82f4fac4073fa9430762d6bb0b5b34c16def9", + "README.md": "d3339535217e2c2e214a620e7826878d2ae635eec288041f57012966e95765ca", + "pcb-draft-notes.md": "7be3fa469867b98530a84a61fc978b89d853a1652963a8d24373a64f367f8360", + "fp-lib-table": "a56dc436d1442de03c7953b426a90444dce078d57b24f70f1675d0beb19acd4e", + "sym-lib-table": "f3520b095a4f6238fb7a46dd5c8ab460a8e842dc085a53d2c7f912609015b5ae", + "Carrier.kicad_sym": "ba642459312b5b5cb5b5021d0b573c427c3ab93a2cde51941f018bbcba07716a", + "Carrier.pretty/OLED_26mm_I2C_Provisional.kicad_mod": "ab2aa7cb0e84d31f18e2493088830964b04764f44873dfb0e30a4c7faa43ef37", + "Carrier.pretty/HW678_2x22_Provisional.kicad_mod": "87a32630a388ebd1646ca04a1152e29833735a62e2fca980eaa187c7ca386e20", + "Carrier.pretty/MAX3243_Reference_Provisional.kicad_mod": "90c7c0b24007a7e8cb6815641363880fe420fe60e76ea7670c83c217a6d47ecd" + }, + "remaining_tracks": 0 +} diff --git a/hardware/PCB/validation/pcb-routing-reposition.py b/hardware/PCB/validation/pcb-routing-reposition.py new file mode 100644 index 0000000..7933f41 --- /dev/null +++ b/hardware/PCB/validation/pcb-routing-reposition.py @@ -0,0 +1,133 @@ +#!/usr/bin/python3 +"""One-shot A0 -> A1 placement migration of the existing board, never regeneration. + +Requires --apply and the untouched pcb-a0-before-reposition.kicad_pcb snapshot. +Never replaces the snapshot or accepts an already edited/migrated input. +""" +import argparse +import hashlib +import json +from pathlib import Path +import sys + +import pcbnew as p + +ROOT = Path(__file__).resolve().parent.parent +sys.path.insert(0, str(ROOT)) +from route_pcb_draft import identity + +PCB = ROOT / 'serial-carrier.kicad_pcb' +BACKUP = ROOT / 'validation/pcb-a0-before-reposition.kicad_pcb' +LOCK = ROOT / '~serial-carrier.kicad_pcb.lck' +OLD = [(0,0),(82,0),(82,80),(36,80),(36,61),(0,61)] +NEW = [(36,0),(82,0),(82,80),(0,80),(0,19),(36,19)] +MOVES = {'U1': ((8,4),(8,23)), 'U2': ((43,30),(43,26.670)), + 'H1': ((3.5,3.5),(3.5,22.5)), 'H2': ((3.5,56),(3.5,75))} +TEXT_MOVES = {'RF RESERVE':19, 'VERIFY ANTENNA':19, 'ESP32 HW678':19, + 'USB ACCESS - VERIFY':19, 'DE-9 OUT / VERIFY MALE':-3.330, + 'MAX3243 REF':-3.330} + + +def vec(x,y): + return p.VECTOR2I(p.FromMM(x),p.FromMM(y)) + + +def local(v): + return (round(p.ToMM(v.x)-100,6),round(p.ToMM(v.y)-100,6)) + + +def sha(path): + return hashlib.sha256(path.read_bytes()).hexdigest() + + +def normalized_footprints(board): + # Normalize placement only, retaining UUIDs, local pad geometry and linkage. + entries = identity(board)[1] + normalized = [] + for entry in entries: + fields = list(entry) + x,y = fields[5] + fields[5] = (0,0) + pads = [] + for pad in fields[-1]: + values = list(pad) + values[3] = (round(values[3][0]-x,6),round(values[3][1]-y,6)) + pads.append(tuple(values)) + fields[-1] = pads + normalized.append(tuple(fields)) + return normalized + + +def main(): + parser=argparse.ArgumentParser(description=__doc__) + parser.add_argument('--apply',action='store_true') + args=parser.parse_args() + if not args.apply: + parser.error('explicit --apply required; only accepts the original A0 snapshot') + assert not LOCK.exists(), 'PCB Editor lock exists' + assert BACKUP.exists(), 'make the one-time A0 snapshot first' + before=PCB.read_bytes() + assert before==BACKUP.read_bytes(), 'current board differs from A0 snapshot; refusing migration' + protected=[ROOT/name for name in ('serial-carrier.kicad_pro','serial-carrier.kicad_sch', + 'serial-carrier.kicad_prl','README.md','pcb-draft-notes.md','fp-lib-table', + 'sym-lib-table','Carrier.kicad_sym')] + protected+=list((ROOT/'Carrier.pretty').glob('*')) + hashes={str(path.relative_to(ROOT)):sha(path) for path in protected if path.is_file()} + board=p.LoadBoard(str(PCB)) + immutable=normalized_footprints(board) + net_table=identity(board)[-1] + footprints={f.GetReference():f for f in board.GetFootprints()} + for ref,(old,new) in MOVES.items(): + fp=footprints[ref] + assert local(fp.GetPosition())==old,(ref,local(fp.GetPosition())) + fp.SetPosition(vec(new[0]+100,new[1]+100)) + for track in list(board.GetTracks()): + board.Delete(track) + edges=[d for d in board.GetDrawings() if d.GetLayer()==p.Edge_Cuts] + assert len(edges)==6 + for i,(a,b) in enumerate(zip(OLD,OLD[1:]+OLD[:1])): + edge=next(e for e in edges if frozenset((local(e.GetStart()),local(e.GetEnd())))==frozenset((a,b))) + aa,bb=NEW[i],NEW[(i+1)%6] + edge.SetStart(vec(aa[0]+100,aa[1]+100)) + edge.SetEnd(vec(bb[0]+100,bb[1]+100)) + assert len(board.Zones())==1 and board.Zones()[0].GetIsRuleArea() + zone=board.Zones()[0] + contour=zone.Outline().COutline(0) + assert {local(contour.CPoint(i)) for i in range(contour.PointCount())}=={(10,0),(31,0),(31,13),(10,13)} + zone.Move(vec(0,19)) + changed_texts=[] + for text,dy in TEXT_MOVES.items(): + found=[d for d in board.GetDrawings() if isinstance(d,p.PCB_TEXT) and d.GetText()==text] + assert len(found)==1,(text,len(found)) + drawing=found[0] + drawing.Move(vec(0,dy)) + if text=='DE-9 OUT / VERIFY MALE': + drawing.SetText('DE-9 OUT / NOMINAL MALE') + changed_texts.append(drawing.m_Uuid.AsString()) + for d in board.GetDrawings(): + if isinstance(d,p.PCB_TEXT) and d.GetText()=='Carrier envelope only; module overhang and connector clearance not qualified': + d.SetText('Nominal RS-232 metal verified; ESP32 USB / antenna / assembly clearance pending') + changed_texts.append(d.m_Uuid.AsString()) + title=board.GetTitleBlock() + title.SetRevision('A1 DRAFT') + title.SetComment(0,'NOT FOR FABRICATION - USB / antenna geometry pending; verify module pinout / assembly') + assert normalized_footprints(board)==immutable + assert identity(board)[-1]==net_table + candidate=ROOT/'validation/pcb-routing-reposition-candidate.kicad_pcb' + assert p.SaveBoard(str(candidate),board,True) + saved=p.LoadBoard(str(candidate)) + assert normalized_footprints(saved)==immutable + assert identity(saved)==identity(board) + assert not LOCK.exists() and PCB.read_bytes()==before + assert all(sha(ROOT/name)==digest for name,digest in hashes.items()), 'protected input changed' + candidate.replace(PCB) + report=dict(revision='A1',a0_snapshot_sha256=sha(BACKUP),a1_unrouted_sha256=sha(PCB), + outline_local_mm=NEW,moves_local_mm=MOVES,changed_board_text_uuids=changed_texts, + normalized_footprints_preserved=True,nets_preserved=True, + protected_file_sha256=hashes,remaining_tracks=len(saved.GetTracks())) + ROOT.joinpath('validation/pcb-routing-reposition.json').write_text(json.dumps(report,indent=2)+'\n') + print(json.dumps(report,indent=2)) + + +if __name__=='__main__': + main() diff --git a/hardware/PCB/validation/pcb-routing-run.json b/hardware/PCB/validation/pcb-routing-run.json index 70611b4..c7d0bd3 100644 --- a/hardware/PCB/validation/pcb-routing-run.json +++ b/hardware/PCB/validation/pcb-routing-run.json @@ -6,19 +6,36 @@ "safety_margin_mm": 0.02, "via_diameter_mm": 0.7, "via_drill_mm": 0.3, - "elapsed_seconds": 26.517815405000874, + "elapsed_seconds": 32.44472043699898, "connections": [ + { + "net": "/GND", + "start": "U1.43", + "end": "U1.44", + "start_mm": [ + 133.4, + 173.8 + ], + "end_mm": [ + 133.4, + 176.34 + ], + "routed": true, + "width_mm": 0.5, + "power_fallback": false, + "expansions": 52 + }, { "net": "/+3V3", "start": "U1.1", "end": "U1.2", "start_mm": [ 108.0, - 104.0 + 123.0 ], "end_mm": [ 108.0, - 106.54 + 125.54 ], "routed": true, "width_mm": 0.5, @@ -42,448 +59,6 @@ "power_fallback": false, "expansions": 911 }, - { - "net": "/+3V3", - "start": "U2.1", - "end": "R1.1", - "start_mm": [ - 143.0, - 130.0 - ], - "end_mm": [ - 143.0, - 134.0 - ], - "routed": true, - "width_mm": 0.5, - "power_fallback": false, - "expansions": 81 - }, - { - "net": "/BTN_NEXT", - "start": "SW3.1", - "end": "SW3.1", - "start_mm": [ - 167.0, - 168.0 - ], - "end_mm": [ - 173.5, - 168.0 - ], - "routed": true, - "width_mm": 0.25, - "power_fallback": false, - "expansions": 131 - }, - { - "net": "/BTN_PREVIOUS", - "start": "SW1.1", - "end": "SW1.1", - "start_mm": [ - 149.5, - 168.0 - ], - "end_mm": [ - 143.0, - 168.0 - ], - "routed": true, - "width_mm": 0.25, - "power_fallback": false, - "expansions": 131 - }, - { - "net": "/BTN_SELECT", - "start": "SW2.1", - "end": "SW2.1", - "start_mm": [ - 155.0, - 168.0 - ], - "end_mm": [ - 161.5, - 168.0 - ], - "routed": true, - "width_mm": 0.25, - "power_fallback": false, - "expansions": 131 - }, - { - "net": "/+3V3", - "start": "DS1.2", - "end": "R3.1", - "start_mm": [ - 154.73, - 137.5 - ], - "end_mm": [ - 165.0, - 134.0 - ], - "routed": true, - "width_mm": 0.5, - "power_fallback": false, - "expansions": 5139 - }, - { - "net": "/+3V3", - "start": "R1.1", - "end": "R2.1", - "start_mm": [ - 143.0, - 134.0 - ], - "end_mm": [ - 154.0, - 134.0 - ], - "routed": true, - "width_mm": 0.5, - "power_fallback": false, - "expansions": 14153 - }, - { - "net": "/BTN_SELECT", - "start": "SW2.1", - "end": "R2.2", - "start_mm": [ - 161.5, - 168.0 - ], - "end_mm": [ - 161.62, - 134.0 - ], - "routed": true, - "width_mm": 0.25, - "power_fallback": false, - "expansions": 2039 - }, - { - "net": "/BTN_NEXT", - "start": "SW3.1", - "end": "R3.2", - "start_mm": [ - 173.5, - 168.0 - ], - "end_mm": [ - 172.62, - 134.0 - ], - "routed": true, - "width_mm": 0.25, - "power_fallback": false, - "expansions": 12615 - }, - { - "net": "/BTN_PREVIOUS", - "start": "R1.2", - "end": "SW1.1", - "start_mm": [ - 150.62, - 134.0 - ], - "end_mm": [ - 149.5, - 168.0 - ], - "routed": true, - "width_mm": 0.25, - "power_fallback": false, - "expansions": 15179 - }, - { - "net": "/+3V3", - "start": "U1.2", - "end": "U2.1", - "start_mm": [ - 108.0, - 106.54 - ], - "end_mm": [ - 143.0, - 130.0 - ], - "routed": true, - "width_mm": 0.5, - "power_fallback": false, - "expansions": 894511 - }, - { - "net": "/RS_RX", - "start": "U1.11", - "end": "U2.4", - "start_mm": [ - 108.0, - 129.4 - ], - "end_mm": [ - 150.62, - 130.0 - ], - "routed": true, - "width_mm": 0.25, - "power_fallback": false, - "expansions": 51516 - }, - { - "net": "/BTN_PREVIOUS", - "start": "U1.16", - "end": "R1.2", - "start_mm": [ - 108.0, - 142.1 - ], - "end_mm": [ - 150.62, - 134.0 - ], - "routed": true, - "width_mm": 0.25, - "power_fallback": false, - "expansions": 94479 - }, - { - "net": "/RS_DCD", - "start": "U1.4", - "end": "U2.3", - "start_mm": [ - 108.0, - 111.62 - ], - "end_mm": [ - 148.08, - 130.0 - ], - "routed": true, - "width_mm": 0.25, - "power_fallback": false, - "expansions": 266031 - }, - { - "net": "/RS_TX", - "start": "U1.10", - "end": "U2.5", - "start_mm": [ - 108.0, - 126.86 - ], - "end_mm": [ - 153.16, - 130.0 - ], - "routed": true, - "width_mm": 0.25, - "power_fallback": false, - "expansions": 175689 - }, - { - "net": "/RS_DTR", - "start": "U1.7", - "end": "U2.6", - "start_mm": [ - 108.0, - 119.24 - ], - "end_mm": [ - 155.7, - 130.0 - ], - "routed": true, - "width_mm": 0.25, - "power_fallback": false, - "expansions": 326823 - }, - { - "net": "/OLED_SCL", - "start": "U1.18", - "end": "DS1.3", - "start_mm": [ - 108.0, - 147.18 - ], - "end_mm": [ - 157.27, - 137.5 - ], - "routed": true, - "width_mm": 0.25, - "power_fallback": false, - "expansions": 82557 - }, - { - "net": "/BTN_SELECT", - "start": "SW2.1", - "end": "U1.19", - "start_mm": [ - 155.0, - 168.0 - ], - "end_mm": [ - 108.0, - 149.72 - ], - "routed": true, - "width_mm": 0.25, - "power_fallback": false, - "expansions": 147997 - }, - { - "net": "/OLED_SDA", - "start": "U1.17", - "end": "DS1.4", - "start_mm": [ - 108.0, - 144.64 - ], - "end_mm": [ - 159.81, - 137.5 - ], - "routed": true, - "width_mm": 0.25, - "power_fallback": false, - "expansions": 266428 - }, - { - "net": "/RS_DSR", - "start": "U1.5", - "end": "U2.7", - "start_mm": [ - 108.0, - 114.16 - ], - "end_mm": [ - 158.24, - 130.0 - ], - "routed": true, - "width_mm": 0.25, - "power_fallback": false, - "expansions": 372014 - }, - { - "net": "/RS_RTS", - "start": "U1.8", - "end": "U2.8", - "start_mm": [ - 108.0, - 121.78 - ], - "end_mm": [ - 160.78, - 130.0 - ], - "routed": true, - "width_mm": 0.25, - "power_fallback": false, - "expansions": 298514 - }, - { - "net": "/RS_CTS", - "start": "U1.9", - "end": "U2.9", - "start_mm": [ - 108.0, - 124.32 - ], - "end_mm": [ - 163.32, - 130.0 - ], - "routed": true, - "width_mm": 0.25, - "power_fallback": false, - "expansions": 265272 - }, - { - "net": "/RS_RI", - "start": "U1.6", - "end": "U2.10", - "start_mm": [ - 108.0, - 116.7 - ], - "end_mm": [ - 165.86, - 130.0 - ], - "routed": true, - "width_mm": 0.25, - "power_fallback": false, - "expansions": 332506 - }, - { - "net": "/RS_VALID", - "start": "U1.12", - "end": "U2.11", - "start_mm": [ - 108.0, - 131.94 - ], - "end_mm": [ - 168.4, - 130.0 - ], - "routed": true, - "width_mm": 0.25, - "power_fallback": false, - "expansions": 348384 - }, - { - "net": "/BTN_NEXT", - "start": "U1.20", - "end": "SW3.1", - "start_mm": [ - 108.0, - 152.26 - ], - "end_mm": [ - 167.0, - 168.0 - ], - "routed": true, - "width_mm": 0.25, - "power_fallback": false, - "expansions": 272795 - }, - { - "net": "/RS_OFF_N", - "start": "U1.15", - "end": "U2.12", - "start_mm": [ - 108.0, - 139.56 - ], - "end_mm": [ - 170.94, - 130.0 - ], - "routed": true, - "width_mm": 0.25, - "power_fallback": false, - "expansions": 351630 - }, - { - "net": "/GND", - "start": "U1.44", - "end": "U1.43", - "start_mm": [ - 133.4, - 157.34 - ], - "end_mm": [ - 133.4, - 154.8 - ], - "routed": true, - "width_mm": 0.5, - "power_fallback": false, - "expansions": 52 - }, { "net": "/GND", "start": "SW2.2", @@ -518,6 +93,57 @@ "power_fallback": false, "expansions": 111 }, + { + "net": "/BTN_NEXT", + "start": "SW3.1", + "end": "SW3.1", + "start_mm": [ + 167.0, + 168.0 + ], + "end_mm": [ + 173.5, + 168.0 + ], + "routed": true, + "width_mm": 0.25, + "power_fallback": false, + "expansions": 131 + }, + { + "net": "/BTN_PREVIOUS", + "start": "SW1.1", + "end": "SW1.1", + "start_mm": [ + 143.0, + 168.0 + ], + "end_mm": [ + 149.5, + 168.0 + ], + "routed": true, + "width_mm": 0.25, + "power_fallback": false, + "expansions": 131 + }, + { + "net": "/BTN_SELECT", + "start": "SW2.1", + "end": "SW2.1", + "start_mm": [ + 155.0, + 168.0 + ], + "end_mm": [ + 161.5, + 168.0 + ], + "routed": true, + "width_mm": 0.25, + "power_fallback": false, + "expansions": 131 + }, { "net": "/GND", "start": "SW2.2", @@ -569,6 +195,91 @@ "power_fallback": false, "expansions": 131 }, + { + "net": "/+3V3", + "start": "U2.1", + "end": "R1.1", + "start_mm": [ + 143.0, + 126.67 + ], + "end_mm": [ + 143.0, + 134.0 + ], + "routed": true, + "width_mm": 0.5, + "power_fallback": false, + "expansions": 148 + }, + { + "net": "/GND", + "start": "SW1.2", + "end": "U1.43", + "start_mm": [ + 143.0, + 172.5 + ], + "end_mm": [ + 133.4, + 173.8 + ], + "routed": true, + "width_mm": 0.5, + "power_fallback": false, + "expansions": 4535 + }, + { + "net": "/+3V3", + "start": "DS1.2", + "end": "R3.1", + "start_mm": [ + 154.73, + 137.5 + ], + "end_mm": [ + 165.0, + 134.0 + ], + "routed": true, + "width_mm": 0.5, + "power_fallback": false, + "expansions": 5139 + }, + { + "net": "/+3V3", + "start": "R1.1", + "end": "R2.1", + "start_mm": [ + 143.0, + 134.0 + ], + "end_mm": [ + 154.0, + 134.0 + ], + "routed": true, + "width_mm": 0.5, + "power_fallback": false, + "expansions": 14153 + }, + { + "net": "/GND", + "start": "U2.2", + "end": "U1.23", + "start_mm": [ + 145.54, + 126.67 + ], + "end_mm": [ + 133.4, + 123.0 + ], + "routed": true, + "width_mm": 0.5, + "power_fallback": false, + "expansions": 9372 + }, { "net": "/GND", "start": "DS1.1", @@ -579,29 +290,335 @@ ], "end_mm": [ 145.54, - 130.0 + 126.67 ], "routed": true, "width_mm": 0.5, "power_fallback": false, - "expansions": 17468 + "expansions": 8327 }, { - "net": "/GND", - "start": "SW1.2", - "end": "U1.44", + "net": "/BTN_SELECT", + "start": "SW2.1", + "end": "R2.2", "start_mm": [ - 143.0, - 172.5 + 161.5, + 168.0 ], "end_mm": [ - 133.4, - 157.34 + 161.62, + 134.0 + ], + "routed": true, + "width_mm": 0.25, + "power_fallback": false, + "expansions": 2039 + }, + { + "net": "/BTN_NEXT", + "start": "SW3.1", + "end": "R3.2", + "start_mm": [ + 173.5, + 168.0 + ], + "end_mm": [ + 172.62, + 134.0 + ], + "routed": true, + "width_mm": 0.25, + "power_fallback": false, + "expansions": 12615 + }, + { + "net": "/BTN_PREVIOUS", + "start": "SW1.1", + "end": "R1.2", + "start_mm": [ + 149.5, + 168.0 + ], + "end_mm": [ + 150.62, + 134.0 + ], + "routed": true, + "width_mm": 0.25, + "power_fallback": false, + "expansions": 15179 + }, + { + "net": "/+3V3", + "start": "U1.2", + "end": "U2.1", + "start_mm": [ + 108.0, + 125.54 + ], + "end_mm": [ + 143.0, + 126.67 ], "routed": true, "width_mm": 0.5, "power_fallback": false, - "expansions": 27488 + "expansions": 332527 + }, + { + "net": "/BTN_PREVIOUS", + "start": "U1.16", + "end": "SW1.1", + "start_mm": [ + 108.0, + 161.1 + ], + "end_mm": [ + 143.0, + 168.0 + ], + "routed": true, + "width_mm": 0.25, + "power_fallback": false, + "expansions": 70393 + }, + { + "net": "/RS_DCD", + "start": "U1.4", + "end": "U2.3", + "start_mm": [ + 108.0, + 130.62 + ], + "end_mm": [ + 148.08, + 126.67 + ], + "routed": true, + "width_mm": 0.25, + "power_fallback": false, + "expansions": 21855 + }, + { + "net": "/BTN_SELECT", + "start": "SW2.1", + "end": "U1.19", + "start_mm": [ + 155.0, + 168.0 + ], + "end_mm": [ + 108.0, + 168.72 + ], + "routed": true, + "width_mm": 0.25, + "power_fallback": false, + "expansions": 36364 + }, + { + "net": "/RS_RX", + "start": "U1.11", + "end": "U2.4", + "start_mm": [ + 108.0, + 148.4 + ], + "end_mm": [ + 150.62, + 126.67 + ], + "routed": true, + "width_mm": 0.25, + "power_fallback": false, + "expansions": 123675 + }, + { + "net": "/RS_TX", + "start": "U1.10", + "end": "U2.5", + "start_mm": [ + 108.0, + 145.86 + ], + "end_mm": [ + 153.16, + 126.67 + ], + "routed": true, + "width_mm": 0.25, + "power_fallback": false, + "expansions": 397389 + }, + { + "net": "/RS_DTR", + "start": "U1.7", + "end": "U2.6", + "start_mm": [ + 108.0, + 138.24 + ], + "end_mm": [ + 155.7, + 126.67 + ], + "routed": true, + "width_mm": 0.25, + "power_fallback": false, + "expansions": 294174 + }, + { + "net": "/RS_DSR", + "start": "U1.5", + "end": "U2.7", + "start_mm": [ + 108.0, + 133.16 + ], + "end_mm": [ + 158.24, + 126.67 + ], + "routed": true, + "width_mm": 0.25, + "power_fallback": false, + "expansions": 294332 + }, + { + "net": "/RS_RTS", + "start": "U1.8", + "end": "U2.8", + "start_mm": [ + 108.0, + 140.78 + ], + "end_mm": [ + 160.78, + 126.67 + ], + "routed": true, + "width_mm": 0.25, + "power_fallback": false, + "expansions": 378833 + }, + { + "net": "/OLED_SCL", + "start": "U1.18", + "end": "DS1.3", + "start_mm": [ + 108.0, + 166.18 + ], + "end_mm": [ + 157.27, + 137.5 + ], + "routed": true, + "width_mm": 0.25, + "power_fallback": false, + "expansions": 442107 + }, + { + "net": "/RS_CTS", + "start": "U1.9", + "end": "U2.9", + "start_mm": [ + 108.0, + 143.32 + ], + "end_mm": [ + 163.32, + 126.67 + ], + "routed": true, + "width_mm": 0.25, + "power_fallback": false, + "expansions": 409990 + }, + { + "net": "/OLED_SDA", + "start": "U1.17", + "end": "DS1.4", + "start_mm": [ + 108.0, + 163.64 + ], + "end_mm": [ + 159.81, + 137.5 + ], + "routed": true, + "width_mm": 0.25, + "power_fallback": false, + "expansions": 567654 + }, + { + "net": "/RS_RI", + "start": "U1.6", + "end": "U2.10", + "start_mm": [ + 108.0, + 135.7 + ], + "end_mm": [ + 165.86, + 126.67 + ], + "routed": true, + "width_mm": 0.25, + "power_fallback": false, + "expansions": 436874 + }, + { + "net": "/BTN_NEXT", + "start": "U1.20", + "end": "SW3.1", + "start_mm": [ + 108.0, + 171.26 + ], + "end_mm": [ + 167.0, + 168.0 + ], + "routed": true, + "width_mm": 0.25, + "power_fallback": false, + "expansions": 273975 + }, + { + "net": "/RS_VALID", + "start": "U1.12", + "end": "U2.11", + "start_mm": [ + 108.0, + 150.94 + ], + "end_mm": [ + 168.4, + 126.67 + ], + "routed": true, + "width_mm": 0.25, + "power_fallback": false, + "expansions": 425742 + }, + { + "net": "/RS_OFF_N", + "start": "U1.15", + "end": "U2.12", + "start_mm": [ + 108.0, + 158.56 + ], + "end_mm": [ + 170.94, + 126.67 + ], + "routed": true, + "width_mm": 0.25, + "power_fallback": false, + "expansions": 645804 }, { "net": "/GND", @@ -609,24 +626,24 @@ "end": "U1.22", "start_mm": [ 133.4, - 157.34 + 176.34 ], "end_mm": [ 108.0, - 157.34 + 176.34 ], "routed": true, "width_mm": 0.5, "power_fallback": false, - "expansions": 73753 + "expansions": 509 }, { "net": "/GND", - "start": "U1.43", + "start": "SW1.2", "end": "DS1.1", "start_mm": [ - 133.4, - 154.8 + 149.5, + 172.5 ], "end_mm": [ 152.19, @@ -635,31 +652,14 @@ "routed": true, "width_mm": 0.5, "power_fallback": false, - "expansions": 54021 - }, - { - "net": "/GND", - "start": "U2.2", - "end": "U1.23", - "start_mm": [ - 145.54, - 130.0 - ], - "end_mm": [ - 133.4, - 104.0 - ], - "routed": true, - "width_mm": 0.5, - "power_fallback": false, - "expansions": 98250 + "expansions": 617019 } ], "routed_tree_edges": 38, "total_tree_edges": 38, - "tracks": 569, - "vias": 20, - "immutable_identity_sha256": "81def52e6c1d574b4d3ab1a5859a5266b893df0ea6c5b9aa7d7b688cc4a98519", - "input_sha256": "41643d6089dae5ef2eee1a2071a6d11ae4c00f3c922eddfeaafff619fc5fab19", + "tracks": 565, + "vias": 22, + "immutable_identity_sha256": "783ce7e212880e0836c93e1782d39bbfbc505fae856d9720ee6c50f5ba8f6275", + "input_sha256": "0ea7f0abff371eacc81262dc949f768cd42128f389ea4af9facee5034368d884", "validation": "KiCad DRC must be run separately; tree-edge counts are not DRC connectivity" } diff --git a/hardware/PCB/validation/pcb-routing-summary.md b/hardware/PCB/validation/pcb-routing-summary.md index ff0d8af..bc24eab 100644 --- a/hardware/PCB/validation/pcb-routing-summary.md +++ b/hardware/PCB/validation/pcb-routing-summary.md @@ -1,4 +1,118 @@ -# Two-layer draft routing result +# A1 top-left-notch / bottom-USB routing — current result + +Date: 2026-09-21. Actual revised board: `../serial-carrier.kicad_pcb`. + +**38/38 connections across 17 multi-pad nets; 0 physical DRC violations, +0 unconnected items; exactly 1 expected U2 footprint parity warning.** +The warning is the board-only `Carrier:MAX3243_Reference_Provisional` assignment +versus the intentionally blank schematic footprint, not a net mismatch. + +## Geometry and preservation + +Coordinates below are local to absolute origin (100,100) mm; all dimensions mm. + +- Carrier: 82 x 80, outline `[(36,0),(82,0),(82,80),(0,80),(0,19),(36,19)]`. +- U1 origin: (8,23), formerly (8,4). Header end-pad centres now Y=76.340; + USB guide Y=83 is 3 mm below the bottom edge. No ESP32 body was invented. +- U2 origin: (43,26.670), formerly (43,30). Actual reference F.Fab bare-PCB + front edge is absolute Y=100.000, flush with carrier local Y=0. +- Nominal male metal external dimensions are user-confirmed: shell overhang + 3.870, hex-mouth overhang 2.870, flange front 1.930 behind the carrier edge. + With this placement their local Y positions are -3.870, -2.870 and +1.930. + Integration added seven board-local Dwgs.User graphics for the CAD metal + projections and screw-lock axes. +- H1: (3.5,22.5), H2: (3.5,75). H3/H4 unchanged at (78,4)/(78,76). +- OLED, resistors and switches unchanged. +- RF reserve: local X=10..31 / Y=19..32, absolute X=110..131 / Y=119..132, + both layers; no tracks, vias or fills inside it. Boundary remains provisional. + +The existing A0 board was mutated, **not regenerated**. The one-time +`pcb-a0-before-reposition.kicad_pcb` backup remains byte-for-byte intact. +`pcb-routing-input.kicad_pcb` is now the A1 unrouted audit input, not A0. +`pcb-routing-preservation.py` verified all 13 complete serialized footprints +identical except the four authorized top-level placements, including schematic +fields, pad/net definitions, electrical UUID paths and all footprint graphics. +Non-owned board-graphic UUIDs and unrelated graphics are preserved. ESP/RS/RF +annotations moved with placement; the post-routing silkscreen refresh replaced +91 owned graphics. Its edge clipping avoids silk across U2's flush front edge. + +All board saves used `SaveBoard(..., True)`. Project `.pro`, `.prl`, schematic, +symbol/footprint libraries and library tables retain their original hashes. +README and pcb-draft-notes were intentionally updated during integration. The generator's constants/text were updated but it was **not +run**; its automatic project/netclass writes were removed. PCB Editor lock was +absent at migration, routing, silkscreen refresh and final preservation check. + +## Routing and independent measurements + +- F.Cu/B.Cu; **565 segments, 22 through vias**. +- **451 signal segments at 0.25 mm; 114 +3V3/GND segments at 0.5 mm**. +- Vias: 0.7 mm copper / 0.3 mm drill. No copper pours needed. +- Continuous measured minimum different-net/NPTH clearance: **0.270544 mm**. +- Minimum copper/NPTH-to-edge gap: **1.900 mm**. +- Minimum copper/NPTH-to-RF-reservation gap: **0.025 mm**. +- Minimum via-drill edge to other drilled-hole edge: **0.820544 mm**. + +Two bounded passes, each with 240 seconds / 1,200,000 expansions per search: + +1. 31.18 seconds, 38/38, 674 segments / 16 vias, physical DRC clean. One GND + connection required the router's 0.25 mm fallback; strict width validation + correctly failed. Retained as `pcb-routing-a1-pass1.kicad_pcb` for evidence. +2. 32.44 seconds, 38/38, 565 segments / 22 vias. Short GND connections (<=15 mm) + now route before longer signal fanout; long GND links remain last. All power + and ground now use 0.5 mm; no fallback. This is the saved current result. + +The grid remains 0.05 mm, physical clearance 0.25 mm plus 0.02 mm routing margin. +No rip-up/unbounded retry or external network router was used. + +## Validation / rerun commands + +From `hardware/PCB`: + +```sh +/usr/bin/python3 -B validate_pcb_draft.py +/usr/bin/python3 -B validation/pcb-routing-check.py +/usr/bin/python3 -B validation/pcb-routing-preservation.py +kicad-cli pcb drc --format json --all-track-errors --severity-all --exit-code-violations -o validation/pcb-routing-all-drc.json serial-carrier.kicad_pcb +``` + +All passed on A1. Validators perform fresh KiCad DRC, fresh schematic-netlist +comparison, geometry checks, continuous copper-distance checks, and routing +save-refusal tests. DRC was read-only to preserve project settings; no copper +zones exist to refill. Existing ignored DRC checks were not changed; see reports. +The preservation audit includes the intentional documentation updates and seven +CAD projection graphics while retaining electrical and project preservation checks. + +Rerouting remains explicitly destructive to existing/manual copper and requires: + +```sh +/usr/bin/python3 -B route_pcb_draft.py --route --overwrite --replace-routes --seconds 240 --max-expansions 1200000 +/usr/bin/python3 -B add_device_silkscreen.py +``` + +Then rerun the validators. The one-shot `pcb-routing-reposition.py --apply` +refuses anything except the original A0 snapshot and must **not** be rerun on A1. + +Current evidence: `pcb-routing-a1-pass2.log`, `pcb-routing-run.json`, +`pcb-routing-drc.json`, `pcb-routing-all-drc.json`, `pcb-parity-drc.json`, +`pcb-validation-summary.json`, `pcb-routing-check.json`, +`pcb-routing-reposition.json`, and `pcb-routing-preservation.json`. +The current post-integration board SHA-256 is recorded in +`pcb-routing-check.json`; the CAD projection additions do not change copper. + +**Still a draft, not fabrication-ready.** ESP32 geometry/antenna/USB access, +module pinout/header fit, full assembly/height clearances, power integrity and +hardware operation remain unqualified. Nominal RS-232 metal dimensions alone +are not assembly qualification. Placement PDF, SVG/PNG and carrier-only 3D +preview were refreshed after CAD envelope integration. No Gerbers generated. + +--- + +# Historical A0 routing result — superseded by A1 above + +The following records the earlier A0 routing/integration. Its dimensions, counts, +measurements and no-save reproduction do not describe current A1. A0 `pass1`, +`pass2`, `pass3`, `baseline` and `dry-run` files are historical; use the A1 and +current reports listed above. Date: 2026-09-20. KiCad 10.0.6; system `/usr/bin/python3`. diff --git a/hardware/PCB/validation/pcb-source-netlist.xml b/hardware/PCB/validation/pcb-source-netlist.xml index 1af2293..73e4833 100644 --- a/hardware/PCB/validation/pcb-source-netlist.xml +++ b/hardware/PCB/validation/pcb-source-netlist.xml @@ -2,7 +2,7 @@ /home/mscholz/Repos/ESP32_serial_swiss_army_knife/hardware/PCB/serial-carrier.kicad_sch - 2026-09-20T23:07:27 + 2026-09-21T11:39:08 Eeschema 10.0.6-1.fc44 diff --git a/hardware/PCB/validation/pcb-validation-summary.json b/hardware/PCB/validation/pcb-validation-summary.json index 320439c..75528ce 100644 --- a/hardware/PCB/validation/pcb-validation-summary.json +++ b/hardware/PCB/validation/pcb-validation-summary.json @@ -3,6 +3,100 @@ 82, 80 ], + "outline_local_mm": [ + [ + 36, + 0 + ], + [ + 82, + 0 + ], + [ + 82, + 80 + ], + [ + 0, + 80 + ], + [ + 0, + 19 + ], + [ + 36, + 19 + ] + ], + "placements_local_mm": { + "U1": [ + 8, + 23 + ], + "U2": [ + 43, + 26.67 + ], + "DS1": [ + 43, + 36 + ], + "R1": [ + 43, + 34 + ], + "R2": [ + 54, + 34 + ], + "R3": [ + 65, + 34 + ], + "SW1": [ + 43, + 68 + ], + "SW2": [ + 55, + 68 + ], + "SW3": [ + 67, + 68 + ], + "H1": [ + 3.5, + 22.5 + ], + "H2": [ + 3.5, + 75 + ], + "H3": [ + 78, + 4 + ], + "H4": [ + 78, + 76 + ] + }, + "rf_reserve_absolute_mm": [ + 110, + 119, + 131, + 132 + ], + "u2_bare_pcb_front_local_y_mm": 0.0, + "nominal_user_confirmed_rs232_metal_mm": { + "shell_overhang": 3.87, + "hex_mouth_overhang": 2.87, + "flange_front_inset": 1.93 + }, + "tracks": 565, + "vias": 22, "copper_layers": 2, "draft_thickness_mm": 1.6, "electrical_footprints": 9, @@ -10,7 +104,8 @@ "physical_DRC_violations": 0, "unconnected_items": 0, "schematic_pad_nets_match": true, - "known_parity_warning": "U2 provisional female-reference footprint assigned on PCB only; schematic footprint intentionally blank", + "known_parity_warning": "U2 reference footprint assigned on PCB only; schematic footprint intentionally blank; nominal male external metal dimensions user-confirmed", + "project_settings_sha256": "9ad5b992785ebfe01fa7ea4e1aa391a2c7d7f1f2c3b1c13136173c301ecb6516", "ignored_DRC_checks": [ { "description": "Footprint has no courtyard defined", @@ -34,8 +129,8 @@ } ], "not_validated": [ - "male module pin map/fit", - "assembly envelope and heights", + "male module pin map/header fit", + "ESP32 geometry and complete assembly envelope/heights", "header/socket fit", "RF performance and antenna clearance", "power/return-path integrity",