tools/epro2/kicad: fix two structural ERC bugs — wire_dangling -88%, pin_not_connected -52%

Bisect found two semantics mismatches between EPRO2 and KiCad that cause
the 850 real-connectivity ERC violations on the ESP-VoCat ref project:

1. sym_writer was emitting lib coords without negating Y, but KiCad lib
   uses Y-up and re-flips Y on placement (Y-down schematic). So vertically
   arranged pins ended up at Y-mirrored absolute positions and wires that
   reach the geometric pin tip in EPRO2 missed the rendered pin tip in
   KiCad. Fix: lib_y = -epro2_y, lib_rot = (360 - rot) % 360 for pin/text.

2. sch_writer was treating each LINE as an isolated wire — but EPRO2
   binds segments into nets by NAME (WIRE.NET attr), not just geometry.
   Multi-segment nets like GND/VBUS show up as N disconnected stubs to
   KiCad. Fix: per-LINE, look up lineGroup → WIRE → NET attr and emit a
   `(label "<NET>")` at the LINE's start. Same-named labels on distinct
   physical wires is how KiCad's ERC recognizes a multi-segment net.

ESP-VoCat 9 sheets:
  wire_dangling           444 →  52  (-88%)
  pin_not_connected       406 → 196  (-52%)
  real connectivity total 850 → 248  (-71%)

Why we did NOT round to grid (the obvious-looking fix): EPRO2 places
some pins on a 10-mil pitch (e.g. magnetic socket); rounding to KiCad's
default 50-mil ERC grid would collapse those pins. The 248 residual is
fundamentally cross-sheet — single-sheet ERC can't see a net's other
endpoints on sibling sheets — and is a Phase-3 (hierarchical sheet)
problem, not a per-sheet one.

41 → 46 unit tests pass.

Co-Authored-By: Claude Opus 4.7 (1M context) <noreply@anthropic.com>
This commit is contained in:
2026-04-28 23:43:11 +08:00
parent 5e63924474
commit 54f0173947
6 changed files with 197 additions and 15 deletions

View File

@@ -41,6 +41,7 @@ class WriteStats:
junctions: int = 0
symbol_placements: int = 0
text: int = 0
labels: int = 0
skipped: int = 0
lib_symbols_embedded: int = 0
lib_symbols_missing: int = 0
@@ -92,6 +93,14 @@ def write_sch_page(
elements: list = []
# 1. Wires from LINE primitives. Each LINE contributes one (wire ...).
# EPRO2 binds wires into nets by NAME (WIRE.NET attr), not just geometry,
# so we also emit a (label "<NET>") at one endpoint of each named LINE.
# Same-named labels on physically distinct LINEs are how KiCad's ERC
# recognizes a multi-segment net — without them every LINE looks like a
# dangling stub. We label per-LINE (not per-WIRE id) because a single
# WIRE op may contain segments that don't share endpoints, and KiCad
# flags any unlabeled segment in such a group as wire_dangling.
wire_net_cache: dict[str, str | None] = {}
for oid, obj in doc.objects.items():
if obj.get("_type") != "LINE":
continue
@@ -111,6 +120,24 @@ def write_sch_page(
])
stats.wires += 1
wire_id = obj.get("lineGroup")
if not wire_id:
continue
wid = str(wire_id)
if wid not in wire_net_cache:
wire_net_cache[wid] = (rel.attrs_dict(wid) or {}).get("NET")
net = wire_net_cache[wid]
if not net:
continue
elements.append([
Sym("label"), str(net),
[Sym("at"), x1, y1, 0],
[Sym("effects"), [Sym("font"), [Sym("size"), 1.27, 1.27]],
[Sym("justify"), Sym("left"), Sym("bottom")]],
[Sym("uuid"), _new_uuid()],
])
stats.labels += 1
# 2. Symbol placements from COMPONENT ops. Body deferred to Phase 2 (lib_symbols).
# For now we emit (symbol ...) entries that reference a placeholder lib_id.
# KiCad will draw a red ? but the position + properties are correct.