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

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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:
Knowit
2026-04-28 23:43:11 +08:00
parent 5e63924474
commit 54f0173947
6 changed files with 197 additions and 15 deletions
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47
tools/epro2/kicad/sym_writer.py
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@@ -16,12 +16,15 @@ Coverage / fidelity:
(best-effort; mostly ignored at body level)
Coordinate convention:
EPRO2 SYMBOL primitives use **mil** (same as schematic); we convert via
``MIL_TO_MM = 0.0254``. KiCad lib symbol coords are **Y-up** internally,
but the placement of pins relative to body origin is what matters; for
ESP-VoCat the empirical Y orientation is consistent (pins on left at -X,
pins on right at +X), so we do not flip Y. If KiCad renders flipped, the
fix is a per-axis sign in ``_pt`` here.
EPRO2 SYMBOL primitives use **mil** in a Y-down frame (same as the
schematic). KiCad lib symbol coords are **Y-up**; when a symbol is
placed on a (Y-down) schematic KiCad re-flips the lib's Y. To make the
rendered placement land at the EPRO2 absolute position (so wire endpoints
meet pin tips) we therefore **negate Y in lib coords**, and mirror pin /
text rotations across the X-axis (``rot_lib = -rot_epro2 mod 360``).
Without this, vertically-arranged pins end up at Y-mirrored positions —
ERC then reports ``pin_not_connected`` even when the wire endpoint and
pin tip share the same X.
"""
from __future__ import annotations
@@ -60,6 +63,20 @@ def _pt(v) -> float:
return 0.0
def _y(v) -> float:
"""Y for lib symbol space: negate (Y-down EPRO2 → Y-up KiCad lib)."""
return -_pt(v)
def _lib_rot(rot) -> float:
"""Mirror pin/text rotation across the X-axis to compensate for the lib
Y-up vs schematic Y-down flip KiCad applies on placement."""
try:
return (360.0 - float(rot or 0)) % 360.0
except (TypeError, ValueError):
return 0.0
def _stroke(width: float = 0.254) -> list:
return [Sym("stroke"), [Sym("width"), width], [Sym("type"), Sym("default")]]
@@ -110,8 +127,10 @@ def write_lib_symbol(doc: Document, *, lib_prefix: str = "facere") -> list | Non
if obj.get("partId") != part_id:
continue
if t == "RECT":
x1, y1 = _pt(obj.get("dotX1")), _pt(obj.get("dotY1"))
x2, y2 = _pt(obj.get("dotX2")), _pt(obj.get("dotY2"))
# KiCad lib uses Y-up; we negate Y so the rectangle stays oriented
# the same way it appears in EPRO2 after placement Y-flip.
x1, y1 = _pt(obj.get("dotX1")), _y(obj.get("dotY1"))
x2, y2 = _pt(obj.get("dotX2")), _y(obj.get("dotY2"))
body.append([
Sym("rectangle"),
[Sym("start"), x1, y1],
@@ -122,7 +141,7 @@ def write_lib_symbol(doc: Document, *, lib_prefix: str = "facere") -> list | Non
elif t == "POLY":
pts = obj.get("points") or []
xy_list = [Sym("pts")] + [
[Sym("xy"), _pt(p.get("x")), _pt(p.get("y"))] for p in pts
[Sym("xy"), _pt(p.get("x")), _y(p.get("y"))] for p in pts
if isinstance(p, dict)
]
if len(xy_list) >= 3: # at least 2 points + the "pts" tag
@@ -135,7 +154,7 @@ def write_lib_symbol(doc: Document, *, lib_prefix: str = "facere") -> list | Non
elif t == "CIRCLE":
body.append([
Sym("circle"),
[Sym("center"), _pt(obj.get("centerX")), _pt(obj.get("centerY"))],
[Sym("center"), _pt(obj.get("centerX")), _y(obj.get("centerY"))],
[Sym("radius"), _pt(obj.get("radius"))],
_stroke(),
_fill(),
@@ -146,8 +165,8 @@ def write_lib_symbol(doc: Document, *, lib_prefix: str = "facere") -> list | Non
continue
body.append([
Sym("text"), val,
[Sym("at"), _pt(obj.get("x")), _pt(obj.get("y")),
float(obj.get("rotation") or 0)],
[Sym("at"), _pt(obj.get("x")), _y(obj.get("y")),
_lib_rot(obj.get("rotation"))],
_font(),
])
elif t == "PIN":
@@ -158,8 +177,8 @@ def write_lib_symbol(doc: Document, *, lib_prefix: str = "facere") -> list | Non
elec = PIN_TYPE_MAP.get(pin_type_raw, "passive")
body.append([
Sym("pin"), Sym(elec), Sym("line"),
[Sym("at"), _pt(obj.get("x")), _pt(obj.get("y")),
float(obj.get("rotation") or 0)],
[Sym("at"), _pt(obj.get("x")), _y(obj.get("y")),
_lib_rot(obj.get("rotation"))],
[Sym("length"), _pt(obj.get("length"))],
[Sym("name"), pin_name or "~", _font()],
[Sym("number"), pin_number or "~", _font()],