fusible 0.9.0

Electronic linter: a fuse that blows to block firmware code generation
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//! `trace_clearance`: physical copper clearance design rule check (DRC).

use crate::linter::{Diagnostic, LintContext, Rule};
use crate::parser::Pad;

/// Minimum copper clearance in millimeters (standard 6 mil / 0.15mm PCB manufacturing limit).
const MIN_CLEARANCE_MM: f64 = 0.15;

/// Inspects physical PCB copper geometry (pads, traces, vias) and detects
/// short circuits and clearance violations between distinct electrical nets.
pub struct TraceClearanceRule;

#[derive(Debug)]
struct CopperFeature {
    pub net_id: String,
    pub net_name: String,
    pub layer: String,
    pub x: f64,
    pub y: f64,
    pub half_w: f64,
    pub half_h: f64,
}

impl Rule for TraceClearanceRule {
    fn name(&self) -> &'static str {
        "trace_clearance"
    }

    fn check(&self, ctx: &LintContext<'_>) -> Vec<Diagnostic> {
        let features = extract_copper_features(ctx);
        let mut diagnostics = Vec::new();

        for i in 0..features.len() {
            for j in (i + 1)..features.len() {
                let f1 = &features[i];
                let f2 = &features[j];

                if f1.net_id == f2.net_id || !f1.layer.eq_ignore_ascii_case(&f2.layer) {
                    continue;
                }

                let dx = (f1.x - f2.x).abs();
                let dy = (f1.y - f2.y).abs();

                let clearance_gap = ((dx - (f1.half_w + f2.half_w)).max(0.0))
                    .hypot((dy - (f1.half_h + f2.half_h)).max(0.0));

                if clearance_gap < MIN_CLEARANCE_MM {
                    let is_direct_short =
                        dx < (f1.half_w + f2.half_w) && dy < (f1.half_h + f2.half_h);

                    let msg = if is_direct_short {
                        format!(
                            "direct copper short-circuit on {}: net \"{}\" and net \"{}\" overlap at ({:.2}, {:.2})",
                            f1.layer, f1.net_name, f2.net_name, f1.x, f1.y
                        )
                    } else {
                        format!(
                            "copper clearance violation on {}: net \"{}\" and net \"{}\" have only {:.3}mm spacing (minimum {MIN_CLEARANCE_MM}mm)",
                            f1.layer, f1.net_name, f2.net_name, clearance_gap
                        )
                    };

                    diagnostics.push(Diagnostic {
                        rule: self.name().to_string(),
                        message: msg,
                        help: Some(
                            "reroute copper or relocate pads to maintain at least 0.15mm clearance to prevent manufacturing defects"
                                .to_string(),
                        ),
                    });
                }
            }
        }

        diagnostics
    }
}

/// Half extents of a pad: `width`/`height`, or `radius` for circle pads.
fn half_extents(pad: &Pad) -> (f64, f64) {
    match (pad.width, pad.height, pad.radius) {
        (None, None, Some(r)) => (r, r),
        (w, h, _) => (w.unwrap_or(1.0) / 2.0, h.unwrap_or(1.0) / 2.0),
    }
}

/// Every positioned pad as copper. A pad whose net the netlist cannot
/// resolve is isolated copper: it gets a net of its own, so any overlap with
/// another pad is still a violation.
fn extract_copper_features(ctx: &LintContext<'_>) -> Vec<CopperFeature> {
    ctx.circuit
        .pads()
        .enumerate()
        .filter_map(|(index, pad)| {
            let (x, y) = (pad.x?, pad.y?);
            let (half_w, half_h) = half_extents(pad);
            let label = pad.pad_id.clone().unwrap_or_else(|| format!("#{index}"));
            let (net_id, net_name) = match pad
                .pad_id
                .as_deref()
                .and_then(|id| ctx.netlist.pad_to_net.get(id))
                .and_then(|&idx| ctx.netlist.nets.get(idx))
            {
                Some(node) => (node.id.clone(), node.display_name().to_string()),
                None => (
                    format!("unresolved pad {label}"),
                    format!("<unresolved pad {label}>"),
                ),
            };
            Some(CopperFeature {
                net_id,
                net_name,
                layer: pad.layer.clone().unwrap_or_else(|| "top".to_string()),
                x,
                y,
                half_w,
                half_h,
            })
        })
        .collect()
}