0hmX/robocraze-ov7670-camera-module-clone

scripts/verify-production.ts

import { checkViaTraceClearance } from "@tscircuit/checks"

type CircuitElement = {
  type: string
  pcb_via_id?: string
  pcb_trace_id?: string
  from_layer?: string
  to_layer?: string
  outer_diameter?: number
  hole_diameter?: number
  layer?: string
  source_net_id?: string
  source_component_id?: string
  source_trace_id?: string
  name?: string
  display_name?: string
  min_trace_thickness?: number
  num_layers?: number
  min_trace_width?: number
  min_via_hole_diameter?: number
  min_via_pad_diameter?: number
  min_trace_to_pad_edge_clearance?: number
  min_via_edge_to_pad_edge_clearance?: number
  min_pad_edge_to_pad_edge_clearance?: number
  min_plated_hole_drill_edge_to_drill_edge_clearance?: number
  min_via_hole_edge_to_via_hole_edge_clearance?: number
  min_board_edge_clearance?: number
  brep_shape?: { outer_ring?: { vertices?: Array<{ x: number; y: number }> } }
  route?: Array<{ route_type: string; layer?: string; width?: number }>
}

const projectDir = new URL("../", import.meta.url).pathname
const outputDir = `${projectDir}dist/index`
const circuitJsonPath = `${outputDir}/circuit.json`
const archivePath = `${outputDir}/robocraze-ov7670-gerbers.zip`

const elements = (await Bun.file(circuitJsonPath).json()) as CircuitElement[]
const diagnostics = elements.filter((element) => /error|warning/.test(element.type))
if (diagnostics.length > 0) {
  throw new Error(`Circuit JSON contains ${diagnostics.length} error/warning records`)
}

const board = elements.find((element) => element.type === "pcb_board")
if (
  board?.num_layers !== 4 ||
  board.min_trace_width !== 0.1 ||
  board.min_via_hole_diameter !== 0.2 ||
  board.min_via_pad_diameter !== 0.45 ||
  board.min_trace_to_pad_edge_clearance !== 0.1 ||
  board.min_via_edge_to_pad_edge_clearance !== 0.1 ||
  board.min_pad_edge_to_pad_edge_clearance !== 0.1 ||
  board.min_via_hole_edge_to_via_hole_edge_clearance !== 0.2 ||
  board.min_plated_hole_drill_edge_to_drill_edge_clearance !== 0.15 ||
  board.min_board_edge_clearance !== 0.3
) {
  throw new Error("PCB fabrication-rule assertions do not match the qualified 4-layer build")
}

const sourceTraces = elements.filter(
  (element) => element.type === "source_trace",
)
const sourceTraceById = new Map(
  sourceTraces.map((trace) => [trace.source_trace_id, trace]),
)
const expectedSourceTraceWidths = new Map<string, number>([
  ["J1_3V3_TO_net_V3V3", 0.3],
  ["J1_GND_TO_net_GND", 0.3],
  ["U1_VOUT_TO_C2_pin1", 0.25],
  ["U2_VOUT_TO_C6_pin1", 0.25],
  ["R1_pin2_TO_C12_pin1", 0.2],
  ["R2_pin2_TO_C9_pin1", 0.2],
  ["C16_pin1_TO_U3_DVDD", 0.2],
])
for (const [name, width] of expectedSourceTraceWidths) {
  const trace = sourceTraces.find((candidate) => candidate.name === name)
  if (trace?.min_trace_thickness !== width) {
    throw new Error(`${name} must request ${width.toFixed(2)} mm copper`)
  }
}

const pcbTraces = elements.filter((element) => element.type === "pcb_trace")
const wireSegments = pcbTraces.flatMap((trace) =>
  (trace.route ?? []).filter(
    (point): point is { route_type: string; layer?: string; width: number } =>
      point.route_type === "wire" && point.width !== undefined,
  ),
)
const minWireWidth = Math.min(...wireSegments.map((segment) => segment.width))
const maxWireWidth = Math.max(...wireSegments.map((segment) => segment.width))
if (minWireWidth < 0.1 || maxWireWidth < 0.3) {
  throw new Error(
    `Unexpected routed width range ${minWireWidth.toFixed(3)}-${maxWireWidth.toFixed(3)} mm`,
  )
}

const allowedMinimumWidthSourceNames = new Set([
  "J1_HREF_TO_U3_HREF",
  "J1_XCLK_TO_U3_XCLK",
  "J1_D6_TO_U3_D6",
  "U3_VREF1_TO_C13_pin1",
  "U3_VREF2_TO_C14_pin1",
])
for (const trace of pcbTraces) {
  const hasMinimumWidth = (trace.route ?? []).some(
    (point) =>
      point.route_type === "wire" &&
      point.width !== undefined &&
      point.width <= 0.1000001,
  )
  if (!hasMinimumWidth) continue
  const sourceName = sourceTraceById.get(trace.source_trace_id)?.name
  if (!sourceName || !allowedMinimumWidthSourceNames.has(sourceName)) {
    throw new Error(
      `${trace.pcb_trace_id ?? trace.source_trace_id} uses 0.10 mm outside an approved CSP escape`,
    )
  }
}

const hrefRoute = pcbTraces.find(
  (trace) => trace.pcb_trace_id === "HREF_CSP_ESCAPE_AND_HEADER_ROUTE",
)
const hrefWidths = new Set(
  (hrefRoute?.route ?? [])
    .filter((point) => point.route_type === "wire")
    .map((point) => point.width),
)
if (!hrefWidths.has(0.1) || !hrefWidths.has(0.15)) {
  throw new Error("HREF must use a 0.10 mm CSP escape and 0.15 mm board route")
}

const vias = elements.filter((element) => element.type === "pcb_via")
const invalidViaSpans = vias.filter(
  (via) => new Set([via.from_layer, via.to_layer]).size !== 2 ||
    ![via.from_layer, via.to_layer].every((layer) => layer === "top" || layer === "bottom"),
)
if (invalidViaSpans.length > 0) {
  throw new Error(`${invalidViaSpans.length} vias are not top-to-bottom through vias`)
}

const viaById = new Map(vias.map((via) => [via.pcb_via_id, via]))
const viaTracePairs = checkViaTraceClearance(elements as never, {
  // A deliberately high threshold returns every foreign via/trace pair so
  // the verifier can compute the actual minimum hole-edge clearance.
  minClearance: 100,
})
const holeEdgeClearances = viaTracePairs.map((error) => {
  const via = viaById.get(error.pcb_via_id)
  if (!via?.outer_diameter || via.hole_diameter === undefined) {
    throw new Error(`Missing via geometry for ${error.pcb_via_id}`)
  }
  if (error.actual_clearance === undefined) {
    throw new Error(`Missing via/trace clearance for ${error.pcb_via_id}`)
  }
  const annularRing = (via.outer_diameter - via.hole_diameter) / 2
  return error.actual_clearance + annularRing
})
const minViaHoleToTraceClearance = Math.min(...holeEdgeClearances)
if (minViaHoleToTraceClearance < 0.2) {
  throw new Error(
    `Via-hole-to-foreign-trace clearance is ${minViaHoleToTraceClearance.toFixed(3)} mm; minimum is 0.200 mm`,
  )
}

const routedWireLayers = new Set(
  pcbTraces
    .flatMap((element) => element.route ?? [])
    .filter((point) => point.route_type === "wire")
    .map((point) => point.layer),
)
if ([...routedWireLayers].some((layer) => layer !== "top" && layer !== "bottom")) {
  throw new Error(`Signal routing uses inner layers: ${[...routedWireLayers].join(", ")}`)
}

const groundNet = elements.find(
  (element) => element.type === "source_net" && element.name === "GND",
)
const v2v8Net = elements.find(
  (element) => element.type === "source_net" && element.name === "V2V8",
)
const innerGroundPours = elements.filter(
  (element) =>
    element.type === "pcb_copper_pour" &&
    element.layer === "inner2" &&
    element.source_net_id === groundNet?.source_net_id,
)
if (
  innerGroundPours.length !== 1 ||
  !innerGroundPours[0].brep_shape?.outer_ring?.vertices?.length
) {
  throw new Error("Expected one connected inner2 GND copper-pour body")
}
const innerPowerPours = elements.filter(
  (element) =>
    element.type === "pcb_copper_pour" &&
    element.layer === "inner1" &&
    element.source_net_id === v2v8Net?.source_net_id,
)
if (
  innerPowerPours.length !== 1 ||
  !innerPowerPours[0].brep_shape?.outer_ring?.vertices?.length
) {
  throw new Error("Expected one connected inner1 V2V8 copper-pour body")
}

const platedDrillFilename = "drill-L1-L4.drl"
const drillText = await Bun.



  

  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  

  
  

  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  

  unzip -p ${archivePath} ${platedDrillFilename}`.text()\nconst toolDiameters = new Map\u003cstring, number\u003e()\nfor (const match of drillText.matchAll(/^T(\\d+)C([0-9.]+)$/gm)) {\n  toolDiameters.set(match[1], Number(match[2]))\n}\n\nlet activeTool = \"\"\nlet viaDrillCount = 0\nfor (const line of drillText.split(/\\r?\\n/)) {\n  const toolMatch = line.match(/^T(\\d+)$/)\n  if (toolMatch) {\n    activeTool = toolMatch[1]\n    continue\n  }\n  if (line.startsWith(\"X\") \u0026\u0026 Math.abs((toolDiameters.get(activeTool) ?? 0) - 0.2) \u003c 1e-6) {\n    viaDrillCount += 1\n  }\n}\nif (viaDrillCount !== vias.length) {\n  throw new Error(\n    `Via/drill mismatch: Circuit JSON has ${vias.length} vias but ${platedDrillFilename} has ${viaDrillCount} 0.20 mm drills`,\n  )\n}\n\nconst parseDesignators = async (path: string, column: number) =\u003e\n  (await Bun.file(path).text())\n    .trim()\n    .split(/\\r?\\n/)\n    .slice(1)\n    .map((line) =\u003e line.split(\",\")[column])\n    .filter(Boolean)\n    .sort()\n\nconst bomDesignators = await parseDesignators(`${outputDir}/jlc_bom.csv`, 1)\nconst cplDesignators = await parseDesignators(`${outputDir}/jlc_cpl.csv`, 0)\nconst manualDesignators = await parseDesignators(`${outputDir}/manual_assembly.csv`, 0)\nconst dnpDesignators = await parseDesignators(`${outputDir}/dnp.csv`, 0)\nif (bomDesignators.join(\"|\") !== cplDesignators.join(\"|\")) {\n  throw new Error(\"JLC BOM and CPL designator sets do not match\")\n}\nif (manualDesignators.join(\"|\") !== [\"J1\", \"U3\", \"U3-OPTICS\"].sort().join(\"|\")) {\n  throw new Error(`Unexpected manual/consigned set: ${manualDesignators.join(\", \")}`)\n}\nif (dnpDesignators.join(\"|\") !== [\"D0_IND\", \"R0\"].sort().join(\"|\")) {\n  throw new Error(`Unexpected DNP set: ${dnpDesignators.join(\", \")}`)\n}\nfor (const excluded of [\"J1\", \"U3\", \"R0\", \"D0_IND\"]) {\n  if (bomDesignators.includes(excluded)) {\n    throw new Error(`${excluded} must not appear in the JLC SMT BOM/CPL`)\n  }\n}\n\nconst bomText = await Bun.file(`${outputDir}/jlc_bom.csv`).text()\nfor (const [designator, footprint, lcsc] of [\n  [\"U1\", \"SOT-23-5_LCSC_C53099\", \"C53099\"],\n  [\"U2\", \"SOT-23-5_LCSC_C236671\", \"C236671\"],\n] as const) {\n  const row = bomText\n    .trim()\n    .split(/\\r?\\n/)\n    .find((line) =\u003e line.split(\",\")[1] === designator)\n  if (!row || !row.includes(footprint) || !row.endsWith(`,${lcsc}`)) {\n    throw new Error(`${designator} is missing its verified imported footprint/C-number`)\n  }\n}\nconst manualText = await Bun.file(`${outputDir}/manual_assembly.csv`).text()\nif (!manualText.includes(\"J1,Manual/rear-side THT\") || !manualText.includes(\"C492426\")) {\n  throw new Error(\"J1 must remain a manual rear-side C492426 THT operation\")\n}\nif (!manualText.includes(\"OV7670-VL2A\") || manualText.includes(\"OV07670-VL2A\")) {\n  throw new Error(\"U3 must use the exact OV7670-VL2A manual/consigned MPN\")\n}\n\nconsole.log(\n  `Production verification passed: ${vias.length}/${viaDrillCount} through vias, ` +\n    `${minViaHoleToTraceClearance.toFixed(3)} mm minimum via-hole-to-trace clearance, ` +\n    `${bomDesignators.length} matched JLC SMT placements, ${minWireWidth.toFixed(2)}-${maxWireWidth.toFixed(2)} mm routed copper, ` +\n    `connected V2V8/GND inner planes, explicit manual/consigned and DNP sets.`,\n)\n","content_mimetype":"text/typescript","created_at":"2026-08-24T13:23:42.504Z"}; window.SSR_PACKAGE_RELEASES = 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  unzip -p ${archivePath} ${platedDrillFilename}`.text()
const toolDiameters = new Map<string, number>()
for (const match of drillText.matchAll(/^T(\d+)C([0-9.]+)$/gm)) {
  toolDiameters.set(match[1], Number(match[2]))
}

let activeTool = ""
let viaDrillCount = 0
for (const line of drillText.split(/\r?\n/)) {
  const toolMatch = line.match(/^T(\d+)$/)
  if (toolMatch) {
    activeTool = toolMatch[1]
    continue
  }
  if (line.startsWith("X") && Math.abs((toolDiameters.get(activeTool) ?? 0) - 0.2) < 1e-6) {
    viaDrillCount += 1
  }
}
if (viaDrillCount !== vias.length) {
  throw new Error(
    `Via/drill mismatch: Circuit JSON has ${vias.length} vias but ${platedDrillFilename} has ${viaDrillCount} 0.20 mm drills`,
  )
}

const parseDesignators = async (path: string, column: number) =>
  (await Bun.file(path).text())
    .trim()
    .split(/\r?\n/)
    .slice(1)
    .map((line) => line.split(",")[column])
    .filter(Boolean)
    .sort()

const bomDesignators = await parseDesignators(`${outputDir}/jlc_bom.csv`, 1)
const cplDesignators = await parseDesignators(`${outputDir}/jlc_cpl.csv`, 0)
const manualDesignators = await parseDesignators(`${outputDir}/manual_assembly.csv`, 0)
const dnpDesignators = await parseDesignators(`${outputDir}/dnp.csv`, 0)
if (bomDesignators.join("|") !== cplDesignators.join("|")) {
  throw new Error("JLC BOM and CPL designator sets do not match")
}
if (manualDesignators.join("|") !== ["J1", "U3", "U3-OPTICS"].sort().join("|")) {
  throw new Error(`Unexpected manual/consigned set: ${manualDesignators.join(", ")}`)
}
if (dnpDesignators.join("|") !== ["D0_IND", "R0"].sort().join("|")) {
  throw new Error(`Unexpected DNP set: ${dnpDesignators.join(", ")}`)
}
for (const excluded of ["J1", "U3", "R0", "D0_IND"]) {
  if (bomDesignators.includes(excluded)) {
    throw new Error(`${excluded} must not appear in the JLC SMT BOM/CPL`)
  }
}

const bomText = await Bun.file(`${outputDir}/jlc_bom.csv`).text()
for (const [designator, footprint, lcsc] of [
  ["U1", "SOT-23-5_LCSC_C53099", "C53099"],
  ["U2", "SOT-23-5_LCSC_C236671", "C236671"],
] as const) {
  const row = bomText
    .trim()
    .split(/\r?\n/)
    .find((line) => line.split(",")[1] === designator)
  if (!row || !row.includes(footprint) || !row.endsWith(`,${lcsc}`)) {
    throw new Error(`${designator} is missing its verified imported footprint/C-number`)
  }
}
const manualText = await Bun.file(`${outputDir}/manual_assembly.csv`).text()
if (!manualText.includes("J1,Manual/rear-side THT") || !manualText.includes("C492426")) {
  throw new Error("J1 must remain a manual rear-side C492426 THT operation")
}
if (!manualText.includes("OV7670-VL2A") || manualText.includes("OV07670-VL2A")) {
  throw new Error("U3 must use the exact OV7670-VL2A manual/consigned MPN")
}

console.log(
  `Production verification passed: ${vias.length}/${viaDrillCount} through vias, ` +
    `${minViaHoleToTraceClearance.toFixed(3)} mm minimum via-hole-to-trace clearance, ` +
    `${bomDesignators.length} matched JLC SMT placements, ${minWireWidth.toFixed(2)}-${maxWireWidth.toFixed(2)} mm routed copper, ` +
    `connected V2V8/GND inner planes, explicit manual/consigned and DNP sets.`,
)