SN-L00/hardware/kicad/scripts/autoroute_headless.py

#!/usr/bin/env python3
"""
SN-L00 Headless Autoroute Pipeline
Fully automated: place → export DSN → freeroute → import SES → DRC

Usage:
  # Install dependencies first:
  sudo apt install xvfb
  pip install kigadgets

  # Run:
  python3 scripts/autoroute_headless.py

Based on: https://github.com/atait/kicad-python
"""

import os
import sys
import subprocess
import tempfile

SCRIPT_DIR = os.path.dirname(os.path.abspath(__file__))
KICAD_DIR = os.path.dirname(SCRIPT_DIR)
PCB_FILE = os.path.join(KICAD_DIR, "SN-L00.kicad_pcb")
DSN_FILE = os.path.join(KICAD_DIR, "SN-L00.dsn")
SES_FILE = os.path.join(KICAD_DIR, "SN-L00.ses")
DRC_FILE = os.path.join(KICAD_DIR, "DRC.rpt")
FREEROUTING_JAR = "/tmp/freerouting.jar"

# Component positions for 8HP (40mm x 100mm) layout v2
PLACEMENTS = {
    "MOD3": (20, 15, 90),
    "J3": (10, 35, 0),
    "J4": (30, 35, 0),
    "SW1": (20, 48, 0),
    "D5": (32, 48, 0),
    "MOD2": (20, 62, 0),
    "U2": (8, 78, 0),
    "U4": (32, 78, 0),
    "C4": (4, 78, 90),
    "C5": (14, 78, 90),
    "C6": (28, 82, 90),
    "D3": (4, 82, 0),
    "D4": (36, 78, 0),
    "R2": (4, 86, 90),
    "R3": (10, 86, 90),
    "R4": (16, 86, 90),
    "R5": (24, 86, 90),
    "R6": (30, 86, 90),
    "R7": (36, 86, 90),
    "J2": (20, 88, 0),
    "D2": (4, 92, 0),
    "U3": (32, 94, 180),
    "C2": (10, 94, 90),
    "C3": (26, 94, 90),
}


def check_dependencies():
    """Check if required tools are available."""
    missing = []

    # Check xvfb
    if subprocess.run(["which", "xvfb-run"], capture_output=True).returncode != 0:
        missing.append("xvfb (sudo apt install xvfb)")

    # Check java
    if subprocess.run(["which", "java"], capture_output=True).returncode != 0:
        missing.append("java (sudo apt install default-jre)")

    # Check kicad-cli
    if subprocess.run(["which", "kicad-cli"], capture_output=True).returncode != 0:
        missing.append("kicad-cli (install KiCad)")

    if missing:
        print("Missing dependencies:")
        for dep in missing:
            print(f"  - {dep}")
        sys.exit(1)


def download_freerouting():
    """Download Freerouting if not present."""
    if not os.path.exists(FREEROUTING_JAR):
        print("Downloading Freerouting...")
        url = "https://github.com/freerouting/freerouting/releases/download/v2.0.1/freerouting-2.0.1.jar"
        subprocess.run(["curl", "-L", "-o", FREEROUTING_JAR, url], check=True)


def run_pcbnew_script(script_content):
    """Run a Python script inside pcbnew using xvfb."""
    with tempfile.NamedTemporaryFile(mode='w', suffix='.py', delete=False) as f:
        f.write(script_content)
        script_path = f.name

    try:
        # Run pcbnew with xvfb, execute script, then exit
        # This is a workaround since pcbnew doesn't have a direct script execution mode
        result = subprocess.run(
            ["xvfb-run", "-a", "python3", "-c", f"""
import sys
sys.path.insert(0, '/usr/lib/python3/dist-packages')
try:
    import pcbnew
    exec(open('{script_path}').read())
except Exception as e:
    print(f"Error: {{e}}")
    sys.exit(1)
"""],
            capture_output=True,
            text=True,
            timeout=120
        )
        print(result.stdout)
        if result.stderr:
            print(result.stderr)
        return result.returncode == 0
    finally:
        os.unlink(script_path)


def place_and_export():
    """Place components and export DSN using pcbnew API."""
    script = f'''
import pcbnew

board = pcbnew.LoadBoard("{PCB_FILE}")

def mm(val):
    return pcbnew.FromMM(val)

def place(x, y):
    return pcbnew.VECTOR2I(mm(x), mm(y))

# Update board outline
for drawing in board.GetDrawings():
    if drawing.GetClass() == "PCB_SHAPE":
        if drawing.GetShape() == pcbnew.SHAPE_T_RECT:
            drawing.SetStart(pcbnew.VECTOR2I(mm(0), mm(0)))
            drawing.SetEnd(pcbnew.VECTOR2I(mm(40), mm(100)))
            print("Updated board outline")
            break

# Delete tracks
tracks = list(board.GetTracks())
for track in tracks:
    board.Delete(track)
print(f"Deleted {{len(tracks)}} tracks")

# Place components
placements = {repr(PLACEMENTS)}

placed = 0
for ref, (x, y, rot) in placements.items():
    fp = board.FindFootprintByReference(ref)
    if fp:
        fp.SetPosition(place(x, y))
        fp.SetOrientationDegrees(rot)
        placed += 1

print(f"Placed {{placed}} components")

# Save board
board.Save("{PCB_FILE}")
print("Saved board")

# Export DSN
try:
    result = pcbnew.ExportSpecctraDSN("{DSN_FILE}")
    if result:
        print("Exported DSN")
    else:
        print("DSN export returned False - trying alternate method")
        # Try with board parameter
        result = pcbnew.ExportSpecctraDSN(board, "{DSN_FILE}")
        print(f"Alternate export result: {{result}}")
except Exception as e:
    print(f"DSN export error: {{e}}")
'''
    return run_pcbnew_script(script)


def run_freerouting():
    """Run Freerouting autorouter."""
    print("Running Freerouting...")
    result = subprocess.run(
        ["java", "-jar", FREEROUTING_JAR,
         "-de", DSN_FILE,
         "-do", SES_FILE,
         "-mp", "200",
         "-mt", "1",
         "-oit"],
        capture_output=True,
        text=True,
        cwd=KICAD_DIR
    )

    for line in (result.stdout + result.stderr).split('\n'):
        if 'completed' in line.lower() or 'error' in line.lower():
            print(f"  {line.split(']')[-1].strip()}")

    return os.path.exists(SES_FILE)


def import_ses():
    """Import SES file using pcbnew API."""
    script = f'''
import pcbnew

board = pcbnew.LoadBoard("{PCB_FILE}")

try:
    result = pcbnew.ImportSpecctraSES("{SES_FILE}")
    if result:
        print("Imported SES")
        board.Save("{PCB_FILE}")
        print("Saved board")
    else:
        print("SES import returned False - trying alternate method")
        result = pcbnew.ImportSpecctraSES(board, "{SES_FILE}")
        if result:
            board.Save("{PCB_FILE}")
            print("Saved board")
except Exception as e:
    print(f"SES import error: {{e}}")
'''
    return run_pcbnew_script(script)


def run_drc():
    """Run DRC using kicad-cli."""
    print("Running DRC...")
    result = subprocess.run(
        ["kicad-cli", "pcb", "drc",
         "--severity-all",
         "--units", "mm",
         "-o", DRC_FILE,
         PCB_FILE],
        capture_output=True,
        text=True
    )
    print(result.stdout)

    # Count errors
    if os.path.exists(DRC_FILE):
        with open(DRC_FILE) as f:
            content = f.read()
        errors = content.count('; error')
        warnings = content.count('; warning')
        print(f"DRC: {errors} errors, {warnings} warnings")
        return errors == 0
    return False


def main():
    print("=" * 50)
    print("SN-L00 Headless Autoroute Pipeline")
    print("=" * 50)

    check_dependencies()
    download_freerouting()

    print("\n[1/4] Placing components and exporting DSN...")
    if not place_and_export():
        print("Failed to place/export")
        # Fall back to manual DSN check
        if not os.path.exists(DSN_FILE):
            print(f"ERROR: {DSN_FILE} not found")
            print("Export manually: File → Export → Specctra DSN")
            sys.exit(1)

    print("\n[2/4] Running Freerouting...")
    if not run_freerouting():
        print("Freerouting failed")
        sys.exit(1)

    print("\n[3/4] Importing routed session...")
    if not import_ses():
        print("SES import failed - import manually in KiCad")

    print("\n[4/4] Running DRC...")
    success = run_drc()

    print("\n" + "=" * 50)
    if success:
        print("SUCCESS! Board routed with no DRC errors.")
    else:
        print("Done. Check DRC.rpt for remaining issues.")
    print("=" * 50)


if __name__ == "__main__":
    main()