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Colby Knox AI Flow 0.2.52: bottom parts, pour replacing, Gerber layers, test point files, clip pulls, cleaner routes d09912e 9d ago

name: aiflow-test-plan description: >- Use when an adom-aiflow run reaches its test-plan step, or whenever someone asks where the board will be probed. The test-plan step of an adom-aiflow run: before the schematic is drawn, think through how the built board will be tested on the Adom probing workcell (the rails, the switch node, feedback, ripple, enable, power-good, every LED, the ground pin), write tests.json, and let `adom-aiflow testplan check` give every measurement a real probe spot, adding 0.5 mm round test points (adom/testpoint-pad-0-5mm) for the gaps; then check the landings again on the placed and finished board. Trigger words: test plan, test points, probe points, probing workcell, design for test, DFT, where will we probe, TP, testpoint, probe spot, bring-up measurements, what should we measure.

Parent skill: adom-aiflow

aiflow-test-plan: decide what you will measure, then make sure you can

Every Adom board goes to the probing workcell after it is built: a gantry lands a pogo-tipped scope probe on the board while a ground tether is plugged into a ground machine contact. A board can only be tested where there is copper the probe can land on. This step makes the AI decide, before the schematic is drawn, what a careful engineer would measure at the bench, and makes the binary prove each measurement has a spot. It is a required step: step and finish refuse to go past it.

1. Think like the engineer at the bench

Write tests.json, one entry per measurement, from THIS circuit and its simulation, not a template:

[
  {"id": "vin",  "what": "12 V arriving on the board",       "net": "VIN",  "why": "input path and the input cap", "kind": "dc",       "expect": "11.4 to 12.6 V"},
  {"id": "sw",   "what": "switch node: frequency, ringing", "net": "SW",   "why": "500 kHz, edges, dead time",    "kind": "waveform", "expect": "0 to 12 V square, 500 kHz"},
  {"id": "vout", "what": "5 V out, ripple at 1 A",           "net": "VOUT", "why": "regulation and ripple",       "kind": "ripple",   "expect": "5.0 V, under 20 mV p-p"},
  {"id": "fb",   "what": "feedback node",                    "net": "FB",   "why": "loop at 0.596 V",              "kind": "dc",       "expect": "0.596 V"},
  {"id": "led",  "what": "power LED lit",                    "net": "LED",  "why": "camera check",                "kind": "camera",   "expect": "on above 4.5 V in"}
]

Kinds: dc, ripple, waveform need a probe landing; camera (an LED, a display) needs none; ground is the tether's machine contact, which must be a free MachineContactMedium on that net (the tether ends in a medium pin; a test point or a large contact cannot take it). Typical for a regulator: the input at the board, the output, the switch node, both inductor ends, feedback, enable, power-good, the bulk caps' ripple, every LED.

Probe face: a test is probed from the top unless it says otherwise. "face": "bottom" (or "back") on a test, or "probeFace": "bottom" beside "tests" for the whole plan, lands it on bottom-side copper only (a board whose top is wall-to-wall parts, probed from below); "both" accepts either face. testplan check reports the face each landing was found on.

2. Give every measurement a spot (before the schematic)

adom-aiflow testplan check --tests tests.json --netlist <netlist.json> --add maps each measurement to its net and adds TP<n> (adom/testpoint-pad-0-5mm: a 0.5 mm round exposed-copper pad, no paste, a 1.1 mm courtyard) on every net with no landing. A MachineContactLarge already is a landing, so its net gets no test point. A MachineContactMedium is not one for now (see below), and neither is a corner pin. A ground test with no medium contact is a gap --add cannot fix: add the contact. The test points go into the library and the schematic like any part. --add also writes the test point's footprint, symbol, Fusion library and 3D model to testpoint/ beside the netlist, because its wiki page is private and most accounts cannot read it; fusion library falls back to the same files by itself. Read the table to the human: what you will measure and where the probe lands.

3. Check again on the real board

Run testplan check again after placement and before finish (finish runs it itself). On a board it looks for a real landing on each net: a test point, the ring of a large contact, or an exposed pad where a 0.5 mm landing fits clear of every part body (an inductor's pads under its body, a 1206's end caps, an IC's pins do not count) and 0.3 mm from other nets' copper, within 50 mm of a ground machine contact. A gap names why; fix it by moving a part, adding a test point (back to the schematic), or widening copper.

The workcell's numbers (Stephen's spec, adom/probing-workcell)

Smallest probing pad 200 um; pads under 300 um may need a human crosshair check, so 0.5 mm is the default test point. Use 1.0 mm for a signal you know you will need often.
Two probe tips work about 3 mm apart (the 2.5 mm pogo mount).
Every probed point within 50 mm of a MachineContactMedium ground contact; put one near each corner.
Parts directly under a probed point under 18 mm tall; within 50 mm of it, under 40 mm.
adom-aiflow-probing's planner still assumes a 0.3 mm tip and 0.15 mm XY error (unconfirmed); with those, a 0.5 mm pad shows negative landing margin there until the tip and error are measured.

Where test pads go on the board

At least 1.5 mm centre to centre from every other test pad, so a probe lands on one pad only; DRC passing is not enough (two pads 0.86 mm apart pass DRC and still share a probe).
Out of the machine-contact columns and corner-pin zones: the contacts keep their grid positions and their silkscreen tags; the test pads move.
A net on a MachineContactLarge needs no test pad: its ring is about 1 mm wide, clear of the bore, so the landing fits. A net only on a MachineContactMedium or a corner pin keeps its test pad for now: a medium contact's ring is about 0.3 mm wide around the bore, thinner than the 0.5 mm landing, and the human crosshair check for pads that small is not built.

---
name: aiflow-test-plan
description: >-
  Use when an adom-aiflow run reaches its test-plan step, or whenever someone asks where the board will be probed. The test-plan step of an adom-aiflow run: before the schematic is drawn, think through how the built board will be tested on the Adom probing workcell (the rails, the switch node, feedback, ripple, enable, power-good, every LED, the ground pin), write tests.json, and let `adom-aiflow testplan check` give every measurement a real probe spot, adding 0.5 mm round test points (adom/testpoint-pad-0-5mm) for the gaps; then check the landings again on the placed and finished board. Trigger words: test plan, test points, probe points, probing workcell, design for test, DFT, where will we probe, TP, testpoint, probe spot, bring-up measurements, what should we measure.
---

Parent skill: **adom-aiflow**

# aiflow-test-plan: decide what you will measure, then make sure you can

Every Adom board goes to the probing workcell after it is built: a gantry lands a pogo-tipped scope
probe on the board while a ground tether is plugged into a ground machine contact. A board can only be
tested where there is copper the probe can land on. This step makes the AI decide, before the schematic
is drawn, what a careful engineer would measure at the bench, and makes the binary prove each
measurement has a spot. It is a required step: `step` and `finish` refuse to go past it.

## 1. Think like the engineer at the bench

Write `tests.json`, one entry per measurement, from THIS circuit and its simulation, not a template:

```json
[
  {"id": "vin",  "what": "12 V arriving on the board",       "net": "VIN",  "why": "input path and the input cap", "kind": "dc",       "expect": "11.4 to 12.6 V"},
  {"id": "sw",   "what": "switch node: frequency, ringing", "net": "SW",   "why": "500 kHz, edges, dead time",    "kind": "waveform", "expect": "0 to 12 V square, 500 kHz"},
  {"id": "vout", "what": "5 V out, ripple at 1 A",           "net": "VOUT", "why": "regulation and ripple",       "kind": "ripple",   "expect": "5.0 V, under 20 mV p-p"},
  {"id": "fb",   "what": "feedback node",                    "net": "FB",   "why": "loop at 0.596 V",              "kind": "dc",       "expect": "0.596 V"},
  {"id": "led",  "what": "power LED lit",                    "net": "LED",  "why": "camera check",                "kind": "camera",   "expect": "on above 4.5 V in"}
]
```

Kinds: `dc`, `ripple`, `waveform` need a probe landing; `camera` (an LED, a display) needs none;
`ground` is the tether's machine contact, which must be a free `MachineContactMedium` on that net (the tether ends in a medium pin; a test point or a large contact cannot take it). Typical for a regulator: the input at the board, the output,
the switch node, both inductor ends, feedback, enable, power-good, the bulk caps' ripple, every LED.

Probe face: a test is probed from the top unless it says otherwise. `"face": "bottom"` (or `"back"`) on a
test, or `"probeFace": "bottom"` beside `"tests"` for the whole plan, lands it on bottom-side copper only (a
board whose top is wall-to-wall parts, probed from below); `"both"` accepts either face. `testplan check`
reports the face each landing was found on.

## 2. Give every measurement a spot (before the schematic)

`adom-aiflow testplan check --tests tests.json --netlist <netlist.json> --add` maps each measurement to
its net and adds `TP<n>` (adom/testpoint-pad-0-5mm: a 0.5 mm round exposed-copper pad, no paste, a 1.1 mm
courtyard) on every net with no landing. A `MachineContactLarge` already is a landing, so its net gets no
test point. A `MachineContactMedium` is not one for now (see below), and neither is a corner pin. A `ground`
test with no medium contact is a gap `--add` cannot fix: add the contact. The test points go into the library and the schematic like any
part. `--add` also writes the test point's footprint, symbol, Fusion library and 3D model to `testpoint/` beside the
netlist, because its wiki page is private and most accounts cannot read it; `fusion library` falls back to the same
files by itself. Read the table to the human: what you will measure and where the probe lands.

## 3. Check again on the real board

Run `testplan check` again after placement and before finish (finish runs it itself). On a board it
looks for a real landing on each net: a test point, the ring of a large contact, or an exposed pad where a 0.5 mm landing fits clear
of every part body (an inductor's pads under its body, a 1206's end caps, an IC's pins do not count) and
0.3 mm from other nets' copper, within 50 mm of a ground machine contact. A gap names why; fix it by
moving a part, adding a test point (back to the schematic), or widening copper.

## The workcell's numbers (Stephen's spec, adom/probing-workcell)

- Smallest probing pad 200 um; pads under 300 um may need a human crosshair check, so 0.5 mm is the
  default test point. Use 1.0 mm for a signal you know you will need often.
- Two probe tips work about 3 mm apart (the 2.5 mm pogo mount).
- Every probed point within 50 mm of a MachineContactMedium ground contact; put one near each corner.
- Parts directly under a probed point under 18 mm tall; within 50 mm of it, under 40 mm.
- adom-aiflow-probing's planner still assumes a 0.3 mm tip and 0.15 mm XY error (unconfirmed); with
  those, a 0.5 mm pad shows negative landing margin there until the tip and error are measured.

## Where test pads go on the board

- At least 1.5 mm centre to centre from every other test pad, so a probe lands on one pad only; DRC passing is not enough (two pads 0.86 mm apart pass DRC and still share a probe).
- Out of the machine-contact columns and corner-pin zones: the contacts keep their grid positions and their silkscreen tags; the test pads move.
- A net on a `MachineContactLarge` needs no test pad: its ring is about 1 mm wide, clear of the bore, so the landing fits. A net only on a `MachineContactMedium` or a corner pin keeps its test pad for now: a medium contact's ring is about 0.3 mm wide around the bore, thinner than the 0.5 mm landing, and the human crosshair check for pads that small is not built.