From 15a457d2bef8fc43b1e47524bd99458f8383e88a Mon Sep 17 00:00:00 2001 From: Antoine Date: Tue, 10 Feb 2026 21:57:21 +0000 Subject: [PATCH] KB introspection: corrected mass 1133 kg, DV baselines, full expression map from Beam.prt binary --- projects/hydrotech-beam/CONTEXT.md | 89 +++++++++++++++++++++++------- 1 file changed, 70 insertions(+), 19 deletions(-) diff --git a/projects/hydrotech-beam/CONTEXT.md b/projects/hydrotech-beam/CONTEXT.md index 586b360c..5895a242 100644 --- a/projects/hydrotech-beam/CONTEXT.md +++ b/projects/hydrotech-beam/CONTEXT.md @@ -6,35 +6,84 @@ Hydrotech (internal test fixture) ## Objective Minimize beam mass while meeting displacement and stress constraints. Single-objective: minimize mass, constrain displacement (≤ 10 mm) and stress (≤ 130 MPa). -## Key Parameters — Confirmed (Gen 002) +## Key Parameters — Confirmed (Gen 002 + Introspection) | Parameter | NX Expression | Current | Range | Units | DV? | Notes | |-----------|--------------|---------|-------|-------|-----|-------| -| beam_half_core_thickness | `beam_half_core_thickness` | 20 | 10–40 | mm | Yes (DV1) | Core half-thickness | -| beam_face_thickness | `beam_face_thickness` | 20 | 10–40 | mm | Yes (DV2) | Face sheet thickness | -| holes_diameter | ❓ (Gap G14) | 300 | 150–450 | mm | Yes (DV3) | Lightening hole diameter | -| hole_count | `hole_count` | 10 | 5–15 | integer | Yes (DV4) | Number of lightening holes | -| beam_length | `beam_length` | 5,000 | Fixed | mm | No | ✅ Confirmed KBS | -| beam_half_height | `beam_half_height` | ❓ (Gap G12) | — | mm | No | Half I-beam height | -| beam_half_width | `beam_half_width` | ❓ (Gap G13) | — | mm | No | Half flange width | -| hole_span | `p6` | 4,000 | TBD | mm | Potential (G15) | Total span for hole distribution | +| beam_half_core_thickness | `beam_half_core_thickness` | **25.162** | 10–40 | mm | Yes (DV1) | Core half-thickness | +| beam_face_thickness | `beam_face_thickness` | **21.504** | 10–40 | mm | Yes (DV2) | Face sheet thickness | +| holes_diameter | `holes_diameter` | 300 | 150–450 | mm | Yes (DV3) | ✅ G14 closed | +| hole_count | `hole_count` (→ `Pattern_p7`) | 10 | 5–15 | integer | Yes (DV4) | Pattern parameter link | +| beam_length | `beam_lenght` ⚠️ | 5,000 | Fixed | mm | No | **Typo in NX — no 'h'** | +| beam_half_height | `beam_half_height` | **250** | — | mm | No | ✅ G12 closed | +| beam_half_width | `beam_half_width` | **150** | — | mm | No | ✅ G13 closed | +| hole_span | `p6` (→ `Pattern_p9`) | 4,000 | TBD | mm | Potential (G15) | Total span for hole distribution | ## Constraints - Max tip displacement: ≤ 10 mm - Max von Mises stress: ≤ ~130 MPa (steel, conservative — Gap G9) -- Mass tracked via NX expression **`p1`** ← CORRECTED from `p173` (Gen 002) +- Mass tracked via NX expression **`p173`** (`body_property147.mass` [kg]) -## Baseline Performance — Confirmed (Gen 002) +## Baseline Performance — Confirmed (Introspection) | Metric | Value | Source | Confidence | |--------|-------|--------|------------| -| Mass | **11.33 kg** | NX expression `p1`, KBS session | ✅ High | -| Tip displacement | ❓ **NEEDS RE-VERIFICATION** (Gap G10) | Was 22 mm at old model state | ⚠️ Low | +| Mass | **1,133.01 kg** | NX expression `p173`, CEO correction + binary introspection | ✅ High | +| Tip displacement | ❓ **NEEDS RE-VERIFICATION** (Gap G10) | Was ~22 mm from intake | ⚠️ Low | | Max stress | ❓ **NEVER MEASURED** (Gap G11) | — | ❌ None | -| Material | **AISI Steel 1005** | KBS session | ✅ High | +| Material | **AISI Steel 1005** | `physicalmateriallibrary.xml` | ✅ High | | Density | **7.3 g/cm³** | KBS session | ✅ High | -> ⚠️ **Mass discrepancy resolved:** Intake reported ~974 kg (`p173`). KBS session confirmed 11.33 kg (`p1`). See `kb/dev/gen-002.md` for full analysis. +> ⚠️ **Mass history:** Intake reported ~974 kg → CEO corrected to 1,133.01 kg (`p173`). Discrepancy with intake likely due to different parameter state. Binary introspection confirms `p173: body_property147.mass` in kg. + +## NX Expression Map — Full Introspection + +### Design Variables +| Expression | Value | Unit | Type | +|-----------|-------|------|------| +| `beam_face_thickness` | 21.504404775742785 | mm | Number — continuous | +| `beam_half_core_thickness` | 25.162078968746705 | mm | Number — continuous | +| `holes_diameter` | 300 | mm | Number — continuous | +| `hole_count` | 10 | — | Integer (via `Pattern_p7`) | + +### Fixed Geometry Parameters +| Expression | Value | Unit | +|-----------|-------|------| +| `beam_half_height` | 250 | mm | +| `beam_half_width` | 150 | mm | +| `beam_lenght` | 5,000 | mm | + +### Hole Pattern Expressions +| Expression | Value/Formula | Notes | +|-----------|--------------|-------| +| `p6` | 4,000 mm | Hole span — potential DV | +| `Pattern_p7` | → `hole_count` | Count link | +| `Pattern_p8` | 444.444 mm | Computed spacing (span / (count-1)) | +| `Pattern_p9` | → `p6` | Span link | +| `Pattern_p10` | (linked) | | +| `Pattern_p11` | 10 mm | | +| `Pattern_p12` | 0 mm | | + +### Mass Properties (Measure Body) +| Expression | Formula | Unit | +|-----------|---------|------| +| `p170` | surface_area | mm² | +| `p171` | volume | mm³ | +| `p172` | center_of_mass | mm (point) | +| **`p173`** | **mass** | **kg** | +| `p174` | weight | N | +| `p175` | density | kg/mm³ | + +### Other +| Expression | Value | Notes | +|-----------|-------|-------| +| `p4` | → `beam_lenght` | Alias | +| `p119` | 4,000 mm | | +| `p132` | 444.444 mm | Computed | +| `p134` | 4,000 mm | | +| `p135` | 4,000 mm | | +| `p139` | 10 mm | | +| `p141` | 0 mm | | ## Boundary Conditions — Confirmed (Gen 002) @@ -59,6 +108,7 @@ Minimize beam mass while meeting displacement and stress constraints. Single-obj | Span | 4,000 mm (expression `p6`) | Total distribution length | | Start offset | 500 mm from beam start | Fixed requirement — not parametric | | End offset | 500 mm from beam end | Fixed requirement — not parametric | +| Computed spacing | 444.444 mm (4000 / 9) | At baseline (10 holes) | | Collision check | Required at DV extremes | 15 × 450 mm in 4,000 mm → overlap | ## Model Files @@ -70,15 +120,16 @@ Minimize beam mass while meeting displacement and stress constraints. Single-obj ## Future Expansion - Material alternatives: Aluminum 6061, Stainless Steel ANSI 310 (per Antoine, KBS session) -- `p6` (hole span) as additional design variable (pending decision) +- `p6` (hole span) as additional design variable (pending decision G15) - Mesh refinement (Antoine: "Eventually we're going to be able to refine the element size") ## Decisions - 2026-02-08: Project received from Antoine -- 2026-02-10: KBS sessions processed → Gen 002 KB update. Mass corrected, BCs confirmed. +- 2026-02-10: KBS sessions processed → Gen 002 KB update. BCs confirmed. +- 2026-02-10: Binary introspection — all expression names/values confirmed. Mass = 1,133.01 kg. ## Status -Phase: Pre-optimization (baseline re-verification needed) -Generation: 002 +Phase: Pre-optimization (baseline displacement + stress verification needed) +Generation: 002 (+ introspection corrections) Channel: #project-hydrotech-beam Last KBS session: 2026-02-10T16:38:01