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KB introspection: corrected mass 1133 kg, DV baselines, full expression map from Beam.prt binary

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Antoine
2026-02-10 21:57:21 +00:00
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projects/hydrotech-beam/CONTEXT.md
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@@ -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