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feat: Add substudy system with live history tracking and workflow fixes

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Major Features:
- Hierarchical substudy system (like NX Solutions/Subcases)
  * Shared model files across all substudies
  * Independent configuration per substudy
  * Continuation support from previous substudies
  * Real-time incremental history updates
- Live history tracking with optimization_history_incremental.json
- Complete bracket_displacement_maximizing study with substudy examples

Core Fixes:
- Fixed expression update workflow to pass design_vars through simulation_runner
  * Restored working NX journal expression update mechanism
  * OP2 timestamp verification instead of file deletion
  * Resolved issue where all trials returned identical objective values
- Fixed LLMOptimizationRunner to pass design variables to simulation runner
- Enhanced NXSolver with timestamp-based file regeneration verification

New Components:
- optimization_engine/llm_optimization_runner.py - LLM-driven optimization runner
- optimization_engine/optimization_setup_wizard.py - Phase 3.3 setup wizard
- studies/bracket_displacement_maximizing/ - Complete substudy example
  * run_substudy.py - Substudy runner with continuation
  * run_optimization.py - Standalone optimization runner
  * config/substudy_template.json - Template for new substudies
  * substudies/coarse_exploration/ - 20-trial coarse search
  * substudies/fine_tuning/ - 50-trial refinement (continuation example)
  * SUBSTUDIES_README.md - Complete substudy documentation

Technical Improvements:
- Incremental history saving after each trial (optimization_history_incremental.json)
- Expression update workflow: .prt update → NX journal receives values → geometry update → FEM update → solve
- Trial indexing fix in substudy result saving
- Updated README with substudy system documentation

Testing:
- Successfully ran 20-trial coarse_exploration substudy
- Verified different objective values across trials (workflow fix validated)
- Confirmed live history updates in real-time
- Tested shared model file usage across substudies

🤖 Generated with [Claude Code](https://claude.com/claude-code)

Co-Authored-By: Claude <noreply@anthropic.com>
This commit is contained in:
Anto01
2025-11-16 21:29:54 -05:00
parent 90a9e020d8
commit 2f3afc3813
126 changed files with 15592 additions and 97 deletions
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56
optimization_engine/nx_solver.py
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@@ -194,22 +194,16 @@ class NXSolver:
print(f" Working dir: {working_dir}")
print(f" Mode: {'Journal' if self.use_journal else 'Direct'}")
# Delete old result files (.op2, .log, .f06) to force fresh solve
# (.dat file is needed by NX, don't delete it!)
# (Otherwise NX may reuse cached results)
files_to_delete = [op2_file, log_file, f06_file]
# Record timestamps of old files BEFORE solving
# We'll verify files are regenerated by checking timestamps AFTER solve
# This is more reliable than deleting (which can fail due to file locking on Windows)
old_op2_time = op2_file.stat().st_mtime if op2_file.exists() else None
old_f06_time = f06_file.stat().st_mtime if f06_file.exists() else None
old_log_time = log_file.stat().st_mtime if log_file.exists() else None
deleted_count = 0
for old_file in files_to_delete:
if old_file.exists():
try:
old_file.unlink()
deleted_count += 1
except Exception as e:
print(f" Warning: Could not delete {old_file.name}: {e}")
if deleted_count > 0:
print(f" Deleted {deleted_count} old result file(s) to force fresh solve")
if old_op2_time:
print(f" Found existing OP2 (modified: {time.ctime(old_op2_time)})")
print(f" Will verify NX regenerates it with newer timestamp")
# Build command based on mode
if self.use_journal and sim_file.suffix == '.sim':
@@ -308,19 +302,41 @@ sys.argv = ['', {argv_str}] # Set argv for the main function
for line in result.stderr.strip().split('\n')[:5]:
print(f" {line}")
# Wait for output files to appear (journal mode runs solve in background)
# Wait for output files to appear AND be regenerated (journal mode runs solve in background)
if self.use_journal:
max_wait = 30 # seconds - background solves can take time
wait_start = time.time()
print("[NX SOLVER] Waiting for solve to complete...")
while not (f06_file.exists() and op2_file.exists()) and (time.time() - wait_start) < max_wait:
# Wait for files to exist AND have newer timestamps than before
while (time.time() - wait_start) < max_wait:
files_exist = f06_file.exists() and op2_file.exists()
if files_exist:
# Verify files were regenerated (newer timestamps)
new_op2_time = op2_file.stat().st_mtime
new_f06_time = f06_file.stat().st_mtime
# If no old files, or new files are newer, we're done!
if (old_op2_time is None or new_op2_time > old_op2_time) and \
(old_f06_time is None or new_f06_time > old_f06_time):
elapsed = time.time() - wait_start
print(f"[NX SOLVER] Fresh output files detected after {elapsed:.1f}s")
if old_op2_time:
print(f" OP2 regenerated: {time.ctime(old_op2_time)} -> {time.ctime(new_op2_time)}")
break
time.sleep(0.5)
if (time.time() - wait_start) % 2 < 0.5: # Print every 2 seconds
elapsed = time.time() - wait_start
print(f" Waiting... ({elapsed:.0f}s)")
print(f" Waiting for fresh results... ({elapsed:.0f}s)")
if f06_file.exists() and op2_file.exists():
print(f"[NX SOLVER] Output files detected after {time.time() - wait_start:.1f}s")
# Final check - warn if files weren't regenerated
if op2_file.exists():
current_op2_time = op2_file.stat().st_mtime
if old_op2_time and current_op2_time <= old_op2_time:
print(f" WARNING: OP2 file was NOT regenerated! (Still has old timestamp)")
print(f" Old: {time.ctime(old_op2_time)}, Current: {time.ctime(current_op2_time)}")
# Check for completion
success = self._check_solution_success(f06_file, log_file)