diff --git a/optimization_engine/README.md b/optimization_engine/README.md new file mode 100644 index 00000000..4eae81f4 --- /dev/null +++ b/optimization_engine/README.md @@ -0,0 +1,115 @@ +# Optimization Engine + +Core optimization engine for Atomizer structural optimization projects. + +## Overview + +The optimization engine provides NX Nastran integration, result extraction, and optimization orchestration. Originally developed for the SAT3 mirror project, now generalized for multiple projects including Hydrotech Beam. + +## NX Integration (`nx/`) + +### Supported NX Versions + +| Version | Status | Notes | +|---------|--------|-------| +| NX 2412 | ⚠️ Legacy | Original development version | +| **DesigncenterNX 2512** | ✅ Current | Siemens rebranded NX to "DesigncenterNX". Install path: `C:\Program Files\Siemens\DesigncenterNX2512` | + +> **Important:** Siemens rebranded NX to "DesigncenterNX" starting with version 2512. The install directory, executable paths, and search paths all use the new name. Solver configuration must specify `2512` and include `DesigncenterNX` in search paths. + +### Key Files + +| File | Purpose | +|------|---------| +| `solver.py` | NX solver interface — manages NX session, expression updates, solve execution | +| `solve_simulation.py` | NX journal script — runs inside NXOpen Python, handles simple + assembly workflows | +| `solve_simulation_simple.py` | Simplified journal for single-part (simple) workflow | +| `updater.py` | Expression updater — writes `.exp` files, handles unit types | +| `export_expressions.py` | Export expressions from NX model | +| `import_expressions.py` | Import expressions into NX model | +| `session_manager.py` | NX session lifecycle management | +| `model_cleanup.py` | Model cleanup utilities | +| `mesh_converter.py` | Mesh format conversion | + +### Path Resolution — CRITICAL on Windows + +**`Path.absolute()` on Windows does NOT resolve `..` components.** Use `Path.resolve()` everywhere. + +```python +# WRONG — NX cannot follow ".." in paths +path = Path("../../models/Beam_sim1.sim").absolute() +# → C:\...\studies\01_doe_landscape\..\..\models\Beam_sim1.sim ← BROKEN + +# CORRECT — fully resolved path +path = Path("../../models/Beam_sim1.sim").resolve() +# → C:\...\projects\hydrotech-beam\models\Beam_sim1.sim ← WORKS +``` + +This applies to ALL paths passed to NX journals, including: +- `.sim` file path +- `.exp` file path +- Model directory path +- Output file paths + +### NX File References — In-Place Solving Required + +NX `.sim` files store **absolute internal references** to `.fem` and `.prt` files. Copying model files to different directories breaks these references (`Parts.Open` returns `None`). + +**Solution:** Always solve on master model files in-place. Use backup/restore for isolation between optimization trials: + +1. Backup master model files before trial +2. Write expressions, rebuild, solve in original location +3. Archive outputs (OP2, F06) to trial-specific folder +4. Restore master from backup + +### Expression Units + +When writing `.exp` files for NX: +- Length design variables: unit = `MilliMeter` +- Integer expressions (e.g., `hole_count`): unit = `Constant` +- **Critical:** Using wrong unit silently corrupts the model + +### Workflow Types + +**Simple workflow** (single-part, e.g., Hydrotech Beam): +``` +Beam.prt → Beam_fem1_i.prt → Beam_fem1.fem → Beam_sim1.sim +``` + +**Assembly FEM workflow** (multi-part, e.g., SAT3 mirror): +``` +Multiple .prt → .afm → .sim (node merge, label conflicts) +``` + +The journal auto-detects workflow type by checking for `.afm` files. + +## Result Extraction + +### pyNastran Compatibility + +pyNastran warns "nx version 2512 not supported" but **reads OP2 files correctly**. Safe to ignore the warning. + +**Unit note:** pyNastran returns stress in kPa for NX models using kg-mm-s unit system. Divide by 1000 for MPa. + +### Mass Extraction + +Mass is extracted via NX expression `p173` (or project-specific expression). The journal writes the value to a temp file (`_temp_mass.txt`) after solve, which Python reads. + +## Dependencies + +- Python 3.10+ +- pyNastran (OP2 parsing) +- NXOpen Python API (on Windows solver node) +- Optuna (optimization orchestration) +- scipy, numpy, pandas + +## Projects Using This Engine + +| Project | Status | NX Version | Workflow | +|---------|--------|------------|----------| +| Hydrotech Beam | Active (DOE Phase 1) | DesigncenterNX 2512 | Simple | +| SAT3 Mirror | Legacy reference | NX 2412 | Assembly FEM | + +--- + +*Last updated: 2026-02-11* diff --git a/projects/hydrotech-beam/CONTEXT.md b/projects/hydrotech-beam/CONTEXT.md index c8178f1d..31a9778a 100644 --- a/projects/hydrotech-beam/CONTEXT.md +++ b/projects/hydrotech-beam/CONTEXT.md @@ -117,6 +117,19 @@ Minimize beam mass while meeting displacement and stress constraints. Single-obj - Idealized part: `Beam_fem1_i.prt` - Simulation: `Beam_sim1.sim` - Solver: NX Nastran SOL 101 (static structural) +- **NX Version:** DesigncenterNX 2512 (Siemens rebranded NX → "DesigncenterNX") +- **Install path:** `C:\Program Files\Siemens\DesigncenterNX2512` (on dalidou) + +## First Results (2026-02-11) + +| Metric | Value | Notes | +|--------|-------|-------| +| Displacement | **17.93 mm** | At baseline-ish DVs | +| Von Mises stress | **111.9 MPa** | At baseline-ish DVs | +| Solve time | **~12 s/trial** | On dalidou (Windows) | +| Mass extraction | Via `p173` expression | Journal writes `_temp_mass.txt` | + +> Both constraints violated at baseline (disp > 10mm). Optimization will need to find stiffer/heavier designs or relaxed constraints. ## Future Expansion - Material alternatives: Aluminum 6061, Stainless Steel ANSI 310 (per Antoine, KBS session) @@ -127,9 +140,24 @@ Minimize beam mass while meeting displacement and stress constraints. Single-obj - 2026-02-08: Project received from Antoine - 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. +- 2026-02-11: NX version fixed (DesigncenterNX 2512), path resolution bugs fixed, iteration architecture finalized (backup/restore in-place), history DB added. First real solve results. ## Status -Phase: Baseline characterized — proceeding to optimization strategy finalization -Generation: 002 (+ introspection corrections) +Phase: **DOE execution** — solver pipeline operational, first results obtained +Generation: 003 Channel: #project-hydrotech-beam -Last KBS session: 2026-02-10T16:38:01 +Last update: 2026-02-11 + +### Solver Pipeline Status +- ✅ NX journal solve working (DesigncenterNX 2512) +- ✅ Mass extraction via `p173` expression +- ✅ Displacement & stress extraction via pyNastran OP2 parsing +- ✅ Iteration archival (params, results, OP2, F06) +- ✅ History DB (SQLite + CSV, append-only, survives --clean) +- ✅ Geometric pre-checks (hole overlap, web clearance) +- 🔄 Full 51-trial DOE run pending + +### Development Workflow +- **Git only** for development (git push/pull between server and dalidou) +- **Syncthing paused** to avoid conflicts during active development +- Resume Syncthing for production/delivery phases diff --git a/projects/hydrotech-beam/DECISIONS.md b/projects/hydrotech-beam/DECISIONS.md index 9e0cf282..86b73b47 100644 --- a/projects/hydrotech-beam/DECISIONS.md +++ b/projects/hydrotech-beam/DECISIONS.md @@ -52,3 +52,36 @@ Numbered decision log. Check here before proposing anything that contradicts a p - **Decision:** All project data lives in `/repos/Atomizer/projects/`. This is the single source of truth for all current and future projects. Synced to Windows (dalidou) via Syncthing. No duplicate local folders. - **Rationale:** One place for everything — agents, CEO, and Windows all reference the same files. Version-controlled via Gitea, bidirectional sync via Syncthing. - **Status:** Approved + +## DEC-HB-008: Backup/restore in-place solving (not iteration copies) +- **Date:** 2026-02-11 +- **By:** CEO + Technical Lead 🔧 +- **Decision:** Solve on master model files **in-place** (in `models/` directory) using backup/restore for iteration isolation. Do NOT copy `.sim`/`.fem`/`.prt` files to per-iteration folders. +- **Rationale:** NX `.sim` files store absolute internal references to `.fem` and `.prt` files. Copying model files to iteration folders breaks these references (`Parts.Open` returns `None`). Backup/restore preserves all internal references while still providing isolation between trials. +- **Workflow per trial:** + 1. Restore master model files from backup + 2. Write `.exp` file with trial DVs, open `.sim`, rebuild, solve + 3. Archive outputs (OP2, F06, params.json, results.json) to `iterations/iterNNN/` + 4. Iteration folders contain outputs only — NOT model files +- **Status:** Approved — implemented and tested + +## DEC-HB-009: Iteration folder architecture +- **Date:** 2026-02-11 +- **By:** CEO + Technical Lead 🔧 +- **Decision:** Each trial archived to `studies/01_doe_landscape/iterations/iterNNN/` with: `params.json`, `params.exp`, `results.json`, OP2, F06. +- **Rationale:** Full traceability per trial. Any result can be audited, re-examined, or debugged. Smart retention policy keeps last 10 + best 3 with full data, strips the rest to save space. +- **Status:** Approved — implemented in `iteration_manager.py` + +## DEC-HB-010: Persistent history database +- **Date:** 2026-02-11 +- **By:** Technical Lead 🔧 +- **Decision:** Maintain `history.db` (SQLite, append-only) + `history.csv` that survives `--clean` and Optuna resets. Logs all DVs, results, feasibility, timestamps across all studies. +- **Rationale:** Optuna DB is study-scoped and can be cleaned/reset. History DB provides permanent record across studies, enabling cross-study learning, debugging, and auditability. Append-only means no data loss. +- **Status:** Approved — implemented and tested + +## DEC-HB-011: Git-only development workflow (Syncthing paused) +- **Date:** 2026-02-11 +- **By:** CEO +- **Decision:** During active development, use Git (push/pull) exclusively for code sync between server and dalidou. Syncthing paused to avoid conflicts. +- **Rationale:** Syncthing's bidirectional sync creates conflicts when both sides edit files simultaneously during development. Git provides explicit merge control. +- **Status:** Active — resume Syncthing for production/delivery phases diff --git a/projects/hydrotech-beam/kb/_index.md b/projects/hydrotech-beam/kb/_index.md index b4ad07f5..f44b2539 100644 --- a/projects/hydrotech-beam/kb/_index.md +++ b/projects/hydrotech-beam/kb/_index.md @@ -1,8 +1,8 @@ # Knowledge Base — Hydrotech Beam **Project:** Hydrotech Beam Structural Optimization -**Generation:** 002 -**Last updated:** 2026-02-10 +**Generation:** 003 +**Last updated:** 2026-02-11 --- @@ -10,13 +10,15 @@ I-beam optimization for a test fixture. Steel (AISI 1005) cantilever beam with lightening holes in the web. Goal: minimize mass from **1,133.01 kg** baseline while meeting displacement (≤ 10 mm) and stress (≤ 130 MPa) constraints. -**Key confirmed parameters (Gen 002 + Introspection):** +**Key confirmed parameters (Gen 003):** - Beam length: 5,000 mm (`beam_lenght` ⚠️ typo in NX), cantilever — left fixed, right loaded - Load: 10,000 kgf downward at free end - Baseline mass: **1,133.01 kg** (expression `p173: body_property147.mass`) - DV baselines: face=21.504mm, core=25.162mm, holes_dia=300mm, hole_count=10 - Material: AISI Steel 1005 (density 7.3 g/cm³) - Mesh: CQUAD4 thin shell, 33.7 mm element size +- **Solver:** DesigncenterNX 2512 (NX Nastran SOL 101) +- **First results (2026-02-11):** Displacement=17.93mm, Stress=111.9MPa, Solve time ~12s/trial ## Components @@ -34,14 +36,15 @@ I-beam optimization for a test fixture. Steel (AISI 1005) cantilever beam with l | Model | File | Status | |-------|------|--------| -| Static Analysis (SOL 101) | [fea/models/sol101-static.md](fea/models/sol101-static.md) | ✅ Updated Gen 002 — BCs confirmed, baseline run needed | +| Static Analysis (SOL 101) | [fea/models/sol101-static.md](fea/models/sol101-static.md) | ✅ Updated Gen 003 — Solver running, first results obtained | ## Generations | Gen | Date | Summary | |-----|------|---------| | 001 | 2026-02-09 | Initial KB from intake + technical breakdown | -| **002** | **2026-02-10** | **KBS session processing — confirmed geometry, BCs, mesh, material, mass correction** | +| 002 | 2026-02-10 | KBS session processing — confirmed geometry, BCs, mesh, material, mass correction | +| **003** | **2026-02-11** | **First real results! NX version fix (DesigncenterNX 2512), path resolution, backup/restore architecture, history DB, mass extraction via journal** | ## Gap Tracker @@ -60,31 +63,29 @@ I-beam optimization for a test fixture. Steel (AISI 1005) cantilever beam with l | G5 | Hole geometric feasibility | Span = 4,000 mm, offsets = 500 mm fixed. Baseline: 10 holes × 300 mm → ~144 mm ligament (OK) | Need collision check at DV extremes. 15 × 450 mm WILL overlap. Need feasibility constraint. | | G9 | Stress allowable basis | AISI 1005 yield ~285 MPa. 130 MPa → SF ≈ 2.2 | Need confirmation that 130 MPa limit still applies to updated model. | -### ❓ STILL OPEN (from Gen 001) +### ❓ STILL OPEN | # | Item | Why It Matters | Priority | |---|------|---------------|----------| -| G3 | Displacement measurement location | Which node(s)? Which DOF? Magnitude or component? | High | -| G4 | Stress constraint scope | Whole model? Exclude supports? Hole edges? | High | -| G6 | Result sensors in Beam_sim1.sim | Determines extractor approach | Medium | -| G7 | NX parametric rebuild reliability | Untested across DV range | Medium | - -### 🆕 NEW GAPS (from Gen 002) - -| # | Item | Why It Matters | Priority | -|---|------|---------------|----------| -| G10 | Baseline displacement re-verification | 22 mm was from old model state (974 kg). True model is 11.33 kg — displacement likely different. | **High** | -| G11 | Baseline stress value | Never measured. Essential for optimization setup. | **High** | -| G12 | `beam_half_height` starting value | Expression exists but value not captured from KBS screenshots | Medium | -| G13 | `beam_half_width` starting value | Expression exists but value not captured from KBS screenshots | Medium | -| G14 | Hole diameter expression name | Need exact NX expression name (not just the value 300) | Medium | +| G7 | NX parametric rebuild reliability | Untested across full DV range — need corner-case testing | Medium | | G15 | `p6` (hole_span) as potential DV | Antoine suggested it could be optimized. Decision needed. | Medium | +### ✅ CLOSED (Gen 003 — 2026-02-11) + +| # | Item | Resolution | Closed In | +|---|------|------------|-----------| +| G3 | Displacement measurement location | Max Tz at free end, extracted via pyNastran OP2 | Gen 003 | +| G4 | Stress constraint scope | Whole model max von Mises (CQUAD4 shell) | Gen 003 | +| G6 | Result sensors in Beam_sim1.sim | Using pyNastran OP2 parsing, not NX sensors | Gen 003 | +| G10 | Baseline displacement | 17.93 mm at baseline-ish DVs | Gen 003 | +| G11 | Baseline stress | 111.9 MPa at baseline-ish DVs | Gen 003 | +| G12 | `beam_half_height` value | 250 mm — confirmed via binary introspection | Gen 002+ | +| G13 | `beam_half_width` value | 150 mm — confirmed via binary introspection | Gen 002+ | +| G14 | Hole diameter expression name | `holes_diameter` — confirmed via binary introspection | Gen 002+ | + ## Open Tasks -1. **Run baseline SOL 101** — get fresh displacement and stress values (G10, G11) -2. **NX model introspection** — extract all expression names/values, check sensors (G6, G12, G13, G14) -3. **Corner-case testing** — verify NX rebuild at DV extremes (G7) -4. **Geometric feasibility constraint** — implement hole collision check (G5) -5. **Update atomizer_spec_draft.json** — mass expression `p1`, baseline 11.33 kg -6. **Decision on `p6` as DV** — consult Manager/CEO (G15) +1. **Run full 51-trial DOE** — solver pipeline operational, execute Phase 1 +2. **Corner-case testing** — verify NX rebuild at DV extremes (G7) +3. **Decision on `p6` as DV** — consult Manager/CEO (G15) +4. **Phase 1 → Phase 2 gate review** — after DOE completes, assess feasibility landscape diff --git a/projects/hydrotech-beam/kb/fea/models/sol101-static.md b/projects/hydrotech-beam/kb/fea/models/sol101-static.md index 060954ca..281ed6f5 100644 --- a/projects/hydrotech-beam/kb/fea/models/sol101-static.md +++ b/projects/hydrotech-beam/kb/fea/models/sol101-static.md @@ -2,7 +2,7 @@ **Simulation:** Beam_sim1.sim **Solver:** NX Nastran SOL 101 (Linear Static) -**Status:** Setup confirmed from KBS session (Gen 002). Baseline run needed. +**Status:** ✅ Running — first real results obtained 2026-02-11. Automated DOE pipeline operational. --- @@ -29,15 +29,17 @@ - Application: Right side (free end) of beam - Type: This is a **cantilever beam** with end loading — classic bending problem -## Result Extraction +## Result Extraction — Confirmed (Gen 003) | Output | Method | Expression/Sensor | Status | |--------|--------|-------------------|--------| -| Mass | NX expression | **`p1`** (NOT `p173`) | ✅ Confirmed — 11.33 kg baseline | -| Tip displacement | ❓ Sensor or .f06 parse | TBD | Gap G3, G6 — need baseline run | -| Von Mises stress | ❓ Sensor or .f06 parse | TBD | Gap G4, G6 — need baseline run | +| Mass | NX expression | **`p173`** (`body_property147.mass` in kg) | ✅ Confirmed — journal extracts to `_temp_mass.txt` | +| Tip displacement | OP2 parse via pyNastran | Max Tz at free end | ✅ Working — 17.93 mm at baseline-ish DVs | +| Von Mises stress | OP2 parse via pyNastran | CQUAD4 shell max VM | ✅ Working — 111.9 MPa at baseline-ish DVs | -> ⚠️ **Mass expression changed:** `p1` confirmed in KBS session, replacing previous assumption of `p173`. Extractor config must be updated. +> **Mass extraction:** Journal extracts `p173` expression after solve and writes `_temp_mass.txt`. Python reads this file. Expression `p1` from KBS session was incorrect — `p173` confirmed via binary introspection. +> +> **pyNastran note:** Warns "nx version 2512 not supported" but reads OP2 files correctly. Stress output from pyNastran is in kPa — divide by 1000 for MPa. ## Mesh Details @@ -56,28 +58,68 @@ ## Solver Considerations -*From Technical Breakdown (Gen 001), updated with KBS data:* +*From Technical Breakdown (Gen 001), updated with KBS data + Gen 003 run data:* -- **Linear assumption:** With 11.33 kg beam under 98 kN load, deflections may be significant relative to beam dimensions. L/δ ratio needs verification from baseline run. +- **Linear assumption:** With 1,133 kg beam under 98 kN load, deflections are ~18 mm at 5,000 mm span. L/δ ≈ 280 — linear assumption is reasonable. - **Mesh sensitivity:** Stress at hole edges is mesh-dependent. CQUAD4 at 33.7 mm may not fully resolve SCF at 300 mm diameter holes (~28 elements around circumference — probably adequate but needs verification). - **Mesh morphing vs remesh:** Parametric NX models typically remesh on update. Need to confirm behavior across DV range (Gap G7). -- **Runtime estimate:** Single beam, CQUAD4 thin shell → likely **seconds per evaluation**. Very fast. +- **Runtime:** ✅ Confirmed **~12 seconds per evaluation** (single beam, CQUAD4 thin shell on dalidou). Very fast. - **Unit system:** NX model uses kg-mm-s (kgf for force). Nastran output stress in kPa → divide by 1000 for MPa. ## Validation Checklist -- [ ] Baseline mass matches NX expression `p1` (11.33 kg) -- [ ] Baseline displacement measured (was 22 mm at old model state — **needs re-verification** G10) -- [ ] Baseline stress measured (never had a value — **G11**) +- [x] Baseline mass matches NX expression `p173` (1,133.01 kg) +- [x] Displacement measured — 17.93 mm at baseline-ish DVs (G10 closed) +- [x] Stress measured — 111.9 MPa at baseline-ish DVs (G11 closed) - [ ] Mesh convergence verified at baseline - [ ] Mesh quality acceptable at DV range extremes - [ ] Model rebuilds cleanly at all 4 corners of design space (Gap G7) - [ ] Stress at hole edges resolved with current mesh density +## NX Version & Environment — Confirmed (Gen 003) + +| Item | Value | Notes | +|------|-------|-------| +| **NX Version** | **DesigncenterNX 2512** | Siemens rebranded NX to "DesigncenterNX" | +| **Install path** | `C:\Program Files\Siemens\DesigncenterNX2512` | On dalidou (Windows solver node) | +| **Previous config** | NX 2412 | ❌ Failed — "Part file is from a newer version" | +| **pyNastran compat** | Warns "nx version 2512 not supported" | ✅ But reads OP2 files correctly | + +> ⚠️ **Critical lesson (2026-02-11):** Solver was originally configured for NX 2412 but model files are from DesigncenterNX 2512. NX refuses to load with "Part file is from a newer version." Must match version exactly. + +### Path Resolution on Windows — Critical + +**Bug discovered:** `Path.absolute()` on Windows does **NOT** resolve `..` components (unlike `Path.resolve()`). + +```python +# WRONG — leaves ".." in path, NX can't find referenced parts +path = Path("../../models/Beam_sim1.sim").absolute() +# → C:\Users\antoi\Atomizer\projects\hydrotech-beam\studies\01_doe_landscape\..\..\models\Beam_sim1.sim + +# CORRECT — fully resolves path +path = Path("../../models/Beam_sim1.sim").resolve() +# → C:\Users\antoi\Atomizer\projects\hydrotech-beam\models\Beam_sim1.sim +``` + +**Rule:** Use `.resolve()` everywhere when constructing paths for NX. NX cannot follow `..` references in paths. + +### NX File References — In-Place Solving Required + +NX `.sim` files store **absolute internal references** to `.fem` and `.prt` files. Copying model files to iteration folders breaks these references (`Parts.Open` returns `None`). + +**Solution:** Solve on master model **in-place** (in the `models/` directory) with backup/restore for isolation: +1. Backup master model files before each trial +2. Write expressions, rebuild, solve in `models/` +3. Archive outputs (OP2, F06, params, results) to iteration folder +4. Restore master from backup + +See DEC-HB-008 in DECISIONS.md. + ## History - **Gen 001** (2026-02-09): Initial documentation from technical breakdown. All solver details pending gap resolution. -- **Gen 002** (2026-02-10): Confirmed from KBS session — CQUAD4 thin shell, 33.7 mm element size, cantilever BCs (left fixed, right 10,000 kgf down), mass via `p1`. Material: AISI 1005. +- **Gen 002** (2026-02-10): Confirmed from KBS session — CQUAD4 thin shell, 33.7 mm element size, cantilever BCs (left fixed, right 10,000 kgf down), mass via `p173`. Material: AISI 1005. +- **Gen 003** (2026-02-11): First real results! DesigncenterNX 2512 version confirmed, path resolution bugs fixed, backup/restore in-place solving architecture, mass extraction via journal. Displacement=17.93mm, Stress=111.9MPa, Solve time ~12s/trial. ## NX Automation Workflow diff --git a/projects/hydrotech-beam/studies/01_doe_landscape/README.md b/projects/hydrotech-beam/studies/01_doe_landscape/README.md index 307926eb..fa0362d1 100644 --- a/projects/hydrotech-beam/studies/01_doe_landscape/README.md +++ b/projects/hydrotech-beam/studies/01_doe_landscape/README.md @@ -16,7 +16,10 @@ Map the design space of the Hydrotech sandwich I-beam to identify feasible regio | **Algorithm** | Phase 1: LHS DoE (50 trials + 1 baseline) | | **Total budget** | 51 evaluations | | **Constraint handling** | Deb's feasibility rules (Optuna constraint interface) | -| **Status** | Code complete — ready for execution | +| **Status** | ✅ Pipeline operational — first results obtained 2026-02-11 | +| **Solver** | DesigncenterNX 2512 (NX Nastran SOL 101) | +| **Solve time** | ~12 s/trial (~10 min for full DOE) | +| **First results** | Displacement=17.93mm, Stress=111.9MPa | ## Design Variables (confirmed via NX binary introspection) @@ -56,10 +59,14 @@ python run_doe.py --backend stub --study-name my_test_run ### Production Run (NXOpen on Windows) ```bash -# On dalidou (Windows node with NX): -python run_doe.py --backend nxopen --model-dir "C:/path/to/syncthing/Beam" +# On dalidou (Windows node with DesigncenterNX 2512): +cd C:\Users\antoi\Atomizer\projects\hydrotech-beam\studies\01_doe_landscape +conda activate atomizer +python run_doe.py --backend nxopen --model-dir "../../models" ``` +> ⚠️ `--model-dir` can be relative — the code resolves it with `Path.resolve()`. NX requires fully resolved paths (no `..` components). + ### Resume Interrupted Study ```bash @@ -77,6 +84,7 @@ python run_doe.py --backend stub --resume --study-name hydrotech_beam_doe_phase1 | `--seed` | 42 | Random seed for reproducibility | | `--results-dir` | `results/` | Output directory | | `--resume` | false | Resume existing study | +| `--clean` | false | Delete Optuna DB and start fresh (history DB preserved) | | `-v` | false | Verbose (DEBUG) logging | ## Files @@ -86,10 +94,12 @@ python run_doe.py --backend stub --resume --study-name hydrotech_beam_doe_phase1 | `run_doe.py` | Main entry point — orchestrates the DoE study | | `sampling.py` | LHS generation with stratified integer sampling | | `geometric_checks.py` | Pre-flight geometric feasibility filter | -| `nx_interface.py` | NX automation module (stub + NXOpen template) | +| `nx_interface.py` | AtomizerNXSolver wrapping optimization_engine | +| `iteration_manager.py` | Smart retention — last 10 + best 3 with full data | | `requirements.txt` | Python dependencies | | `OPTIMIZATION_STRATEGY.md` | Full strategy document | | `results/` | Output directory (CSV, JSON, Optuna DB) | +| `iterations/` | Per-trial archived outputs | ## Output Files @@ -100,23 +110,44 @@ After a study run, `results/` will contain: | `doe_results.csv` | All trials — DVs, objectives, constraints, status | | `doe_summary.json` | Study metadata, statistics, best feasible design | | `optuna_study.db` | SQLite database (Optuna persistence, resume support) | +| `history.db` | **Persistent** SQLite — all DVs, results, feasibility (survives `--clean`) | +| `history.csv` | CSV mirror of history DB | + +### Iteration Folders + +Each trial produces `iterations/iterNNN/` containing: + +| File | Description | +|------|-------------| +| `params.json` | Design variable values for this trial | +| `params.exp` | NX expression file used for this trial | +| `results.json` | Extracted results (mass, displacement, stress, feasibility) | +| `*.op2` | Nastran binary results (for post-processing) | +| `*.f06` | Nastran text output (for debugging) | + +**Smart retention policy** (runs every 5 iterations): +- Keep last 10 iterations with full data +- Keep best 3 feasible iterations with full data +- Strip model files from all others, keep solver outputs ## Architecture ``` run_doe.py - ├── sampling.py Generate 50 LHS + 1 baseline + ├── sampling.py Generate 50 LHS + 1 baseline │ └── scipy.stats.qmc.LatinHypercube - ├── geometric_checks.py Pre-flight feasibility filter + ├── geometric_checks.py Pre-flight feasibility filter │ ├── Hole overlap: span/(n-1) - d ≥ 30mm │ └── Web clearance: 500 - 2·face - d > 0 - ├── nx_interface.py NX solver (stub or NXOpen) - │ ├── NXStubSolver → synthetic results (development) - │ └── NXOpenSolver → real NX Nastran SOL 101 (production) - └── Optuna study - ├── SQLite storage (resume support) - ├── Enqueued trials (deterministic LHS) - └── Deb's feasibility rules (constraint interface) + ├── nx_interface.py AtomizerNXSolver (wraps optimization_engine) + │ ├── NXStubSolver → synthetic results (development) + │ └── AtomizerNXSolver → real DesigncenterNX 2512 SOL 101 (production) + ├── iteration_manager.py Smart retention (last 10 + best 3) + ├── Optuna study + │ ├── SQLite storage (resume support) + │ ├── Enqueued trials (deterministic LHS) + │ └── Deb's feasibility rules (constraint interface) + └── history.db Persistent history (append-only, survives --clean) ``` ## Pipeline per Trial @@ -130,15 +161,24 @@ Trial N │ ├── FAIL → record as infeasible, skip NX │ └── PASS ↓ │ - ├── 3. NX evaluation - │ ├── Update expressions (exact NX names) - │ ├── Rebuild model - │ ├── Solve SOL 101 - │ └── Extract: mass (p173), displacement, stress + ├── 3. Restore master model from backup │ - ├── 4. Record results + constraint violations + ├── 4. NX evaluation (IN-PLACE in models/ directory) + │ ├── Write .exp file with trial DVs + │ ├── Open .sim (loads model chain) + │ ├── Import expressions, rebuild geometry + │ ├── Update FEM (remesh) + │ ├── Solve SOL 101 (~12s) + │ └── Extract: mass (p173 → _temp_mass.txt), displacement, stress (via OP2) │ - └── 5. Log to CSV + Optuna DB + ├── 5. Archive outputs to iterations/iterNNN/ + │ └── params.json, params.exp, results.json, OP2, F06 + │ + ├── 6. Record results + constraint violations + │ + ├── 7. Log to Optuna DB + history.db + CSV + │ + └── 8. Smart retention check (every 5 iterations) ``` ## Phase 1 → Phase 2 Gate Criteria @@ -162,18 +202,26 @@ Before proceeding to Phase 2 (TPE optimization), these checks must pass: ## NX Integration Notes +**Solver:** DesigncenterNX 2512 (Siemens rebrand of NX). Install: `C:\Program Files\Siemens\DesigncenterNX2512`. + The `nx_interface.py` module provides: - **`NXStubSolver`** — synthetic results from simplified beam mechanics (for pipeline testing) -- **`NXOpenSolver`** — template for real NXOpen Python API integration (to be completed on Windows) +- **`AtomizerNXSolver`** — wraps `optimization_engine` NXSolver for real DesigncenterNX 2512 solves Expression names are exact from binary introspection. Critical: `beam_lenght` has a typo in NX (no 'h') — use exact spelling. -### Outputs to extract from NX: +### Outputs extracted from NX: | Output | Source | Unit | Notes | |--------|--------|------|-------| -| Mass | Expression `p173` | kg | Direct read | -| Tip displacement | SOL 101 results | mm | TBD: sensor or .op2 parsing | -| Max VM stress | SOL 101 results | MPa | ⚠️ pyNastran returns kPa — divide by 1000 | +| Mass | Expression `p173` → `_temp_mass.txt` | kg | Journal extracts after solve | +| Tip displacement | OP2 parse via pyNastran | mm | Max Tz at free end | +| Max VM stress | OP2 parse via pyNastran | MPa | ⚠️ pyNastran returns kPa — divide by 1000 | + +### Critical Lessons Learned (2026-02-11) +1. **Path resolution:** Use `Path.resolve()` NOT `Path.absolute()` on Windows. `.absolute()` doesn't resolve `..` components — NX can't follow them. +2. **File references:** NX `.sim` files have absolute internal refs to `.fem`/`.prt`. Never copy model files to iteration folders — solve in-place with backup/restore. +3. **NX version:** Must match exactly. Model files from 2512 won't load in 2412 ("Part file is from a newer version"). +4. **pyNastran:** Warns about unsupported NX version 2512 but works fine. Safe to ignore. ## References @@ -184,4 +232,4 @@ Expression names are exact from binary introspection. Critical: `beam_lenght` ha --- -*Code: 🏗️ Study Builder (Technical Lead) | Strategy: ⚡ Optimizer Agent | 2026-02-10* +*Code: 🏗️ Study Builder (Technical Lead) | Strategy: ⚡ Optimizer Agent | Updated: 2026-02-11*