feat: add Atomizer HQ multi-agent cluster infrastructure
- 8-agent OpenClaw cluster (Manager, Tech-Lead, Secretary, Auditor, Optimizer, Study-Builder, NX-Expert, Webster) - Orchestration engine: orchestrate.py (sync delegation + handoffs) - Workflow engine: YAML-defined multi-step pipelines - Agent workspaces: SOUL.md, AGENTS.md, MEMORY.md per agent - Shared skills: delegate, orchestrate, atomizer-protocols - Capability registry (AGENTS_REGISTRY.json) - Cluster management: cluster.sh, systemd template - All secrets replaced with env var references
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# Phase 0 — Technical Breakdown
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## M1 Conical Primary Mirror — WFE Optimization
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| Field | Value |
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|-------|-------|
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| **Study ID** | M1-CONICAL-001 |
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| **Phase** | 0 — Problem Definition |
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| **Author** | Technical Lead 🔧 |
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| **Date** | 2025-07-12 |
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| **Status** | Ready for Optimizer |
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---
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## 1. Geometry — What Are We Working With
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### 1.1 Optical Surface
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| Parameter | Value | Notes |
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|-----------|-------|-------|
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| Type | Conical (conic constant TBD by client) | Near-parabolic likely; conic constant K ≈ −1 |
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| Clear Aperture | 500 mm (∅) | Optical active zone |
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| Substrate Material | Aluminum alloy (likely 6061-T6 or RSA-6061) | High thermal conductivity, CTE ~23.6 µm/m·°C |
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| Mounting Interface | Central bore or 3-point peripheral (TBD) | Kinematic mount assumed |
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### 1.2 Structural Architecture (Typical Lightweighted Mirror)
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The mirror assembly consists of three structural zones:
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```
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┌──────────────────────────────────┐
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│ Optical Facesheet │ ← Reflecting surface
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├──────────────────────────────────┤
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│ Lightweighting Core │ ← Pocket pattern (hex/triangular/arch)
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│ (ribs + pockets) │
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├──────────────────────────────────┤
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│ Back Facesheet │ ← Structural closure
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└──────────────────────────────────┘
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↕ Mounting features
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```
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### 1.3 Key Geometric Assumptions
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- **Open-back vs. closed-back:** Closed-back assumed (back facesheet present) for thermal stability. Open-back is lighter but thermally worse — flag as trade study candidate.
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- **Pocket geometry:** Hexagonal pocket pattern assumed as baseline (best stiffness-to-weight for circular apertures).
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- **Mounting:** 3-point kinematic mount at ~70% radius (minimizes gravity-induced WFE per classical mirror support theory). Exact mount config is a design variable.
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- **Central obscuration:** Assumed present (Cassegrain-family), ~100mm bore — confirm with client.
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---
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## 2. Design Parameters — What Can We Change
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These are the variables the Optimizer will manipulate:
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### 2.1 Structural Sizing
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| Parameter | Symbol | Suggested Range | Units | Notes |
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|-----------|--------|----------------|-------|-------|
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| Front facesheet thickness | t_f | 3.0 – 8.0 | mm | Below 3mm → print-through risk |
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| Back facesheet thickness | t_b | 2.0 – 6.0 | mm | Can be thinner than front |
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| Rib thickness | t_r | 1.5 – 5.0 | mm | Manufacturing floor ~1.5mm for machined Al |
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| Rib height (core depth) | h_c | 25 – 60 | mm | Drives bending stiffness (∝ h³) |
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| Number of ring ribs | N_ring | 2 – 5 | — | Radial stiffening |
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| Number of circumferential ribs | N_circ | 12 – 36 | — | Must satisfy pocket symmetry |
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| Pocket pattern type | — | {hex, tri, arch} | discrete | Hex = baseline |
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### 2.2 Mount Configuration
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| Parameter | Symbol | Suggested Range | Units | Notes |
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|-----------|--------|----------------|-------|-------|
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| Mount radial position | r_mount | 0.60 – 0.80 × R | ratio | ~0.7R is classical optimum for uniform plates |
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| Number of mount points | N_mount | 3 or 6 | discrete | 3-point baseline; 6-point for larger mirrors |
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| Mount pad diameter | d_pad | 10 – 25 | mm | Affects local stress concentration |
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| Mount compliance | k_mount | 1e4 – 1e7 | N/m | If flexure-mounted (optional) |
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### 2.3 Material Selection (if open)
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| Option | E (GPa) | ρ (kg/m³) | CTE (µm/m·°C) | κ (W/m·K) | Notes |
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|--------|---------|-----------|---------------|-----------|-------|
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| Al 6061-T6 | 68.9 | 2700 | 23.6 | 167 | Baseline — standard optical Al |
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| RSA-6061 | 68.9 | 2700 | 23.6 | 167 | Rapid-solidified — superior polishability |
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| Al 7075-T6 | 71.7 | 2810 | 23.4 | 130 | Higher strength, similar stiffness |
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| AlBeMet 162 | 193 | 2071 | 13.9 | 210 | Exotic — 3× specific stiffness, cost flag ⚠️ |
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> **Recommendation:** Fix at 6061-T6 unless client opens material as a trade variable.
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---
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## 3. Objectives — What Are We Optimizing
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### 3.1 Primary Objective: Minimize Wavefront Error (WFE)
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The WFE is the critical performance metric. We decompose it via **Zernike polynomials** on the optical surface:
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| Objective | Metric | Target | Notes |
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|-----------|--------|--------|-------|
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| **RMS WFE (gravity)** | RSS of gravity-induced surface error, rigid-body-removed | < λ/10 RMS @ 632.8nm → **< 63.3 nm RMS** | Under 1G, optical axis horizontal (worst case) |
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| **RMS WFE (thermal)** | RSS of thermally-induced surface error, focus-removed | < λ/10 RMS @ 632.8nm → **< 63.3 nm RMS** | Under 5°C axial gradient |
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| **RMS WFE (combined)** | RSS of gravity + thermal | < λ/10 RMS → **< 63.3 nm** | This is the real target |
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### 3.2 Zernike Decomposition Strategy
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We extract surface deformations and project onto Zernike basis:
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- **Remove:** Piston (Z₀⁰), Tip/Tilt (Z₁±¹), Defocus (Z₂⁰) — these are correctable by alignment
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- **Retain & Minimize:** Astigmatism (Z₂±²), Coma (Z₃±¹), Trefoil (Z₃±³), Spherical (Z₄⁰), and all higher-order terms
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- **Key concern for lightweighted mirrors:** Trefoil and hexafoil from rib print-through
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### 3.3 Secondary Objective: Minimize Mass
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| Objective | Target | Hard/Soft |
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|-----------|--------|-----------|
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| Total assembly mass | ≤ 8.0 kg | **Hard** constraint (see §4) |
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| Mass (stretch goal) | ≤ 6.5 kg | Soft — report if achievable without WFE penalty |
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> **Note:** For a 500mm ∅ solid Al disk ~50mm thick, mass ≈ 25 kg. We need ~70% lightweighting → this is aggressive but achievable.
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### 3.4 Objective Formulation for Optimizer
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```
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MINIMIZE: f(x) = RMS_WFE_combined(x)
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SUBJECT TO: g₁(x) = mass(x) ≤ 8.0 kg
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g₂(x) = σ_max(x) ≤ σ_allow
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g₃(x) = f₁(x) ≥ f₁_min (fundamental frequency)
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g₄(x) = t_f(x) ≥ t_f_min (manufacturing)
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...
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```
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---
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## 4. Constraints — Hard Limits
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### 4.1 Performance Constraints
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| Constraint | Value | Rationale |
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|------------|-------|-----------|
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| RMS WFE (total) | ≤ 63.3 nm (λ/10 @ 632.8nm) | Client requirement |
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| Fundamental frequency | ≥ 80 Hz (suggested) | Typical for ground instrument — prevents coupling with support structure. **Confirm with client.** |
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| Peak stress | ≤ 0.5 × σ_yield | Safety factor of 2 on yield (σ_y = 276 MPa for 6061-T6 → σ_allow = 138 MPa) |
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### 4.2 Mass & Envelope Constraints
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| Constraint | Value | Rationale |
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|------------|-------|-----------|
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| Total mass | ≤ 8.0 kg | Client mass budget — hard limit |
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| Outer diameter | 500 mm (fixed by aperture) | Optical requirement |
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| Total depth (axial) | ≤ 80 mm (suggested) | Package envelope — **confirm with client** |
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### 4.3 Manufacturing Constraints
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| Constraint | Value | Rationale |
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|------------|-------|-----------|
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| Minimum rib thickness | ≥ 1.5 mm | CNC machinability for Al pocketing |
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| Minimum facesheet thickness | ≥ 3.0 mm | Print-through mitigation during polishing |
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| Minimum pocket corner radius | ≥ 2.0 mm | Tool access |
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| Pocket depth uniformity | All pockets same depth | Simplifies machining, reduces cost |
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### 4.4 Thermal Constraints
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| Constraint | Value | Rationale |
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|------------|-------|-----------|
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| Operating temperature range | 20°C ± 10°C (assumed) | Standard lab/observatory — **confirm** |
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| Thermal gradient (axial) | 5°C front-to-back | Client spec — drives thermal WFE |
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| Thermal gradient (radial) | 0°C (assumed uniform) | Conservative assumption — **confirm** |
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### 4.5 Boundary Condition Notes
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- Gravity load: 1G along optical axis (axial) **AND** 1G lateral (transverse) — both must be checked. Transverse is typically the worst case for primary mirrors.
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- Mount preload: Zero-preload kinematic assumed. If bolted, include preload in analysis.
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---
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## 5. Solver Requirements — What Analysis Types Are Needed
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### 5.1 Analysis Chain
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The optimization requires a **multi-physics analysis chain** executed per design iteration:
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```
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┌─────────────────┐ ┌─────────────────┐ ┌─────────────────┐
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│ SOL 101 │ │ SOL 153 │ │ SOL 101 │
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│ Linear Static │ │ Steady Thermal │ │ Linear Static │
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│ (Gravity) │ │ (Gradient) │ │ (Thermal Loads) │
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│ │ │ │ │ │
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│ Load: 1G axial │ │ BC: ΔT = 5°C │ │ Load: Temp field│
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│ Load: 1G lateral│ │ front-to-back │ │ from SOL 153 │
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└────────┬─────────┘ └────────┬─────────┘ └────────┬─────────┘
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│ │ │
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▼ └────────────┬────────────┘
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┌────────────┐ ▼
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│ WFE Extract│ ┌────────────────┐
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│ (gravity) │ │ WFE Extract │
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└────────────┘ │ (thermal) │
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│ └────────────────┘
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│ │
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└──────────────┬──────────────────────┘
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▼
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┌──────────────────┐
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│ RSS Combination │
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│ → Total WFE │
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└──────────────────┘
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```
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### 5.2 Solver Details
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| Solver | Nastran SOL | Purpose | Key Outputs |
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|--------|------------|---------|-------------|
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| **Linear Static (gravity)** | SOL 101 | Surface deformation under 1G (2 subcases: axial + lateral) | Displacement field on optical surface |
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| **Steady-State Thermal** | SOL 153 | Temperature distribution under 5°C gradient | Nodal temperatures |
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| **Linear Static (thermal)** | SOL 101 | Thermo-elastic deformation from SOL 153 temp field | Displacement field on optical surface |
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| **Normal Modes** | SOL 103 | Fundamental frequency check | Eigenvalues, mode shapes |
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| **Design Optimization** | SOL 200 | Nastran-native optimization (if using gradient-based) | Optimal sizing variables |
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### 5.3 WFE Extraction Requirements
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Post-processing pipeline (per load case):
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1. **Extract** optical surface node displacements (UX, UY, UZ)
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2. **Transform** to local optical coordinates (sag direction = Z along optical axis)
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3. **Fit rigid-body motions** (piston, tip, tilt) → remove
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4. **Optionally remove** defocus (client-correctable)
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5. **Project** residual onto Zernike basis through order N ≥ 15 (captures rib print-through harmonics)
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6. **Compute** RMS WFE = sqrt(Σ cₙ²) for non-removed terms
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7. **Report** Zernike coefficients, PV, RMS, and surface error map
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> **This is where Atomizer's LAC framework is critical** — the Zernike extraction and parameter monitoring pipeline.
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### 5.4 Mesh Requirements
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| Requirement | Specification | Rationale |
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|-------------|--------------|-----------|
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| Element type | CQUAD4/CQUAD8 (shells) or CHEXA (solids) | Shells preferred for parametric sizing; solids for accuracy |
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| Optical surface mesh density | ≥ 5 elements per rib cell across | Must resolve print-through quilting |
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| Minimum elements across facesheet thickness | ≥ 3 (if solid) | Through-thickness bending accuracy |
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| Mesh convergence study | **Required** before optimization | Per standard practice — run at 1×, 2×, 4× baseline density |
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| Optical surface node pattern | Regular grid or ring pattern | Clean Zernike fitting requires well-distributed sample points |
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### 5.5 Optimization Strategy Recommendation
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| Approach | Pros | Cons | Recommendation |
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|----------|------|------|----------------|
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| **SOL 200 (gradient-based)** | Fast convergence, native Nastran | Limited to sizing, requires smooth design space | ✅ **Phase 1 — sizing optimization** |
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| **Surrogate + GA** | Handles discrete variables, global search | Expensive (many FEA calls), needs DOE | ✅ **Phase 2 — if topology/layout changes needed** |
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| **Hybrid (SOL 200 → Surrogate)** | Best of both — fast local + global exploration | Complex setup | ✅ **Phase 3 — refinement** |
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**Recommended approach:** Start with SOL 200 for continuous sizing variables (facesheets, ribs, core depth), then move to surrogate-based if discrete layout changes (pocket pattern, mount count) are needed.
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---
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## 6. Risk Register & Open Items
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### 6.1 Technical Risks
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| Risk | Likelihood | Impact | Mitigation |
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|------|-----------|--------|------------|
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| Print-through dominates WFE | High | High | Ensure facesheet t_f ≥ 3mm; may need t_f ≥ 5mm |
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| Thermal WFE exceeds budget | Medium | High | Al is thermally well-behaved (high κ, uniform CTE) but 5°C gradient is non-trivial at λ/10 |
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| Mass budget too tight for λ/10 | Medium | High | 8 kg at 500mm with λ/10 is ambitious. ~70% lightweighting needed. May need to trade WFE vs. mass. |
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| Mount-induced distortion | Medium | Medium | Kinematic design critical; include mount pad compliance in model |
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| Mesh-dependent WFE extraction | Low | High | Convergence study is mandatory |
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### 6.2 Open Items (Need Client Input)
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| # | Question | Default Assumption |
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|---|----------|--------------------|
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| 1 | Conic constant of optical surface? | K = −1 (parabolic) |
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| 2 | Central obscuration diameter? | 100 mm |
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| 3 | Open-back or closed-back preference? | Closed-back |
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| 4 | Gravity vector orientation during operation? | Both axial and lateral checked |
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| 5 | Fundamental frequency requirement? | ≥ 80 Hz |
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| 6 | Axial envelope (total mirror depth)? | ≤ 80 mm |
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| 7 | Material locked to 6061-T6? | Yes |
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| 8 | Is defocus correctable (removable from WFE)? | Yes — remove from budget |
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| 9 | Operating thermal environment details? | 20°C ± 10°C, 5°C axial gradient |
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| 10 | Mount type preference (flexure/pad/bipod)? | 3-point pad, kinematic |
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---
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## 7. Summary — Optimizer Input Checklist
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- [x] Geometry defined (conical, 500mm, Al alloy, lightweighted)
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- [x] Design variables identified with ranges (12 parameters)
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- [x] Objective function defined (minimize RMS WFE, Zernike-decomposed)
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- [x] Constraints enumerated (mass ≤ 8kg, stress, frequency, manufacturing)
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- [x] Solver chain specified (SOL 101 + SOL 153 + SOL 103, optional SOL 200)
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- [x] WFE extraction pipeline defined (rigid-body removal, Zernike projection)
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- [x] Mesh requirements specified
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- [x] Risks flagged
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- [ ] Open items awaiting client input (10 items)
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> **This document is ready for the Optimizer to consume.**
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> Open items use conservative defaults — optimization can proceed, with results refined once client clarifies.
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---
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*Technical Lead 🔧 — Physics is the boss. We just translate.*
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