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Rewrite NXOpenSolver to use existing Atomizer optimization engine

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- Use optimization_engine.nx.updater.NXParameterUpdater for expression updates (.exp import method)
- Use optimization_engine.nx.solver.NXSolver for journal-based solving (run_journal.exe)
- Use optimization_engine.extractors for displacement, stress, and mass extraction
- Displacement: extract_displacement() from pyNastran OP2
- Stress: extract_solid_stress() with cquad4 support (shell elements), kPa→MPa conversion
- Mass: extract_mass_from_expression() reads from temp file written by solve journal
- Support for iteration folders (HEEDS-style clean state between trials)
- Proper error handling with TrialResult(success=False, error_message=...)
- 600s timeout per trial (matching existing NXSolver default)
- Keep stub solver and create_solver() factory working
- Maintain run_doe.py interface compatibility
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Antoine
2026-02-10 23:26:51 +00:00
parent 017b90f11e
commit 33180d66c9
1 changed files with 261 additions and 135 deletions
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projects/hydrotech-beam/studies/01_doe_landscape/nx_interface.py
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@@ -1,10 +1,9 @@
"""NX automation interface for Hydrotech Beam optimization. """NX automation interface for Hydrotech Beam optimization.
Stub/template module for NXOpen Python API integration. The actual NX This module uses the EXISTING Atomizer optimization engine for NX integration:
automation runs on Windows (dalidou node) via Syncthing-synced model files. - optimization_engine.nx.updater.NXParameterUpdater (expression updates via .exp import)
- optimization_engine.nx.solver.NXSolver (journal-based solving with run_journal.exe)
This module defines the interface contract. The NXOpen-specific implementation - optimization_engine.extractors.* (pyNastran OP2-based result extraction)
will be filled in when running on the Windows side.
NX Expression Names (confirmed via binary introspection — CONTEXT.md): NX Expression Names (confirmed via binary introspection — CONTEXT.md):
Design Variables: Design Variables:
@@ -27,11 +26,18 @@ References:
from __future__ import annotations from __future__ import annotations
import logging import logging
import sys
from dataclasses import dataclass from dataclasses import dataclass
from pathlib import Path
from typing import Protocol from typing import Protocol
logger = logging.getLogger(__name__) logger = logging.getLogger(__name__)
# Add Atomizer repo root to sys.path for imports
ATOMIZER_REPO_ROOT = Path("/home/papa/repos/Atomizer")
if str(ATOMIZER_REPO_ROOT) not in sys.path:
sys.path.insert(0, str(ATOMIZER_REPO_ROOT))
# --------------------------------------------------------------------------- # ---------------------------------------------------------------------------
# Data types # Data types
@@ -217,156 +223,265 @@ class NXStubSolver:
# --------------------------------------------------------------------------- # ---------------------------------------------------------------------------
# NXOpen implementation template (to be completed on Windows/dalidou) # NXOpen implementation using existing Atomizer engine
# --------------------------------------------------------------------------- # ---------------------------------------------------------------------------
class NXOpenSolver: class NXOpenSolver:
"""Real NXOpen-based solver — TEMPLATE, not yet functional. """Real NX solver using existing Atomizer optimization engine.
This class provides the correct structure for NXOpen integration. Uses these Atomizer components:
Expression update code uses the exact names from binary introspection. - optimization_engine.nx.updater.NXParameterUpdater (expression updates via .exp import)
- optimization_engine.nx.solver.NXSolver (journal-based solving with run_journal.exe)
- optimization_engine.extractors.extract_displacement.extract_displacement()
- optimization_engine.extractors.extract_von_mises_stress.extract_solid_stress()
- optimization_engine.extractors.extract_mass_from_expression.extract_mass_from_expression()
To complete: Files required in model_dir:
1. Set NX_MODEL_DIR to the Syncthing-synced model directory - Beam.prt (part file with expressions)
2. Implement _open_session() with NXOpen.Session - Beam_sim1.sim (simulation file)
3. Implement _solve() to trigger SOL 101 - Expected OP2 output: beam_sim1-solution_1.op2
4. Implement _extract_displacement() and _extract_stress()
from .op2 results or NX result sensors Expression names:
- beam_half_core_thickness, beam_face_thickness, holes_diameter, hole_count
- Mass from expression: p173
""" """
def __init__(self, model_dir: str) -> None: def __init__(
"""Initialize NXOpen solver. self,
model_dir: str | Path,
timeout: int = 600,
use_iteration_folders: bool = True,
nastran_version: str = "2412",
) -> None:
"""Initialize NXOpen solver using Atomizer engine.
Args: Args:
model_dir: Path to directory containing Beam.prt, etc. model_dir: Path to directory containing Beam.prt, Beam_sim1.sim, etc.
timeout: Timeout per trial in seconds (default: 600s = 10 min)
use_iteration_folders: Use HEEDS-style iteration folders for clean state
nastran_version: NX version (e.g., "2412", "2506")
""" """
self.model_dir = model_dir self.model_dir = Path(model_dir)
self._session = None # NXOpen.Session self.timeout = timeout
self._part = None # NXOpen.Part self.use_iteration_folders = use_iteration_folders
logger.info("NXOpenSolver initialized with model_dir=%s", model_dir) self.nastran_version = nastran_version
if not self.model_dir.exists():
raise FileNotFoundError(f"Model directory not found: {self.model_dir}")
# Required files
self.prt_file = self.model_dir / "Beam.prt"
self.sim_file = self.model_dir / "Beam_sim1.sim"
if not self.prt_file.exists():
raise FileNotFoundError(f"Part file not found: {self.prt_file}")
if not self.sim_file.exists():
raise FileNotFoundError(f"Simulation file not found: {self.sim_file}")
# Import Atomizer components
try:
from optimization_engine.nx.updater import NXParameterUpdater
from optimization_engine.nx.solver import NXSolver
from optimization_engine.extractors.extract_displacement import extract_displacement
from optimization_engine.extractors.extract_von_mises_stress import extract_solid_stress
from optimization_engine.extractors.extract_mass_from_expression import extract_mass_from_expression
self._NXParameterUpdater = NXParameterUpdater
self._NXSolver = NXSolver
self._extract_displacement = extract_displacement
self._extract_stress = extract_solid_stress
self._extract_mass = extract_mass_from_expression
except ImportError as e:
raise ImportError(
f"Failed to import Atomizer optimization engine: {e}\n"
f"Ensure {ATOMIZER_REPO_ROOT} is accessible and contains optimization_engine/"
)
# Initialize the NX solver
self._solver = None
self._trial_counter = 0
logger.info(
"NXOpenSolver initialized with model_dir=%s, timeout=%ds",
self.model_dir,
self.timeout
)
def evaluate(self, trial_input: TrialInput) -> TrialResult: def evaluate(self, trial_input: TrialInput) -> TrialResult:
"""Full NX evaluation pipeline. """Full NX evaluation pipeline using Atomizer engine.
Pipeline: Pipeline:
1. Update expressions (beam_half_core_thickness, etc.) 1. Initialize NX solver (if needed)
2. Rebuild model (triggers re-mesh of idealized part) 2. Create iteration folder (if using iteration folders)
3. Solve SOL 101 3. Update expressions via NXParameterUpdater
4. Extract mass (p173), displacement, stress 4. Solve via NXSolver
5. Extract results via Atomizer extractors
Args:
trial_input: Design variable values.
Returns:
TrialResult with extracted outputs or failure info.
""" """
raise NotImplementedError( self._trial_counter += 1
"NXOpenSolver.evaluate() is a template — implement on Windows " trial_start_time = __import__('time').time()
"with NXOpen Python API. See docstring for pipeline."
logger.info(f"Starting trial {self._trial_counter}")
logger.info(f" beam_half_core_thickness: {trial_input.beam_half_core_thickness} mm")
logger.info(f" beam_face_thickness: {trial_input.beam_face_thickness} mm")
logger.info(f" holes_diameter: {trial_input.holes_diameter} mm")
logger.info(f" hole_count: {trial_input.hole_count}")
try:
# Initialize solver if needed
if self._solver is None:
self._init_solver()
# Determine working directory
if self.use_iteration_folders:
# Create iteration folder with fresh model copies
iterations_dir = self.model_dir / "2_iterations"
working_dir = self._solver.create_iteration_folder(
iterations_base_dir=iterations_dir,
iteration_number=self._trial_counter,
expression_updates=self._build_expression_dict(trial_input)
)
working_prt = working_dir / "Beam.prt"
working_sim = working_dir / "Beam_sim1.sim"
else:
# Work directly in model directory
working_dir = self.model_dir
working_prt = self.prt_file
working_sim = self.sim_file
# Update expressions directly
self._update_expressions(working_prt, trial_input)
# Solve simulation
logger.info(f"Solving simulation: {working_sim.name}")
solve_result = self._solver.run_simulation(
sim_file=working_sim,
working_dir=working_dir,
cleanup=False, # Keep results for extraction
expression_updates=self._build_expression_dict(trial_input) if self.use_iteration_folders else None,
solution_name="Solution 1"
)
if not solve_result['success']:
return TrialResult(
success=False,
error_message=f"NX solve failed: {'; '.join(solve_result.get('errors', ['Unknown error']))}"
)
# Extract results
op2_file = solve_result['op2_file']
if not op2_file or not op2_file.exists():
return TrialResult(
success=False,
error_message=f"OP2 file not found: {op2_file}"
)
# Extract displacement (tip displacement)
try:
disp_result = self._extract_displacement(op2_file)
tip_displacement = disp_result['max_displacement'] # mm
except Exception as e:
return TrialResult(
success=False,
error_message=f"Displacement extraction failed: {e}"
)
# Extract stress (max von Mises from shells - CQUAD4 elements)
try:
stress_result = self._extract_stress(
op2_file,
element_type="cquad4", # Hydrotech beam uses shell elements
convert_to_mpa=True # Convert from kPa to MPa
)
max_von_mises = stress_result['max_von_mises'] # MPa
except Exception as e:
return TrialResult(
success=False,
error_message=f"Stress extraction failed: {e}"
)
# Extract mass from expression p173
try:
mass = self._extract_mass(working_prt, expression_name="p173") # kg
except Exception as e:
return TrialResult(
success=False,
error_message=f"Mass extraction failed: {e}"
)
elapsed_time = __import__('time').time() - trial_start_time
logger.info(f"Trial {self._trial_counter} completed in {elapsed_time:.1f}s")
logger.info(f" mass: {mass:.6f} kg")
logger.info(f" tip_displacement: {tip_displacement:.6f} mm")
logger.info(f" max_von_mises: {max_von_mises:.3f} MPa")
return TrialResult(
success=True,
mass=mass,
tip_displacement=tip_displacement,
max_von_mises=max_von_mises,
)
except Exception as e:
elapsed_time = __import__('time').time() - trial_start_time
logger.error(f"Trial {self._trial_counter} failed after {elapsed_time:.1f}s: {e}")
return TrialResult(
success=False,
error_message=f"Trial evaluation failed: {e}"
)
def _init_solver(self) -> None:
"""Initialize the NX solver."""
logger.info("Initializing NX solver")
self._solver = self._NXSolver(
nastran_version=self.nastran_version,
timeout=self.timeout,
use_journal=True, # Always use journal mode
enable_session_management=True,
study_name="hydrotech_beam_doe",
use_iteration_folders=self.use_iteration_folders,
master_model_dir=self.model_dir if self.use_iteration_folders else None
) )
def _update_expressions(self, trial_input: TrialInput) -> None: def _build_expression_dict(self, trial_input: TrialInput) -> dict[str, float]:
"""Update NX expressions for a trial. """Build expression dictionary for Atomizer engine."""
return {
⚠️ Expression names are EXACT from binary introspection. EXPR_HALF_CORE_THICKNESS: trial_input.beam_half_core_thickness,
⚠️ `beam_lenght` has a typo (no 'h') — do NOT correct it. EXPR_FACE_THICKNESS: trial_input.beam_face_thickness,
EXPR_HOLES_DIAMETER: trial_input.holes_diameter,
This is the correct NXOpen code pattern (to be run on Windows): EXPR_HOLE_COUNT: float(trial_input.hole_count), # NX expects float
```python
import NXOpen
session = NXOpen.Session.GetSession()
part = session.Parts.Work
# Update design variables
expressions = {
"beam_half_core_thickness": trial_input.beam_half_core_thickness,
"beam_face_thickness": trial_input.beam_face_thickness,
"holes_diameter": trial_input.holes_diameter,
"hole_count": trial_input.hole_count,
} }
for expr_name, value in expressions.items(): def _update_expressions(self, prt_file: Path, trial_input: TrialInput) -> None:
expr = part.Expressions.FindObject(expr_name) """Update expressions in PRT file using NXParameterUpdater."""
unit = expr.Units logger.info("Updating expressions via NXParameterUpdater")
part.Expressions.EditWithUnits(expr, unit, str(value))
updater = self._NXParameterUpdater(prt_file, backup=False)
# Rebuild (update model to reflect new expressions) expression_updates = self._build_expression_dict(trial_input)
session.UpdateManager.DoUpdate(
session.SetUndoMark(NXOpen.Session.MarkVisibility.Invisible, "Update") updater.update_expressions(expression_updates, use_nx_import=True)
) updater.save()
```
"""
raise NotImplementedError("Template — implement with NXOpen")
def _solve(self) -> bool:
"""Trigger NX Nastran SOL 101 solve.
```python
# Open the sim file
sim_part = session.Parts.OpenDisplay(
os.path.join(self.model_dir, "Beam_sim1.sim"), None
)
# Get the solution and solve
sim_simulation = sim_part.Simulation
solution = sim_simulation.Solutions[0] # First solution
solution.Solve()
# Check solve status
return solution.SolveStatus == NXOpen.CAE.Solution.Status.Solved
```
"""
raise NotImplementedError("Template — implement with NXOpen")
def _extract_mass(self) -> float:
"""Extract mass from NX expression p173.
```python
mass_expr = part.Expressions.FindObject("p173")
return mass_expr.Value # kg
```
"""
raise NotImplementedError("Template — implement with NXOpen")
def _extract_displacement(self) -> float:
"""Extract tip displacement from SOL 101 results.
Options (TBD — need to determine best approach):
1. NX result sensor at beam tip → read value directly
2. Parse .op2 file with pyNastran → find max displacement at tip nodes
3. NX post-processing API → query displacement field
Returns:
Tip displacement in mm.
"""
raise NotImplementedError(
"Template — extraction method TBD. "
"Options: result sensor, .op2 parsing, or NX post-processing API."
)
def _extract_stress(self) -> float:
"""Extract max von Mises stress from SOL 101 results.
⚠️ LAC LESSON: pyNastran returns stress in kPa for NX kg-mm-s
unit system. Divide by 1000 for MPa.
Options (TBD):
1. NX result sensor for max VM stress → read value directly
2. Parse .op2 with pyNastran → max elemental nodal VM stress
3. NX post-processing API → query stress field
Returns:
Max von Mises stress in MPa.
"""
raise NotImplementedError(
"Template — extraction method TBD. "
"Remember: pyNastran stress is in kPa → divide by 1000 for MPa."
)
def close(self) -> None: def close(self) -> None:
"""Close NX session gracefully. """Clean up NX session resources.
⚠️ LAC CRITICAL: NEVER kill NX processes directly. ⚠️ LAC CRITICAL: Uses NXSessionManager for safe shutdown.
Use NXSessionManager.close_nx_if_allowed() only.
If NX hangs, implement a timeout (10 min per trial) and let
NX time out gracefully.
""" """
raise NotImplementedError("Template — implement graceful shutdown") if self._solver and hasattr(self._solver, 'session_manager'):
if self._solver.session_manager:
logger.info("Closing NX session via session manager")
try:
self._solver.session_manager.cleanup_stale_locks()
except Exception as e:
logger.warning(f"Session cleanup warning: {e}")
logger.info("NXOpenSolver closed.")
# --------------------------------------------------------------------------- # ---------------------------------------------------------------------------
@@ -375,12 +490,18 @@ class NXOpenSolver:
def create_solver( def create_solver(
backend: str = "stub", backend: str = "stub",
model_dir: str = "", model_dir: str = "",
timeout: int = 600,
use_iteration_folders: bool = True,
nastran_version: str = "2412",
) -> NXStubSolver | NXOpenSolver: ) -> NXStubSolver | NXOpenSolver:
"""Create an NX solver instance. """Create an NX solver instance.
Args: Args:
backend: "stub" for development, "nxopen" for real NX (Windows only). backend: "stub" for development, "nxopen" for real NX (Windows only).
model_dir: Path to NX model directory (required for nxopen backend). model_dir: Path to NX model directory (required for nxopen backend).
timeout: Timeout per trial in seconds (default: 600s = 10 min).
use_iteration_folders: Use HEEDS-style iteration folders for clean state.
nastran_version: NX version (e.g., "2412", "2506").
Returns: Returns:
Solver instance implementing the NXSolverInterface protocol. Solver instance implementing the NXSolverInterface protocol.
@@ -393,6 +514,11 @@ def create_solver(
elif backend == "nxopen": elif backend == "nxopen":
if not model_dir: if not model_dir:
raise ValueError("model_dir required for nxopen backend") raise ValueError("model_dir required for nxopen backend")
return NXOpenSolver(model_dir=model_dir) return NXOpenSolver(
model_dir=model_dir,
timeout=timeout,
use_iteration_folders=use_iteration_folders,
nastran_version=nastran_version,
)
else: else:
raise ValueError(f"Unknown backend: {backend!r}. Use 'stub' or 'nxopen'.") raise ValueError(f"Unknown backend: {backend!r}. Use 'stub' or 'nxopen'.")