feat: Add MLP surrogate with Turbo Mode for 100x faster optimization

Neural Acceleration (MLP Surrogate): - Add run_nn_optimization.py with hybrid FEA/NN workflow - MLP architecture: 4-layer (64->128->128->64) with BatchNorm/Dropout - Three workflow modes: - --all: Sequential export->train->optimize->validate - --hybrid-loop: Iterative Train->NN->Validate->Retrain cycle - --turbo: Aggressive single-best validation (RECOMMENDED) - Turbo mode: 5000 NN trials + 50 FEA validations in ~12 minutes - Separate nn_study.db to avoid overloading dashboard Performance Results (bracket_pareto_3obj study): - NN prediction errors: mass 1-5%, stress 1-4%, stiffness 5-15% - Found minimum mass designs at boundary (angle~30deg, thick~30mm) - 100x speedup vs pure FEA exploration Protocol Operating System: - Add .claude/skills/ with Bootstrap, Cheatsheet, Context Loader - Add docs/protocols/ with operations (OP_01-06) and system (SYS_10-14) - Update SYS_14_NEURAL_ACCELERATION.md with MLP Turbo Mode docs NX Automation: - Add optimization_engine/hooks/ for NX CAD/CAE automation - Add study_wizard.py for guided study creation - Fix FEM mesh update: load idealized part before UpdateFemodel() New Study: - bracket_pareto_3obj: 3-objective Pareto (mass, stress, stiffness) - 167 FEA trials + 5000 NN trials completed - Demonstrates full hybrid workflow 🤖 Generated with [Claude Code](https://claude.com/claude-code) Co-Authored-By: Claude Opus 4.5 <noreply@anthropic.com>
2025-12-06 20:01:59 -05:00
parent 0cb2808c44
commit 602560c46a
70 changed files with 31018 additions and 289 deletions
--- a/optimization_engine/hooks/nx_cad/feature_manager.py
+++ b/optimization_engine/hooks/nx_cad/feature_manager.py
@@ -0,0 +1,711 @@
+"""
+NX Feature Manager Hook
+=======================
+
+Provides Python functions to manage NX features (suppress, unsuppress, etc.).
+
+API Reference (verified via Siemens MCP docs):
+- Part.Features() -> FeatureCollection
+- Feature.Suppress() -> Suppresses the feature
+- Feature.Unsuppress() -> Unsuppresses the feature
+- Feature.Name, Feature.IsSuppressed
+- Session.UpdateManager.DoUpdate() -> Update the model
+
+Usage:
+    from optimization_engine.hooks.nx_cad import feature_manager
+
+    # Get all features
+    result = feature_manager.get_features("C:/path/to/part.prt")
+
+    # Suppress a feature
+    result = feature_manager.suppress_feature("C:/path/to/part.prt", "HOLE(1)")
+
+    # Unsuppress a feature
+    result = feature_manager.unsuppress_feature("C:/path/to/part.prt", "HOLE(1)")
+
+    # Get feature status
+    result = feature_manager.get_feature_status("C:/path/to/part.prt", "HOLE(1)")
+"""
+
+import os
+import json
+import subprocess
+import tempfile
+from pathlib import Path
+from typing import Optional, Dict, Any, List, Tuple
+
+# NX installation path (configurable)
+NX_BIN_PATH = os.environ.get(
+    "NX_BIN_PATH",
+    r"C:\Program Files\Siemens\NX2506\NXBIN"
+)
+
+# Journal template for feature operations
+FEATURE_OPERATIONS_JOURNAL = '''
+# NX Open Python Journal - Feature Operations
+# Auto-generated by Atomizer hooks
+#
+# Based on Siemens NX Open Python API:
+# - Part.Features()
+# - Feature.Suppress() / Feature.Unsuppress()
+# - Feature.Name, Feature.IsSuppressed
+
+import NXOpen
+import NXOpen.Features
+import json
+import sys
+import os
+
+def main():
+    """Execute feature operation based on command arguments."""
+    # Get the NX session
+    session = NXOpen.Session.GetSession()
+
+    # Parse arguments: operation, part_path, output_json, [extra_args...]
+    args = sys.argv[1:] if len(sys.argv) > 1 else []
+
+    if len(args) < 3:
+        raise ValueError("Usage: script.py <operation> <part_path> <output_json> [args...]")
+
+    operation = args[0]
+    part_path = args[1]
+    output_json = args[2]
+    extra_args = args[3:] if len(args) > 3 else []
+
+    result = {"success": False, "error": None, "data": {}}
+
+    try:
+        # Ensure part is open
+        part = ensure_part_open(session, part_path)
+
+        if part is None:
+            result["error"] = f"Failed to open part: {part_path}"
+        elif operation == "get_all":
+            result = get_all_features(part)
+        elif operation == "get_status":
+            feature_name = extra_args[0] if extra_args else None
+            result = get_feature_status(part, feature_name)
+        elif operation == "suppress":
+            feature_name = extra_args[0] if extra_args else None
+            result = suppress_feature(session, part, feature_name)
+        elif operation == "unsuppress":
+            feature_name = extra_args[0] if extra_args else None
+            result = unsuppress_feature(session, part, feature_name)
+        elif operation == "suppress_multiple":
+            feature_names = json.loads(extra_args[0]) if extra_args else []
+            result = suppress_multiple_features(session, part, feature_names)
+        elif operation == "unsuppress_multiple":
+            feature_names = json.loads(extra_args[0]) if extra_args else []
+            result = unsuppress_multiple_features(session, part, feature_names)
+        else:
+            result["error"] = f"Unknown operation: {operation}"
+
+    except Exception as e:
+        import traceback
+        result["error"] = str(e)
+        result["traceback"] = traceback.format_exc()
+
+    # Write result to output JSON
+    with open(output_json, 'w') as f:
+        json.dump(result, f, indent=2)
+
+    return result
+
+
+def ensure_part_open(session, part_path):
+    """Ensure the part is open and return it."""
+    # Check if already open
+    part_path_normalized = os.path.normpath(part_path).lower()
+
+    for part in session.Parts:
+        if os.path.normpath(part.FullPath).lower() == part_path_normalized:
+            return part
+
+    # Need to open it
+    if not os.path.exists(part_path):
+        return None
+
+    try:
+        # Set load options for the working directory
+        working_dir = os.path.dirname(part_path)
+        session.Parts.LoadOptions.ComponentLoadMethod = NXOpen.LoadOptions.LoadMethod.FromDirectory
+        session.Parts.LoadOptions.SetSearchDirectories([working_dir], [True])
+
+        # Use OpenActiveDisplay instead of OpenBase for better compatibility
+        part, load_status = session.Parts.OpenActiveDisplay(
+            part_path,
+            NXOpen.DisplayPartOption.AllowAdditional
+        )
+        load_status.Dispose()
+        return part
+    except:
+        return None
+
+
+def find_feature_by_name(part, feature_name):
+    """Find a feature by name."""
+    for feature in part.Features:
+        if feature.Name == feature_name:
+            return feature
+    return None
+
+
+def get_all_features(part):
+    """Get all features from a part.
+
+    NX Open API: Part.Features()
+    """
+    result = {"success": False, "error": None, "data": {}}
+
+    try:
+        features = []
+
+        for feature in part.Features:
+            try:
+                feature_data = {
+                    "name": feature.Name,
+                    "type": feature.FeatureType,
+                    "is_suppressed": feature.IsSuppressed,
+                    "is_internal": feature.IsInternal,
+                }
+                features.append(feature_data)
+            except:
+                # Skip features that can't be read
+                pass
+
+        result["success"] = True
+        result["data"] = {
+            "count": len(features),
+            "suppressed_count": sum(1 for f in features if f["is_suppressed"]),
+            "features": features
+        }
+
+    except Exception as e:
+        result["error"] = str(e)
+
+    return result
+
+
+def get_feature_status(part, feature_name):
+    """Get status of a specific feature.
+
+    NX Open API: Feature properties
+    """
+    result = {"success": False, "error": None, "data": {}}
+
+    if not feature_name:
+        result["error"] = "Feature name is required"
+        return result
+
+    try:
+        feature = find_feature_by_name(part, feature_name)
+
+        if feature is None:
+            result["error"] = f"Feature not found: {feature_name}"
+            return result
+
+        result["success"] = True
+        result["data"] = {
+            "name": feature.Name,
+            "type": feature.FeatureType,
+            "is_suppressed": feature.IsSuppressed,
+            "is_internal": feature.IsInternal,
+        }
+
+    except Exception as e:
+        result["error"] = str(e)
+
+    return result
+
+
+def suppress_feature(session, part, feature_name):
+    """Suppress a feature.
+
+    NX Open API: Feature.Suppress()
+    """
+    result = {"success": False, "error": None, "data": {}}
+
+    if not feature_name:
+        result["error"] = "Feature name is required"
+        return result
+
+    try:
+        feature = find_feature_by_name(part, feature_name)
+
+        if feature is None:
+            result["error"] = f"Feature not found: {feature_name}"
+            return result
+
+        if feature.IsSuppressed:
+            result["success"] = True
+            result["data"] = {
+                "name": feature_name,
+                "action": "already_suppressed",
+                "is_suppressed": True
+            }
+            return result
+
+        # Set undo mark
+        mark_id = session.SetUndoMark(NXOpen.Session.MarkVisibility.Visible, "Suppress Feature")
+
+        # Suppress the feature
+        feature.Suppress()
+
+        # Update the model
+        session.UpdateManager.DoUpdate(mark_id)
+
+        result["success"] = True
+        result["data"] = {
+            "name": feature_name,
+            "action": "suppressed",
+            "is_suppressed": True
+        }
+
+    except Exception as e:
+        result["error"] = str(e)
+
+    return result
+
+
+def unsuppress_feature(session, part, feature_name):
+    """Unsuppress a feature.
+
+    NX Open API: Feature.Unsuppress()
+    """
+    result = {"success": False, "error": None, "data": {}}
+
+    if not feature_name:
+        result["error"] = "Feature name is required"
+        return result
+
+    try:
+        feature = find_feature_by_name(part, feature_name)
+
+        if feature is None:
+            result["error"] = f"Feature not found: {feature_name}"
+            return result
+
+        if not feature.IsSuppressed:
+            result["success"] = True
+            result["data"] = {
+                "name": feature_name,
+                "action": "already_unsuppressed",
+                "is_suppressed": False
+            }
+            return result
+
+        # Set undo mark
+        mark_id = session.SetUndoMark(NXOpen.Session.MarkVisibility.Visible, "Unsuppress Feature")
+
+        # Unsuppress the feature
+        feature.Unsuppress()
+
+        # Update the model
+        session.UpdateManager.DoUpdate(mark_id)
+
+        result["success"] = True
+        result["data"] = {
+            "name": feature_name,
+            "action": "unsuppressed",
+            "is_suppressed": False
+        }
+
+    except Exception as e:
+        result["error"] = str(e)
+
+    return result
+
+
+def suppress_multiple_features(session, part, feature_names):
+    """Suppress multiple features.
+
+    Args:
+        session: NX session
+        part: NX part
+        feature_names: List of feature names to suppress
+    """
+    result = {"success": False, "error": None, "data": {}}
+
+    if not feature_names:
+        result["error"] = "No feature names provided"
+        return result
+
+    try:
+        # Set undo mark for all changes
+        mark_id = session.SetUndoMark(NXOpen.Session.MarkVisibility.Visible, "Suppress Multiple Features")
+
+        suppressed = []
+        errors = []
+
+        for feature_name in feature_names:
+            feature = find_feature_by_name(part, feature_name)
+
+            if feature is None:
+                errors.append(f"Feature not found: {feature_name}")
+                continue
+
+            try:
+                if not feature.IsSuppressed:
+                    feature.Suppress()
+                suppressed.append(feature_name)
+            except Exception as e:
+                errors.append(f"Failed to suppress {feature_name}: {str(e)}")
+
+        # Update the model
+        session.UpdateManager.DoUpdate(mark_id)
+
+        result["success"] = len(errors) == 0
+        result["data"] = {
+            "suppressed": suppressed,
+            "errors": errors,
+            "suppressed_count": len(suppressed),
+            "error_count": len(errors),
+        }
+
+    except Exception as e:
+        result["error"] = str(e)
+
+    return result
+
+
+def unsuppress_multiple_features(session, part, feature_names):
+    """Unsuppress multiple features.
+
+    Args:
+        session: NX session
+        part: NX part
+        feature_names: List of feature names to unsuppress
+    """
+    result = {"success": False, "error": None, "data": {}}
+
+    if not feature_names:
+        result["error"] = "No feature names provided"
+        return result
+
+    try:
+        # Set undo mark for all changes
+        mark_id = session.SetUndoMark(NXOpen.Session.MarkVisibility.Visible, "Unsuppress Multiple Features")
+
+        unsuppressed = []
+        errors = []
+
+        for feature_name in feature_names:
+            feature = find_feature_by_name(part, feature_name)
+
+            if feature is None:
+                errors.append(f"Feature not found: {feature_name}")
+                continue
+
+            try:
+                if feature.IsSuppressed:
+                    feature.Unsuppress()
+                unsuppressed.append(feature_name)
+            except Exception as e:
+                errors.append(f"Failed to unsuppress {feature_name}: {str(e)}")
+
+        # Update the model
+        session.UpdateManager.DoUpdate(mark_id)
+
+        result["success"] = len(errors) == 0
+        result["data"] = {
+            "unsuppressed": unsuppressed,
+            "errors": errors,
+            "unsuppressed_count": len(unsuppressed),
+            "error_count": len(errors),
+        }
+
+    except Exception as e:
+        result["error"] = str(e)
+
+    return result
+
+
+if __name__ == "__main__":
+    main()
+'''
+
+
+def _get_run_journal_exe() -> str:
+    """Get the path to run_journal.exe."""
+    return os.path.join(NX_BIN_PATH, "run_journal.exe")
+
+
+def _run_journal(journal_path: str, args: list) -> Tuple[bool, str]:
+    """Run an NX journal with arguments.
+
+    Returns:
+        Tuple of (success, output_or_error)
+    """
+    run_journal = _get_run_journal_exe()
+
+    if not os.path.exists(run_journal):
+        return False, f"run_journal.exe not found at {run_journal}"
+
+    cmd = [run_journal, journal_path, "-args"] + args
+
+    try:
+        result = subprocess.run(
+            cmd,
+            capture_output=True,
+            text=True,
+            timeout=120  # 2 minute timeout
+        )
+
+        if result.returncode != 0:
+            return False, f"Journal execution failed: {result.stderr}"
+
+        return True, result.stdout
+
+    except subprocess.TimeoutExpired:
+        return False, "Journal execution timed out"
+    except Exception as e:
+        return False, str(e)
+
+
+def _execute_feature_operation(
+    operation: str,
+    part_path: str,
+    extra_args: list = None
+) -> Dict[str, Any]:
+    """Execute a feature operation via NX journal.
+
+    Args:
+        operation: The operation to perform
+        part_path: Path to the part file
+        extra_args: Additional arguments for the operation
+
+    Returns:
+        Dict with operation result
+    """
+    # Create temporary journal file
+    with tempfile.NamedTemporaryFile(
+        mode='w',
+        suffix='.py',
+        delete=False
+    ) as journal_file:
+        journal_file.write(FEATURE_OPERATIONS_JOURNAL)
+        journal_path = journal_file.name
+
+    # Create temporary output file
+    output_file = tempfile.NamedTemporaryFile(
+        mode='w',
+        suffix='.json',
+        delete=False
+    ).name
+
+    try:
+        # Build arguments
+        args = [operation, part_path, output_file]
+        if extra_args:
+            args.extend(extra_args)
+
+        # Run the journal
+        success, output = _run_journal(journal_path, args)
+
+        if not success:
+            return {"success": False, "error": output, "data": {}}
+
+        # Read the result
+        if os.path.exists(output_file):
+            with open(output_file, 'r') as f:
+                return json.load(f)
+        else:
+            return {"success": False, "error": "Output file not created", "data": {}}
+
+    finally:
+        # Cleanup temporary files
+        if os.path.exists(journal_path):
+            os.unlink(journal_path)
+        if os.path.exists(output_file):
+            os.unlink(output_file)
+
+
+# =============================================================================
+# Public API
+# =============================================================================
+
+def get_features(part_path: str) -> Dict[str, Any]:
+    """Get all features from an NX part.
+
+    Args:
+        part_path: Full path to the .prt file
+
+    Returns:
+        Dict with keys:
+            - success: bool
+            - error: Optional error message
+            - data: Dict with count, suppressed_count, features list
+
+    Example:
+        >>> result = get_features("C:/models/bracket.prt")
+        >>> if result["success"]:
+        ...     for f in result["data"]["features"]:
+        ...         status = "suppressed" if f["is_suppressed"] else "active"
+        ...         print(f"{f['name']} ({f['type']}): {status}")
+    """
+    part_path = os.path.abspath(part_path)
+
+    if not os.path.exists(part_path):
+        return {
+            "success": False,
+            "error": f"Part file not found: {part_path}",
+            "data": {}
+        }
+
+    return _execute_feature_operation("get_all", part_path)
+
+
+def get_feature_status(part_path: str, feature_name: str) -> Dict[str, Any]:
+    """Get status of a specific feature.
+
+    Args:
+        part_path: Full path to the .prt file
+        feature_name: Name of the feature
+
+    Returns:
+        Dict with keys:
+            - success: bool
+            - error: Optional error message
+            - data: Dict with name, type, is_suppressed, is_internal
+
+    Example:
+        >>> result = get_feature_status("C:/models/bracket.prt", "HOLE(1)")
+        >>> if result["success"]:
+        ...     print(f"Suppressed: {result['data']['is_suppressed']}")
+    """
+    part_path = os.path.abspath(part_path)
+
+    if not os.path.exists(part_path):
+        return {
+            "success": False,
+            "error": f"Part file not found: {part_path}",
+            "data": {}
+        }
+
+    return _execute_feature_operation("get_status", part_path, [feature_name])
+
+
+def suppress_feature(part_path: str, feature_name: str) -> Dict[str, Any]:
+    """Suppress a feature in an NX part.
+
+    Args:
+        part_path: Full path to the .prt file
+        feature_name: Name of the feature to suppress
+
+    Returns:
+        Dict with keys:
+            - success: bool
+            - error: Optional error message
+            - data: Dict with name, action, is_suppressed
+
+    Example:
+        >>> result = suppress_feature("C:/models/bracket.prt", "HOLE(1)")
+        >>> if result["success"]:
+        ...     print(f"Feature {result['data']['action']}")
+    """
+    part_path = os.path.abspath(part_path)
+
+    if not os.path.exists(part_path):
+        return {
+            "success": False,
+            "error": f"Part file not found: {part_path}",
+            "data": {}
+        }
+
+    return _execute_feature_operation("suppress", part_path, [feature_name])
+
+
+def unsuppress_feature(part_path: str, feature_name: str) -> Dict[str, Any]:
+    """Unsuppress a feature in an NX part.
+
+    Args:
+        part_path: Full path to the .prt file
+        feature_name: Name of the feature to unsuppress
+
+    Returns:
+        Dict with keys:
+            - success: bool
+            - error: Optional error message
+            - data: Dict with name, action, is_suppressed
+
+    Example:
+        >>> result = unsuppress_feature("C:/models/bracket.prt", "HOLE(1)")
+        >>> if result["success"]:
+        ...     print(f"Feature {result['data']['action']}")
+    """
+    part_path = os.path.abspath(part_path)
+
+    if not os.path.exists(part_path):
+        return {
+            "success": False,
+            "error": f"Part file not found: {part_path}",
+            "data": {}
+        }
+
+    return _execute_feature_operation("unsuppress", part_path, [feature_name])
+
+
+def suppress_features(part_path: str, feature_names: List[str]) -> Dict[str, Any]:
+    """Suppress multiple features in an NX part.
+
+    Args:
+        part_path: Full path to the .prt file
+        feature_names: List of feature names to suppress
+
+    Returns:
+        Dict with keys:
+            - success: bool
+            - error: Optional error message
+            - data: Dict with suppressed list, errors list, counts
+
+    Example:
+        >>> result = suppress_features("C:/models/bracket.prt", ["HOLE(1)", "HOLE(2)"])
+        >>> if result["success"]:
+        ...     print(f"Suppressed {result['data']['suppressed_count']} features")
+    """
+    part_path = os.path.abspath(part_path)
+
+    if not os.path.exists(part_path):
+        return {
+            "success": False,
+            "error": f"Part file not found: {part_path}",
+            "data": {}
+        }
+
+    # Convert list to JSON string
+    names_json = json.dumps(feature_names)
+
+    return _execute_feature_operation("suppress_multiple", part_path, [names_json])
+
+
+def unsuppress_features(part_path: str, feature_names: List[str]) -> Dict[str, Any]:
+    """Unsuppress multiple features in an NX part.
+
+    Args:
+        part_path: Full path to the .prt file
+        feature_names: List of feature names to unsuppress
+
+    Returns:
+        Dict with keys:
+            - success: bool
+            - error: Optional error message
+            - data: Dict with unsuppressed list, errors list, counts
+
+    Example:
+        >>> result = unsuppress_features("C:/models/bracket.prt", ["HOLE(1)", "HOLE(2)"])
+        >>> if result["success"]:
+        ...     print(f"Unsuppressed {result['data']['unsuppressed_count']} features")
+    """
+    part_path = os.path.abspath(part_path)
+
+    if not os.path.exists(part_path):
+        return {
+            "success": False,
+            "error": f"Part file not found: {part_path}",
+            "data": {}
+        }
+
+    # Convert list to JSON string
+    names_json = json.dumps(feature_names)
+
+    return _execute_feature_operation("unsuppress_multiple", part_path, [names_json])