Commit Graph

5 Commits

Author SHA1 Message Date
Antoine
01a7d7d121 docs: Complete M1 mirror optimization campaign V11-V15
## M1 Mirror Campaign Summary
- V11-V15 optimization campaign completed (~1,400 FEA evaluations)
- Best design: V14 Trial #725 with Weighted Sum = 121.72
- V15 NSGA-II confirmed V14 TPE found optimal solution
- Campaign improved from WS=129.33 (V11) to WS=121.72 (V14): -5.9%

## Key Results
- 40° tracking: 5.99 nm (target 4.0 nm)
- 60° tracking: 13.10 nm (target 10.0 nm)
- Manufacturing: 26.28 nm (target 20.0 nm)
- Targets not achievable within current design space

## Documentation Added
- V15 STUDY_REPORT.md: Detailed NSGA-II results analysis
- M1_MIRROR_CAMPAIGN_SUMMARY.md: Full V11-V15 campaign overview
- Updated CLAUDE.md, ATOMIZER_CONTEXT.md with NXSolver patterns
- Updated 01_CHEATSHEET.md with --resume guidance
- Updated OP_01_CREATE_STUDY.md with FEARunner template

## Studies Added
- m1_mirror_adaptive_V13: TPE validation (291 trials)
- m1_mirror_adaptive_V14: TPE intensive (785 trials, BEST)
- m1_mirror_adaptive_V15: NSGA-II exploration (126 new FEA)

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

Co-Authored-By: Claude Opus 4.5 <noreply@anthropic.com>
2025-12-16 14:55:23 -05:00
Antoine
1bb201e0b7 feat: Add post-optimization tools and mandatory best design archiving
New Tools (tools/):
- analyze_study.py: Generate comprehensive optimization reports
- find_best_iteration.py: Find best iteration folder, optionally copy it
- archive_best_design.py: Archive best design to 3_results/best_design_archive/<timestamp>/

Protocol Updates:
- OP_02_RUN_OPTIMIZATION.md v1.1: Add mandatory archive_best_design step
  in Post-Run Actions. This MUST be done after every optimization run.

V14 Updates:
- run_optimization.py: Auto-archive best design at end of optimization
- optimization_config.json: Expand bounds for V14 continuation
  - lateral_outer_angle: min 13->11 deg (was at 4.7%)
  - lateral_inner_pivot: min 7->5 mm (was at 8.1%)
  - lateral_middle_pivot: max 23->27 mm (was at 99.4%)
  - whiffle_min: max 60->72 mm (was at 96.3%)

Usage:
  python tools/analyze_study.py m1_mirror_adaptive_V14
  python tools/find_best_iteration.py m1_mirror_adaptive_V14
  python tools/archive_best_design.py m1_mirror_adaptive_V14

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

Co-Authored-By: Claude Opus 4.5 <noreply@anthropic.com>
2025-12-12 10:28:35 -05:00
Antoine
70ac34e3d3 feat: Add E11 Part Mass extractor, document pyNastran mass accuracy issue
New E11 Part Mass Extractor:
- Add nx_journals/extract_part_mass_material.py - NX journal using
  NXOpen.MeasureManager.NewMassProperties() for accurate geometry-based mass
- Add optimization_engine/extractors/extract_part_mass_material.py - Python
  wrapper that reads JSON output from journal
- Add E11 entry to extractors/catalog.json

Documentation Updates:
- SYS_12_EXTRACTOR_LIBRARY.md: Add mass accuracy warning noting pyNastran
  get_mass_breakdown() under-reports ~7% on hex-dominant meshes with
  tet/pyramid fill elements. E11 (geometry .prt) should be preferred over
  E4 (BDF) unless material is overridden at FEM level.
- 01_CHEATSHEET.md: Add mass extraction tip

V14 Config:
- Expand design variable bounds (blank_backface_angle max 4.5°,
  whiffle_triangle_closeness max 80mm, whiffle_min max 60mm)

Testing showed:
- E11 from .prt: 97.66 kg (accurate - matches NX GUI)
- E4 pyNastran get_mass_breakdown(): 90.73 kg (~7% under-reported)

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

Co-Authored-By: Claude Opus 4.5 <noreply@anthropic.com>
2025-12-11 22:15:36 -05:00
Antoine
3d90097b2b feat: Expand V14 design space bounds based on V13 analysis
Analysis of 258 FEA trials showed best trial (#45) hitting bounds on
5 parameters. Expanded bounds to allow exploration of promising regions:

- lateral_inner_angle: max 28.5 → 30.0° (was at 99.2% of range)
- lateral_inner_pivot: min 9.0 → 7.0 mm (was at 4.6% of range)
- lateral_middle_pivot: min 18.0 → 15.0 mm (was at 7.7% of range)
- whiffle_min: min 35.0 → 30.0 mm (was at 4.0% of range)
- whiffle_outer_to_vertical: min 68.0 → 60.0° (was at 5.3% of range)
- blank_backface_angle: narrowed to 4.1-4.2° (focus on optimal region)

V14 seeds from 496 prior FEA trials (V11+V12+V13) using TPE sampler.

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

Co-Authored-By: Claude Opus 4.5 <noreply@anthropic.com>
2025-12-11 16:42:34 -05:00
Antoine
48404fd743 feat: Add Zernike wavefront viewer and V14 TPE optimization study
Dashboard Zernike Analysis:
- Add ZernikeViewer component with tabbed UI (40°, 60°, 90° vs 20°)
- Generate 3D surface mesh plots with Mesh3d triangulation
- Full 50-mode Zernike coefficient tables with mode names
- Manufacturing metrics for 90_vs_20 (optician workload analysis)
- OP2 availability filter for FEA trials only
- Fix duplicate trial display with unique React keys
- Tab switching with proper event propagation

Backend API Enhancements:
- GET /studies/{id}/trials/{num}/zernike - Generate Zernike HTML on-demand
- GET /studies/{id}/zernike-available - List trials with OP2 files
- compute_manufacturing_metrics() for aberration analysis
- compute_rms_filter_j1to3() for optician workload metric

M1 Mirror V14 Study:
- TPE (Tree-structured Parzen Estimator) optimization
- Seeds from 496 prior FEA trials (V11+V12+V13)
- Weighted-sum objective: 5*obj_40 + 5*obj_60 + 1*obj_mfg
- Multivariate TPE with constant_liar for efficient exploration
- Ready for 8-hour overnight runs

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

Co-Authored-By: Claude Opus 4.5 <noreply@anthropic.com>
2025-12-10 21:34:07 -05:00