Self-Aware Turbo v3 optimization validated on M1 Mirror flat back:
- Best WS: 205.58 (12% better than previous best 218.26)
- 100% feasibility rate, 100% unique designs
- Uses 556 training samples from V5-V8 campaign data
Key innovations in V9:
- Adaptive exploration schedule (15% → 8% → 3%)
- Mass threshold at 118 kg (optimal sweet spot)
- 70% exploitation near best design
- Seeded with best known design from V7
- Ensemble surrogate with R²=0.99
Updated documentation:
- SYS_16: SAT protocol updated to v3.0 VALIDATED
- Cheatsheet: Added SAT v3 as recommended method
- Context: Updated protocol overview
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- Add TrialManager (trial_manager.py) for consistent trial_NNNN naming
- Add DashboardDB (dashboard_db.py) for Optuna-compatible database schema
- Update CLAUDE.md with trial management documentation
- Update ATOMIZER_CONTEXT.md with v1.8 trial system
- Update cheatsheet v2.2 with new utilities
- Update SYS_14 protocol to v2.3 with TrialManager integration
- Add LAC learnings for trial management patterns
- Add archive/README.md for deprecated code policy
Key principles:
- Trial numbers NEVER reset (monotonic)
- Folders NEVER get overwritten
- Database always synced with filesystem
- Surrogate predictions are NOT trials (only FEA results)
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Major improvements to Zernike WFE visualization:
- Add ZernikeDashboardInsight: Unified dashboard with all orientations (40°, 60°, 90°)
on one page with light theme and executive summary
- Add OPD method toggle: Switch between Standard (Z-only) and OPD (X,Y,Z) methods
in ZernikeWFEInsight with interactive buttons
- Add lateral displacement maps: Visualize X,Y displacement for each orientation
- Add displacement component views: Toggle between WFE, ΔX, ΔY, ΔZ in relative views
- Add metrics comparison table showing both methods side-by-side
New extractors:
- extract_zernike_figure.py: ZernikeOPDExtractor using BDF geometry interpolation
- extract_zernike_opd.py: Parabola-based OPD with focal length
Key finding: OPD method gives 8-11% higher WFE values than Standard method
(more conservative/accurate for surfaces with lateral displacement under gravity)
Documentation updates:
- SYS_12: Added E22 ZernikeOPD as recommended method
- SYS_16: Added ZernikeDashboard, updated ZernikeWFE with OPD features
- Cheatsheet: Added Zernike method comparison table
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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
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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)
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The Method Selector now uses relative accuracy thresholds to assess
NN suitability by comparing NN error to problem variability (CV ratio).
NNQualityAssessor features:
- Physics-based objective classification (linear, smooth, nonlinear, chaotic)
- CV ratio computation: nn_error / coefficient_of_variation
- Turbo suitability score based on relative thresholds
- Data collection from validation_report.json, turbo_report.json, and study.db
Quality thresholds by objective type:
- Linear (mass, volume): max 2% error, CV ratio < 0.5
- Smooth (frequency): max 5% error, CV ratio < 1.0
- Nonlinear (stress, stiffness): max 10% error, CV ratio < 2.0
- Chaotic (contact, buckling): max 20% error, CV ratio < 3.0
CLI output now includes:
- Per-objective NN quality table with error, CV, ratio, and quality indicator
- Turbo suitability and hybrid suitability percentages
- Warnings when NN error exceeds physics-based thresholds
Updated SYS_15_METHOD_SELECTOR.md to v2.0 with full NN Quality Assessment documentation.
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Phase 2 - Structural Analysis:
- extract_principal_stress: σ1, σ2, σ3 principal stresses from OP2
- extract_strain_energy: Element and total strain energy
- extract_spc_forces: Reaction forces at boundary conditions
Phase 3 - Multi-Physics:
- extract_temperature: Nodal temperatures from thermal OP2 (SOL 153/159)
- extract_temperature_gradient: Thermal gradient approximation
- extract_heat_flux: Element heat flux from thermal analysis
- extract_modal_mass: Modal effective mass from F06 (SOL 103)
- get_first_frequency: Convenience function for first natural frequency
Documentation:
- Updated SYS_12_EXTRACTOR_LIBRARY.md with E12-E18 specifications
- Updated NX_OPEN_AUTOMATION_ROADMAP.md marking Phase 3 complete
- Added test_phase3_extractors.py for validation
All extractors follow consistent API pattern returning Dict with
success, data, and error fields for robust error handling.
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