Complete rewrite of triangulation engine:
- Regular hexagonal-packed vertex grid (equilateral triangles)
- Density-adaptive refinement: denser near holes, coarser in open areas
- Boundary-conforming vertices along frame edge and hole keepouts
- Delaunay on point set + clip to valid region (inside frame, outside keepouts)
- Result: proper isogrid layout, 87 pockets from 234 triangles
- 553 NX entities, min fillet 4.89mm, mass 2770g
- No more dependency on Shewchuk Triangle library (scipy.spatial.Delaunay)
- Switched to uniform triangulation (no density-adaptive refinement for
initial pass — saves that for stress-informed iterations)
- s_min=45mm, s_max=55mm (was 12/35) — larger triangles fit 6mm fillets
- Boss keepout circles: 12 segments (was 32) — less boundary clutter
- Fillet must be >= 80% of r_f at every corner or pocket is skipped
- Result: 75 pockets, 481 NX entities, min fillet 4.85mm, mass 4066g
- adaptive_density=True param enables density refinement for future stress iterations
- Default r_f raised from 1.5mm to 6mm (machining constraint)
- Default min_pocket_radius raised to 6mm
- Pockets that can't fit r_f at any corner (within 80% tolerance) are
skipped entirely — left solid for more stiffness in tight areas
- Result: 26 pockets (was 432), 187 NX entities (was 13,061)
- Min fillet radius: 4.88mm, all >= 4.8mm (80% of 6mm)
- Mass: 4,601g (was 3,480g — more solid = heavier but manufacturable)
Model curves (part.Curves.CreateLine) are SmartObjects that can't be added
to a sketch via AddGeometry. Switch to SketchLineBuilder which creates
native sketch geometry directly (SetStartPoint/SetEndPoint/Commit).
Archive Management:
- Moved RALPH_LOOP, CANVAS, and dashboard implementation plans to archive/review/ for CEO review
- Moved completed restructuring plan and protocol v1 to archive/historical/
- Moved old session summaries to archive/review/
New HQ Documentation (docs/hq/):
- README.md: Overview of Atomizer-HQ multi-agent optimization team
- PROJECT_STRUCTURE.md: Standard KB-integrated project layout with Hydrotech reference
- KB_CONVENTIONS.md: Knowledge Base accumulation principles with generation tracking
- AGENT_WORKFLOWS.md: Project lifecycle phases and agent handoffs (OP_09 integration)
- STUDY_CONVENTIONS.md: Technical study execution standards and atomizer_spec.json format
Index Update:
- Reorganized docs/00_INDEX.md with HQ docs prominent
- Updated structure to reflect new agent-focused organization
- Maintained core documentation access for engineers
No files deleted, only moved to appropriate archive locations.
- Embed Plotly.js inline for offline viewing (fixes CDN loading issues)
- Add 4x resolution PNG export for all charts via toImageButtonOptions
- Add SAT3_Trajectory_V7 study (TPE warm-start from V5, 86 trials, WS=277.37)
- Include V7 optimization report and configuration
Co-Authored-By: Claude Opus 4.5 <noreply@anthropic.com>
Generates publication-ready PSD figures from OP2 FEA data:
- psd_multi_angle.png: PSD curves for all elevation angles
- psd_band_decomposition.png: LSF/MSF/HSF bar chart
- psd_40deg_composite.png: WFE surface + PSD side-by-side
- psd_trajectory.png: Band evolution vs elevation
Uses Atomizer's full OPD pipeline for consistency with CDR WFE numbers.
- tools/wfe_psd.py: Quick PSD computation for WFE surfaces
- optimization_engine/insights/wfe_psd.py: Full PSD module with band
decomposition (LSF/MSF/HSF), radial averaging, Hann windowing,
and visualization support
- knowledge_base/lac/session_insights/stopp_command_20260129.jsonl:
Session insight from stopp command implementation
PSD analysis decomposes WFE into spatial frequency bands per Tony Hull's
JWST methodology. Used for CDR V7 to validate that MSF (support
print-through) dominates the residual WFE at 85-89% of total RMS.
- X-axis now auto-ranges from data (was going to 10^21)
- Band annotations clamped to actual data extent
- Legend moved to upper-right (was overlapping data)
- Thicker lines (2.5px), larger axis labels
- dtick=1 for clean log-scale tick marks
- Band RMS now uses direct Parseval: sqrt(sum(|FFT|²) / N⁴ / hann_power)
- Previous approach had dimensional mismatch (cycles/apt vs cycles/mm)
- Results now match Zernike filtered RMS within ~10%:
40° vs 20°: PSD=6.18nm vs Zernike=7.70nm
60° vs 20°: PSD=15.83nm vs Zernike=17.69nm
90° Abs: PSD=27.01nm vs Zernike=22.33nm
- PSD plot curve uses separate normalization (shape, not absolute)
- Refactored compute_surface_psd to return dict with freqs, psd, bands
- Remove compute_spatial_freq_metrics() and _spatial_freq_html()
- Add compute_surface_psd(): 2D FFT + Hann window + radial averaging
- Add compute_psd_band_rms(): gravity/support/HF band decomposition
- Add make_psd_plot(): interactive log-log PSD plot with band annotations
- Add _psd_summary_html(): band RMS cards with % breakdown
- New section in report: Power Spectral Density Analysis
- Zernike details now show only coefficient bar charts (cleaner)
- Methodology: Tony Hull JWST approach for WFE spatial frequency analysis
New tool: tools/generate_optical_report.py
- CDR-ready single HTML report from OP2 results
- Executive summary with pass/fail vs targets
- Per-angle WFE analysis with 3D surface plots
- Zernike trajectory analysis (mode-specific RMS)
- Axial vs lateral sensitivity matrix
- Manufacturing correction metrics
- Collapsible Zernike coefficient bar charts
- Optional study DB integration for design params
- Annular aperture support (default M1 inner R=135.75mm)
- Dark theme, interactive Plotly charts, print-friendly
- Replace brittle order-based subcase mapping with name-based search
- Tools now directly search for required angles (20, 40, 60, 90) by label
- Ignores extra subcases (e.g., 30, 50 degrees) without errors
- Falls back to numeric IDs (1,2,3,4) if angle labels not found
- Clear error messages show exactly which subcases are missing
This allows running WFE analysis on simulations with >4 subcases
without manual file/code modifications.
Co-Authored-By: Claude Sonnet 4.5 <noreply@anthropic.com>
