Antoine
390ffed450
Complete the NXOpenSolver class in nx_interface.py with production-ready evaluate() and close() methods, following proven patterns from M1_Mirror/SAT3_Trajectory_V7. Pipeline per trial: 1. NXSolver.create_iteration_folder() — HEEDS-style isolation with fresh model copies + params.exp generation 2. NXSolver.run_simulation() — journal-based solve via run_journal.exe (handles expression import, geometry rebuild, FEM update, SOL 101) 3. extract_displacement() — max displacement from OP2 4. extract_solid_stress() — max von Mises with auto-detect element type (tries all solid types first, falls back to CQUAD4 shell) 5. extract_mass_from_expression() — reads _temp_mass.txt from journal, with _temp_part_properties.json fallback Key decisions: - Auto-detect element type for stress (element_type=None) instead of hardcoding CQUAD4 — the beam model may use solid or shell elements - Lazy solver init on first evaluate() call for clean error handling - OP2 fallback path: tries solver result first, then expected naming convention (beam_sim1-solution_1.op2) - Mass fallback: _temp_mass.txt -> _temp_part_properties.json - LAC-compliant close(): only uses session_manager.cleanup_stale_locks(), never kills NX processes directly Expression mapping (confirmed from binary introspection): - beam_half_core_thickness, beam_face_thickness, holes_diameter, hole_count - Mass output: p173 (body_property147.mass, kg) Refs: OP_09, OPTIMIZATION_STRATEGY.md §8.2
629 lines
25 KiB
Python
629 lines
25 KiB
Python
"""NX automation interface for Hydrotech Beam optimization.
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This module uses the EXISTING Atomizer optimization engine for NX integration:
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- optimization_engine.nx.updater.NXParameterUpdater (expression updates via .exp import)
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- optimization_engine.nx.solver.NXSolver (journal-based solving with run_journal.exe)
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- optimization_engine.extractors.* (pyNastran OP2-based result extraction)
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NX Expression Names (confirmed via binary introspection — CONTEXT.md):
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Design Variables:
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- beam_half_core_thickness (mm, continuous)
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- beam_face_thickness (mm, continuous)
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- holes_diameter (mm, continuous)
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- hole_count (integer, links to Pattern_p7)
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Outputs:
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- p173 (mass in kg, body_property147.mass)
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Fixed:
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- beam_lenght (⚠️ TYPO in NX — no 'h', 5000 mm)
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- beam_half_height (250 mm)
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- beam_half_width (150 mm)
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References:
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CONTEXT.md — Full expression map
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OPTIMIZATION_STRATEGY.md §8.2 — Extractor requirements
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"""
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from __future__ import annotations
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import logging
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import sys
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from dataclasses import dataclass
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from pathlib import Path
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from typing import Protocol
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logger = logging.getLogger(__name__)
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# Add Atomizer repo root to sys.path for imports
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ATOMIZER_REPO_ROOT = Path("/home/papa/repos/Atomizer")
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if str(ATOMIZER_REPO_ROOT) not in sys.path:
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sys.path.insert(0, str(ATOMIZER_REPO_ROOT))
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# ---------------------------------------------------------------------------
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# Data types
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# ---------------------------------------------------------------------------
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@dataclass(frozen=True)
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class TrialInput:
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"""Design variable values for a single trial."""
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beam_half_core_thickness: float # mm — DV1
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beam_face_thickness: float # mm — DV2
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holes_diameter: float # mm — DV3
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hole_count: int # — DV4
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@dataclass
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class TrialResult:
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"""Results extracted from NX after a trial solve.
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All values populated after a successful SOL 101 solve.
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On failure, success=False and error_message explains the failure.
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"""
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success: bool
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mass: float = float("nan") # kg — from expression `p173`
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tip_displacement: float = float("nan") # mm — from SOL 101 results
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max_von_mises: float = float("nan") # MPa — from SOL 101 results
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error_message: str = ""
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# ---------------------------------------------------------------------------
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# NX expression name constants
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# ---------------------------------------------------------------------------
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# ⚠️ These are EXACT NX expression names from binary introspection.
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# Do NOT change spelling — `beam_lenght` has a typo (no 'h') in NX.
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EXPR_HALF_CORE_THICKNESS = "beam_half_core_thickness"
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EXPR_FACE_THICKNESS = "beam_face_thickness"
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EXPR_HOLES_DIAMETER = "holes_diameter"
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EXPR_HOLE_COUNT = "hole_count"
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EXPR_MASS = "p173" # body_property147.mass, kg
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EXPR_BEAM_LENGTH = "beam_lenght" # ⚠️ TYPO IN NX — intentional
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# ---------------------------------------------------------------------------
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# Interface protocol
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# ---------------------------------------------------------------------------
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class NXSolverInterface(Protocol):
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"""Protocol for NX solver backends.
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Implementors must provide the full pipeline:
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1. Update expressions → 2. Rebuild model → 3. Solve SOL 101 → 4. Extract results
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"""
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def evaluate(self, trial_input: TrialInput) -> TrialResult:
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"""Run a full NX evaluation cycle for one trial.
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Args:
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trial_input: Design variable values.
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Returns:
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TrialResult with extracted outputs or failure info.
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"""
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...
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def close(self) -> None:
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"""Clean up NX session resources.
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⚠️ LAC CRITICAL: NEVER kill NX processes directly.
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Use NXSessionManager.close_nx_if_allowed() only.
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"""
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...
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# ---------------------------------------------------------------------------
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# Stub implementation (for development/testing without NX)
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# ---------------------------------------------------------------------------
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class NXStubSolver:
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"""Stub NX solver for development and testing.
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Returns synthetic results based on simple analytical approximations
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of the beam behavior. NOT physically accurate — use only for
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testing the optimization pipeline.
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The stub uses rough scaling relationships:
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- Mass ∝ (core + face) and inversely with hole area
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- Displacement ∝ 1/I where I depends on core and face thickness
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- Stress ∝ M*y/I (bending stress approximation)
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"""
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def __init__(self) -> None:
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"""Initialize stub solver."""
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logger.warning(
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"Using NX STUB solver — results are synthetic approximations. "
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"Replace with NXOpenSolver for real evaluations."
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)
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def evaluate(self, trial_input: TrialInput) -> TrialResult:
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"""Return synthetic results based on simplified beam mechanics.
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Args:
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trial_input: Design variable values.
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Returns:
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TrialResult with approximate values.
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"""
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try:
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return self._compute_approximate(trial_input)
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except Exception as e:
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logger.error("Stub evaluation failed: %s", e)
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return TrialResult(
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success=False,
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error_message=f"Stub evaluation error: {e}",
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)
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def _compute_approximate(self, inp: TrialInput) -> TrialResult:
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"""Simple analytical approximation of beam response.
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This is a ROUGH approximation for pipeline testing only.
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Real physics requires NX Nastran SOL 101.
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"""
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import math
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# Geometry
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L = 5000.0 # mm — beam length
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b = 300.0 # mm — beam width (2 × beam_half_width)
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h_core = inp.beam_half_core_thickness # mm — half core
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t_face = inp.beam_face_thickness # mm — face thickness
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d_hole = inp.holes_diameter # mm
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n_holes = inp.hole_count
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# Total height and section properties (simplified I-beam)
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h_total = 500.0 # mm — 2 × beam_half_height (fixed)
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# Approximate second moment of area (sandwich beam)
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# I ≈ b*h_total^3/12 - b*(h_total-2*t_face)^3/12 + web contribution
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h_inner = h_total - 2.0 * t_face
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I_section = (b * h_total**3 / 12.0) - (b * max(h_inner, 0.0) ** 3 / 12.0)
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# Add core contribution
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I_section += 2.0 * h_core * h_total**2 / 4.0 # approximate
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# Hole area reduction (mass)
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hole_area = n_holes * math.pi * (d_hole / 2.0) ** 2 # mm²
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# Approximate mass (steel: 7.3 g/cm³ = 7.3e-6 kg/mm³)
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rho = 7.3e-6 # kg/mm³
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# Gross cross-section area (very simplified)
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A_gross = 2.0 * b * t_face + 2.0 * h_core * h_total
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# Remove holes from web
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web_thickness = 2.0 * h_core # approximate web thickness
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A_holes = n_holes * math.pi * (d_hole / 2.0) ** 2
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V_solid = A_gross * L
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V_holes = A_holes * web_thickness
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mass = rho * (V_solid - min(V_holes, V_solid * 0.8))
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# Approximate tip displacement (cantilever, point load)
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# δ = PL³/(3EI)
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P = 10000.0 * 9.81 # 10,000 kgf → N
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E = 200000.0 # MPa (steel)
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if I_section > 0:
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displacement = P * L**3 / (3.0 * E * I_section)
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else:
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displacement = 9999.0
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# Approximate max bending stress
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# σ = M*y/I where M = P*L, y = h_total/2
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M_max = P * L # N·mm
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y_max = h_total / 2.0
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if I_section > 0:
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stress = M_max * y_max / I_section # MPa
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else:
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stress = 9999.0
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return TrialResult(
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success=True,
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mass=mass,
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tip_displacement=displacement,
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max_von_mises=stress,
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)
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def close(self) -> None:
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"""No-op for stub solver."""
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logger.info("Stub solver closed.")
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# ---------------------------------------------------------------------------
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# NXOpen implementation using existing Atomizer engine
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# ---------------------------------------------------------------------------
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class NXOpenSolver:
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"""Real NX solver using existing Atomizer optimization engine.
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Uses these Atomizer components:
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- optimization_engine.nx.solver.NXSolver (journal-based solving with run_journal.exe)
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→ handles iteration folders, expression import via .exp, and NX solve
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- optimization_engine.extractors.extract_displacement.extract_displacement()
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- optimization_engine.extractors.extract_von_mises_stress.extract_solid_stress()
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- optimization_engine.extractors.extract_mass_from_expression.extract_mass_from_expression()
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Pipeline per trial (HEEDS-style iteration folder pattern):
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1. NXSolver.create_iteration_folder() — copies model files + writes params.exp
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2. NXSolver.run_simulation() — runs solve_simulation.py journal via run_journal.exe
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→ The journal imports params.exp, rebuilds geometry, updates FEM, solves, extracts mass
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3. extract_displacement(op2) — max displacement from SOL 101
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4. extract_solid_stress(op2) — max von Mises (auto-detect element type)
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5. extract_mass_from_expression(prt) — reads _temp_mass.txt written by journal
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Files required in model_dir:
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- Beam.prt (part file with expressions)
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- Beam_sim1.sim (simulation file)
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- Expected OP2 output: beam_sim1-solution_1.op2
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Expression names (confirmed from binary introspection):
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- DVs: beam_half_core_thickness, beam_face_thickness, holes_diameter, hole_count
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- Mass output: p173 (body_property147.mass, kg)
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References:
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- M1_Mirror/SAT3_Trajectory_V7/run_optimization.py — FEARunner pattern
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- optimization_engine/nx/solver.py — NXSolver API
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- optimization_engine/nx/solve_simulation.py — Journal internals
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"""
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# SIM filename and solution name for this model
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SIM_FILENAME = "Beam_sim1.sim"
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PRT_FILENAME = "Beam.prt"
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SOLUTION_NAME = "Solution 1"
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# Expected OP2: <sim_stem>-<solution_name_lower_underscored>.op2
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# = beam_sim1-solution_1.op2
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def __init__(
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self,
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model_dir: str | Path,
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nx_install_dir: str | Path | None = None,
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timeout: int = 600,
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nastran_version: str = "2412",
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) -> None:
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"""Initialize NXOpen solver using Atomizer engine.
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Args:
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model_dir: Path to directory containing Beam.prt, Beam_sim1.sim, etc.
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This is the "master model" directory — files are copied per iteration.
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nx_install_dir: Path to NX installation (auto-detected if None).
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timeout: Timeout per trial in seconds (default: 600s = 10 min).
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nastran_version: NX version string (e.g., "2412", "2506", "2512").
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"""
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import time as _time # avoid repeated __import__
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self._time = _time
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self.model_dir = Path(model_dir)
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self.timeout = timeout
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self.nastran_version = nastran_version
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self.nx_install_dir = str(nx_install_dir) if nx_install_dir else None
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if not self.model_dir.exists():
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raise FileNotFoundError(f"Model directory not found: {self.model_dir}")
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# Validate required files
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self.prt_file = self.model_dir / self.PRT_FILENAME
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self.sim_file = self.model_dir / self.SIM_FILENAME
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for f in (self.prt_file, self.sim_file):
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if not f.exists():
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raise FileNotFoundError(f"Required file not found: {f}")
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# Iterations output directory (sibling to model_dir per study convention)
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# Layout: studies/01_doe_landscape/
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# 1_setup/model/ ← model_dir (master)
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# 2_iterations/ ← iteration folders
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# 3_results/ ← final outputs
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self.iterations_dir = self.model_dir.parent.parent / "2_iterations"
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self.iterations_dir.mkdir(parents=True, exist_ok=True)
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# Import Atomizer components at init time (fail-fast on missing engine)
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try:
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from optimization_engine.nx.solver import NXSolver
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from optimization_engine.extractors.extract_displacement import (
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extract_displacement,
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)
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from optimization_engine.extractors.extract_von_mises_stress import (
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extract_solid_stress,
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)
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from optimization_engine.extractors.extract_mass_from_expression import (
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extract_mass_from_expression,
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)
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self._NXSolver = NXSolver
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self._extract_displacement = staticmethod(extract_displacement)
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self._extract_stress = staticmethod(extract_solid_stress)
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self._extract_mass = staticmethod(extract_mass_from_expression)
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except ImportError as e:
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raise ImportError(
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f"Failed to import Atomizer optimization engine: {e}\n"
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f"Ensure {ATOMIZER_REPO_ROOT} is accessible and contains optimization_engine/"
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) from e
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# Lazy-init solver on first evaluate() call
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self._solver: object | None = None
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self._trial_counter: int = 0
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logger.info(
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"NXOpenSolver initialized — model_dir=%s, timeout=%ds, nastran=%s",
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self.model_dir,
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self.timeout,
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self.nastran_version,
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)
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# ------------------------------------------------------------------
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# Public API
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# ------------------------------------------------------------------
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def evaluate(self, trial_input: TrialInput) -> TrialResult:
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"""Full NX evaluation pipeline for one trial.
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Pipeline (mirrors M1_Mirror/SAT3_Trajectory_V7 FEARunner.run_fea):
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1. create_iteration_folder → copies model + writes params.exp
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2. run_simulation → journal updates expressions, rebuilds, solves
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3. extract displacement, stress, mass from results
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Args:
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trial_input: Design variable values.
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Returns:
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TrialResult with extracted outputs or failure info.
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"""
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self._trial_counter += 1
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trial_num = self._trial_counter
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t_start = self._time.time()
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logger.info(
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"Trial %d — DVs: core=%.3f mm, face=%.3f mm, hole_d=%.3f mm, n_holes=%d",
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trial_num,
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trial_input.beam_half_core_thickness,
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trial_input.beam_face_thickness,
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trial_input.holes_diameter,
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trial_input.hole_count,
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)
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try:
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# 0. Lazy-init solver
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if self._solver is None:
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self._init_solver()
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expressions = self._build_expression_dict(trial_input)
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# 1. Create iteration folder with fresh model copies + params.exp
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iter_folder = self._solver.create_iteration_folder(
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iterations_base_dir=self.iterations_dir,
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iteration_number=trial_num,
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expression_updates=expressions,
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)
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logger.info(" Iteration folder: %s", iter_folder)
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working_sim = iter_folder / self.SIM_FILENAME
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working_prt = iter_folder / self.PRT_FILENAME
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if not working_sim.exists():
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return TrialResult(
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success=False,
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error_message=f"SIM file missing in iteration folder: {working_sim}",
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)
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# 2. Solve — journal handles expression import + geometry rebuild + FEM update + solve
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# expression_updates are passed as argv to the journal (key=value pairs)
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logger.info(" Solving: %s", working_sim.name)
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solve_result = self._solver.run_simulation(
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sim_file=working_sim,
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working_dir=iter_folder,
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cleanup=False, # keep OP2/F06 for extraction
|
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expression_updates=expressions,
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solution_name=self.SOLUTION_NAME,
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)
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|
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if not solve_result["success"]:
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errors = solve_result.get("errors", ["Unknown error"])
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rc = solve_result.get("return_code", "?")
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msg = f"NX solve failed (rc={rc}): {'; '.join(errors)}"
|
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logger.error(" %s", msg)
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return TrialResult(success=False, error_message=msg)
|
||
|
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# 3. Locate OP2
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op2_file = solve_result.get("op2_file")
|
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if op2_file is None or not Path(op2_file).exists():
|
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# Fallback: try the expected naming convention
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op2_file = iter_folder / "beam_sim1-solution_1.op2"
|
||
if not op2_file.exists():
|
||
return TrialResult(
|
||
success=False,
|
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error_message=f"OP2 not found. Expected: {op2_file}",
|
||
)
|
||
else:
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op2_file = Path(op2_file)
|
||
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logger.info(" OP2: %s", op2_file.name)
|
||
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# 4a. Extract displacement
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try:
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disp_result = self._extract_displacement(op2_file)
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||
tip_displacement = disp_result["max_displacement"] # mm
|
||
except Exception as e:
|
||
logger.error(" Displacement extraction failed: %s", e)
|
||
return TrialResult(
|
||
success=False,
|
||
error_message=f"Displacement extraction failed: {e}",
|
||
)
|
||
|
||
# 4b. Extract stress — auto-detect element type (solid or shell)
|
||
# Pass element_type=None so it checks CTETRA, CHEXA, CPENTA, CPYRAM
|
||
try:
|
||
stress_result = self._extract_stress(
|
||
op2_file,
|
||
element_type=None, # auto-detect from OP2 contents
|
||
convert_to_mpa=True, # NX kg-mm-s → kPa, convert to MPa
|
||
)
|
||
max_von_mises = stress_result["max_von_mises"] # MPa
|
||
except Exception as e:
|
||
# Fallback: try shell elements if solid extraction failed
|
||
logger.warning(" Solid stress extraction failed, trying shell: %s", e)
|
||
try:
|
||
stress_result = self._extract_stress(
|
||
op2_file,
|
||
element_type="cquad4",
|
||
convert_to_mpa=True,
|
||
)
|
||
max_von_mises = stress_result["max_von_mises"]
|
||
except Exception as e2:
|
||
logger.error(" Stress extraction failed (all types): %s", e2)
|
||
return TrialResult(
|
||
success=False,
|
||
error_message=f"Stress extraction failed: {e}; shell fallback: {e2}",
|
||
)
|
||
|
||
# 4c. Extract mass — reads _temp_mass.txt written by solve_simulation.py journal
|
||
try:
|
||
mass = self._extract_mass(working_prt, expression_name=EXPR_MASS) # kg
|
||
except FileNotFoundError:
|
||
# _temp_mass.txt not found — journal may not have written it for single-part models
|
||
# Fallback: try reading from _temp_part_properties.json
|
||
logger.warning(" _temp_mass.txt not found, trying _temp_part_properties.json")
|
||
mass = self._extract_mass_fallback(iter_folder)
|
||
if mass is None:
|
||
return TrialResult(
|
||
success=False,
|
||
error_message="Mass extraction failed: _temp_mass.txt not found",
|
||
)
|
||
except Exception as e:
|
||
logger.error(" Mass extraction failed: %s", e)
|
||
return TrialResult(
|
||
success=False,
|
||
error_message=f"Mass extraction failed: {e}",
|
||
)
|
||
|
||
elapsed = self._time.time() - t_start
|
||
logger.info(
|
||
" Trial %d OK (%.1fs) — mass=%.4f kg, disp=%.4f mm, σ_vm=%.2f MPa",
|
||
trial_num,
|
||
elapsed,
|
||
mass,
|
||
tip_displacement,
|
||
max_von_mises,
|
||
)
|
||
|
||
return TrialResult(
|
||
success=True,
|
||
mass=mass,
|
||
tip_displacement=tip_displacement,
|
||
max_von_mises=max_von_mises,
|
||
)
|
||
|
||
except Exception as e:
|
||
elapsed = self._time.time() - t_start
|
||
logger.error(" Trial %d FAILED (%.1fs): %s", trial_num, elapsed, e)
|
||
return TrialResult(
|
||
success=False,
|
||
error_message=f"Unexpected error in trial {trial_num}: {e}",
|
||
)
|
||
|
||
def close(self) -> None:
|
||
"""Clean up NX session resources.
|
||
|
||
⚠️ LAC CRITICAL: NEVER kill NX processes directly.
|
||
Uses NXSessionManager for safe lock cleanup only.
|
||
"""
|
||
if self._solver is not None:
|
||
sm = getattr(self._solver, "session_manager", None)
|
||
if sm is not None:
|
||
logger.info("Cleaning up NX session locks via session manager")
|
||
try:
|
||
sm.cleanup_stale_locks()
|
||
except Exception as e:
|
||
logger.warning("Session lock cleanup warning: %s", e)
|
||
|
||
self._solver = None
|
||
logger.info("NXOpenSolver closed.")
|
||
|
||
# ------------------------------------------------------------------
|
||
# Private helpers
|
||
# ------------------------------------------------------------------
|
||
|
||
def _init_solver(self) -> None:
|
||
"""Lazy-initialize NXSolver (matches SAT3_V7 FEARunner.setup pattern)."""
|
||
logger.info("Initializing NXSolver (nastran=%s, timeout=%ds)", self.nastran_version, self.timeout)
|
||
|
||
kwargs: dict = {
|
||
"nastran_version": self.nastran_version,
|
||
"timeout": self.timeout,
|
||
"use_journal": True,
|
||
"enable_session_management": True,
|
||
"study_name": "hydrotech_beam_doe",
|
||
"use_iteration_folders": True,
|
||
"master_model_dir": str(self.model_dir),
|
||
}
|
||
if self.nx_install_dir:
|
||
kwargs["nx_install_dir"] = self.nx_install_dir
|
||
|
||
self._solver = self._NXSolver(**kwargs)
|
||
logger.info("NXSolver ready")
|
||
|
||
def _build_expression_dict(self, trial_input: TrialInput) -> dict[str, float]:
|
||
"""Build NX expression name→value dict for the solver.
|
||
|
||
These are passed to:
|
||
- create_iteration_folder() → writes params.exp (unit defaulting to mm)
|
||
- run_simulation(expression_updates=...) → passed as argv to solve journal
|
||
"""
|
||
return {
|
||
EXPR_HALF_CORE_THICKNESS: trial_input.beam_half_core_thickness,
|
||
EXPR_FACE_THICKNESS: trial_input.beam_face_thickness,
|
||
EXPR_HOLES_DIAMETER: trial_input.holes_diameter,
|
||
EXPR_HOLE_COUNT: float(trial_input.hole_count), # NX expressions are float
|
||
}
|
||
|
||
@staticmethod
|
||
def _extract_mass_fallback(iter_folder: Path) -> float | None:
|
||
"""Try to read mass from _temp_part_properties.json (backup path)."""
|
||
import json as _json
|
||
|
||
props_file = iter_folder / "_temp_part_properties.json"
|
||
if not props_file.exists():
|
||
return None
|
||
try:
|
||
with open(props_file) as f:
|
||
props = _json.load(f)
|
||
mass = props.get("mass_kg", 0.0)
|
||
if mass > 0:
|
||
logger.info(" Mass from _temp_part_properties.json: %.6f kg", mass)
|
||
return mass
|
||
return None
|
||
except Exception as e:
|
||
logger.warning(" Failed to read %s: %s", props_file, e)
|
||
return None
|
||
|
||
|
||
# ---------------------------------------------------------------------------
|
||
# Factory
|
||
# ---------------------------------------------------------------------------
|
||
def create_solver(
|
||
backend: str = "stub",
|
||
model_dir: str = "",
|
||
nx_install_dir: str | None = None,
|
||
timeout: int = 600,
|
||
nastran_version: str = "2412",
|
||
) -> NXStubSolver | NXOpenSolver:
|
||
"""Create an NX solver instance.
|
||
|
||
Args:
|
||
backend: "stub" for development, "nxopen" for real NX (Windows/dalidou only).
|
||
model_dir: Path to NX model directory (required for nxopen backend).
|
||
nx_install_dir: Path to NX installation (auto-detected if None).
|
||
timeout: Timeout per trial in seconds (default: 600s = 10 min).
|
||
nastran_version: NX version (e.g., "2412", "2506", "2512").
|
||
|
||
Returns:
|
||
Solver instance implementing the NXSolverInterface protocol.
|
||
|
||
Raises:
|
||
ValueError: If backend is unknown or model_dir missing for nxopen.
|
||
"""
|
||
if backend == "stub":
|
||
return NXStubSolver()
|
||
elif backend == "nxopen":
|
||
if not model_dir:
|
||
raise ValueError("model_dir required for nxopen backend")
|
||
return NXOpenSolver(
|
||
model_dir=model_dir,
|
||
nx_install_dir=nx_install_dir,
|
||
timeout=timeout,
|
||
nastran_version=nastran_version,
|
||
)
|
||
else:
|
||
raise ValueError(f"Unknown backend: {backend!r}. Use 'stub' or 'nxopen'.") |