SAT3_Trajectory_V7 - Final Converged Optimization (TPE Warm-Start)
See ../README.md for M1 Mirror project overview
Overview
Final study in the SAT3 Trajectory series. Return to proven TPE after SAT V6 underperformed (~30% FEA success rate due to geometry infeasibility). Warm-started with all 194 V5 trials for immediate TPE model knowledge. Ran 86 additional trials with 100% FEA success rate, confirming the design space is fully converged.
Result: The optimum found in V5 (trial #181, WS=277.55) was confirmed as the global minimum. V7's best independent trial (#222, WS=277.60) matched it to within 0.08%.
Changes from V6
- Algorithm: SAT v3 (surrogate) → TPE (Optuna) — back to proven method
- Warm-start: Pre-loaded 194 V5 trials into Optuna DB, n_startup=0 (fully informed TPE)
- Bounds: Same as V6 (lateral_inner_pivot expanded to [5, 19])
- Seed: 77 (different from V5's 42) for fresh exploration
- NX fixes: sys.exit(0) bug fix in solve_simulation.py, early-exit crash detection in solver.py, NX process cleanup with force-kill
Results Summary
| Metric |
Value |
| Best WS |
277.37 (trial #0, baseline re-eval) |
| Best V7 independent |
277.60 (trial #222) |
| V7 completed trials |
86 |
| V7 FEA failures |
0 (100% success rate) |
| Total trials (V5+V7) |
275 completed |
| Winning mass |
97.2 kg (22.8 kg under 120 kg limit) |
| Convergence |
Top 10 within 0.85 WS of each other |
Winning Design Parameters
Winning Design Optical Performance
| Metric |
Value (nm) |
Weight |
| WFE 40/20 |
6.97 |
5.0 |
| WFE 60/20 |
13.01 |
5.0 |
| MFG 90 |
28.59 |
4.0 |
| Total filtered RMS |
3.24 |
4.0 |
| Coma RMS |
8.81 |
3.0 |
| Astigmatism RMS |
2.53 |
3.0 |
| Trefoil RMS |
3.41 |
2.0 |
| Spherical RMS |
4.64 |
2.0 |
| Weighted Sum |
277.37 |
|
Constraints: Mass = 97.2 kg (PASS), R^2 = 1.0000 (PASS), Pivot = angle/2 (ENFORCED)
Method
- Algorithm: TPE (Optuna, warm-started from V5)
- Extraction: HYBRID (Trajectory + Discrete Angle OPD with annular aperture)
- Annular inner radius: 135.75 mm (271.5 mm central hole)
- Solver: NX Nastran 2512
Objectives (8 weighted, same as V3-V6)
| Metric |
Weight |
Type |
| wfe_40_20 |
5.0 |
Discrete angle OPD |
| wfe_60_20 |
5.0 |
Discrete angle OPD |
| mfg_90 |
4.0 |
Discrete angle OPD |
| total_filtered_rms_nm |
4.0 |
Trajectory |
| coma_rms_nm |
3.0 |
Trajectory |
| astigmatism_rms_nm |
3.0 |
Trajectory |
| trefoil_rms_nm |
2.0 |
Trajectory |
| spherical_rms_nm |
2.0 |
Trajectory |
Design Variables (8 active + 1 derived)
| Variable |
Min |
Max |
Optimal |
Units |
Notes |
| lateral_inner_angle |
20.0 |
35.0 |
29.788 |
deg |
Interior optimum |
| lateral_outer_angle |
9.0 |
17.0 |
15.336 |
deg |
Drives pivot |
| lateral_inner_pivot |
5.0 |
19.0 |
15.513 |
mm |
Expanded in V6 |
| lateral_middle_pivot |
12.0 |
25.0 |
16.681 |
mm |
Interior optimum |
| lateral_closeness |
5.0 |
15.0 |
8.403 |
mm |
Most sensitive param |
| whiffle_min |
25.0 |
80.0 |
61.929 |
mm |
Interior optimum |
| triangle_width |
155.0 |
185.0 |
171.390 |
mm |
Interior optimum |
| offset_plane |
-10.0 |
15.0 |
3.048 |
mm |
Must be small positive |
| lateral_outer_pivot |
— |
— |
7.668 |
mm |
DERIVED = angle/2 |
Reports & Deliverables
| File |
Location |
| Optimization report |
3_results/OPTIMIZATION_REPORT.md |
| Optimization log |
3_results/optimization.log |
| Study database |
3_results/study.db |
| Full optical report (HTML) |
2_iterations/iter0/*_OPTICAL_REPORT_*.html |
| Zernike 40/20 annular (HTML) |
2_iterations/iter0/*_40_vs_20_ANNULAR.html |
| Zernike 60/20 annular (HTML) |
2_iterations/iter0/*_60_vs_20_ANNULAR.html |
| Zernike 90 mfg annular (HTML) |
2_iterations/iter0/*_90_mfg_ANNULAR.html |
| Winning params.exp |
2_iterations/iter0/params.exp |
| OP2 results |
2_iterations/iter0/*-solution_1.op2 |
| Updated NX model |
2_iterations/iter0/M1_Blank.prt |
Study History
| Version |
Algorithm |
Trials |
Best WS |
FEA Success |
Outcome |
| V1 |
TPE |
69 |
~350 |
~90% |
Initial exploration |
| V2 |
TPE |
101 |
~310 |
~90% |
Refined bounds |
| V3 |
TPE |
160 |
~290 |
~95% |
Trajectory method added |
| V4 |
TPE |
140 |
279.97 |
~95% |
Derived pivot constraint |
| V5 |
TPE |
189 |
277.55 |
~100% |
HYBRID extraction |
| V6 |
SAT v3 |
27 |
307.91 |
~30% |
Surrogate failed |
| V7 |
TPE (warm) |
86 |
277.37 |
100% |
CONVERGED |
Total FEA evaluations: 772
Usage
Anto01
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