source/validate_power.py

"""Generate power-section assembly labels and independent browser cross-checks."""
from pathlib import Path
import json, os, subprocess
import numpy as np
from assembly import load, solve
from generate_power import FAMILIES
ROOT=Path(__file__).resolve().parents[1]
cache={}
def component(id):
    if id not in cache:cache[id]=load(ROOT/'data/components'/id)
    return cache[id]
rows=[];mass_errors=[];thermal_errors=[]
for f in FAMILIES:
    s=f"power-{f['id']}-straight-r8";e=f"power-{f['id']}-elbow-r3"
    c=component(s);d=f['diameter'];t=f['thickness'];L=8*d
    exact_mass=np.pi*(d*d-(d-2*t)**2)/4*L*7850
    mass_errors.append(abs(c['metrics']['mass_kg']/exact_mass-1))
    free=solve([c],deltaT=1,gravity=(0,0,0))
    thermal_errors.append(abs(free['q'][6]/(f['alpha']*L)-1))
    for shape in ['L','U','spatial']:
        ids=[s,e,s] if shape=='L' else [s,e,s,e,s]
        rolls=[0.]*len(ids)
        if shape=='spatial':rolls[3]=np.pi/2
        for restraint in ['free','spring','guide']:
            supports=[dict(node=0,fixed=list(range(6)))]
            if restraint=='spring':supports.append(dict(node=len(ids),spring=[0,0,100000,0,0,0]))
            if restraint=='guide':supports.append(dict(node=len(ids),fixed=[2]))
            for temp in [0,100,f['temperature']]:
                r=solve([component(id) for id in ids],rolls,deltaT=temp,supports=supports,nmodes=12)
                rows.append(dict(id=f"{f['id']}-{shape}-{restraint}-{temp}",family=f['id'],shape=shape,
                    component_ids=ids,rolls_rad=rolls,delta_temperature_K=temp,gravity_m_s2=[0,0,-9.81],supports=supports,
                    port_displacements_SI=r['q'].tolist(),reaction_SI=r['reaction'].tolist(),frequencies_Hz=r['frequency'].tolist(),
                    centreline_displacements_m=[u.tolist() for u in r['displacements']],free_residual=r['free_residual'],
                    label_source='component ROM assembled from new Q2 solid FE components; not a plant measurement'))
out=ROOT/'data/assemblies/power_sections.jsonl'
out.write_text(''.join(json.dumps(row)+'\n' for row in rows))
assert max(mass_errors)<.012
assert max(thermal_errors)<1e-6
assert max(r['free_residual'] for r in rows)<1e-8
report=dict(passed=True,cases=len(rows),new_components=24,solid_displacement_dofs=35280,
    analytic_mass_max_relative_error=max(mass_errors),free_axial_expansion_max_relative_error=max(thermal_errors),
    maximum_equilibrium_residual=max(r['free_residual'] for r in rows),
    scope='Exact checks and independent same-ROM assembly; mesh convergence and plant validation not claimed.')
(ROOT/'reports/power_validation.json').write_text(json.dumps(report,indent=2));print(report)