| """Compare steady heat flow through two STEP-meshed standoffs.""" |
|
|
| import argparse |
| import hashlib |
| import json |
| import math |
| import subprocess |
| import sys |
| from pathlib import Path |
|
|
| ROOT = Path(__file__).resolve().parent |
|
|
|
|
| def measure(step: Path, setup: dict) -> dict: |
| import cadquery as cq |
| import gmsh |
| from OCP.BRepGProp import BRepGProp |
| from OCP.GProp import GProp_GProps |
|
|
| shape = cq.importers.importStep(str(step)).val() |
| if shape.ShapeType() != "Solid" or not shape.isValid() or len(shape.Solids()) != 1: |
| raise ValueError(f"Expected one valid solid: {step}") |
| props = GProp_GProps() |
| BRepGProp.VolumeProperties_s(shape.wrapped, props) |
| if props.Mass() <= 0: |
| raise ValueError("Standoff volume must be positive") |
| pad0 = cq.Solid.makeBox(10, 20, 10, cq.Vector(0, -10, -5)) |
| pad1 = cq.Solid.makeBox(10, 20, 10, cq.Vector(90, -10, -5)) |
| slabs = [cq.Solid.makeBox(10, 30, 10, cq.Vector(x, -15, -5)) |
| for x in (0, 90)] |
| envelope = cq.Solid.makeBox(100, 30, 10, cq.Vector(0, -15, -5)) |
| pads = (pad0, pad1) |
| pad_overlap = sum(pad.intersect(shape).Volume() for pad in pads) |
| slab_overlap = sum(slab.intersect(shape).Volume() for slab in slabs) |
| result = { |
| "step_sha256": hashlib.sha256(step.read_bytes()).hexdigest(), |
| "volume_mm3": props.Mass(), |
| "mass_kg": props.Mass() * setup["material_density_kg_m3"] * 1e-9, |
| "end_pad_missing_mm3": max(0.0, sum(p.Volume() for p in pads) - pad_overlap), |
| "end_pad_excess_mm3": max(0.0, slab_overlap - pad_overlap), |
| "envelope_excess_mm3": max(0.0, shape.Volume() - |
| shape.intersect(envelope).Volume()), |
| "meshes": {}, |
| } |
| gmsh.initialize() |
| try: |
| gmsh.option.setNumber("General.Terminal", 0) |
| gmsh.model.add("thermal_standoff") |
| gmsh.model.occ.importShapes(str(step)) |
| gmsh.model.occ.synchronize() |
| if len(gmsh.model.getEntities(3)) != 1: |
| raise ValueError("STEP import must produce one volume") |
| for size in setup["mesh_sizes_mm"]: |
| gmsh.model.mesh.clear() |
| gmsh.option.setNumber("Mesh.CharacteristicLengthMin", size) |
| gmsh.option.setNumber("Mesh.CharacteristicLengthMax", size) |
| gmsh.option.setNumber("Mesh.Algorithm3D", 1) |
| gmsh.model.mesh.generate(3) |
| tags, coordinates, _ = gmsh.model.mesh.getNodes() |
| nodes = {str(int(tag)): [coordinates[3 * i + axis] / 1000 |
| for axis in range(3)] |
| for i, tag in enumerate(tags)} |
| types, _, element_nodes = gmsh.model.mesh.getElements(3) |
| tets = [] |
| for kind, connectivity in zip(types, element_nodes): |
| if kind != 4: |
| raise ValueError(f"Expected first-order tetrahedra, got {kind}") |
| tets.extend([[int(value) for value in connectivity[i:i + 4]] |
| for i in range(0, len(connectivity), 4)]) |
| if not nodes or not tets: |
| raise ValueError("Gmsh produced an empty mesh") |
| result["meshes"][str(size)] = {"nodes": nodes, "tets": tets} |
| finally: |
| gmsh.finalize() |
| return result |
|
|
|
|
| def dynamics(meshes: dict, setup: dict) -> dict: |
| import pychrono as ch |
| import pychrono.fea as fea |
| import numpy as np |
|
|
| results = {} |
| for size, data in meshes.items(): |
| system = ch.ChSystemSMC() |
| system.SetGravitationalAcceleration(ch.ChVector3d(0, 0, 0)) |
| system.SetSolver(ch.ChSolverSparseLU()) |
| mesh = fea.ChMesh() |
| material = fea.ChContinuumThermal() |
| material.SetThermalConductivity( |
| setup["thermal_conductivity_W_m_K"]) |
| material.SetSpecificHeatCapacity(setup["specific_heat_J_kg_K"]) |
| material.SetDensity(setup["material_density_kg_m3"]) |
| hot_ids = [key for key, point in data["nodes"].items() |
| if abs(point[0]) < 1e-8] |
| cold_ids = [key for key, point in data["nodes"].items() |
| if abs(point[0] - 0.1) < 1e-8] |
| if len(hot_ids) < 4 or len(cold_ids) < 4: |
| raise ValueError("Mesh is missing a thermal boundary face") |
| nodes = {} |
| for key, point in data["nodes"].items(): |
| node = fea.ChNodeFEAxyzP(ch.ChVector3d(*point)) |
| node.SetFieldVal(setup["cold_face_temperature_K"]) |
| if key in hot_ids: |
| node.SetFieldVal(setup["hot_face_temperature_K"]) |
| node.SetFixed(True) |
| if key in cold_ids: |
| node.SetFieldVal(setup["cold_face_temperature_K"]) |
| node.SetFixed(True) |
| mesh.AddNode(node) |
| nodes[int(key)] = node |
| for a, b, c, d in data["tets"]: |
| element = fea.ChElementTetraCorot_4_P() |
| element.SetNodes(nodes[a], nodes[b], nodes[c], nodes[d]) |
| element.SetMaterial(material) |
| mesh.AddElement(element) |
| system.Add(mesh) |
| system.DoStaticLinear() |
| energy_rate_over_temperature = 0.0 |
| for tetrahedron in data["tets"]: |
| positions = np.array([data["nodes"][str(key)] |
| for key in tetrahedron]) |
| temperatures = np.array([nodes[key].GetFieldVal() |
| for key in tetrahedron]) |
| edges = positions[1:] - positions[0] |
| gradient = np.linalg.solve(edges, |
| temperatures[1:] - temperatures[0]) |
| volume = abs(np.linalg.det(edges)) / 6 |
| energy_rate_over_temperature += ( |
| setup["thermal_conductivity_W_m_K"] * |
| float(np.dot(gradient, gradient)) * volume) |
| delta_t = (setup["hot_face_temperature_K"] - |
| setup["cold_face_temperature_K"]) |
| heat_flow = energy_rate_over_temperature / delta_t |
| temperatures = [node.GetFieldVal() for node in nodes.values()] |
| if not math.isfinite(heat_flow) or heat_flow <= 0: |
| raise ValueError("Invalid steady heat flow") |
| results[size] = { |
| "steady_heat_flow_W": heat_flow, |
| "minimum_temperature_K": min(temperatures), |
| "maximum_temperature_K": max(temperatures), |
| "node_count": len(nodes), |
| "tetrahedron_count": len(data["tets"]), |
| "hot_node_count": len(hot_ids), |
| "cold_node_count": len(cold_ids), |
| } |
| return results |
|
|
|
|
| def invoke(python: str, phase: str, payload: dict) -> dict: |
| run = subprocess.run([python, str(Path(__file__).resolve()), "--phase", phase], |
| input=json.dumps(payload), text=True, capture_output=True) |
| if run.returncode: |
| raise RuntimeError(f"{phase} failed:\n{run.stderr[-1600:]}") |
| return json.loads(run.stdout) |
|
|
|
|
| def main() -> None: |
| parser = argparse.ArgumentParser() |
| parser.add_argument("--cad-python", default=sys.executable) |
| parser.add_argument("--physics-python", default=sys.executable) |
| parser.add_argument("--phase", choices=("measure", "dynamics")) |
| args = parser.parse_args() |
| if args.phase: |
| payload = json.load(sys.stdin) |
| result = (measure(Path(payload["step"]), payload["setup"]) |
| if args.phase == "measure" |
| else dynamics(payload["meshes"], payload["setup"])) |
| print(json.dumps(result)) |
| return |
| setup = json.loads((ROOT / "setup.json").read_text()) |
| results = {} |
| for name in ("before", "after"): |
| properties = invoke(args.cad_python, "measure", { |
| "step": str(ROOT / f"{name}.step"), "setup": setup, |
| }) |
| meshes = properties.pop("meshes") |
| results[name] = { |
| "step_properties": properties, |
| "simulation_result": invoke(args.physics_python, "dynamics", { |
| "meshes": meshes, "setup": setup, |
| }), |
| } |
| before = results["before"] |
| after = results["after"] |
| bp, ap = before["step_properties"], after["step_properties"] |
| bs, gs = before["simulation_result"], after["simulation_result"] |
| sizes = [str(size) for size in setup["mesh_sizes_mm"]] |
| baseline = [bs[size]["steady_heat_flow_W"] for size in sizes] |
| candidate = [gs[size]["steady_heat_flow_W"] for size in sizes] |
| reductions = [1 - a / b for a, b in zip(candidate, baseline)] |
| checks = { |
| "baseline_conducts_heat": min(baseline) >= |
| setup["minimum_baseline_heat_flow_W"], |
| "heat_flow_reduced_both_meshes": min(reductions) >= |
| setup["required_relative_heat_flow_reduction"], |
| "mesh_response_stable": all( |
| abs(values[1] / values[0] - 1) <= |
| setup["maximum_relative_mesh_heat_flow_change"] |
| for values in (baseline, candidate)), |
| "temperature_bounds": all( |
| gs[size]["minimum_temperature_K"] >= |
| setup["cold_face_temperature_K"] - 1e-6 and |
| gs[size]["maximum_temperature_K"] <= |
| setup["hot_face_temperature_K"] + 1e-6 |
| for size in sizes), |
| "mass_fixed": abs(ap["mass_kg"] / bp["mass_kg"] - 1) <= |
| setup["maximum_relative_mass_change"], |
| "end_pads_fixed": ap["end_pad_missing_mm3"] <= |
| setup["maximum_end_pad_missing_mm3"] and |
| ap["end_pad_excess_mm3"] <= setup["maximum_end_pad_excess_mm3"], |
| "envelope_fixed": ap["envelope_excess_mm3"] <= |
| setup["maximum_envelope_excess_mm3"], |
| } |
| after["comparison_to_before"] = { |
| "relative_heat_flow_reductions": reductions, |
| "checks": checks, "passed": all(checks.values()), |
| } |
| for name, result in results.items(): |
| (ROOT / f"{name}.results.json").write_text(json.dumps(result, indent=2) + "\n") |
| print(f"Steady heat flow: {baseline} -> {candidate} W") |
| print(f"Task passed: {all(checks.values())}") |
| if not all(checks.values()): |
| raise SystemExit(1) |
|
|
|
|
| if __name__ == "__main__": |
| main() |
|
|
