from __future__ import annotations import unittest from pathlib import Path from app.simulation.reporting.amesim_results import load_test_mql_amesim_results from app.simulation.examples.test_mql.solver import SolveIVPConfig from app.simulation.reporting.test_mql_variables import build_test_mql_variable_catalog from app.simulation.examples.test_mql.system import TestMqlSystem from app.simulation.examples.test_mql.mechanical import ( TestMqlMechanicalMassClosure, build_test_mql_mechanical_assembly, circular_area, mm_to_m, n_per_mm_per_s_to_n_per_m_per_s, n_per_mm_to_n_per_m, ) REPO_ROOT = Path(__file__).resolve().parents[1] TEST_MQL_AME = REPO_ROOT / "AmesimModels" / "test_mql.ame" class TestMqlMechanicalAssemblyTests(unittest.TestCase): @classmethod def setUpClass(cls) -> None: cls.amesim_results = load_test_mql_amesim_results(TEST_MQL_AME) cls.variable_catalog = build_test_mql_variable_catalog(cls.amesim_results) cls.assembly = build_test_mql_mechanical_assembly( amesim_results=cls.amesim_results, variable_catalog=cls.variable_catalog, ) def test_assembles_expected_mechanical_component_counts(self) -> None: self.assertEqual(len(self.assembly.pistons), 8) self.assertEqual(len(self.assembly.masses), 10) self.assertEqual(len(self.assembly.elastic_endstops), 8) self.assertEqual(len(self.assembly.mechanical_nodes), 2) self.assertEqual(len(self.assembly.piecewise_signals), 2) self.assertEqual(len(self.assembly.force_connectors), 2) self.assertEqual(len(self.assembly.zero_force_sources), 16) self.assertEqual(self.assembly.component_count, 48) def test_piecewise_force_sources_match_amesim_samples(self) -> None: front_signal = self.assembly.piecewise_signals["piecewiselinear_1"] rear_signal = self.assembly.piecewise_signals["piecewiselinear"] self.assertAlmostEqual(front_signal.output_at(0.0), 1.0e12) self.assertAlmostEqual(front_signal.output_at(0.8000000000000009), 0.0) self.assertAlmostEqual(rear_signal.output_at(0.0), 1.0e17) self.assertAlmostEqual(rear_signal.output_at(0.8000000000000009), 49000.0) self.assertEqual( self.assembly.force_connectors["forcecon_2"].target_mass_alias, "mass_friction_endstops_18", ) self.assertEqual( self.assembly.force_connectors["forcecon_1"].target_mass_alias, "mass_friction_endstops_19", ) self.assertAlmostEqual( self.assembly.force_connectors["forcecon_2"].force_at( 0.0, self.assembly.piecewise_signals, ), self.amesim_results.series("force@forcecon_2")[0], ) self.assertAlmostEqual( self.assembly.force_connectors["forcecon_1"].force_at( 0.8000000000000009, self.assembly.piecewise_signals, ), self.amesim_results.series("force@forcecon_1")[80], ) def test_mechanical_mass_closure_exposes_all_mecmas21_states(self) -> None: closure = TestMqlMechanicalMassClosure(self.assembly) state = closure.initial_state_vector() snapshot = closure.snapshot(state) rhs = closure.rhs(state) self.assertEqual(closure.mass_aliases, tuple(self.assembly.masses)) self.assertEqual(len(closure.mass_aliases), 10) self.assertEqual(len(state), 20) self.assertEqual(snapshot.state_count, 20) self.assertEqual(len(rhs), 20) self.assertEqual(snapshot.states[0].alias, "mass_friction_endstops_10") self.assertAlmostEqual( snapshot.states[0].velocity_m_s, self.amesim_results.series("v1@mass_friction_endstops_10")[0], ) self.assertAlmostEqual( snapshot.states[0].displacement_m, self.amesim_results.series("x1@mass_friction_endstops_10")[0], ) for index, mass_state in enumerate(snapshot.states): self.assertAlmostEqual(rhs[2 * index + 1], mass_state.velocity_m_s) def test_mechanical_mass_snapshot_exposes_lmechan1_node_kinematics(self) -> None: closure = TestMqlMechanicalMassClosure(self.assembly) state = closure.initial_state_vector() state[16] = 0.2 state[17] = 0.37 state[18] = -0.3 state[19] = -0.72 snapshot = closure.snapshot(state) front = snapshot.node_kinematics_by_alias[ "dynamic_mechanical_node_alternative_2" ] rear = snapshot.node_kinematics_by_alias[ "dynamic_mechanical_node_alternative_3" ] self.assertEqual(set(front.velocities_m_s), set(range(1, 9))) self.assertEqual(set(front.displacements_m), set(range(1, 9))) self.assertEqual(set(rear.velocities_m_s), set(range(1, 9))) self.assertEqual(set(rear.displacements_m), set(range(1, 9))) self.assertAlmostEqual(front.velocities_m_s[1], -0.2) self.assertAlmostEqual(front.displacements_m[8], -0.37) self.assertAlmostEqual(rear.velocities_m_s[1], -0.3) self.assertAlmostEqual(rear.displacements_m[8], -0.72) def test_mechanical_mass_snapshot_exposes_piston_kinematics(self) -> None: closure = TestMqlMechanicalMassClosure(self.assembly) state = closure.initial_state_vector() state[0] = 0.4 state[1] = 0.37 state[18] = -0.3 state[19] = -0.72 snapshot = closure.snapshot(state) piston = snapshot.piston_kinematics_by_alias["pn_brp2_8"] self.assertEqual(set(snapshot.piston_kinematics_by_alias), set(self.assembly.pistons)) self.assertAlmostEqual(piston.port_2_velocity_m_s, 0.4) self.assertAlmostEqual(piston.port_2_displacement_m, 0.37) self.assertAlmostEqual(piston.port_3_velocity_m_s, -0.3) self.assertAlmostEqual(piston.port_3_displacement_m, -0.72) self.assertAlmostEqual( self.assembly.pistons["pn_brp2_8"].geometry().chamber_length_mm( piston.port_3_displacement_m, piston.port_2_displacement_m, ), 1090.0, ) def test_system_simulates_mechanical_mass_state_closure(self) -> None: system = TestMqlSystem() solution = system.simulate_mechanical_masses( config=SolveIVPConfig(t_start=0.0, t_stop=1.0e-5, max_step=1.0e-6), t_eval=[0.0, 1.0e-5], ) self.assertTrue(solution.success) self.assertEqual(len(system.mechanical_state_vector()), 20) self.assertEqual(len(solution.t), 2) self.assertEqual(len(solution.y), 20) self.assertEqual([len(row) for row in solution.y], [2] * 20) def test_piston_geometry_is_converted_to_si_units(self) -> None: piston = self.assembly.pistons["pn_brp2_8"] self.assertAlmostEqual(piston.piston_diameter_m, 0.2) self.assertAlmostEqual(piston.rod_diameter_m, 0.001) self.assertAlmostEqual(piston.zero_displacement_m, 0.0) self.assertAlmostEqual(piston.piston_area_m2, circular_area(0.2)) self.assertAlmostEqual(piston.rod_area_m2, circular_area(0.001)) self.assertAlmostEqual(piston.annulus_area_m2, piston.piston_area_m2 - piston.rod_area_m2) self.assertIn("vvol1@pn_brp2_8", piston.data_paths) self.assertIn("f2@pn_brp2_8", piston.data_paths) def test_mass_endstop_parameters_are_converted_to_si_units(self) -> None: mass = self.assembly.masses["mass_friction_endstops_10"] self.assertEqual(mass.mass_kg, 50.0) self.assertEqual(mass.xmin_m, -1.0) self.assertEqual(mass.xmax_m, 0.8) self.assertEqual(mass.min_stiffness_n_per_m, 1.0e9) self.assertEqual(mass.max_stiffness_n_per_m, 1.0e9) self.assertEqual(mass.min_damping_n_per_m_per_s, 1.0e4) self.assertEqual(mass.max_damping_n_per_m_per_s, 1.0e4) self.assertAlmostEqual(mass.min_penetration_m, 1.0e-4) self.assertAlmostEqual(mass.max_penetration_m, 1.0e-4) self.assertEqual(mass.stiction_force_n, 0.0) self.assertEqual(mass.coulomb_friction_n, 0.0) self.assertEqual(mass.viscous_friction_n_per_m_per_s, 0.0) self.assertEqual(mass.windage_n_per_m2_per_s2, 0.0) self.assertEqual(mass.stick_velocity_threshold_m_s, 1.0e-6) self.assertEqual(mass.reset_velocity_threshold_m_s, 1.0e-6) self.assertEqual(mass.rest_coeff, 0.65) self.assertEqual(mass.stribeck_constant_m_s, 1.0e-3) self.assertTrue(mass.use_friction) self.assertEqual(mass.stop_type, 4) self.assertIn("v1@mass_friction_endstops_10", mass.data_paths) self.assertIn("x1@mass_friction_endstops_10", mass.data_paths) def test_large_load_masses_keep_distinct_limits(self) -> None: front = self.assembly.masses["mass_friction_endstops_18"] rear = self.assembly.masses["mass_friction_endstops_19"] self.assertEqual(front.mass_kg, 170000.0) self.assertEqual(front.xmin_m, 0.0) self.assertEqual(front.xmax_m, 0.37) self.assertEqual(rear.mass_kg, 90000.0) self.assertEqual(rear.xmin_m, -0.72) self.assertEqual(rear.xmax_m, 0.0) def test_elastic_endstop_parameters_are_converted_to_si_units(self) -> None: endstop = self.assembly.elastic_endstops["elasticendstop_8"] self.assertEqual(endstop.gap_m, 0.0) self.assertEqual(endstop.contact_stiffness_n_per_m, 1.0e11) self.assertEqual(endstop.contact_damping_n_per_m_per_s, 1.0e11) self.assertAlmostEqual(endstop.spring_diameter_m, 0.02) self.assertAlmostEqual(endstop.wire_diameter_m, 0.002) def test_mechanical_nodes_keep_port_count(self) -> None: node = self.assembly.mechanical_nodes["dynamic_mechanical_node_alternative_2"] self.assertEqual(node.port_count, 8) self.assertEqual(node.sum_mode, 1) self.assertIn("dynamic_mechanical_node_alternative_2", self.assembly.aliases) def test_all_piston_geometry_observables_match_amesim_final_sample(self) -> None: for alias, piston in self.assembly.pistons.items(): with self.subTest(alias=alias): geometry = piston.geometry() x4 = self.amesim_results.series(f"x4@{alias}")[-1] x5 = self.amesim_results.series(f"x5@{alias}")[-1] v4 = self.amesim_results.series(f"v4@{alias}")[-1] v5 = self.amesim_results.series(f"v5@{alias}")[-1] self.assertAlmostEqual( geometry.chamber_length_mm(x4, x5), self.amesim_results.series(f"length@{alias}")[-1], ) self.assertAlmostEqual( geometry.chamber_volume_cm3(x4, x5), self.amesim_results.series(f"vol1@{alias}")[-1], delta=1.0e-6, ) self.assertAlmostEqual( geometry.chamber_volume_rate_l_min(v4, v5), self.amesim_results.series(f"vvol1@{alias}")[-1], delta=1.0e-8, ) def test_all_elastic_endstop_forces_match_amesim_final_sample(self) -> None: for endstop_alias, endstop_spec in self.assembly.elastic_endstops.items(): piston_alias = endstop_alias.replace("elasticendstop", "pn_brp2") with self.subTest(alias=endstop_alias): endstop = endstop_spec.endstop() gap_mm = self.amesim_results.series(f"gap@{endstop_alias}")[-1] penetration_velocity_m_s = self.amesim_results.series(f"v5@{piston_alias}")[-1] self.assertAlmostEqual( endstop.contact_force(gap_mm, penetration_velocity_m_s), self.amesim_results.series(f"f1@{endstop_alias}")[-1], delta=1.0e-3, ) def test_mass_endstop_second_port_observables_are_opposite_sign(self) -> None: for alias in self.assembly.masses: with self.subTest(alias=alias): for signal in ("x1", "v1", "acc1"): primary = self.amesim_results.series(f"{signal}@{alias}") second_port = self.amesim_results.series(f"{signal}dup@{alias}") for index in (0, len(primary) // 2, -1): self.assertAlmostEqual(primary[index], -second_port[index]) def test_mass_endstop_force_observables_match_inactive_amesim_contacts(self) -> None: for alias, mass_spec in self.assembly.masses.items(): endstop = mass_spec.endstop() with self.subTest(alias=alias): x1 = self.amesim_results.series(f"x1@{alias}")[-1] v1 = self.amesim_results.series(f"v1@{alias}")[-1] self.assertAlmostEqual( endstop.viscous_friction_force(v1), self.amesim_results.series(f"Fvisc@{alias}")[-1], ) self.assertAlmostEqual(self.amesim_results.series(f"Ffric@{alias}")[-1], 0.0) self.assertAlmostEqual(self.amesim_results.series(f"Fmin@{alias}")[-1], 0.0) self.assertAlmostEqual(self.amesim_results.series(f"Fmax@{alias}")[-1], 0.0) self.assertLessEqual(endstop.lower_penetration_m(x1), 1.0e-12) self.assertLessEqual(endstop.upper_penetration_m(x1), 1.0e-12) def test_unit_helpers(self) -> None: self.assertAlmostEqual(mm_to_m(20.0), 0.02) self.assertAlmostEqual(n_per_mm_to_n_per_m(1.0e6), 1.0e9) self.assertAlmostEqual(n_per_mm_per_s_to_n_per_m_per_s(10.0), 1.0e4) if __name__ == "__main__": unittest.main()