pcb-afm-simulation-system/scripts/verify_enable_thermal.py

"""Verify the executor enable_thermal plumbing end-to-end on real Motor-CAD.

Runs RobustMotorCADSolver with enable_thermal=True for a single point and
checks that:
    1. The EM and thermal solves both complete.
    2. Thermal metrics are merged into the point result.
    3. Thermal metric columns are written to scan_results.csv.

Ambient temperature is overridden to 25 C in-memory (the MARS model ships an
abnormal 125 C) so the temperature-rise / thermal-resistance metrics come out
physically positive.

Run with the venv python that has ansys-motorcad-core installed, e.g.:
    <venv>/Scripts/python.exe scripts/verify_enable_thermal.py

All source is ASCII only.
"""
from __future__ import annotations

import os
import sys
import time
from pathlib import Path

_ROOT = Path(__file__).resolve().parent.parent
sys.path.insert(0, str(_ROOT / "src"))
sys.path.insert(0, str(_ROOT / "scripts"))

from robust_motorcad import RobustMotorCADSolver  # noqa: E402

MODEL = str(_ROOT / "models" / "MARS-12S10P_SSSR_D76-C150_V5.0-0819.mot")

THERMAL_KEYS = [
    "winding_temp_c", "winding_hotspot_temp_c", "magnet_temp_c",
    "stator_temp_c", "bearing_temp_c", "temp_rise_c",
    "thermal_resistance_k_w",
]


def main(thermal_mode: str = "coupled") -> int:
    output_dir = str(_ROOT / "output" / (
        "verify_thermal_" + time.strftime("%Y%m%d_%H%M%S")
    ))
    solver = RobustMotorCADSolver(
        model_path=MODEL, output_dir=output_dir, ambient_temperature=25.0,
        thermal_mode=thermal_mode,
    )
    solver.connect()
    try:
        result = solver.run_single_point(
            {"RMSCurrent": 21.0, "Shaft_Speed": 5000.0},
            point_index=0, point_label="verify",
        )
        print("status: %s" % result["status"], flush=True)
        print("=== thermal metrics in point result ===", flush=True)
        for key in THERMAL_KEYS:
            print("  %s = %s" % (key, result.get("metrics", {}).get(key)),
                  flush=True)

        csv_path = os.path.join(output_dir, "scan_results.csv")
        csv_ok = os.path.exists(csv_path)
        print("scan_results.csv exists: %s" % csv_ok, flush=True)
        thermal_in_csv = False
        if csv_ok:
            header = open(csv_path, encoding="utf-8").readline().rstrip()
            thermal_in_csv = all(k in header for k in THERMAL_KEYS)
            print("thermal columns present in CSV header: %s" % thermal_in_csv,
                  flush=True)

        merged = all(
            key in result.get("metrics", {}) for key in THERMAL_KEYS
        )
        ok = (
            result["status"] == "OK" and merged and csv_ok and thermal_in_csv
        )
        print("")
        print("ENABLE_THERMAL END-TO-END: %s" % ("PASS" if ok else "FAIL"),
              flush=True)
        return 0 if ok else 1
    finally:
        solver.disconnect()


if __name__ == "__main__":
    import argparse
    parser = argparse.ArgumentParser()
    parser.add_argument("--thermal-mode", choices=["off", "steady", "coupled"],
                        default="coupled")
    args = parser.parse_args()
    sys.exit(main(thermal_mode=args.thermal_mode))