Add detailed logging and clarify manual vs automated specifications #39

Workflow file for this run

.github/workflows/openscad-render.yml at af8511c

	name: OpenSCAD Render and Export

	on:
	push:
	paths:
	- 'LifeTrac-v25/mechanical_design/*/.scad'
	- '.github/workflows/openscad-render.yml'
	pull_request:
	paths:
	- 'LifeTrac-v25/mechanical_design/*/.scad'
	workflow_dispatch:

	jobs:
	render:
	runs-on: ubuntu-latest
	name: Generate Renders and Outputs

	steps:
	- name: Checkout repository
	uses: actions/checkout@v4

	- name: Install OpenSCAD
	run: \|
	sudo apt-get update
	sudo apt-get install -y openscad xvfb x11-utils
	openscad --version

	- name: Start Xvfb
	run: \|
	Xvfb :99 -screen 0 1024x768x16 &
	XVFB_PID=$!
	echo "XVFB_PID=$XVFB_PID" >> $GITHUB_ENV

	# Wait for Xvfb to be ready (max 10 seconds)
	for i in {1..10}; do
	if xdpyinfo -display :99 >/dev/null 2>&1; then
	echo "Xvfb is ready on display :99"
	break
	fi
	if [ $i -eq 10 ]; then
	echo "Timeout waiting for Xvfb to start"
	exit 1
	fi
	sleep 1
	done

	echo "DISPLAY=:99" >> $GITHUB_ENV


	- name: Create output directories
	run: \|
	cd LifeTrac-v25/mechanical_design
	mkdir -p output/{dxf,renders,animations}

	- name: Generate assembly.png and cnclayout.svg
	run: \|
	cd LifeTrac-v25/mechanical_design

	# Generate assembly.png (1024x768 matching CEB-Press example)
	echo "Generating assembly.png..."
	openscad -o assembly.png \
	--camera=3000,3000,2000,0,0,500 \
	--imgsize=1024,768 \
	--projection=p \
	--colorscheme=Nature \
	openscad/lifetrac_v25.scad

	# Generate cnclayout.svg (2D projection for CNC cutting)
	echo "Generating cnclayout.svg..."
	openscad -o cnclayout.svg \
	--projection=o \
	--viewall \
	cnclayout.scad

	echo "✓ assembly.png and cnclayout.svg generated successfully"
	ls -lh assembly.png cnclayout.svg

	- name: Render preview images
	run: \|
	cd LifeTrac-v25/mechanical_design

	# Main assembly view
	echo "Rendering main assembly..."
	openscad -o output/renders/lifetrac_v25_main.png \
	--camera=3000,3000,2000,0,0,500 \
	--imgsize=1920,1080 \
	--projection=p \
	--colorscheme=Nature \
	openscad/lifetrac_v25.scad

	# Front view
	echo "Rendering front view..."
	openscad -o output/renders/lifetrac_v25_front.png \
	--camera=0,3000,1000,0,0,500 \
	--imgsize=1920,1080 \
	--projection=p \
	--colorscheme=Nature \
	openscad/lifetrac_v25.scad

	# Side view
	echo "Rendering side view..."
	openscad -o output/renders/lifetrac_v25_side.png \
	--camera=3000,0,1000,0,0,500 \
	--imgsize=1920,1080 \
	--projection=p \
	--colorscheme=Nature \
	openscad/lifetrac_v25.scad

	# Top view
	echo "Rendering top view..."
	openscad -o output/renders/lifetrac_v25_top.png \
	--camera=0,0,3000,0,0,500 \
	--imgsize=1920,1080 \
	--projection=o \
	--colorscheme=Nature \
	openscad/lifetrac_v25.scad

	echo "Preview images rendered successfully"

	- name: Render module examples
	run: \|
	cd LifeTrac-v25/mechanical_design

	# Render each module's example
	for module in modules/*.scad; do
	filename=$(basename "$module" .scad)
	echo "Rendering $filename examples..."
	openscad -o "output/renders/${filename}_examples.png" \
	--camera=500,500,500,0,0,0 \
	--imgsize=1600,900 \
	--projection=p \
	--colorscheme=Nature \
	"$module"
	done

	- name: Generate animation frames
	run: \|
	cd LifeTrac-v25/mechanical_design

	echo "Generating animation frames..."
	mkdir -p output/animations/frames

	# Generate 36 frames for animation (every 10 degrees)
	for i in {0..35}; do
	t=$(awk "BEGIN {print $i/36}")
	printf "Frame %d (t=%.4f)\n" $i $t
	openscad -o "output/animations/frames/frame_$(printf %03d $i).png" \
	--camera=3000,3000,2000,0,0,500 \
	--imgsize=1280,720 \
	--projection=p \
	--colorscheme=Nature \
	-D "\$t=$t" \
	openscad/lifetrac_v25.scad
	done

	echo "Animation frames generated"

	- name: Create animation GIF
	run: \|
	sudo apt-get install -y imagemagick
	cd LifeTrac-v25/mechanical_design/output/animations

	echo "Creating animation GIF of arm movement..."
	convert -delay 10 -loop 0 frames/frame_*.png lifetrac_v25_animation.gif

	# Copy to parent directory for easy access
	cp lifetrac_v25_animation.gif ../../lifetrac_v25_animation.gif

	echo "✓ Animation GIF created successfully"
	ls -lh ../../lifetrac_v25_animation.gif

	- name: Generate summary report
	run: \|
	cd LifeTrac-v25/mechanical_design

	cat > output/RENDER_REPORT.md << 'EOF'
	# OpenSCAD Render Report

	Generated: $(date)
	Commit: ${{ github.sha }}
	Branch: ${{ github.ref_name }}

	## Files Generated

	### Preview Renders
	- Main assembly view
	- Front view
	- Side view
	- Top view
	- Module examples (5 modules)

	### Animations
	- 36 animation frames (1280x720 PNG)
	- Animated GIF showing arm movement (lifetrac_v25_animation.gif)

	### CNC Files
	- assembly.png (3D render of complete assembly)
	- cnclayout.svg (2D layout for CNC cutting)

	## Next Steps

	1. Review rendered images in the artifacts
	2. View lifetrac_v25_animation.gif to see arm movement
	3. Use cnclayout.svg for CNC plasma cutting
	4. Use animation frames to create videos
	5. Export DXF files for individual parts using export_all_cnc_parts.sh
	6. Check the Structural Analysis workflow for design validation results

	---
	Generated by GitHub Actions
	EOF

	- name: Upload render artifacts
	uses: actions/upload-artifact@v4
	with:
	name: openscad-renders
	path: \|
	LifeTrac-v25/mechanical_design/output/renders/
	LifeTrac-v25/mechanical_design/output/RENDER_REPORT.md
	retention-days: 90

	- name: Upload animation artifacts
	uses: actions/upload-artifact@v4
	with:
	name: openscad-animations
	path: LifeTrac-v25/mechanical_design/output/animations/
	retention-days: 90

	- name: Extract specifications and update README
	run: \|
	cd LifeTrac-v25

	echo "Extracting specifications from OpenSCAD file..."

	# Create Python script to extract specs
	cat > /tmp/extract_specs.py << 'PYTHON_EOF'
	import re
	import sys

	# Read the OpenSCAD file
	try:
	with open('mechanical_design/openscad/lifetrac_v25.scad', 'r') as f:
	content = f.read()
	except FileNotFoundError:
	print("ERROR: OpenSCAD file not found", file=sys.stderr)
	sys.exit(1)

	# Extract key dimensions with error handling
	def extract_value(pattern, content, name):
	try:
	match = re.search(pattern, content)
	if match:
	return float(match.group(1))
	print(f"WARNING: Could not find {name} in OpenSCAD file", file=sys.stderr)
	return None
	except (ValueError, AttributeError) as e:
	print(f"ERROR: Failed to extract {name}: {e}", file=sys.stderr)
	return None

	MACHINE_WIDTH = extract_value(r'MACHINE_WIDTH\s=\s(\d+)', content, 'MACHINE_WIDTH')
	MACHINE_LENGTH = extract_value(r'MACHINE_LENGTH\s=\s(\d+)', content, 'MACHINE_LENGTH')
	MACHINE_HEIGHT = extract_value(r'MACHINE_HEIGHT\s=\s(\d+)', content, 'MACHINE_HEIGHT')
	WHEEL_DIAMETER = extract_value(r'WHEEL_DIAMETER\s=\s(\d+)', content, 'WHEEL_DIAMETER')
	GROUND_CLEARANCE = extract_value(r'GROUND_CLEARANCE\s=\s(\d+)', content, 'GROUND_CLEARANCE')
	HYDRAULIC_PRESSURE_PSI = extract_value(r'HYDRAULIC_PRESSURE_PSI\s=\s(\d+)', content, 'HYDRAULIC_PRESSURE_PSI')
	LIFT_CYLINDER_BORE = extract_value(r'LIFT_CYLINDER_BORE\s=\s([\d.]+)', content, 'LIFT_CYLINDER_BORE')

	# Validate that all required values were found
	required_values = {
	'MACHINE_WIDTH': MACHINE_WIDTH,
	'MACHINE_LENGTH': MACHINE_LENGTH,
	'MACHINE_HEIGHT': MACHINE_HEIGHT,
	'WHEEL_DIAMETER': WHEEL_DIAMETER,
	'GROUND_CLEARANCE': GROUND_CLEARANCE,
	'HYDRAULIC_PRESSURE_PSI': HYDRAULIC_PRESSURE_PSI,
	'LIFT_CYLINDER_BORE': LIFT_CYLINDER_BORE
	}

	missing_values = [k for k, v in required_values.items() if v is None]
	if missing_values:
	print(f"ERROR: Missing required values: {', '.join(missing_values)}", file=sys.stderr)
	print("The following patterns failed to match:", file=sys.stderr)
	for val in missing_values:
	print(f" - {val}", file=sys.stderr)
	print("Skipping README update to avoid breaking existing content", file=sys.stderr)
	print("If OpenSCAD file structure changed, update the regex patterns in this workflow", file=sys.stderr)
	sys.exit(0) # Exit gracefully without updating

	# Conservative lift capacity estimate based on typical loader geometry
	# NOTE: This is a simplified estimate. The actual lift capacity calculation in the
	# OpenSCAD file uses complex lever arm geometry and moment calculations which would
	# require additional extraction logic. For now, we use a conservative estimate.
	# If design changes significantly, this value should be reviewed and updated.
	ESTIMATED_LIFT_CAPACITY_KG = 1200
	ESTIMATED_LIFT_CAPACITY_LBS = ESTIMATED_LIFT_CAPACITY_KG * 2.205

	# Read current README
	with open('README.md', 'r') as f:
	readme = f.read()

	# Build the specifications table
	specs_table = f"""\| Specification \| Value (mm) \| Value (inches) \| Value (meters) \|
	\|--------------\|------------\|----------------\|----------------\|
	\| Overall Width \| {int(MACHINE_WIDTH):,} mm \| {MACHINE_WIDTH/25.4:.1f}" \| {MACHINE_WIDTH/1000:.2f} m \|
	\| Overall Length \| {int(MACHINE_LENGTH):,} mm \| {MACHINE_LENGTH/25.4:.1f}" \| {MACHINE_LENGTH/1000:.2f} m \|
	\| Height to Frame Top \| {int(MACHINE_HEIGHT):,} mm \| {MACHINE_HEIGHT/25.4:.1f}" \| {MACHINE_HEIGHT/1000:.2f} m \|
	\| Ground Clearance \| {int(GROUND_CLEARANCE)} mm \| {GROUND_CLEARANCE/25.4:.1f}" \| {GROUND_CLEARANCE/1000:.2f} m \|
	\| Wheel Diameter \| {int(WHEEL_DIAMETER)} mm \| {WHEEL_DIAMETER/25.4:.1f}" \| {WHEEL_DIAMETER/1000:.2f} m \|"""

	perf_table = f"""\| Specification \| Value \|
	\|--------------\|-------\|
	\| Hydraulic System Pressure \| {int(HYDRAULIC_PRESSURE_PSI):,} PSI \|
	\| Estimated Lift Capacity \| ~{int(ESTIMATED_LIFT_CAPACITY_KG):,} kg (~{int(ESTIMATED_LIFT_CAPACITY_LBS):,} lbs) \|
	\| Drive Configuration \| All-wheel drive (4 hydraulic motors) \|
	\| Cylinder Bore (Lift) \| {LIFT_CYLINDER_BORE} mm ({LIFT_CYLINDER_BORE/25.4:.1f}") \|"""

	# Update the specs in README using regex with validation
	original_readme = readme

	# Update technical specifications table
	updated_readme = re.sub(
	r'(\\| Specification \\| Value $mm$ \\| Value $inches$ \\| Value $meters$ \\|.?\n)(\\| \\Wheel Diameter\\* \\|[^\n]+)',
	specs_table,
	readme,
	count=1,
	flags=re.DOTALL
	)

	if updated_readme == readme:
	print("WARNING: Technical specifications table pattern not found, trying alternative pattern", file=sys.stderr)
	# Try simpler pattern that looks for the table header
	pattern_start = readme.find('### Technical Specifications')
	if pattern_start != -1:
	# Find the end of the table
	table_start = readme.find('\| Specification \| Value (mm)', pattern_start)
	if table_start != -1:
	# Find next section header or blank line after table
	table_end = readme.find('\n\n###', table_start)
	if table_end == -1:
	table_end = readme.find('\n\n\| Specification \| Value \|', table_start)
	if table_end != -1:
	# Extract table and replace
	old_table = readme[table_start:readme.find('\n', readme.rfind('\|', table_start, table_end))+1]
	updated_readme = readme.replace(old_table, specs_table + '\n', 1)

	readme = updated_readme

	# Update performance specifications table
	updated_readme = re.sub(
	r'(### Performance Specifications\s\n\n\\| Specification \\| Value \\|.?\n)(\\| \\Cylinder Bore $Lift$\\ \\|[^\n]+)',
	f'### Performance Specifications\n\n{perf_table}',
	readme,
	count=1,
	flags=re.DOTALL
	)

	if updated_readme == readme:
	print("WARNING: Performance specifications table pattern not found", file=sys.stderr)
	else:
	readme = updated_readme

	# Only write if changes were made
	if readme != original_readme:
	try:
	with open('README.md', 'w') as f:
	f.write(readme)
	print("✓ README specifications updated successfully")
	except IOError as e:
	print(f"ERROR: Failed to write README: {e}", file=sys.stderr)
	sys.exit(1)
	else:
	print("INFO: No changes needed to README specifications")
	print(f" Width: {int(MACHINE_WIDTH)} mm")
	print(f" Length: {int(MACHINE_LENGTH)} mm")
	print(f" Height: {int(MACHINE_HEIGHT)} mm")
	print(f" Lift Capacity: ~{int(ESTIMATED_LIFT_CAPACITY_KG)} kg")
	PYTHON_EOF

	python3 /tmp/extract_specs.py

	echo "README specifications updated"

	- name: Commit and push rendered outputs
	run: \|
	cd LifeTrac-v25
	git config --global user.name 'github-actions[bot]'
	git config --global user.email 'github-actions[bot]@users.noreply.github.com'

	# Add the generated files (mechanical_design images and updated README)
	git add mechanical_design/assembly.png mechanical_design/cnclayout.svg mechanical_design/lifetrac_v25_animation.gif README.md

	# Check if there are changes
	if ! git diff --staged --quiet; then
	git commit -m "Update rendered outputs and specifications [skip ci]"
	git push --force-with-lease origin HEAD \|\| {
	echo "INFO: git push failed. This is expected on PRs from forks."
	echo "The files are available as workflow artifacts."
	}
	else
	echo "No changes to rendered output files or README"
	fi
	env:
	GITHUB_TOKEN: ${{ secrets.GITHUB_TOKEN }}

	- name: Cleanup Xvfb
	if: always()
	run: \|
	if [ -n "$XVFB_PID" ]; then
	echo "Stopping Xvfb process (PID: $XVFB_PID)"
	# Try graceful shutdown first
	kill -TERM $XVFB_PID 2>/dev/null \|\| true
	# Wait up to 5 seconds for process to terminate
	for i in {1..5}; do
	if ! kill -0 $XVFB_PID 2>/dev/null; then
	echo "Xvfb stopped gracefully"
	break
	fi
	sleep 1
	done
	# Force kill if still running
	kill -KILL $XVFB_PID 2>/dev/null \|\| true
	echo "Xvfb force stopped"
	fi

	- name: Comment on PR with results
	if: github.event_name == 'pull_request'
	uses: actions/github-script@v7
	with:
	script: \|
	const fs = require('fs');
	const comment = `## OpenSCAD Render Results 🎨

	✅ Rendering completed successfully!

	### Generated Outputs
	- 📸 Preview renders (main, front, side, top views)
	- 🎬 Animation frames (36 frames)
	- 🎞️ Animated GIF of arm movement (lifetrac_v25_animation.gif)
	- 🔧 Module examples
	- 🖼️ Assembly image and CNC layout (assembly.png, cnclayout.svg)

	### Artifacts
	Download the generated files from the workflow artifacts:
	- \`openscad-renders\` - Preview images
	- \`openscad-animations\` - Animation frames and GIF

	### Committed Files
	The following files have been committed to the repository:
	- \`assembly.png\` - 3D assembly render
	- \`cnclayout.svg\` - 2D CNC cutting layout
	- \`lifetrac_v25_animation.gif\` - Animation showing arm movement

	_Note: Check the OpenSCAD Structural Analysis workflow for design validation and structural analysis results._

	Workflow Run: [#${{ github.run_number }}](${{ github.server_url }}/${{ github.repository }}/actions/runs/${{ github.run_id }})
	`;

	github.rest.issues.createComment({
	owner: context.repo.owner,
	repo: context.repo.repo,
	issue_number: context.issue.number,
	body: comment
	});

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Add detailed logging and clarify manual vs automated specifications #39

Workflow file

Add detailed logging and clarify manual vs automated specifications #39

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Workflow file for this run