Add clarifying comments about duplicate parts and calculation method #40

Workflow file for this run

.github/workflows/openscad-structural-analysis.yml at 88c6f31

	name: OpenSCAD Structural Analysis

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

	jobs:
	structural-analysis:
	runs-on: ubuntu-latest
	name: Validate Structural Design

	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: Validate OpenSCAD syntax
	run: \|
	echo "Validating OpenSCAD files..."
	cd LifeTrac-v25/mechanical_design

	# Check main design file
	openscad -o /dev/null --export-format echo openscad/lifetrac_v25.scad
	if [ $? -eq 0 ]; then
	echo "✓ Main design file is valid"
	else
	echo "✗ Main design file has errors"
	exit 1
	fi

	# Check module files
	for module in modules/*.scad; do
	echo "Checking $module..."
	openscad -o /dev/null --export-format echo "$module"
	if [ $? -eq 0 ]; then
	echo "✓ $module is valid"
	else
	echo "✗ $module has errors"
	exit 1
	fi
	done

	- name: Run structural analysis
	run: \|
	echo "Running structural analysis on main design..."
	cd LifeTrac-v25/mechanical_design

	# Run OpenSCAD with echo output to capture structural analysis
	openscad -o /dev/null --export-format echo openscad/lifetrac_v25.scad 2>&1 \| tee structural_analysis.log

	echo "Structural analysis complete. Check logs for results."

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

	# Extract key metrics from the log
	echo "# Structural Analysis Report" > structural_report.md
	echo "" >> structural_report.md
	echo "Generated: $(date)" >> structural_report.md
	echo "Commit: ${{ github.sha }}" >> structural_report.md
	echo "Branch: ${{ github.ref_name }}" >> structural_report.md
	echo "" >> structural_report.md

	# Extract structural summary if present
	if grep -q "COMPLETE STRUCTURAL ANALYSIS SUMMARY" structural_analysis.log; then
	echo "## Structural Analysis Results" >> structural_report.md
	echo "" >> structural_report.md
	echo "\`\`\`" >> structural_report.md
	# Extract from summary start to next delimiter or end of relevant section
	sed -n '/COMPLETE STRUCTURAL ANALYSIS SUMMARY/,/========================================/{p;/========================================/q}' structural_analysis.log \| tail -n +2 >> structural_report.md \|\| \
	sed -n '/COMPLETE STRUCTURAL ANALYSIS SUMMARY/,$p' structural_analysis.log \| tail -n +2 \| head -n 20 >> structural_report.md
	echo "\`\`\`" >> structural_report.md
	else
	echo "No structural analysis summary found in output." >> structural_report.md
	fi

	cat structural_report.md

	- name: Create persistent structural analysis log
	run: \|
	cd LifeTrac-v25/mechanical_design

	# Create or update the persistent log file
	echo "# Structural Analysis Test Log" > STRUCTURAL_ANALYSIS_LOG.md
	echo "" >> STRUCTURAL_ANALYSIS_LOG.md
	echo "This file tracks the history of structural analysis test results." >> STRUCTURAL_ANALYSIS_LOG.md
	echo "" >> STRUCTURAL_ANALYSIS_LOG.md
	echo "---" >> STRUCTURAL_ANALYSIS_LOG.md
	echo "" >> STRUCTURAL_ANALYSIS_LOG.md
	echo "## Latest Analysis" >> STRUCTURAL_ANALYSIS_LOG.md
	echo "" >> STRUCTURAL_ANALYSIS_LOG.md
	echo "Date: $(date -u '+%Y-%m-%d %H:%M:%S UTC')" >> STRUCTURAL_ANALYSIS_LOG.md
	echo "Commit: ${{ github.sha }}" >> STRUCTURAL_ANALYSIS_LOG.md
	echo "Branch: ${{ github.ref_name }}" >> STRUCTURAL_ANALYSIS_LOG.md
	echo "Workflow Run: ${{ github.server_url }}/${{ github.repository }}/actions/runs/${{ github.run_id }}" >> STRUCTURAL_ANALYSIS_LOG.md
	echo "" >> STRUCTURAL_ANALYSIS_LOG.md

	# Extract and format the structural analysis results
	if grep -q "COMPLETE STRUCTURAL ANALYSIS SUMMARY" structural_analysis.log; then
	echo "### Results Summary" >> STRUCTURAL_ANALYSIS_LOG.md
	echo "" >> STRUCTURAL_ANALYSIS_LOG.md
	echo "\`\`\`" >> STRUCTURAL_ANALYSIS_LOG.md
	sed -n '/COMPLETE STRUCTURAL ANALYSIS SUMMARY/,/========================================/{p;/========================================/q}' structural_analysis.log \| tail -n +2 >> STRUCTURAL_ANALYSIS_LOG.md \|\| \
	sed -n '/COMPLETE STRUCTURAL ANALYSIS SUMMARY/,$p' structural_analysis.log \| tail -n +2 \| head -n 20 >> STRUCTURAL_ANALYSIS_LOG.md
	echo "\`\`\`" >> STRUCTURAL_ANALYSIS_LOG.md
	echo "" >> STRUCTURAL_ANALYSIS_LOG.md

	# Extract detailed failure information if any tests failed
	if grep -q "FAIL" structural_analysis.log; then
	echo "### ⚠️ Failed Components" >> STRUCTURAL_ANALYSIS_LOG.md
	echo "" >> STRUCTURAL_ANALYSIS_LOG.md

	# Extract rated capacity
	CAPACITY=$(grep "RATED LIFT CAPACITY:" structural_analysis.log \| head -1 \| sed 's/ECHO: "RATED LIFT CAPACITY:", //')
	echo "Current Rated Capacity: $CAPACITY" >> STRUCTURAL_ANALYSIS_LOG.md
	echo "" >> STRUCTURAL_ANALYSIS_LOG.md

	# List each failed component with details
	echo "#### Detailed Failure Analysis" >> STRUCTURAL_ANALYSIS_LOG.md
	echo "" >> STRUCTURAL_ANALYSIS_LOG.md

	# Arm Bending
	if grep -q "Arm Bending.*FAIL" structural_analysis.log; then
	echo "1. Arm Bending Stress" >> STRUCTURAL_ANALYSIS_LOG.md
	grep -A 5 "=== ARM BENDING STRESS ANALYSIS ===" structural_analysis.log \| grep "ECHO:" \| sed 's/ECHO: /- /' >> STRUCTURAL_ANALYSIS_LOG.md
	echo "" >> STRUCTURAL_ANALYSIS_LOG.md
	fi

	# Arm Deflection
	if grep -q "Arm Deflection.*FAIL" structural_analysis.log; then
	echo "2. Arm Deflection" >> STRUCTURAL_ANALYSIS_LOG.md
	grep -A 5 "=== ARM DEFLECTION ANALYSIS ===" structural_analysis.log \| grep "ECHO:" \| sed 's/ECHO: /- /' >> STRUCTURAL_ANALYSIS_LOG.md
	echo "" >> STRUCTURAL_ANALYSIS_LOG.md
	fi

	# Cross Beam
	if grep -q "Cross Beam.*FAIL" structural_analysis.log; then
	echo "3. Cross Beam Bending" >> STRUCTURAL_ANALYSIS_LOG.md
	grep -A 5 "=== CROSS BEAM STRESS ANALYSIS ===" structural_analysis.log \| grep "ECHO:" \| sed 's/ECHO: /- /' >> STRUCTURAL_ANALYSIS_LOG.md
	echo "" >> STRUCTURAL_ANALYSIS_LOG.md
	fi

	# Pivot Ring Welds
	if grep -q "Pivot Ring.*FAIL" structural_analysis.log; then
	echo "4. Pivot Ring Welds" >> STRUCTURAL_ANALYSIS_LOG.md
	grep -A 5 "=== PIVOT RING WELD ANALYSIS ===" structural_analysis.log \| grep "ECHO:" \| sed 's/ECHO: /- /' >> STRUCTURAL_ANALYSIS_LOG.md
	echo "" >> STRUCTURAL_ANALYSIS_LOG.md
	fi

	echo "### Recommended Actions" >> STRUCTURAL_ANALYSIS_LOG.md
	echo "" >> STRUCTURAL_ANALYSIS_LOG.md
	echo "See [STRUCTURAL_ANALYSIS.md](STRUCTURAL_ANALYSIS.md) for design modification recommendations." >> STRUCTURAL_ANALYSIS_LOG.md
	echo "" >> STRUCTURAL_ANALYSIS_LOG.md
	else
	echo "### ✅ All Tests Passed" >> STRUCTURAL_ANALYSIS_LOG.md
	echo "" >> STRUCTURAL_ANALYSIS_LOG.md
	echo "All structural analysis checks passed successfully." >> STRUCTURAL_ANALYSIS_LOG.md
	echo "" >> STRUCTURAL_ANALYSIS_LOG.md
	fi
	else
	echo "### Error" >> STRUCTURAL_ANALYSIS_LOG.md
	echo "" >> STRUCTURAL_ANALYSIS_LOG.md
	echo "No structural analysis summary found in output. Check the workflow logs for errors." >> STRUCTURAL_ANALYSIS_LOG.md
	echo "" >> STRUCTURAL_ANALYSIS_LOG.md
	fi

	echo "---" >> STRUCTURAL_ANALYSIS_LOG.md
	echo "" >> STRUCTURAL_ANALYSIS_LOG.md
	echo "_This file is automatically updated by the OpenSCAD Structural Analysis workflow._" >> STRUCTURAL_ANALYSIS_LOG.md

	cat STRUCTURAL_ANALYSIS_LOG.md

	- name: Commit structural analysis log
	run: \|
	cd LifeTrac-v25/mechanical_design
	git config --global user.name 'github-actions[bot]'
	git config --global user.email 'github-actions[bot]@users.noreply.github.com'

	# Add the log file
	git add STRUCTURAL_ANALYSIS_LOG.md

	# Check if there are changes
	if ! git diff --staged --quiet; then
	git commit -m "Update structural analysis log [skip ci]"
	git push --force-with-lease origin HEAD \|\| {
	echo "INFO: git push failed. This is expected on PRs from forks."
	echo "The log file is available as a workflow artifact."
	}
	else
	echo "No changes to structural analysis log"
	fi
	env:
	GITHUB_TOKEN: ${{ secrets.GITHUB_TOKEN }}

	- name: Upload structural analysis artifacts
	uses: actions/upload-artifact@v4
	with:
	name: structural-analysis
	path: \|
	LifeTrac-v25/mechanical_design/structural_analysis.log
	LifeTrac-v25/mechanical_design/structural_report.md
	LifeTrac-v25/mechanical_design/STRUCTURAL_ANALYSIS_LOG.md
	retention-days: 90

	- 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 structural analysis
	if: github.event_name == 'pull_request'
	uses: actions/github-script@v7
	with:
	script: \|
	const fs = require('fs');

	// Read the structural report
	let reportContent = 'Structural analysis completed. Check artifacts for detailed results.';
	try {
	const report = fs.readFileSync('LifeTrac-v25/mechanical_design/structural_report.md', 'utf8');
	// Extract just the results section
	const match = report.match(/## Structural Analysis Results[\s\S]*$/);
	if (match) {
	reportContent = match[0];
	}
	} catch (err) {
	console.log('Could not read structural report:', err);
	}

	const comment = `## OpenSCAD Structural Analysis Results 🔧

	✅ Structural analysis completed!

	${reportContent}

	### Persistent Log
	A detailed log with failure descriptions has been committed to:
	- \`LifeTrac-v25/mechanical_design/STRUCTURAL_ANALYSIS_LOG.md\`

	### Artifacts
	Download the detailed analysis from the workflow artifacts:
	- \`structural-analysis\` - Complete logs and report

	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 clarifying comments about duplicate parts and calculation method #40

Workflow file

Add clarifying comments about duplicate parts and calculation method #40

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Workflow file for this run