openscad-structural-analysis.yml

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
            });