EngineDesign overnight sweep: solver window, config-driven stability, flight dedupe, lockout heartbeat, UI cleanup

EngineDesign/backend/routers/flight.py

@@ -342,14 +342,8 @@ def build_flight_config(base_config, request: FlightSimRequest):
         config_dict["environment"]["date"] = request.environment.date
         config_dict["environment"]["atmosphere_model"] = request.environment.atmosphere_model
     elif config_dict.get("environment") is None:
-        # Set defaults
-        config_dict["environment"] = {
-            "latitude": 35.0,
-            "longitude": -117.0,
-            "elevation": 0.0,
-            "date": [2025, 1, 1, 12],
-            "atmosphere_model": "standard_atmosphere",
-        }
+        # No launch site anywhere: the request model's defaults, stated once, up in EnvironmentConfig.
+        config_dict["environment"] = EnvironmentConfig().model_dump()
 
     # Update rocket
     if request.rocket:
@@ -379,20 +373,20 @@ def build_flight_config(base_config, request: FlightSimRequest):
                 "fin_position": request.rocket.fins.fin_position,
             }
     elif config_dict.get("rocket") is None:
-        # Set defaults
+        # No vehicle anywhere: derive from the request model's defaults so this block cannot drift
+        # from RocketConfig (the literal copy that used to sit here said propulsion_dry_mass 24 kg
+        # while its own component defaults summed to 16).
+        rd = RocketConfig()
         config_dict["rocket"] = {
-            "airframe_mass": 78.72,
-            "propulsion_dry_mass": 24.0,
-            "radius": 0.1015,
-            "motor_position": 0.0,
-            "inertia": [8.0, 8.0, 0.5],
-            "fins": {
-                "no_fins": 3,
-                "root_chord": 0.2,
-                "tip_chord": 0.1,
-                "fin_span": 0.3,
-                "fin_position": 0.1,
-            },
+            "airframe_mass": rd.airframe_mass,
+            "propulsion_dry_mass": rd.engine_mass + rd.lox_tank_structure_mass + rd.fuel_tank_structure_mass,
+            "radius": rd.radius,
+            "motor_position": rd.motor_position,
+            "inertia": list(rd.inertia),
+            "nose_kind": rd.nose_kind,
+            "nose_fineness_ratio": rd.nose_fineness_ratio,
+            "avionics_payload_length_m": rd.avionics_payload_length_m,
+            "fins": FinsConfig().model_dump(),
         }
 
     return config_dict
@@ -424,39 +418,39 @@ def _apply_propellant_mass_caps(config_dict: dict, base_config) -> tuple[dict, d
         lox_tank_max = lox_max
         fill_factor = lox_ff
         current_lox = float(config_dict.get("lox_tank", {}).get("mass", 0) or 0)
-        effective = min(current_lox, lox_max) if current_lox > lox_max else current_lox
+        effective = min(current_lox, lox_max)
         if current_lox > lox_max:
             config_dict["lox_tank"]["mass"] = lox_max
             cap_note = "explicit capacity" if lox_explicit else f"{lox_ff * 100:.0f}% fill"
             print(f"[Flight] Capped LOX mass: {current_lox:.2f} -> {lox_max:.2f} kg ({cap_note}, vol {lox_vol * 1000:.1f}L)")
         mass_adjustments["lox"] = {
             "original": current_lox,
-            "capped": effective if current_lox <= lox_max else lox_max,
+            "capped": effective,
             "max_fill_kg": lox_max,
             "tank_volume_m3": lox_vol,
             "fill_factor": lox_ff,
             "was_capped": current_lox > lox_max + 1e-6,
-            "explicit_capacity_kg": lox_explicit,
+            "explicit_capacity_kg": lox_max if lox_explicit else None,
         }
 
     if cap_config.fuel_tank is not None:
         fuel_max, fuel_vol, fuel_ff, fuel_explicit = resolve_fuel_tank_limits(cap_config, fuel_density)
         fuel_tank_max = fuel_max
         fill_factor = fuel_ff
         current_fuel = float(config_dict.get("fuel_tank", {}).get("mass", 0) or 0)
-        effective = min(current_fuel, fuel_max) if current_fuel > fuel_max else current_fuel
+        effective = min(current_fuel, fuel_max)
         if current_fuel > fuel_max:
             config_dict["fuel_tank"]["mass"] = fuel_max
             cap_note = "explicit capacity" if fuel_explicit else f"{fuel_ff * 100:.0f}% fill"
             print(f"[Flight] Capped Fuel mass: {current_fuel:.2f} -> {fuel_max:.2f} kg ({cap_note}, vol {fuel_vol * 1000:.1f}L)")
         mass_adjustments["fuel"] = {
             "original": current_fuel,
-            "capped": effective if current_fuel <= fuel_max else fuel_max,
+            "capped": effective,
             "max_fill_kg": fuel_max,
             "tank_volume_m3": fuel_vol,
             "fill_factor": fuel_ff,
             "was_capped": current_fuel > fuel_max + 1e-6,
-            "explicit_capacity_kg": fuel_explicit,
+            "explicit_capacity_kg": fuel_max if fuel_explicit else None,
         }
 
     return mass_adjustments, lox_tank_max, fuel_tank_max, fill_factor

EngineDesign/configs/canonical/impinging.yaml

@@ -28,11 +28,17 @@ feed_system:
   # under-predicted LOX feed loss by ~3.8x (dP ~ 1/A^2).
   fuel:
     line_size: 3/8_NPT
+    # Tank outlet to injector manifold. Sets the chug-model line inertance (length/area);
+    # 0.305 m is the value the model used to carry hardcoded -- measure it on the vehicle.
+    length: 0.305
     K0: 2.0
     K1: 0.0
     phi_type: none
   oxidizer:
     line_size: 3/8_NPT
+    # Tank outlet to injector manifold. Sets the chug-model line inertance (length/area);
+    # 0.305 m is the value the model used to carry hardcoded -- measure it on the vehicle.
+    length: 0.305
     K0: 2.0
     K1: 0.0
     phi_type: none
@@ -67,7 +73,6 @@ regen_cooling:
   n_segments: 20
   gas_turbulence_intensity: 0.1
   coolant_turbulence_intensity: 0.05
-  hot_gas_cp: 2200.0
   recovery_factor: null
 film_cooling:
   enabled: false

EngineDesign/configs/canonical/pintle.yaml

@@ -33,7 +33,7 @@ chamber_geometry:
   Cf: 1.5422822280584674
   Lstar: 1.239905396733828
   chamber_diameter: 0.11344154349849075
-  design_MR: 2.55
+  design_MR: 1.4
   design_pressure: 2413166.0
   design_thrust: 7000.0
   exit_diameter: 0.101
@@ -173,11 +173,17 @@ feed_system:
   # under-predicted LOX feed loss by ~3.8x (dP ~ 1/A^2).
   fuel:
     line_size: 3/8_NPT
+    # Tank outlet to injector manifold. Sets the chug-model line inertance (length/area);
+    # 0.305 m is the value the model used to carry hardcoded -- measure it on the vehicle.
+    length: 0.305
     K0: 2.0
     K1: 0.0
     phi_type: none
   oxidizer:
     line_size: 3/8_NPT
+    # Tank outlet to injector manifold. Sets the chug-model line inertance (length/area);
+    # 0.305 m is the value the model used to carry hardcoded -- measure it on the vehicle.
+    length: 0.305
     K0: 2.0
     K1: 0.0
     phi_type: none
@@ -421,7 +427,6 @@ regen_cooling:
   d_outlet: null
   enabled: false
   gas_turbulence_intensity: 0.1
-  hot_gas_cp: 2200.0
   hot_gas_prandtl: 0.7
   hot_gas_thermal_conductivity: 0.12
   hot_gas_viscosity: 4.0e-05

EngineDesign/configs/default.yaml

@@ -45,11 +45,17 @@ feed_system:
   # under-predicted LOX feed loss by ~3.8x (dP ~ 1/A^2).
   fuel:
     line_size: 3/8_NPT
+    # Tank outlet to injector manifold. Sets the chug-model line inertance (length/area);
+    # 0.305 m is the value the model used to carry hardcoded -- measure it on the vehicle.
+    length: 0.305
     K0: 2.0
     K1: 0.0
     phi_type: none
   oxidizer:
     line_size: 3/8_NPT
+    # Tank outlet to injector manifold. Sets the chug-model line inertance (length/area);
+    # 0.305 m is the value the model used to carry hardcoded -- measure it on the vehicle.
+    length: 0.305
     K0: 2.0
     K1: 0.0
     phi_type: none
@@ -84,7 +90,6 @@ regen_cooling:
   n_segments: 20
   gas_turbulence_intensity: 0.1
   coolant_turbulence_intensity: 0.05
-  hot_gas_cp: 2200.0
   recovery_factor: null
 film_cooling:
   enabled: false

EngineDesign/configs/impinging_lox_ch4.yaml

@@ -400,7 +400,6 @@ regen_cooling:
   d_outlet: null
   enabled: false
   gas_turbulence_intensity: 0.1
-  hot_gas_cp: 2200.0
   hot_gas_prandtl: 0.7
   hot_gas_thermal_conductivity: 0.12
   hot_gas_viscosity: 4.0e-05

EngineDesign/configs/impinging_lox_ch4_8000N.yaml

@@ -443,7 +443,6 @@ regen_cooling:
   d_outlet: null
   enabled: false
   gas_turbulence_intensity: 0.1
-  hot_gas_cp: 2200.0
   hot_gas_prandtl: 0.7
   hot_gas_thermal_conductivity: 0.12
   hot_gas_viscosity: 4.0e-05

EngineDesign/configs/impinging_lox_ch4_8000N_optimal.yaml

@@ -82,7 +82,6 @@ regen_cooling:
   n_segments: 20
   gas_turbulence_intensity: 0.1
   coolant_turbulence_intensity: 0.05
-  hot_gas_cp: 2200.0
   recovery_factor: null
 film_cooling:
   enabled: false

EngineDesign/configs/impinging_smoke.yaml

@@ -56,7 +56,6 @@ regen_cooling:
   n_segments: 20
   gas_turbulence_intensity: 0.1
   coolant_turbulence_intensity: 0.05
-  hot_gas_cp: 2200.0
   recovery_factor: null
 film_cooling:
   enabled: false

EngineDesign/configs/test.yaml

@@ -76,7 +76,6 @@ regen_cooling:
   n_segments: 20
   gas_turbulence_intensity: 0.1
   coolant_turbulence_intensity: 0.05
-  hot_gas_cp: 2200.0
   recovery_factor: null
 film_cooling:
   enabled: false

EngineDesign/engine/accel/kernels.py

@@ -966,8 +966,11 @@ def _solve_exit_mach(eps, g):
 @njit(cache=True)
 def evaluate_core(P, Pcg, MRg, epsg, cstar, Cf, Tc_t, gam, Rt, Mt, Cfv, P_O, P_F, Pa):
     """Returns (ok, Pc, F, Isp, MR, cstar_actual, gamma, Tc, mdot_total, v_exit, Cf_actual)."""
-    Pc_min = 100000.0
-    Pc_max = min(P_O, P_F)*(1.0 - 0.15)
+    # Search window and bracket scan: VERBATIM mirror of engine/core/chamber_solver.py
+    # (PC_CHOKE_FLOOR_PA, PC_MIN_TOTAL_DROP_FRAC, ChamberSolver._highest_sign_change). The parity
+    # gate requires the two root-finds to agree, so change both or neither.
+    Pc_min = 2.0*101325.0
+    Pc_max = min(P_O, P_F)*(1.0 - 0.02)
     Pc_min = max(Pc_min, P[SV_PCMIN]); Pc_max = min(Pc_max, P[SV_PCMAX])
     if Pc_max <= Pc_min:
         return (0.0,)*22
@@ -976,41 +979,28 @@ def evaluate_core(P, Pcg, MRg, epsg, cstar, Cf, Tc_t, gam, Rt, Mt, Cfv, P_O, P_F
     rmax = _residual(Pc_max, P, Pcg, MRg, epsg, cstar, Cf, Tc_t, gam, Rt, Mt, Cfv, P_O, P_F)
     if not np.isfinite(rmin) or not np.isfinite(rmax):
         return (0.0,)*22
-    if _sign(rmin) == _sign(rmax):
-        # The residual is not always monotonic in Pc: on the canonical impinging design at
-        # asymmetric tank pressures it is NEGATIVE at Pc_min, turns POSITIVE mid-range, and goes
-        # negative again by Pc_max, so an endpoint-only sign test sees "no root" and bails where
-        # a root plainly exists (measured: -0.214 at 1.0 bar, +0.76 at 20 bar, -0.96 at 27.4 bar,
-        # root at 23.75 bar). Scan for a sign-changing sub-interval before giving up -- the pure
-        # Python solver finds these, and the parity gate requires the accelerator to agree.
-        # Scan from the HIGH end down: a non-monotonic residual can also cross near Pc_min
-        # (a spurious low-pressure crossing where the chamber is barely flowing). The physical
-        # operating point is the HIGHEST-Pc root, which is the one the pure Python solver
-        # converges to; taking the first crossing from the bottom picked the spurious one and
-        # diverged from Python by 3.3x.
-        _n = 32
-        _lo = 0.0; _hi = 0.0; _found = False
-        _pb = Pc_max; _rb = rmax
-        for _i in range(_n - 1, -1, -1):
-            _pa = Pc_min + (Pc_max - Pc_min)*(_i/_n)
-            _ra = _residual(_pa, P, Pcg, MRg, epsg, cstar, Cf, Tc_t, gam, Rt, Mt, Cfv, P_O, P_F)
-            if np.isfinite(_ra) and np.isfinite(_rb) and _sign(_ra) != _sign(_rb):
-                _lo = _pa; _hi = _pb; _found = True
-                break
-            _pb = _pa; _rb = _ra
-        if _found:
-            Pc = _brentq(P, Pcg, MRg, epsg, cstar, Cf, Tc_t, gam, Rt, Mt, Cfv, P_O, P_F,
-                         _lo, _hi, xtol, rtol, maxit)
-            if not np.isfinite(Pc):
-                return (0.0,)*22
-        elif rmin > 0 and rmax > 0 and rmax < 0.1:
-            Pc = Pc_max
-        else:
-            return (0.0,)*22
-    else:
-        Pc = _brentq(P, Pcg, MRg, epsg, cstar, Cf, Tc_t, gam, Rt, Mt, Cfv, P_O, P_F, Pc_min, Pc_max, xtol, rtol, maxit)
-        if not np.isfinite(Pc):
-            return (0.0,)*22
+    # The residual is not monotonic in Pc: it is negative near the choking floor (barely flowing,
+    # the spurious crossing), positive through the operating range, and negative again once the
+    # injector drop gets small. The physical operating point is the HIGHEST-Pc root, so scan from
+    # Pc_max down for the first sign change and bracket Brent inside it. Endpoint-only tests
+    # missed interior roots (measured on canonical/impinging: -0.214 at 1 bar, +0.76 at 20 bar,
+    # -0.96 at 27.4 bar, root at 23.75 bar) and a whole-window Brent picked the spurious low one.
+    _n = 32
+    _lo = 0.0; _hi = 0.0; _found = False
+    _pb = Pc_max; _rb = rmax
+    for _i in range(_n - 1, -1, -1):
+        _pa = Pc_min + (Pc_max - Pc_min)*(_i/_n)
+        _ra = rmin if _i == 0 else _residual(_pa, P, Pcg, MRg, epsg, cstar, Cf, Tc_t, gam, Rt, Mt, Cfv, P_O, P_F)
+        if np.isfinite(_ra) and np.isfinite(_rb) and _sign(_ra) != _sign(_rb):
+            _lo = _pa; _hi = _pb; _found = True
+            break
+        _pb = _pa; _rb = _ra
+    if not _found:
+        return (0.0,)*22
+    Pc = _brentq(P, Pcg, MRg, epsg, cstar, Cf, Tc_t, gam, Rt, Mt, Cfv, P_O, P_F,
+                 _lo, _hi, xtol, rtol, maxit)
+    if not np.isfinite(Pc):
+        return (0.0,)*22
     # recompute converged state
     (ok, mO, mF, uO, uF, D32O, D32F, momR, CdO, CdF, PiO, PiF, dpiO, dpiF, AgO, AgF,
      dpfO, dpfF, WeO, WeF, urel, xstar, constr, nit, tiO, tiF) = _solve_injector(P, P_O, P_F, Pc)

EngineDesign/engine/control/robust_ddp/data_models.py

@@ -267,6 +267,15 @@ class ControllerConfig:
     # Regulator model
     reg_setpoint: Optional[float] = None  # Regulator setpoint [Pa] (None = derived from COPV)
     reg_ratio: float = 0.8          # P_reg / P_copv ratio if setpoint not specified
+    # Pressurisation-path hardware. Previously literals inside dynamics.step(); surfaced here so
+    # a vehicle with a different regulator or solenoid can be modelled without editing code.
+    # See docs/adr/0001 -- this chain is one of the feed models lib/feedtwin absorbs.
+    gamma_gas: float = 1.4          # Pressurant specific heat ratio (N2)
+    Cd_regulator: float = 0.7       # Discharge coefficient, regulator orifice
+    Cd_valve: float = 0.65          # Discharge coefficient, solenoid valve orifice
+    A_regulator: float = 2e-5       # Regulator orifice area [m^2]
+    A_valve_F: float = 5e-5         # Fuel solenoid valve flow area [m^2]
+    A_valve_O: float = 5e-5         # Oxidiser solenoid valve flow area [m^2]
 
     # Ullage pressurization flow coefficients [1/s]
     alpha_F: float = 10.0           # Fuel pressurization flow coefficient