Snapshot WIP: solver HP epic progress, BPHX/HX physics, BMAD skill refresh.

Capture uncommitted solver robustness work (regularization, domain errors, linear solver lifecycle, tube DP/MSH), web workbench updates, and synced BMAD skills across IDE agent folders before starting BPHX pressure-drop.

Co-authored-by: Cursor <cursoragent@cursor.com>

crates/cli/tests/batch_execution.rs

@@ -92,6 +92,7 @@ fn test_simulation_result_statuses() {
             initialization_diagnostics: None,
             dof: None,
             elapsed_ms: 50,
+            raw_state_vector: None,
         },
         SimulationResult {
             input: "fail.json".to_string(),
@@ -105,6 +106,7 @@ fn test_simulation_result_statuses() {
             initialization_diagnostics: None,
             dof: None,
             elapsed_ms: 0,
+            raw_state_vector: None,
         },
         SimulationResult {
             input: "timeout.json".to_string(),
@@ -118,6 +120,7 @@ fn test_simulation_result_statuses() {
             initialization_diagnostics: None,
             dof: None,
             elapsed_ms: 1000,
+            raw_state_vector: None,
         },
     ];
 
@@ -146,12 +149,12 @@ fn test_batch_aggregator_csv_output() {
             input: "scenario1.json".to_string(),
             status: SimulationStatus::Converged,
             convergence: Some(entropyk_cli::run::ConvergenceInfo {
-            final_residual: 1e-8,
-            tolerance: 1e-6,
-            iterations: None,
-            strategy: None,
-            iteration_history: vec![],
-        }),
+                final_residual: 1e-8,
+                tolerance: 1e-6,
+                iterations: None,
+                strategy: None,
+                iteration_history: vec![],
+            }),
             iterations: Some(25),
             state: None,
             performance: None,
@@ -160,17 +163,18 @@ fn test_batch_aggregator_csv_output() {
             initialization_diagnostics: None,
             dof: None,
             elapsed_ms: 150,
+            raw_state_vector: None,
         },
         SimulationResult {
             input: "scenario2.json".to_string(),
             status: SimulationStatus::Converged,
             convergence: Some(entropyk_cli::run::ConvergenceInfo {
-            final_residual: 5e-7,
-            tolerance: 1e-6,
-            iterations: None,
-            strategy: None,
-            iteration_history: vec![],
-        }),
+                final_residual: 5e-7,
+                tolerance: 1e-6,
+                iterations: None,
+                strategy: None,
+                iteration_history: vec![],
+            }),
             iterations: Some(30),
             state: None,
             performance: None,
@@ -179,6 +183,7 @@ fn test_batch_aggregator_csv_output() {
             initialization_diagnostics: None,
             dof: None,
             elapsed_ms: 200,
+            raw_state_vector: None,
         },
         SimulationResult {
             input: "scenario3.json".to_string(),
@@ -192,6 +197,7 @@ fn test_batch_aggregator_csv_output() {
             initialization_diagnostics: None,
             dof: None,
             elapsed_ms: 0,
+            raw_state_vector: None,
         },
     ];
 
@@ -223,6 +229,7 @@ fn test_batch_aggregator_json_summary() {
             initialization_diagnostics: None,
             dof: None,
             elapsed_ms: 50,
+            raw_state_vector: None,
         },
         SimulationResult {
             input: "test2.json".to_string(),
@@ -236,6 +243,7 @@ fn test_batch_aggregator_json_summary() {
             initialization_diagnostics: None,
             dof: None,
             elapsed_ms: 75,
+            raw_state_vector: None,
         },
         SimulationResult {
             input: "test3.json".to_string(),
@@ -249,6 +257,7 @@ fn test_batch_aggregator_json_summary() {
             initialization_diagnostics: None,
             dof: None,
             elapsed_ms: 5000,
+            raw_state_vector: None,
         },
     ];
 
@@ -313,6 +322,7 @@ fn test_batch_summary_csv_with_convergence() {
         initialization_diagnostics: None,
         dof: None,
         elapsed_ms: 300,
+        raw_state_vector: None,
     }];
 
     let summary = BatchSummary {

crates/cli/tests/hx_standalone.rs

@@ -304,9 +304,13 @@ fn test_hx_air_ref_condenser_4port() {
           { "from": "hx:secondary_outlet", "to": "cold_out:inlet" }
         ]
       }],
-      "solver": { "strategy": "newton", "max_iterations": 300, "tolerance": 1e-6 }
+      "solver": { "strategy": "newton", "max_iterations": 1000, "tolerance": 1e-6 }
     }
     "#;
+    // NOTE: with the Modelica Free-P AirSource default, this case converges
+    // linearly (~450 iterations) because the Condenser Jacobian is partially
+    // finite-difference (see audit plan Step 4 — exact HX Jacobians). Restore
+    // max_iterations: 300 once the analytic Jacobian lands.
     let result = run_config(json);
     assert_converged(&result, "Air/Ref Condenser");
 

crates/cli/tests/single_run.rs

@@ -29,6 +29,7 @@ fn test_simulation_result_serialization() {
         initialization_diagnostics: None,
         dof: None,
         elapsed_ms: 50,
+        raw_state_vector: None,
     };
 
     let json = serde_json::to_string_pretty(&result).unwrap();
@@ -69,6 +70,7 @@ fn test_error_result_serialization() {
         initialization_diagnostics: None,
         dof: None,
         elapsed_ms: 0,
+        raw_state_vector: None,
     };
 
     let json = serde_json::to_string(&result).unwrap();
@@ -94,6 +96,7 @@ fn test_error_result_serializes_failure_diagnostics() {
         initialization_diagnostics: None,
         dof: None,
         elapsed_ms: 0,
+        raw_state_vector: None,
     };
 
     let json = serde_json::to_string(&result).unwrap();
@@ -1293,13 +1296,13 @@ fn test_bphx_bounded_circuit_reaches_solver_stage() {
     }
 }
 
-/// AC2 + spec-cli-failure-diagnostics.md: Given a closed-loop simulation that
-/// the solver fails to converge (limited iterations), the JSON result includes
-/// `failure_diagnostics` with `dominant_residual_index` and `dominant_residual_value`.
+/// AC2 + spec-cli-failure-diagnostics.md: Given a DoF-square closed-loop simulation
+/// that the solver fails to converge (iteration budget exhausted), the JSON result
+/// includes `failure_diagnostics` with a finite residual norm.
 ///
-/// This test uses a 2-component closed loop (Pump → Pump) with extremely tight
-/// tolerance so Newton runs at least one iteration before reporting NonConvergence,
-/// verifying that the CLI captures and surfaces the post-mortem diagnostics.
+/// Fixture: a DoF-square R134a vapor-compression cycle. Solver budget is capped so
+/// Newton cannot reach tolerance; the run must fail at the solver stage (not during
+/// finalize) and surface post-mortem diagnostics.
 #[test]
 fn test_failed_run_json_includes_failure_diagnostics() {
     use entropyk_cli::run::run_simulation;
@@ -1307,25 +1310,53 @@ fn test_failed_run_json_includes_failure_diagnostics() {
     let dir = tempdir().unwrap();
     let config_path = dir.path().join("tight_tolerance_failure.json");
 
-    // A closed water loop (two pumps) with an impossibly tight tolerance
-    // ensures Newton runs at least one iteration then reports NonConvergence.
-    // The CLI wraps this in a FallbackSolver with VerboseConfig enabled,
-    // so `failure_diagnostics` must be present in the result.
     let json = r#"
     {
-        "name": "Tight tolerance failure diagnostics test",
-        "fluid": "Water",
-        "circuits": [{
-            "id": 0,
-            "components": [
-                { "type": "Pump", "name": "pump1" },
-                { "type": "Pump", "name": "pump2" }
-            ],
-            "edges": [
-                { "from": "pump1:outlet", "to": "pump2:inlet" },
-                { "from": "pump2:outlet", "to": "pump1:inlet" }
-            ]
-        }],
+        "fluid": "R134a",
+        "fluid_backend": "CoolProp",
+        "circuits": [
+            {
+                "id": 0,
+                "components": [
+                    {
+                        "type": "IsentropicCompressor", "name": "comp",
+                        "isentropic_efficiency": 0.70,
+                        "t_cond_k": 318.15, "t_evap_k": 278.15, "superheat_k": 5.0,
+                        "emergent_pressure": true,
+                        "displacement_m3": 6.5e-5, "speed_hz": 50.0,
+                        "volumetric_efficiency": 0.92
+                    },
+                    {
+                        "type": "Condenser", "name": "cond", "ua": 766.0,
+                        "emergent_pressure": true, "subcooling_k": 5.0,
+                        "secondary_fluid": "Water"
+                    },
+                    {
+                        "type": "IsenthalpicExpansionValve", "name": "exv",
+                        "t_evap_k": 278.15, "emergent_pressure": true
+                    },
+                    {
+                        "type": "Evaporator", "name": "evap", "ua": 1468.0,
+                        "emergent_pressure": true,
+                        "secondary_fluid": "Water"
+                    },
+                    { "type": "BrineSource", "name": "cond_water_in", "fluid": "Water", "p_set_bar": 2.0, "t_set_c": 30.0, "m_flow_kg_s": 0.3583 },
+                    { "type": "BrineSink", "name": "cond_water_out", "fluid": "Water", "p_back_bar": 2.0 },
+                    { "type": "BrineSource", "name": "evap_water_in", "fluid": "Water", "p_set_bar": 2.0, "t_set_c": 12.0, "m_flow_kg_s": 0.4778 },
+                    { "type": "BrineSink", "name": "evap_water_out", "fluid": "Water", "p_back_bar": 2.0 }
+                ],
+                "edges": [
+                    { "from": "comp:outlet", "to": "cond:inlet" },
+                    { "from": "cond:outlet", "to": "exv:inlet" },
+                    { "from": "exv:outlet", "to": "evap:inlet" },
+                    { "from": "evap:outlet", "to": "comp:inlet" },
+                    { "from": "cond_water_in:outlet", "to": "cond:secondary_inlet" },
+                    { "from": "cond:secondary_outlet", "to": "cond_water_out:inlet" },
+                    { "from": "evap_water_in:outlet", "to": "evap:secondary_inlet" },
+                    { "from": "evap:secondary_outlet", "to": "evap_water_out:inlet" }
+                ]
+            }
+        ],
         "solver": {
             "strategy": "newton",
             "max_iterations": 2,
@@ -1337,54 +1368,34 @@ fn test_failed_run_json_includes_failure_diagnostics() {
 
     let result = run_simulation(&config_path, None, false).unwrap();
 
-    // The solver must have failed (either NonConverged or Error after iterations).
-    // Accepted statuses: NonConverged or Error — both indicate the solver gave up.
-    let failed = matches!(
+    assert!(
+        matches!(
+            result.status,
+            SimulationStatus::NonConverged | SimulationStatus::Error
+        ),
+        "expected solver-stage failure, got {:?} (error: {:?})",
         result.status,
-        SimulationStatus::NonConverged | SimulationStatus::Error
+        result.error
+    );
+
+    let diagnostics = result.failure_diagnostics.as_ref().unwrap_or_else(|| {
+        panic!(
+            "failure_diagnostics must be present after solver-stage failure \
+             (status: {:?}, error: {:?})",
+            result.status, result.error
+        )
+    });
+
+    let json_str = serde_json::to_string(&result).unwrap();
+    assert!(
+        json_str.contains("failure_diagnostics"),
+        "JSON result must contain 'failure_diagnostics' key"
     );
     assert!(
-        failed || matches!(result.status, SimulationStatus::Converged),
-        "Unexpected status: {:?}",
-        result.status
+        diagnostics.final_residual_norm.is_finite() && diagnostics.final_residual_norm >= 0.0,
+        "failure_diagnostics.final_residual_norm must be finite and non-negative, got {}",
+        diagnostics.final_residual_norm
     );
-
-    // The pump loop must reach the solver stage (2 pumps in a closed loop finalize cleanly).
-    // With max_iterations=2 and tolerance=1e-100, Newton runs 2 iterations then declares
-    // NonConvergence — diagnostics MUST be present.
-    if matches!(
-        result.status,
-        SimulationStatus::NonConverged | SimulationStatus::Error
-    ) {
-        if let Some(ref err_msg) = result.error {
-            let is_pre_solver_error = err_msg.contains("finalization")
-                || err_msg.contains("Unknown component")
-                || err_msg.contains("Failed to add");
-            if is_pre_solver_error {
-                return; // pre-solver failure: no diagnostics expected
-            }
-        }
-
-        // The solver ran and failed: failure_diagnostics MUST be present.
-        assert!(
-            result.failure_diagnostics.is_some(),
-            "failure_diagnostics must be present when solver ran at least one iteration and failed \
-             (status: {:?}, error: {:?})",
-            result.status,
-            result.error
-        );
-
-        let json_str = serde_json::to_string(&result).unwrap();
-        assert!(
-            json_str.contains("failure_diagnostics"),
-            "JSON result must contain 'failure_diagnostics' key"
-        );
-        let fd = result.failure_diagnostics.as_ref().unwrap();
-        assert!(
-            fd.final_residual_norm >= 0.0,
-            "failure_diagnostics.final_residual_norm must be non-negative"
-        );
-    }
 }
 
 /// spec-cli-failure-diagnostics.md AC3 (integration): Given an empty system config that
@@ -2292,6 +2303,7 @@ fn test_structural_failure_serializes_without_diagnostics() {
         initialization_diagnostics: None,
         dof: None,
         elapsed_ms: 0,
+        raw_state_vector: None,
     };
 
     let json = serde_json::to_string(&result).unwrap();
@@ -2336,6 +2348,7 @@ fn test_success_result_does_not_include_failure_diagnostics() {
         initialization_diagnostics: None,
         dof: None,
         elapsed_ms: 120,
+        raw_state_vector: None,
     };
 
     let json = serde_json::to_string(&result).unwrap();