Update after decision to keep saturation threshold within FEMMT.

Author: SevenOfNinePE

femmt/examples/basic_inductor_with_dc_offset.py

@@ -19,7 +19,7 @@
 # Current amplitute
 current_amplitude_list: list[float] = [3]
 # Current offset
-current_offset: float = 20
+current_offset: float = 10
 # Target inductance (L_is)
 target_inductance = 2e-05
 # Deviation to target inductance (abs(L_is/L_shall)
@@ -124,8 +124,6 @@ def basic_example_inductor_with_dc_offset(onelab_folder: str = None, show_visual
     # Set insulation
     geo.set_insulation(insulation)
     geo.set_winding_windows([winding_window])
-    # Increase material saturation maximum
-    geo.set_saturation_threshold(2)
 
     # List of inductance for better approximation
     inductance_list: list[tuple[float, float, float]] = []

femmt/examples/ito_optuna_example.py

@@ -11,9 +11,6 @@
 import femmt as fmt
 from materialdatabase.meta.data_enums import Material, DataSource
 
-i_2 = [[0.0, 3.265248131976911e-07, 2.5e-06, 2.8265248131976912e-06, 5e-06],
-       [-0.9196195846583147, -19.598444313231134, 0.9196195846583122, 19.59844431323113, -0.9196195846583147]]
-
 i_offset = 6
 ac_factor = 1
 
@@ -128,7 +125,7 @@
 
         volume, combined_losses, area_to_heat_sink, winding_loss, core_loss = fmt.InductorOptimization.FemSimulation.full_simulation(
             df_geometry_re_simulation_number, current_waveform=i_1,
-            inductor_config_filepath=config_filepath, process_number=1, print_derivations=False, saturation_threshold=1.5)
+            inductor_config_filepath=config_filepath, process_number=1, print_derivations=False)
 
     if task_plot_study_results:
         fmt.InductorOptimization.ReluctanceModel.show_study_results(fmt_inductor_optimization_dto)

femmt/optimization/io.py

@@ -33,6 +33,9 @@
 class InductorOptimization:
     """Reluctance model and FEM simulation for the inductor optimization."""
 
+    # Saturation threshold for calculation with Inductor optimization
+    _IO_SATURATION_THRESHOLD = 0.8
+
     @staticmethod
     def filter_df(df: pd.DataFrame, x: str = "values_0", y: str = "values_1", factor_min_dc_losses: float = 1.2,
                   factor_max_dc_losses: float = 10) -> pd.DataFrame:
@@ -437,9 +440,9 @@ def single_reluctance_model_simulation_dc_offset(reluctance_input: IoReluctanceM
                 previous_dynamic_mu_r_abs = dynamic_mu_r_abs
 
             # Do not cross out saturation, as the genetic algorithm is missing bad results to improve its suggestions
-            if flux_avg_density > 0.8 * reluctance_input.initial_mag_curve["b"].iloc[-1] or dynamic_mu_r_abs < 0:
-                print(f"Average flux density is too high (80 % of b_sat): {flux_avg_density} "
-                      f"T > 0.8 * {reluctance_input.initial_mag_curve['b'].iloc[-1]} T  mur={dynamic_mu_r_abs}")
+            if flux_avg_density > reluctance_input.initial_mag_curve["b"].iloc[-1] or dynamic_mu_r_abs < 0:
+                logger.info(f"Average flux density exceeds range of initial magnetization curve: {flux_avg_density} "
+                            f"T > {reluctance_input.initial_mag_curve['b'].iloc[-1]} T mur={dynamic_mu_r_abs}")
                 reluctance_model_output = IoReluctanceModelOutput(
                     p_loss_total=float('nan'),
                     volume=float('nan'),
@@ -469,22 +472,6 @@ def single_reluctance_model_simulation_dc_offset(reluctance_input: IoReluctanceM
             flux_amplitude = (flux.max() - flux.min())/2
             flux_amplitude_density = flux_amplitude / core_cross_section
 
-            # Do not cross out saturation, as the genetic algorithm is missing bad results to improve its suggestions
-            if (flux_avg_density + flux_amplitude_density) > 0.8 * reluctance_input.initial_mag_curve["b"].iloc[-1]:
-                print(f"Maximum flux density is too high (80 % of b_sat): {flux_avg_density + flux_amplitude_density} "
-                      f"T > 0.8 * {reluctance_input.initial_mag_curve['b'].iloc[-1]} T mur={dynamic_mu_r_abs}")
-                reluctance_model_output = IoReluctanceModelOutput(
-                    p_loss_total=float('nan'),
-                    volume=float('nan'),
-                    area_to_heat_sink=float('nan'),
-                    p_winding=float('nan'),
-                    p_hyst=float('nan'),
-                    l_air_gap=float('nan'),
-                    flux_density_peak=flux_avg_density + flux_amplitude_density,
-                    dynamic_mu_r_abs=float('nan')
-                )
-                return reluctance_model_output
-
             # p_loss calculation
             # get power loss in W/m³ and estimated H wave in A/m
             p_density_cmp, _ = reluctance_input.magnet_material_model(flux_density, reluctance_input.fundamental_frequency, reluctance_input.temperature)
@@ -1449,7 +1436,7 @@ def filter_combined_loss_list_df(df: pd.DataFrame, factor_min_dc_losses: float =
 
         @staticmethod
         def full_simulation(df_geometry: pd.DataFrame, current_waveform: list, inductor_config_filepath: str, process_number: int = 1,
-                            print_derivations: bool = False, saturation_threshold: float = 0.7) -> tuple:
+                            print_derivations: bool = False) -> tuple:
             """
             FEM simulation (winding losses and hysteresis losses from magnet model) for geometries from df_geometry.
 
@@ -1463,8 +1450,6 @@ def full_simulation(df_geometry: pd.DataFrame, current_waveform: list, inductor_
             :type process_number: int
             :param print_derivations: True to print derivation from FEM simulation to reluctance model
             :type print_derivations: bool
-            :param saturation_threshold: Threshold of maximum material saturation (default: 0.7)
-            :type  saturation_threshold: float
             :return: volume, loss
             :rtype: tuple
             """
@@ -1534,7 +1519,7 @@ def full_simulation(df_geometry: pd.DataFrame, current_waveform: list, inductor_
                 time_vec=target_and_fix_parameters.time_extracted_vec,
                 current_vec=target_and_fix_parameters.current_extracted_vec,
                 current_offset=target_and_fix_parameters.current_offset,
-                saturation_threshold=saturation_threshold
+                saturation_threshold=InductorOptimization._IO_SATURATION_THRESHOLD
             )
 
             # Load reluctance model input for magnet model and litz wire resistance calculation