Wire BPHX channel pressure drop on both sides with selectable correlations.

Replace isobaric 4-port closures with SimplifiedChannel (default) and Martin1996 DP models so z_dp and UI dp_correlation actually affect the Newton solve. Co-authored-by: Cursor <cursoragent@cursor.com>
2026-07-19 16:52:25 +02:00
parent 5bd180b5b8
commit 44f793a583
19 changed files with 1287 additions and 106 deletions
--- a/crates/cli/examples/bphx_evaporator_condenser.json
+++ b/crates/cli/examples/bphx_evaporator_condenser.json
@@ -33,6 +33,7 @@
          "target_subcooling_k": 5.0,
          "emergent_pressure": true,
          "correlation": "Longo2004",
+          "dp_correlation": "SimplifiedChannel",
          "ua": 2500.0
        },
        {
@@ -52,6 +53,7 @@
          "target_superheat_k": 5.0,
          "emergent_pressure": true,
          "correlation": "Longo2004",
+          "dp_correlation": "SimplifiedChannel",
          "ua": 2000.0
        },
        {
--- a/crates/cli/src/batch.rs
+++ b/crates/cli/src/batch.rs
@@ -315,7 +315,7 @@ fn process_single_file(
                initialization_diagnostics: None,
                dof: None,
                elapsed_ms: 0,
-                raw_state_vector: None,
+                raw_state_vector: None, solved_variables: Vec::new(),
            }
        }
    }
@@ -425,7 +425,7 @@ mod tests {
                initialization_diagnostics: None,
                dof: None,
                elapsed_ms: 50,
-                raw_state_vector: None,
+                raw_state_vector: None, solved_variables: Vec::new(),
            },
            SimulationResult {
                input: "test2.json".to_string(),
@@ -439,7 +439,7 @@ mod tests {
                initialization_diagnostics: None,
                dof: None,
                elapsed_ms: 0,
-                raw_state_vector: None,
+                raw_state_vector: None, solved_variables: Vec::new(),
            },
        ];

@@ -483,7 +483,7 @@ mod tests {
                initialization_diagnostics: None,
                dof: None,
                elapsed_ms: 50,
-                raw_state_vector: None,
+                raw_state_vector: None, solved_variables: Vec::new(),
            },
            SimulationResult {
                input: "test2.json".to_string(),
@@ -497,7 +497,7 @@ mod tests {
                initialization_diagnostics: None,
                dof: None,
                elapsed_ms: 0,
-                raw_state_vector: None,
+                raw_state_vector: None, solved_variables: Vec::new(),
            },
        ];

@@ -529,7 +529,7 @@ mod tests {
                initialization_diagnostics: None,
                dof: None,
                elapsed_ms: 50,
-                raw_state_vector: None,
+                raw_state_vector: None, solved_variables: Vec::new(),
            },
            SimulationResult {
                input: "test2.json".to_string(),
@@ -543,7 +543,7 @@ mod tests {
                initialization_diagnostics: None,
                dof: None,
                elapsed_ms: 0,
-                raw_state_vector: None,
+                raw_state_vector: None, solved_variables: Vec::new(),
            },
        ];

@@ -571,7 +571,7 @@ mod tests {
                initialization_diagnostics: None,
                dof: None,
                elapsed_ms: 50,
-                raw_state_vector: None,
+                raw_state_vector: None, solved_variables: Vec::new(),
            },
            SimulationResult {
                input: "test2.json".to_string(),
@@ -585,7 +585,7 @@ mod tests {
                initialization_diagnostics: None,
                dof: None,
                elapsed_ms: 1000,
-                raw_state_vector: None,
+                raw_state_vector: None, solved_variables: Vec::new(),
            },
        ];

@@ -643,7 +643,7 @@ mod tests {
                initialization_diagnostics: None,
                dof: None,
                elapsed_ms: 100,
-                raw_state_vector: None,
+                raw_state_vector: None, solved_variables: Vec::new(),
            }],
        };

@@ -667,7 +667,7 @@ mod tests {
                initialization_diagnostics: None,
                dof: None,
                elapsed_ms: 50,
-                raw_state_vector: None,
+                raw_state_vector: None, solved_variables: Vec::new(),
            },
            SimulationResult {
                input: "ok2.json".to_string(),
@@ -681,7 +681,7 @@ mod tests {
                initialization_diagnostics: None,
                dof: None,
                elapsed_ms: 60,
-                raw_state_vector: None,
+                raw_state_vector: None, solved_variables: Vec::new(),
            },
            SimulationResult {
                input: "fail.json".to_string(),
@@ -695,7 +695,7 @@ mod tests {
                initialization_diagnostics: None,
                dof: None,
                elapsed_ms: 0,
-                raw_state_vector: None,
+                raw_state_vector: None, solved_variables: Vec::new(),
            },
        ];

--- a/crates/cli/src/run.rs
+++ b/crates/cli/src/run.rs
@@ -76,6 +76,13 @@ pub struct SimulationResult {
    /// solve via the `ENTROPYK_INIT_STATE_JSON` environment variable).
    #[serde(default, skip_serializing_if = "Option::is_none")]
    pub raw_state_vector: Option<Vec<f64>>,
+    /// Named solver-computed unknowns (free actuators + calibration factors
+    /// like `z_ua`, `opening`, `z_dp`) read out of `raw_state_vector` and
+    /// labeled with their stable id, owning component, and `[min, max]`
+    /// bounds. Empty for systems with no bounded control variables; skipped
+    /// on serialization when empty so older consumers keep working.
+    #[serde(default, skip_serializing_if = "Vec::is_empty")]
+    pub solved_variables: Vec<entropyk::SolvedVariable>,
 }

 /// Compact DoF summary for CLI / web API consumers.
@@ -365,7 +372,7 @@ fn execute_simulation(
            initialization_diagnostics: None,
            dof: None,
            elapsed_ms,
-            raw_state_vector: None,
+            raw_state_vector: None, solved_variables: Vec::new(),
        };
    }

@@ -400,7 +407,7 @@ fn execute_simulation(
                initialization_diagnostics: None,
                dof: None,
                elapsed_ms,
-                raw_state_vector: None,
+                raw_state_vector: None, solved_variables: Vec::new(),
            };
        }
    };
@@ -710,7 +717,7 @@ fn execute_simulation(
                            initialization_diagnostics: None,
                            dof: None,
                            elapsed_ms,
-                            raw_state_vector: None,
+                            raw_state_vector: None, solved_variables: Vec::new(),
                        };
                    }
                },
@@ -730,7 +737,7 @@ fn execute_simulation(
                        initialization_diagnostics: None,
                        dof: None,
                        elapsed_ms,
-                        raw_state_vector: None,
+                        raw_state_vector: None, solved_variables: Vec::new(),
                    };
                }
            }
@@ -775,7 +782,7 @@ fn execute_simulation(
                                    initialization_diagnostics: None,
                                    dof: None,
                                    elapsed_ms,
-                                    raw_state_vector: None,
+                                    raw_state_vector: None, solved_variables: Vec::new(),
                                };
                            }
                        },
@@ -795,7 +802,7 @@ fn execute_simulation(
                                initialization_diagnostics: None,
                                dof: None,
                                elapsed_ms,
-                raw_state_vector: None,
+                raw_state_vector: None, solved_variables: Vec::new(),
            };
                        }
                        None => 1,
@@ -816,7 +823,7 @@ fn execute_simulation(
                                    initialization_diagnostics: None,
                                    dof: None,
                                    elapsed_ms,
-                                    raw_state_vector: None,
+                                    raw_state_vector: None, solved_variables: Vec::new(),
                                };
                            }
                        },
@@ -836,7 +843,7 @@ fn execute_simulation(
                                initialization_diagnostics: None,
                                dof: None,
                                elapsed_ms,
-                raw_state_vector: None,
+                raw_state_vector: None, solved_variables: Vec::new(),
            };
                        }
                        None => 0,
@@ -860,7 +867,7 @@ fn execute_simulation(
                            initialization_diagnostics: None,
                            dof: None,
                            elapsed_ms,
-                            raw_state_vector: None,
+                            raw_state_vector: None, solved_variables: Vec::new(),
                        };
                    }
                }
@@ -880,7 +887,7 @@ fn execute_simulation(
                        initialization_diagnostics: None,
                        dof: None,
                        elapsed_ms,
-                        raw_state_vector: None,
+                        raw_state_vector: None, solved_variables: Vec::new(),
                    };
                }
            }
@@ -950,7 +957,7 @@ fn execute_simulation(
                initialization_diagnostics: None,
                dof: None,
                elapsed_ms,
-                raw_state_vector: None,
+                raw_state_vector: None, solved_variables: Vec::new(),
            };
        }
    }
@@ -976,7 +983,7 @@ fn execute_simulation(
            initialization_diagnostics: None,
            dof: None,
            elapsed_ms,
-            raw_state_vector: None,
+            raw_state_vector: None, solved_variables: Vec::new(),
        };
        let find_component = |name: &str| {
            config
@@ -1054,7 +1061,7 @@ fn execute_simulation(
                        initialization_diagnostics: None,
                        dof: None,
                        elapsed_ms,
-                        raw_state_vector: None,
+                        raw_state_vector: None, solved_variables: Vec::new(),
                    };
                }
                system.add_saturated_controller(controller);
@@ -1072,7 +1079,7 @@ fn execute_simulation(
                    initialization_diagnostics: None,
                    dof: None,
                    elapsed_ms,
-                    raw_state_vector: None,
+                    raw_state_vector: None, solved_variables: Vec::new(),
                };
            }
        }
@@ -1246,7 +1253,7 @@ fn execute_simulation(
                                initialization_diagnostics: None,
                                dof: None,
                                elapsed_ms,
-                                raw_state_vector: None,
+                                raw_state_vector: None, solved_variables: Vec::new(),
                            };
                        }
                        system.add_free_actuator(var_id);
@@ -1268,7 +1275,7 @@ fn execute_simulation(
                            initialization_diagnostics: None,
                            dof: None,
                            elapsed_ms,
-                            raw_state_vector: None,
+                            raw_state_vector: None, solved_variables: Vec::new(),
                        };
                    }
                }
@@ -1289,7 +1296,7 @@ fn execute_simulation(
            initialization_diagnostics: None,
            dof: None,
            elapsed_ms,
-            raw_state_vector: None,
+            raw_state_vector: None, solved_variables: Vec::new(),
        };
    }

@@ -1320,7 +1327,7 @@ fn execute_simulation(
                initialization_diagnostics: None,
                dof: Some(summary),
                elapsed_ms,
-                raw_state_vector: None,
+                raw_state_vector: None, solved_variables: Vec::new(),
            };
        }
        summary
@@ -1517,7 +1524,7 @@ fn execute_simulation(
            initialization_diagnostics: None,
            dof: Some(dof_summary),
            elapsed_ms,
-            raw_state_vector: None,
+            raw_state_vector: None, solved_variables: Vec::new(),
        };
    }

@@ -1746,6 +1753,7 @@ fn execute_simulation(
                dof: Some(dof_summary.clone()),
                elapsed_ms,
                raw_state_vector: Some(converged.state.clone()),
+                solved_variables: entropyk::extract_solved_variables(&system, &converged.state),
            }
        }
        Err(e) => {
@@ -1791,7 +1799,7 @@ fn execute_simulation(
                initialization_diagnostics: Some(initialization_diagnostics),
                dof: Some(dof_summary),
                elapsed_ms,
-                raw_state_vector: None,
+                raw_state_vector: None, solved_variables: Vec::new(),
            }
        }
    }
@@ -2939,6 +2947,32 @@ fn bphx_correlation_from_params(
    Ok(Some(correlation))
 }

+/// Parse BPHX frictional `dp_correlation` / `DpCorrelation` (independent of HTC).
+///
+/// Default when absent: `SimplifiedChannel`. Unknown ids are rejected (no silent isobaric).
+fn bphx_dp_correlation_from_params(
+    params: &std::collections::HashMap<String, serde_json::Value>,
+    component_name: &str,
+) -> CliResult<entropyk_components::heat_exchanger::BphxDpCorrelation> {
+    use entropyk_components::heat_exchanger::BphxDpCorrelation;
+
+    let Some(value) = params
+        .get("dp_correlation")
+        .or_else(|| params.get("DpCorrelation"))
+        .or_else(|| params.get("dpCorrelation"))
+    else {
+        return Ok(BphxDpCorrelation::default());
+    };
+    let Some(raw) = value.as_str() else {
+        return Err(CliError::Config(format!(
+            "{component_name}: dp_correlation must be a string (got {value})"
+        )));
+    };
+    BphxDpCorrelation::parse(raw).map_err(|msg| {
+        CliError::Config(format!("{component_name}: {msg}"))
+    })
+}
+
 /// Extract calibration Z-factors for BphxEvaporator/BphxCondenser from JSON params.
 ///
 /// Errors if `ua_nominal == 0` and an explicit `ua` override is provided (geometry is
@@ -5095,7 +5129,11 @@ fn create_component(
                .with_target_superheat(target_superheat)
                .with_refrigerant(refrigerant)
                .with_secondary_fluid(secondary_fluid)
-                .with_fluid_backend(Arc::clone(&backend));
+                .with_fluid_backend(Arc::clone(&backend))
+                .with_dp_correlation(bphx_dp_correlation_from_params(
+                    params,
+                    "BphxEvaporator",
+                )?);
            if let Some(correlation) =
                bphx_correlation_from_params(params, "BphxEvaporator")?
            {
@@ -5151,7 +5189,11 @@ fn create_component(
                .with_refrigerant(refrigerant)
                .with_secondary_fluid(secondary_fluid)
                .with_fluid_backend(Arc::clone(&backend))
-                .with_target_subcooling(target_subcooling);
+                .with_target_subcooling(target_subcooling)
+                .with_dp_correlation(bphx_dp_correlation_from_params(
+                    params,
+                    "BphxCondenser",
+                )?);
            if let Some(correlation) =
                bphx_correlation_from_params(params, "BphxCondenser")?
            {
@@ -5630,7 +5672,7 @@ mod tests {
            initialization_diagnostics: None,
            dof: None,
            elapsed_ms: 50,
-            raw_state_vector: None,
+            raw_state_vector: None, solved_variables: Vec::new(),
        };

        let json = serde_json::to_string_pretty(&result).unwrap();
@@ -5787,6 +5829,56 @@ mod tests {
        );
    }

+    #[test]
+    fn test_bphx_dp_correlation_defaults_and_aliases() {
+        use entropyk_components::heat_exchanger::BphxDpCorrelation;
+        use serde_json::json;
+
+        assert_eq!(
+            bphx_dp_correlation_from_params(&std::collections::HashMap::new(), "BphxEvaporator")
+                .unwrap(),
+            BphxDpCorrelation::SimplifiedChannel
+        );
+        let params = std::collections::HashMap::from([(
+            "DpCorrelation".to_string(),
+            json!("Martin1996"),
+        )]);
+        assert_eq!(
+            bphx_dp_correlation_from_params(&params, "BphxCondenser").unwrap(),
+            BphxDpCorrelation::Martin1996
+        );
+    }
+
+    #[test]
+    fn test_bphx_dp_correlation_rejects_unknown() {
+        use serde_json::json;
+
+        let params = std::collections::HashMap::from([(
+            "dp_correlation".to_string(),
+            json!("Amalfi2016"),
+        )]);
+        let error = bphx_dp_correlation_from_params(&params, "BphxEvaporator").unwrap_err();
+        assert!(
+            error.to_string().contains("unsupported dp_correlation"),
+            "{error}"
+        );
+    }
+
+    #[test]
+    fn test_bphx_dp_correlation_rejects_non_string() {
+        use serde_json::json;
+
+        let params = std::collections::HashMap::from([(
+            "dp_correlation".to_string(),
+            json!(42),
+        )]);
+        let error = bphx_dp_correlation_from_params(&params, "BphxEvaporator").unwrap_err();
+        assert!(
+            error.to_string().contains("must be a string"),
+            "{error}"
+        );
+    }
+
    fn comp_from_json(v: serde_json::Value) -> crate::config::ComponentConfig {
        serde_json::from_value(v).expect("valid component JSON")
    }
--- a/crates/cli/tests/batch_execution.rs
+++ b/crates/cli/tests/batch_execution.rs
@@ -92,7 +92,7 @@ fn test_simulation_result_statuses() {
            initialization_diagnostics: None,
            dof: None,
            elapsed_ms: 50,
-            raw_state_vector: None,
+            raw_state_vector: None, solved_variables: Vec::new(),
        },
        SimulationResult {
            input: "fail.json".to_string(),
@@ -106,7 +106,7 @@ fn test_simulation_result_statuses() {
            initialization_diagnostics: None,
            dof: None,
            elapsed_ms: 0,
-            raw_state_vector: None,
+            raw_state_vector: None, solved_variables: Vec::new(),
        },
        SimulationResult {
            input: "timeout.json".to_string(),
@@ -120,7 +120,7 @@ fn test_simulation_result_statuses() {
            initialization_diagnostics: None,
            dof: None,
            elapsed_ms: 1000,
-            raw_state_vector: None,
+            raw_state_vector: None, solved_variables: Vec::new(),
        },
    ];

@@ -163,7 +163,7 @@ fn test_batch_aggregator_csv_output() {
            initialization_diagnostics: None,
            dof: None,
            elapsed_ms: 150,
-            raw_state_vector: None,
+            raw_state_vector: None, solved_variables: Vec::new(),
        },
        SimulationResult {
            input: "scenario2.json".to_string(),
@@ -183,7 +183,7 @@ fn test_batch_aggregator_csv_output() {
            initialization_diagnostics: None,
            dof: None,
            elapsed_ms: 200,
-            raw_state_vector: None,
+            raw_state_vector: None, solved_variables: Vec::new(),
        },
        SimulationResult {
            input: "scenario3.json".to_string(),
@@ -197,7 +197,7 @@ fn test_batch_aggregator_csv_output() {
            initialization_diagnostics: None,
            dof: None,
            elapsed_ms: 0,
-            raw_state_vector: None,
+            raw_state_vector: None, solved_variables: Vec::new(),
        },
    ];

@@ -229,7 +229,7 @@ fn test_batch_aggregator_json_summary() {
            initialization_diagnostics: None,
            dof: None,
            elapsed_ms: 50,
-            raw_state_vector: None,
+            raw_state_vector: None, solved_variables: Vec::new(),
        },
        SimulationResult {
            input: "test2.json".to_string(),
@@ -243,7 +243,7 @@ fn test_batch_aggregator_json_summary() {
            initialization_diagnostics: None,
            dof: None,
            elapsed_ms: 75,
-            raw_state_vector: None,
+            raw_state_vector: None, solved_variables: Vec::new(),
        },
        SimulationResult {
            input: "test3.json".to_string(),
@@ -257,7 +257,7 @@ fn test_batch_aggregator_json_summary() {
            initialization_diagnostics: None,
            dof: None,
            elapsed_ms: 5000,
-            raw_state_vector: None,
+            raw_state_vector: None, solved_variables: Vec::new(),
        },
    ];

@@ -322,7 +322,7 @@ fn test_batch_summary_csv_with_convergence() {
        initialization_diagnostics: None,
        dof: None,
        elapsed_ms: 300,
-        raw_state_vector: None,
+        raw_state_vector: None, solved_variables: Vec::new(),
    }];

    let summary = BatchSummary {
--- a/crates/cli/tests/single_run.rs
+++ b/crates/cli/tests/single_run.rs
@@ -29,7 +29,7 @@ fn test_simulation_result_serialization() {
        initialization_diagnostics: None,
        dof: None,
        elapsed_ms: 50,
-        raw_state_vector: None,
+        raw_state_vector: None, solved_variables: Vec::new(),
    };

    let json = serde_json::to_string_pretty(&result).unwrap();
@@ -70,7 +70,7 @@ fn test_error_result_serialization() {
        initialization_diagnostics: None,
        dof: None,
        elapsed_ms: 0,
-        raw_state_vector: None,
+        raw_state_vector: None, solved_variables: Vec::new(),
    };

    let json = serde_json::to_string(&result).unwrap();
@@ -96,7 +96,7 @@ fn test_error_result_serializes_failure_diagnostics() {
        initialization_diagnostics: None,
        dof: None,
        elapsed_ms: 0,
-        raw_state_vector: None,
+        raw_state_vector: None, solved_variables: Vec::new(),
    };

    let json = serde_json::to_string(&result).unwrap();
@@ -2303,7 +2303,7 @@ fn test_structural_failure_serializes_without_diagnostics() {
        initialization_diagnostics: None,
        dof: None,
        elapsed_ms: 0,
-        raw_state_vector: None,
+        raw_state_vector: None, solved_variables: Vec::new(),
    };

    let json = serde_json::to_string(&result).unwrap();
@@ -2348,7 +2348,7 @@ fn test_success_result_does_not_include_failure_diagnostics() {
        initialization_diagnostics: None,
        dof: None,
        elapsed_ms: 120,
-        raw_state_vector: None,
+        raw_state_vector: None, solved_variables: Vec::new(),
    };

    let json = serde_json::to_string(&result).unwrap();