feat(components): add ThermoState generators and Eurovent backend demo

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Sepehr
2026-02-20 22:01:38 +01:00
parent 375d288950
commit 4a40fddfe3
271 changed files with 28614 additions and 447 deletions

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//! Pump Component Implementation
//!
//! This module provides a pump component for hydraulic systems using
//! polynomial performance curves and affinity laws for variable speed operation.
//!
//! ## Performance Curves
//!
//! **Head Curve:** H = a₀ + a₁Q + a₂Q² + a₃Q³
//!
//! **Efficiency Curve:** η = b₀ + b₁Q + b₂Q²
//!
//! **Hydraulic Power:** P_hydraulic = ρ × g × Q × H / η
//!
//! ## Affinity Laws (Variable Speed)
//!
//! When operating at reduced speed (VFD):
//! - Q₂/Q₁ = N₂/N₁
//! - H₂/H₁ = (N₂/N₁)²
//! - P₂/P₁ = (N₂/N₁)³
use crate::polynomials::{AffinityLaws, PerformanceCurves, Polynomial1D};
use crate::port::{Connected, Disconnected, FluidId, Port};
use crate::state_machine::StateManageable;
use crate::{
CircuitId, Component, ComponentError, ConnectedPort, JacobianBuilder, OperationalState,
ResidualVector, SystemState,
};
use entropyk_core::{MassFlow, Power};
use serde::{Deserialize, Serialize};
use std::marker::PhantomData;
/// Pump performance curve coefficients.
///
/// Defines the polynomial coefficients for the pump's head-flow curve
/// and efficiency curve.
#[derive(Debug, Clone, PartialEq, Serialize, Deserialize)]
pub struct PumpCurves {
/// Performance curves (head, efficiency, optional power)
curves: PerformanceCurves,
}
impl PumpCurves {
/// Creates pump curves from performance curves.
pub fn new(curves: PerformanceCurves) -> Result<Self, ComponentError> {
curves.validate()?;
Ok(Self { curves })
}
/// Creates pump curves from polynomial coefficients.
///
/// # Arguments
///
/// * `head_coeffs` - Head curve coefficients [a0, a1, a2, ...] for H = a0 + a1*Q + a2*Q²
/// * `eff_coeffs` - Efficiency coefficients [b0, b1, b2, ...] for η = b0 + b1*Q + b2*Q²
///
/// # Units
///
/// * Q (flow) in m³/s
/// * H (head) in meters
/// * η (efficiency) as decimal (0.0 to 1.0)
pub fn from_coefficients(
head_coeffs: Vec<f64>,
eff_coeffs: Vec<f64>,
) -> Result<Self, ComponentError> {
let head_curve = Polynomial1D::new(head_coeffs);
let eff_curve = Polynomial1D::new(eff_coeffs);
let curves = PerformanceCurves::simple(head_curve, eff_curve);
Self::new(curves)
}
/// Creates a quadratic pump curve.
///
/// H = a0 + a1*Q + a2*Q²
/// η = b0 + b1*Q + b2*Q²
pub fn quadratic(
h0: f64,
h1: f64,
h2: f64,
e0: f64,
e1: f64,
e2: f64,
) -> Result<Self, ComponentError> {
Self::from_coefficients(vec![h0, h1, h2], vec![e0, e1, e2])
}
/// Creates a cubic pump curve (3rd-order polynomial for head).
///
/// H = a0 + a1*Q + a2*Q² + a3*Q³
/// η = b0 + b1*Q + b2*Q²
pub fn cubic(
h0: f64,
h1: f64,
h2: f64,
h3: f64,
e0: f64,
e1: f64,
e2: f64,
) -> Result<Self, ComponentError> {
Self::from_coefficients(vec![h0, h1, h2, h3], vec![e0, e1, e2])
}
/// Returns the head at the given flow rate (at full speed).
///
/// # Arguments
///
/// * `flow_m3_per_s` - Volumetric flow rate in m³/s
///
/// # Returns
///
/// Head in meters
pub fn head_at_flow(&self, flow_m3_per_s: f64) -> f64 {
self.curves.head_curve.evaluate(flow_m3_per_s)
}
/// Returns the efficiency at the given flow rate (at full speed).
///
/// # Arguments
///
/// * `flow_m3_per_s` - Volumetric flow rate in m³/s
///
/// # Returns
///
/// Efficiency as decimal (0.0 to 1.0)
pub fn efficiency_at_flow(&self, flow_m3_per_s: f64) -> f64 {
let eta = self.curves.efficiency_curve.evaluate(flow_m3_per_s);
// Clamp efficiency to valid range
eta.clamp(0.0, 1.0)
}
/// Returns reference to the performance curves.
pub fn curves(&self) -> &PerformanceCurves {
&self.curves
}
}
impl Default for PumpCurves {
fn default() -> Self {
Self::quadratic(30.0, 0.0, 0.0, 0.7, 0.0, 0.0).unwrap()
}
}
/// A pump component with polynomial performance curves.
///
/// The pump uses the Type-State pattern to ensure ports are connected
/// before use in simulations.
///
/// # Example
///
/// ```ignore
/// use entropyk_components::pump::{Pump, PumpCurves};
/// use entropyk_components::port::{FluidId, Port};
/// use entropyk_core::{Pressure, Enthalpy};
///
/// // Create pump curves: H = 30 - 10*Q - 50*Q² (in m and m³/s)
/// let curves = PumpCurves::quadratic(30.0, -10.0, -50.0, 0.5, 0.3, -0.5).unwrap();
///
/// let inlet = Port::new(
/// FluidId::new("Water"),
/// Pressure::from_bar(1.0),
/// Enthalpy::from_joules_per_kg(100000.0),
/// );
/// let outlet = Port::new(
/// FluidId::new("Water"),
/// Pressure::from_bar(1.0),
/// Enthalpy::from_joules_per_kg(100000.0),
/// );
///
/// let pump = Pump::new(curves, inlet, outlet, 1000.0).unwrap();
/// ```
#[derive(Debug, Clone)]
pub struct Pump<State> {
/// Performance curves
curves: PumpCurves,
/// Inlet port
port_inlet: Port<State>,
/// Outlet port
port_outlet: Port<State>,
/// Fluid density in kg/m³
fluid_density_kg_per_m3: f64,
/// Speed ratio (0.0 to 1.0), default 1.0 (full speed)
speed_ratio: f64,
/// Circuit identifier
circuit_id: CircuitId,
/// Operational state
operational_state: OperationalState,
/// Phantom data for type state
_state: PhantomData<State>,
}
impl Pump<Disconnected> {
/// Creates a new disconnected pump.
///
/// # Arguments
///
/// * `curves` - Pump performance curves
/// * `port_inlet` - Inlet port (disconnected)
/// * `port_outlet` - Outlet port (disconnected)
/// * `fluid_density` - Fluid density in kg/m³
///
/// # Errors
///
/// Returns an error if:
/// - Ports have different fluid types
/// - Fluid density is not positive
pub fn new(
curves: PumpCurves,
port_inlet: Port<Disconnected>,
port_outlet: Port<Disconnected>,
fluid_density: f64,
) -> Result<Self, ComponentError> {
if port_inlet.fluid_id() != port_outlet.fluid_id() {
return Err(ComponentError::InvalidState(
"Inlet and outlet ports must have the same fluid type".to_string(),
));
}
if fluid_density <= 0.0 {
return Err(ComponentError::InvalidState(
"Fluid density must be positive".to_string(),
));
}
Ok(Self {
curves,
port_inlet,
port_outlet,
fluid_density_kg_per_m3: fluid_density,
speed_ratio: 1.0,
circuit_id: CircuitId::default(),
operational_state: OperationalState::default(),
_state: PhantomData,
})
}
/// Returns the fluid identifier.
pub fn fluid_id(&self) -> &FluidId {
self.port_inlet.fluid_id()
}
/// Returns the inlet port.
pub fn port_inlet(&self) -> &Port<Disconnected> {
&self.port_inlet
}
/// Returns the outlet port.
pub fn port_outlet(&self) -> &Port<Disconnected> {
&self.port_outlet
}
/// Returns the fluid density.
pub fn fluid_density(&self) -> f64 {
self.fluid_density_kg_per_m3
}
/// Returns the performance curves.
pub fn curves(&self) -> &PumpCurves {
&self.curves
}
/// Returns the speed ratio.
pub fn speed_ratio(&self) -> f64 {
self.speed_ratio
}
/// Sets the speed ratio (0.0 to 1.0).
pub fn set_speed_ratio(&mut self, ratio: f64) -> Result<(), ComponentError> {
if !(0.0..=1.0).contains(&ratio) {
return Err(ComponentError::InvalidState(
"Speed ratio must be between 0.0 and 1.0".to_string(),
));
}
self.speed_ratio = ratio;
Ok(())
}
}
impl Pump<Connected> {
/// Returns the inlet port.
pub fn port_inlet(&self) -> &Port<Connected> {
&self.port_inlet
}
/// Returns the outlet port.
pub fn port_outlet(&self) -> &Port<Connected> {
&self.port_outlet
}
/// Calculates the pressure rise across the pump.
///
/// Uses the head curve and converts to pressure:
/// ΔP = ρ × g × H
///
/// Applies affinity laws for variable speed operation.
///
/// # Arguments
///
/// * `flow_m3_per_s` - Volumetric flow rate in m³/s
///
/// # Returns
///
/// Pressure rise in Pascals
pub fn pressure_rise(&self, flow_m3_per_s: f64) -> f64 {
// Handle zero speed - pump produces no pressure
if self.speed_ratio <= 0.0 {
return 0.0;
}
// Handle zero flow
if flow_m3_per_s <= 0.0 {
// At zero flow, use the shut-off head scaled by speed
let head_m = self.curves.head_at_flow(0.0);
let actual_head = AffinityLaws::scale_head(head_m, self.speed_ratio);
const G: f64 = 9.80665; // m/s²
return self.fluid_density_kg_per_m3 * G * actual_head;
}
// Apply affinity law to get equivalent flow at full speed
let equivalent_flow = AffinityLaws::unscale_flow(flow_m3_per_s, self.speed_ratio);
// Get head at equivalent flow
let head_m = self.curves.head_at_flow(equivalent_flow);
// Apply affinity law to scale head back to actual speed
let actual_head = AffinityLaws::scale_head(head_m, self.speed_ratio);
// Convert head to pressure: P = ρ × g × H
const G: f64 = 9.80665; // m/s²
self.fluid_density_kg_per_m3 * G * actual_head
}
/// Calculates the efficiency at the given flow rate.
///
/// Applies affinity laws to find the equivalent operating point.
pub fn efficiency(&self, flow_m3_per_s: f64) -> f64 {
// Handle zero speed - pump is not running
if self.speed_ratio <= 0.0 {
return 0.0;
}
// Handle zero flow
if flow_m3_per_s <= 0.0 {
return self.curves.efficiency_at_flow(0.0);
}
let equivalent_flow = AffinityLaws::unscale_flow(flow_m3_per_s, self.speed_ratio);
self.curves.efficiency_at_flow(equivalent_flow)
}
/// Calculates the hydraulic power consumption.
///
/// P_hydraulic = Q × ΔP / η
///
/// # Arguments
///
/// * `flow_m3_per_s` - Volumetric flow rate in m³/s
///
/// # Returns
///
/// Power in Watts
pub fn hydraulic_power(&self, flow_m3_per_s: f64) -> Power {
if flow_m3_per_s <= 0.0 || self.speed_ratio <= 0.0 {
return Power::from_watts(0.0);
}
let delta_p = self.pressure_rise(flow_m3_per_s);
let eta = self.efficiency(flow_m3_per_s);
if eta <= 0.0 {
return Power::from_watts(0.0);
}
// P = Q × ΔP / η
let power_w = flow_m3_per_s * delta_p / eta;
Power::from_watts(power_w)
}
/// Calculates mass flow rate from volumetric flow.
pub fn mass_flow_from_volumetric(&self, flow_m3_per_s: f64) -> MassFlow {
MassFlow::from_kg_per_s(flow_m3_per_s * self.fluid_density_kg_per_m3)
}
/// Calculates volumetric flow rate from mass flow.
pub fn volumetric_from_mass_flow(&self, mass_flow: MassFlow) -> f64 {
mass_flow.to_kg_per_s() / self.fluid_density_kg_per_m3
}
/// Returns the fluid density.
pub fn fluid_density(&self) -> f64 {
self.fluid_density_kg_per_m3
}
/// Returns the performance curves.
pub fn curves(&self) -> &PumpCurves {
&self.curves
}
/// Returns the speed ratio.
pub fn speed_ratio(&self) -> f64 {
self.speed_ratio
}
/// Sets the speed ratio (0.0 to 1.0).
pub fn set_speed_ratio(&mut self, ratio: f64) -> Result<(), ComponentError> {
if !(0.0..=1.0).contains(&ratio) {
return Err(ComponentError::InvalidState(
"Speed ratio must be between 0.0 and 1.0".to_string(),
));
}
self.speed_ratio = ratio;
Ok(())
}
/// Returns both ports as a slice for solver topology.
pub fn get_ports_slice(&self) -> [&Port<Connected>; 2] {
[&self.port_inlet, &self.port_outlet]
}
}
impl Component for Pump<Connected> {
fn compute_residuals(
&self,
state: &SystemState,
residuals: &mut ResidualVector,
) -> Result<(), ComponentError> {
if residuals.len() != self.n_equations() {
return Err(ComponentError::InvalidResidualDimensions {
expected: self.n_equations(),
actual: residuals.len(),
});
}
// Handle operational states
match self.operational_state {
OperationalState::Off => {
residuals[0] = state[0]; // Mass flow = 0
residuals[1] = 0.0; // No energy transfer
return Ok(());
}
OperationalState::Bypass => {
// Behaves as a pipe: no pressure rise, no energy change
let p_in = self.port_inlet.pressure().to_pascals();
let p_out = self.port_outlet.pressure().to_pascals();
let h_in = self.port_inlet.enthalpy().to_joules_per_kg();
let h_out = self.port_outlet.enthalpy().to_joules_per_kg();
residuals[0] = p_in - p_out;
residuals[1] = h_in - h_out;
return Ok(());
}
OperationalState::On => {}
}
if state.len() < 2 {
return Err(ComponentError::InvalidStateDimensions {
expected: 2,
actual: state.len(),
});
}
// State: [mass_flow_kg_s, power_w]
let mass_flow_kg_s = state[0];
let _power_w = state[1];
// Convert to volumetric flow
let flow_m3_s = mass_flow_kg_s / self.fluid_density_kg_per_m3;
// Calculate pressure rise from curves
let delta_p_calc = self.pressure_rise(flow_m3_s);
// Get port pressures
let p_in = self.port_inlet.pressure().to_pascals();
let p_out = self.port_outlet.pressure().to_pascals();
let delta_p_actual = p_out - p_in;
// Residual 0: Pressure balance
residuals[0] = delta_p_calc - delta_p_actual;
// Residual 1: Power balance
let power_calc = self.hydraulic_power(flow_m3_s).to_watts();
residuals[1] = power_calc - _power_w;
Ok(())
}
fn jacobian_entries(
&self,
state: &SystemState,
jacobian: &mut JacobianBuilder,
) -> Result<(), ComponentError> {
if state.len() < 2 {
return Err(ComponentError::InvalidStateDimensions {
expected: 2,
actual: state.len(),
});
}
let mass_flow_kg_s = state[0];
let flow_m3_s = mass_flow_kg_s / self.fluid_density_kg_per_m3;
// Numerical derivative of pressure with respect to mass flow
let h = 0.001;
let p_plus = self.pressure_rise(flow_m3_s + h / self.fluid_density_kg_per_m3);
let p_minus = self.pressure_rise(flow_m3_s - h / self.fluid_density_kg_per_m3);
let dp_dm = (p_plus - p_minus) / (2.0 * h);
// ∂r₀/∂ṁ = dΔP/dṁ
jacobian.add_entry(0, 0, dp_dm);
// ∂r₀/∂P = -1 (constant)
jacobian.add_entry(0, 1, 0.0);
// Numerical derivative of power with respect to mass flow
let pow_plus = self
.hydraulic_power(flow_m3_s + h / self.fluid_density_kg_per_m3)
.to_watts();
let pow_minus = self
.hydraulic_power(flow_m3_s - h / self.fluid_density_kg_per_m3)
.to_watts();
let dpow_dm = (pow_plus - pow_minus) / (2.0 * h);
// ∂r₁/∂ṁ
jacobian.add_entry(1, 0, dpow_dm);
// ∂r₁/∂P = -1
jacobian.add_entry(1, 1, -1.0);
Ok(())
}
fn n_equations(&self) -> usize {
2
}
fn get_ports(&self) -> &[ConnectedPort] {
&[]
}
}
impl StateManageable for Pump<Connected> {
fn state(&self) -> OperationalState {
self.operational_state
}
fn set_state(&mut self, state: OperationalState) -> Result<(), ComponentError> {
if self.operational_state.can_transition_to(state) {
let from = self.operational_state;
self.operational_state = state;
self.on_state_change(from, state);
Ok(())
} else {
Err(ComponentError::InvalidStateTransition {
from: self.operational_state,
to: state,
reason: "Transition not allowed".to_string(),
})
}
}
fn can_transition_to(&self, target: OperationalState) -> bool {
self.operational_state.can_transition_to(target)
}
fn circuit_id(&self) -> &CircuitId {
&self.circuit_id
}
fn set_circuit_id(&mut self, circuit_id: CircuitId) {
self.circuit_id = circuit_id;
}
}
#[cfg(test)]
mod tests {
use super::*;
use crate::port::FluidId;
use approx::assert_relative_eq;
use entropyk_core::{Enthalpy, Pressure};
fn create_test_curves() -> PumpCurves {
// Typical small pump:
// H = 30 - 10*Q - 50*Q² (m, Q in m³/s)
// η = 0.6 + 1.0*Q - 2.0*Q²
PumpCurves::quadratic(30.0, -10.0, -50.0, 0.6, 1.0, -2.0).unwrap()
}
fn create_test_pump_disconnected() -> Pump<Disconnected> {
let curves = create_test_curves();
let inlet = Port::new(
FluidId::new("Water"),
Pressure::from_bar(1.0),
Enthalpy::from_joules_per_kg(100000.0),
);
let outlet = Port::new(
FluidId::new("Water"),
Pressure::from_bar(1.0),
Enthalpy::from_joules_per_kg(100000.0),
);
Pump::new(curves, inlet, outlet, 1000.0).unwrap()
}
fn create_test_pump_connected() -> Pump<Connected> {
let curves = create_test_curves();
let inlet = Port::new(
FluidId::new("Water"),
Pressure::from_bar(1.0),
Enthalpy::from_joules_per_kg(100000.0),
);
let outlet = Port::new(
FluidId::new("Water"),
Pressure::from_bar(1.0),
Enthalpy::from_joules_per_kg(100000.0),
);
let (inlet_conn, outlet_conn) = inlet.connect(outlet).unwrap();
Pump {
curves,
port_inlet: inlet_conn,
port_outlet: outlet_conn,
fluid_density_kg_per_m3: 1000.0,
speed_ratio: 1.0,
circuit_id: CircuitId::default(),
operational_state: OperationalState::default(),
_state: PhantomData,
}
}
#[test]
fn test_pump_curves_creation() {
let curves = create_test_curves();
assert_eq!(curves.head_at_flow(0.0), 30.0);
assert_relative_eq!(curves.efficiency_at_flow(0.0), 0.6);
}
#[test]
fn test_pump_curves_head() {
let curves = create_test_curves();
// H = 30 - 10*0.5 - 50*0.25 = 30 - 5 - 12.5 = 12.5 m
let head = curves.head_at_flow(0.5);
assert_relative_eq!(head, 12.5, epsilon = 1e-10);
}
#[test]
fn test_pump_curves_efficiency_clamped() {
let curves = create_test_curves();
// At very high flow, efficiency might go negative
// Should be clamped to 0
let eff = curves.efficiency_at_flow(10.0);
assert!(eff >= 0.0);
}
#[test]
fn test_pump_creation() {
let pump = create_test_pump_disconnected();
assert_eq!(pump.fluid_density(), 1000.0);
assert_eq!(pump.speed_ratio(), 1.0);
}
#[test]
fn test_pump_invalid_density() {
let curves = create_test_curves();
let inlet = Port::new(
FluidId::new("Water"),
Pressure::from_bar(1.0),
Enthalpy::from_joules_per_kg(100000.0),
);
let outlet = Port::new(
FluidId::new("Water"),
Pressure::from_bar(1.0),
Enthalpy::from_joules_per_kg(100000.0),
);
let result = Pump::new(curves, inlet, outlet, -1.0);
assert!(result.is_err());
}
#[test]
fn test_pump_different_fluids() {
let curves = create_test_curves();
let inlet = Port::new(
FluidId::new("Water"),
Pressure::from_bar(1.0),
Enthalpy::from_joules_per_kg(100000.0),
);
let outlet = Port::new(
FluidId::new("Glycol"),
Pressure::from_bar(1.0),
Enthalpy::from_joules_per_kg(100000.0),
);
let result = Pump::new(curves, inlet, outlet, 1000.0);
assert!(result.is_err());
}
#[test]
fn test_pump_set_speed_ratio() {
let mut pump = create_test_pump_connected();
assert!(pump.set_speed_ratio(0.8).is_ok());
assert_eq!(pump.speed_ratio(), 0.8);
}
#[test]
fn test_pump_set_speed_ratio_invalid() {
let mut pump = create_test_pump_connected();
assert!(pump.set_speed_ratio(1.5).is_err());
assert!(pump.set_speed_ratio(-0.1).is_err());
}
#[test]
fn test_pump_pressure_rise_full_speed() {
let pump = create_test_pump_connected();
// At Q=0: H=30m, P = 1000 * 9.8 * 30 ≈ 294200 Pa
let delta_p = pump.pressure_rise(0.0);
let expected = 1000.0 * 9.80665 * 30.0;
assert_relative_eq!(delta_p, expected, epsilon = 100.0);
}
#[test]
fn test_pump_pressure_rise_reduced_speed() {
let mut pump = create_test_pump_connected();
pump.set_speed_ratio(0.5).unwrap();
// At 50% speed, shut-off head is 25% of full speed
// H = 0.25 * 30 = 7.5 m
let delta_p = pump.pressure_rise(0.0);
let expected = 1000.0 * 9.80665 * 7.5;
assert_relative_eq!(delta_p, expected, epsilon = 100.0);
}
#[test]
fn test_pump_hydraulic_power() {
let pump = create_test_pump_connected();
// At Q=0.1 m³/s: H ≈ 30 - 1 - 0.5 = 28.5 m
// η ≈ 0.6 + 0.1 - 0.02 = 0.68
// P = 1000 * 9.8 * 0.1 * 28.5 / 0.68 ≈ 4110 W
let power = pump.hydraulic_power(0.1);
assert!(power.to_watts() > 0.0);
assert!(power.to_watts() < 50000.0);
}
#[test]
fn test_pump_affinity_laws_power() {
let pump_full = create_test_pump_connected();
let mut pump_half = create_test_pump_connected();
pump_half.set_speed_ratio(0.5).unwrap();
// Power at half speed should be ~12.5% of full speed (cube law)
// At the same equivalent flow point
let power_full = pump_full.hydraulic_power(0.1);
let power_half = pump_half.hydraulic_power(0.05); // Half the flow
// P_half / P_full ≈ 0.5³ = 0.125
let ratio = power_half.to_watts() / power_full.to_watts();
assert_relative_eq!(ratio, 0.125, epsilon = 0.05);
}
#[test]
fn test_pump_component_n_equations() {
let pump = create_test_pump_connected();
assert_eq!(pump.n_equations(), 2);
}
#[test]
fn test_pump_component_compute_residuals() {
let pump = create_test_pump_connected();
let state = vec![50.0, 2000.0]; // mass flow, power
let mut residuals = vec![0.0; 2];
let result = pump.compute_residuals(&state, &mut residuals);
assert!(result.is_ok());
}
#[test]
fn test_pump_state_manageable() {
let pump = create_test_pump_connected();
assert_eq!(pump.state(), OperationalState::On);
assert!(pump.can_transition_to(OperationalState::Off));
}
}