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>
2026-07-19 16:35:31 +02:00
parent 88620790d6
commit 5bd180b5b8
1363 changed files with 101041 additions and 58547 deletions
--- a/crates/cli/examples/bphx_evaporator_condenser.json
+++ b/crates/cli/examples/bphx_evaporator_condenser.json
@@ -1,32 +1,112 @@
 {
-  "name": "BPHX Evaporator and Condenser Bounded Test",
+  "name": "BPHX Water-Cooled Chiller R134a",
+  "description": "Full vapor-compression cycle with brazed-plate evaporator and condenser (4-port). Both Bphx units use emergent_pressure so outlet closures (superheat / subcooling) square the DoF like Condenser/Evaporator.",
+
  "fluid": "R134a",
  "fluid_backend": "CoolProp",
+
  "circuits": [
    {
      "id": 0,
+      "name": "Refrigerant + water loops",
      "components": [
-        { "type": "RefrigerantSource", "name": "src", "fluid": "R134a", "p_set_bar": 5.0, "quality": 0.3 },
-        { "type": "BphxEvaporator", "name": "evap", "ua": 2000.0, "refrigerant": "R134a", "secondary_fluid": "Water", "secondary_inlet_temp_c": 12.0, "secondary_mass_flow_kg_s": 0.5, "secondary_cp_j_per_kgk": 4186.0 },
-        { "type": "RefrigerantSink", "name": "sink", "fluid": "R134a", "p_back_bar": 5.0 }
+        {
+          "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": "BphxCondenser",
+          "name": "cond",
+          "refrigerant": "R134a",
+          "secondary_fluid": "Water",
+          "n_plates": 40,
+          "plate_length_m": 0.40,
+          "plate_width_m": 0.12,
+          "target_subcooling_k": 5.0,
+          "emergent_pressure": true,
+          "correlation": "Longo2004",
+          "ua": 2500.0
+        },
+        {
+          "type": "IsenthalpicExpansionValve",
+          "name": "exv",
+          "t_evap_k": 278.15,
+          "emergent_pressure": true
+        },
+        {
+          "type": "BphxEvaporator",
+          "name": "evap",
+          "refrigerant": "R134a",
+          "secondary_fluid": "Water",
+          "n_plates": 40,
+          "plate_length_m": 0.40,
+          "plate_width_m": 0.12,
+          "target_superheat_k": 5.0,
+          "emergent_pressure": true,
+          "correlation": "Longo2004",
+          "ua": 2000.0
+        },
+        {
+          "type": "BrineSource",
+          "name": "cond_water_in",
+          "fluid": "Water",
+          "p_set_bar": 2.0,
+          "t_set_c": 30.0,
+          "m_flow_kg_s": 0.40,
+          "fix_pressure": false,
+          "fix_temperature": true,
+          "fix_mass_flow": true
+        },
+        {
+          "type": "BrineSink",
+          "name": "cond_water_out",
+          "fluid": "Water",
+          "p_back_bar": 2.0,
+          "fix_pressure": true
+        },
+        {
+          "type": "BrineSource",
+          "name": "evap_water_in",
+          "fluid": "Water",
+          "p_set_bar": 3.0,
+          "t_set_c": 12.0,
+          "m_flow_kg_s": 0.50,
+          "fix_pressure": false,
+          "fix_temperature": true,
+          "fix_mass_flow": true
+        },
+        {
+          "type": "BrineSink",
+          "name": "evap_water_out",
+          "fluid": "Water",
+          "p_back_bar": 3.0,
+          "fix_pressure": true
+        }
      ],
      "edges": [
-        { "from": "src:outlet", "to": "evap:inlet" },
-        { "from": "evap:outlet", "to": "sink:inlet" }
-      ]
-    },
-    {
-      "id": 1,
-      "components": [
-        { "type": "RefrigerantSource", "name": "src2", "fluid": "R134a", "p_set_bar": 15.0, "quality": 1.0 },
-        { "type": "BphxCondenser", "name": "cond", "ua": 2000.0, "refrigerant": "R134a", "secondary_fluid": "Water", "secondary_inlet_temp_c": 30.0, "secondary_mass_flow_kg_s": 0.4, "secondary_cp_j_per_kgk": 4186.0 },
-        { "type": "RefrigerantSink", "name": "sink2", "fluid": "R134a", "p_back_bar": 15.0 }
-      ],
-      "edges": [
-        { "from": "src2:outlet", "to": "cond:inlet" },
-        { "from": "cond:outlet", "to": "sink2:inlet" }
+        { "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": "fallback", "max_iterations": 100, "tolerance": 1e-6 }
+
+  "solver": {
+    "strategy": "fallback",
+    "max_iterations": 300,
+    "tolerance": 1e-6
+  }
 }
--- a/crates/cli/examples/capillary_tube_r134a.json
+++ b/crates/cli/examples/capillary_tube_r134a.json
@@ -1,12 +1,23 @@
 {
-  "schema_version": "1.0",
+  "schema_version": "1",
+  "name": "Capillary Tube R134a Smoke",
+  "description": "WIP smoke fixture: RefrigerantSource → CapillaryTube → RefrigerantSink. DoF can square, but CapillaryTube Component residuals are still stubs (mass/enthalpy continuity only — no frictional ΔP residual), so the Newton Jacobian is singular. Kept for parsing/wiring tests; not yet a UI Load example.",
+
  "fluid": "R134a",
  "fluid_backend": "CoolProp",
+
  "circuits": [
    {
      "id": 0,
      "name": "Capillary smoke",
      "components": [
+        {
+          "type": "RefrigerantSource",
+          "name": "src",
+          "fluid": "R134a",
+          "p_set_bar": 12.0,
+          "quality": 0.0
+        },
        {
          "type": "CapillaryTube",
          "name": "cap",
@@ -17,11 +28,21 @@
          "h_inlet_kj_kg": 250.0,
          "p_outlet_bar": 3.5,
          "h_outlet_kj_kg": 250.0
+        },
+        {
+          "type": "RefrigerantSink",
+          "name": "sink",
+          "fluid": "R134a",
+          "p_back_bar": 3.5
        }
      ],
-      "edges": []
+      "edges": [
+        { "from": "src:outlet", "to": "cap:inlet" },
+        { "from": "cap:outlet", "to": "sink:inlet" }
+      ]
    }
  ],
+
  "solver": {
    "strategy": "newton",
    "max_iterations": 50,
--- a/crates/cli/examples/chiller_aircooled_r134a_fan.json
+++ b/crates/cli/examples/chiller_aircooled_r134a_fan.json
@@ -0,0 +1,122 @@
+{
+  "name": "Air-Cooled Chiller R134a with Condenser Fan",
+  "description": "Same emergent-pressure air-cooled chiller as chiller_aircooled_r134a.json, with an explicit Fan on the condenser air path: AirSource → Fan → Cond(secondary) → AirSink. Fan curve sized for ~1.2 kg/s (~1.0 m³/s) against the coil secondary ΔP (150 Pa). secondary_humidity_ratio MUST match AirSource psychrometrics (W at T_dry, RH, P).",
+
+  "fluid": "R134a",
+  "fluid_backend": "CoolProp",
+
+  "circuits": [
+    {
+      "id": 0,
+      "name": "Refrigerant + secondary loops",
+      "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": 2500.0,
+          "emergent_pressure": true,
+          "subcooling_k": 5.0,
+          "secondary_fluid": "Air",
+          "secondary_humidity_ratio": 0.01412,
+          "dp_model": "isobaric",
+          "secondary_rated_pressure_drop_pa": 150,
+          "secondary_rated_m_flow_kg_s": 1.2
+        },
+        {
+          "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",
+          "dp_model": "isobaric",
+          "secondary_rated_pressure_drop_pa": 40000,
+          "secondary_rated_m_flow_kg_s": 0.4778
+        },
+        {
+          "type": "AirSource",
+          "name": "cond_air_in",
+          "p_set_bar": 1.01325,
+          "t_dry_c": 35.0,
+          "rh": 40.0,
+          "m_flow_kg_s": 1.2,
+          "fix_pressure": false,
+          "fix_temperature": true,
+          "fix_mass_flow": true
+        },
+        {
+          "type": "Fan",
+          "name": "cond_fan",
+          "fluid": "Air",
+          "speed_ratio": 1.0,
+          "air_density_kg_m3": 1.15,
+          "design_flow_m3_s": 1.04,
+          "curve_p0": 250.0,
+          "curve_p1": 0.0,
+          "curve_p2": -20.0,
+          "eff_e0": 0.65,
+          "eff_e1": 0.0,
+          "eff_e2": 0.0
+        },
+        {
+          "type": "AirSink",
+          "name": "cond_air_out",
+          "p_back_bar": 1.01325,
+          "fix_pressure": true
+        },
+        {
+          "type": "BrineSource",
+          "name": "evap_water_in",
+          "fluid": "Water",
+          "p_set_bar": 3.0,
+          "t_set_c": 12.0,
+          "m_flow_kg_s": 0.4778,
+          "fix_pressure": false,
+          "fix_temperature": true,
+          "fix_mass_flow": true
+        },
+        {
+          "type": "BrineSink",
+          "name": "evap_water_out",
+          "fluid": "Water",
+          "p_back_bar": 3.0,
+          "fix_pressure": true
+        }
+      ],
+      "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_air_in:outlet", "to": "cond_fan:inlet" },
+        { "from": "cond_fan:outlet", "to": "cond:secondary_inlet" },
+        { "from": "cond:secondary_outlet", "to": "cond_air_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": 300,
+    "tolerance": 1e-6
+  }
+}