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sepehr 62efea0646 Update project structure and configurations

2026-05-23 10:19:55 +02:00

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Story 7.6: Component Calibration Parameters (Calib)

Status: done

Story

As a R&D engineer matching simulation to real machine test data, I want calibration factors (Calib) on components, so that simulation results align with manufacturer test data and field measurements.

Acceptance Criteria

Calib Implementation (AC: #1)
- Compressor and Expansion Valve support f_m (default 1.0): ṁ_eff = f_m × ṁ_nominal
- Pipe and Heat Exchanger support f_dp (default 1.0): ΔP_eff = f_dp × ΔP_nominal
- Evaporator and Condenser support f_ua (default 1.0): UA_eff = f_ua × UA_nominal
- Compressor support f_power (default 1.0): Ẇ_eff = f_power × Ẇ_nominal
- Compressor support f_etav (default 1.0): η_v,eff = f_etav × η_v,nominal (displacement models; AHRI 540: f_m suffices)
- Default 1.0 = no correction; typical range [0.8, 1.2]
Serialization & Persistence (AC: #2)
- Calib struct serializable in JSON (short keys: f_m, f_dp, f_ua, f_power, f_etav)
- Loading from JSON restores Calib values
- Traceability metadata can include calibration_source (test data hash or identifier)
Calibration Workflow Documentation (AC: #3)
- Document recommended order: f_m → f_dp → f_ua → f_power (prevents parameter fighting)
- Reference: alphaXiv, Buildings Modelica, EnergyPlus, TRNSYS, TIL Suite
Validation Against Test Data (AC: #4)
- With calibrated components, results match test data within configurable tolerance
- Example targets: capacity ±2%, power ±3% (industry typical)
- Unit tests verify scaling (f=1.0 unchanged, f=1.1 scales by 10%)

Tasks / Subtasks

Define Calib struct (AC: #1)
- Create Calib { f_m, f_dp, f_ua, f_power, f_etav } in crates/core
- Default: all 1.0; serde with short keys; validation: 0.5 ≤ f ≤ 2.0
- Document each factor with component mapping and literature ref
Add f_m to Compressor and Expansion Valve (AC: #1)
- Compressor: ṁ_out = f_m × ṁ_ahri540
- Expansion Valve: scale mass flow if orifice model; else f_m on inlet flow
Add f_power and f_etav to Compressor (AC: #1)
- f_power: Ẇ_out = f_power × Ẇ_ahri540
- f_etav: for displacement models; AHRI 540: use f_m only, f_etav=1.0
Add f_dp to Pipe and Heat Exchanger (AC: #1)
- Pipe: ΔP_eff = f_dp × ΔP_darcy_weisbach
- Heat Exchanger: scale refrigerant-side ΔP if modeled
Add f_ua to Evaporator and Condenser (AC: #1)
- Heat transfer models: UA_eff = f_ua × UA_nominal before Q = UA × ΔT_lm
JSON serialization (AC: #2)
- Calib in component schema; round-trip test
- Optional calibration_source in metadata
Documentation and tests (AC: #3, #4)
- Dev Notes: calibration order and literature refs
- Unit tests: f_m, f_dp, f_ua, f_power scaling
- Integration test: calibrated cycle vs synthetic test data

Dev Notes

Naming: Calib (short for Calibration Factors)

Struct name: Calib — 5 chars, standard in HVAC/refrigeration literature ("calibration factors").

Field names (short, JSON-friendly):

Field	Full name	Effect	Components
`f_m`	mass flow factor	ṁ_eff = f_m × ṁ_nominal	Compressor, Expansion Valve
`f_dp`	pressure drop factor	ΔP_eff = f_dp × ΔP_nominal	Pipe, Heat Exchanger
`f_ua`	UA factor	UA_eff = f_ua × UA_nominal	Evaporator, Condenser
`f_power`	power factor	Ẇ_eff = f_power × Ẇ_nominal	Compressor
`f_etav`	volumetric efficiency	η_v,eff = f_etav × η_v,nominal	Compressor (displacement)

Literature: Calibration Coefficients in HVAC/Refrigeration Software

EnergyPlus (RP-1051, DX/Chillers):

Biquadratic capacity/EIR curves: c₁…c₆
Part-Load Fraction (PLF): a + b(PLR) + c(PLR)²
Case Latent Heat Ratio, ambient correction curves

Modelica Buildings (Heat Pumps):

etaEle: Electro-mechanical efficiency
PLos: Constant power losses (W)
leaCoe: Leakage coefficient (kg/s)
UACon, UAEva: Thermal conductance (W/K)
volRat: Built-in volume ratio
V_flow_nominal: Refrigerant volume flow at suction
Optimization minimizes |modeled − manufacturer_data|

TRNSYS (Type 941, Heat Pumps):

Correction Factor: multiplier on interpolated capacity/power from performance map
Heat Loss Coefficient (U-value) for storage

TIL Suite (EN 12900 / ARI 540):

10-coefficient polynomial for ṁ and P
Heat Transfer Multiplier (evaporator/condenser zones)
Zeta value / friction factor multiplier for pressure drop

Compressor Efficiency (alphaXiv, Purdue):

Volumetric efficiency η_v: λ factor for clearance-volume model
Isentropic efficiency η_is: friction factor, heat transfer factor
Calibration: η_v and η_is scaled to match test bench

Calibration Workflow (sequential):

f_m — mass flow (compressor power + ṁ measurements)
f_dp — pressure drops (inlet/outlet pressures)
f_ua — heat transfer (superheat, subcooling, capacity)
f_power — compressor power (if f_m insufficient)

Previous Story Intelligence

Story 1-4 (Compressor AHRI 540):

crates/components/src/compressor.rs
ṁ from M1, M2; Ẇ from M3–M6 (cooling) or M7–M10 (heating)
Apply f_m on ṁ, f_power on Ẇ

Story 1-5 (Heat Exchanger):

crates/components/src/heat_exchanger/ — LmtdModel, EpsNtuModel
Scale UA before Q = UA × ΔT_lm

Story 1-6 (Expansion Valve):

Isenthalpic; ṁ continuity. Apply f_m if flow model exists.

Story 1-8 (Pipe):

Darcy-Weisbach; apply f_dp on ΔP

Technical Requirements

Calib struct:

/// Calibration factors for matching simulation to real machine test data.
/// Short name: Calib. Default 1.0 = no correction. Typical range [0.8, 1.2].
/// Refs: Buildings Modelica, EnergyPlus, TRNSYS, TIL Suite, alphaXiv.
#[derive(Debug, Clone, Copy, PartialEq, Serialize, Deserialize)]
pub struct Calib {
    /// f_m: ṁ_eff = f_m × ṁ_nominal (Compressor, Valve)
    #[serde(default = "one", alias = "calib_flow")]
    pub f_m: f64,
    /// f_dp: ΔP_eff = f_dp × ΔP_nominal (Pipe, HX)
    #[serde(default = "one", alias = "calib_dpr")]
    pub f_dp: f64,
    /// f_ua: UA_eff = f_ua × UA_nominal (Evaporator, Condenser)
    #[serde(default = "one", alias = "calib_ua")]
    pub f_ua: f64,
    /// f_power: Ẇ_eff = f_power × Ẇ_nominal (Compressor)
    #[serde(default = "one")]
    pub f_power: f64,
    /// f_etav: η_v,eff = f_etav × η_v,nominal (Compressor displacement)
    #[serde(default = "one")]
    pub f_etav: f64,
}
fn one() -> f64 { 1.0 }

Validation: 0.5 ≤ f ≤ 2.0. Reject otherwise.

File Structure

New: crates/core/src/calib.rs (or calibration.rs)

Modified:

crates/components/src/compressor.rs — f_m, f_power, f_etav
crates/components/src/pipe.rs — f_dp
crates/components/src/heat_exchanger/model.rs — f_ua
crates/components/src/expansion_valve.rs — f_m
crates/core/src/lib.rs — export Calib

Testing

test_calib_default_all_one
test_f_m_scales_mass_flow
test_f_dp_scales_pressure_drop
test_f_ua_scales_heat_transfer
test_f_power_scales_compressor_power
test_calib_json_roundtrip
test_calib_aliases_backward_compat (calib_flow → f_m)

References

Epic 7.6: planning-artifacts/epics.md
Buildings.Fluid.HeatPumps.Calibration: simulationresearch.lbl.gov/modelica
EnergyPlus VRF: bigladdersoftware.com/epx/docs
TRNSYS Type 941: Correction Factor
TIL Suite: Zeta, heat transfer multiplier
alphaXiv: calib_flow, calib_dpr, UA, η_vol, η_is
Reddy RP-1051: Calibration methodology
Purdue IIAR: Volumetric/isentropic efficiency calibration

Optional / Future (out of scope for this story)

f_cap: Capacity correction factor (TRNSYS, EnergyPlus) — system-level Q scaling; for component-level, f_ua suffices.
PLF / Part-Load: EnergyPlus PLF curve — transient/cycling; steady-state out of scope.

Dev Agent Record

Agent Model Used

Auto (dev-story workflow)

Debug Log References

Completion Notes List

Calib struct added in crates/core (calib.rs) with serde, validation 0.5–2.0, and doc with calibration order.
Compressor: calib field, f_m on mass_flow_rate(), f_power on power_consumption_cooling/heating; calib(), set_calib().
Expansion valve: calib field, f_m in mass flow residual and jacobian; calib(), set_calib().
Pipe: calib field, f_dp in pressure_drop(); calib(), set_calib().
HeatExchanger: calib field; LmtdModel and EpsNtuModel: ua_scale, effective_ua(), set_ua_scale(); exchanger syncs calib.f_ua to model.
Evaporator and Condenser: calib() and set_calib() delegate to inner HeatExchanger.
Unit tests: test_f_m_scales_mass_flow, test_f_power_scales_compressor_power, test_f_dp_scales_pressure_drop, test_f_ua_scales_heat_transfer; core: test_calib_json_roundtrip, test_calib_aliases_backward_compat.
Added calibration_source: Option to Calib with serde skip_serializing_if; removed Copy trait (kept Clone); test_calib_calibration_source validates JSON roundtrip with metadata.
Integration test: calibrated_cycle_integration.rs — 5 tests validating f_ua capacity scaling (±2%), f_m×f_power compressor work scaling (±3%), f_dp pressure drop scaling, nominal baseline, and calibration_source metadata roundtrip through solver cycle.

File List

crates/core/src/calib.rs (modified: added calibration_source field, removed Copy)
crates/core/src/lib.rs (modified)
crates/core/Cargo.toml (modified: dev-deps serde_json)
crates/components/src/compressor.rs (modified)
crates/components/src/expansion_valve.rs (modified)
crates/components/src/pipe.rs (modified)
crates/components/src/heat_exchanger/exchanger.rs (modified: set_calib order)
crates/components/src/heat_exchanger/model.rs (modified)
crates/components/src/heat_exchanger/lmtd.rs (modified)
crates/components/src/heat_exchanger/eps_ntu.rs (modified)
crates/components/src/heat_exchanger/evaporator.rs (modified)
crates/components/src/heat_exchanger/condenser.rs (modified)
crates/cli/src/run.rs (modified: added calibration_source: None)
crates/solver/tests/calibrated_cycle_integration.rs (new: 5 integration tests)
_bmad-output/implementation-artifacts/sprint-status.yaml (modified)
_bmad-output/implementation-artifacts/7-6-component-calibration-parameters.md (modified)

Change Log

2026-02-17: Story 7-6 implemented. Calib in core; f_m, f_power on compressor; f_m on expansion valve; f_dp on pipe and heat exchanger (field); f_ua on LMTD/ε-NTU and evaporator/condenser. JSON round-trip and scaling unit tests added.
2026-04-26: Completed remaining subtasks. Added calibration_source: Option to Calib (removed Copy, kept Clone). Integration test calibrated_cycle_integration.rs with 5 tests validating f_ua, f_m×f_power, f_dp scaling against synthetic test data within industry tolerances.
2026-04-26: Code review (3 layers: Blind Hunter, Edge Case Hunter, Acceptance Auditor). 3 decision-needed, 3 patch, 2 defer, 8 dismissed.

Review Findings

[Review][Decision] f_etav appliqué dans le compresseur — Ajouté × self.calib.f_etav dans mass_flow_rate() AHRI 540 branch + test test_f_etav_scales_volumetric_efficiency. Résolu : implémenté.
[Review][Decision] camelCase → snake_case JSON keys — Retiré #[serde(rename_all = "camelCase")] de Calib. Sérialise maintenant en snake_case (f_m, f_dp...) conforme à la spec. Test intégration mis à jour. Résolu.
[Review][Patch] explicit_f_ua validé — Ajouté validation f_ua > 0 dans bphx_calib_from_params après calcul du f_ua final. [crates/cli/src/run.rs]
[Review][Patch] target_quality et target_superheat validés — target_quality validé dans [0, 1], target_superheat validé >= 0. [crates/cli/src/run.rs]
[Review][Patch] n_plates upper bound ajouté — Vérification n_plates_raw <= u32::MAX avant cast. [crates/cli/src/run.rs]
[Review][Defer] Tests d'intégration utilisent mocks + solution exacte — Les 5 tests seedent le solveur avec la solution analytique exacte et utilisent des composants mock. Vérifient l'identité, pas la convergence depuis un point initial non-trivial. deferred, test quality
[Review][Defer] n_equations doc 3→2 corrige docs pré-existantes — Les docs étaient incorrectes (affirmaient 3 équations). Code residuals[2] en mode OFF de HeatExchanger écrit potentiellement hors-bounds — bug pré-existant, non introduit par ce diff. deferred, pre-existing

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