adding sanity checks for electric components: efficiency must not be greater...

adding sanity checks for electric components: efficiency must not be greater than 1, drag torque must be negative

VectoCore/VectoCore/InputData/Reader/ComponentData/ElectricMotorDragCurveReader.cs

@@ -28,7 +28,12 @@ namespace TUGraz.VectoCore.InputData.Reader.ComponentData
 				MotorSpeed = x.ParseDouble(Fields.MotorSpeed).RPMtoRad(), // / ratio,
 				DragTorque = -x.ParseDouble(Fields.DragTorque).SI<NewtonMeter>() * count, // * ratio / efficiency
 			}).OrderBy(x => x.MotorSpeed).ToList();
+			var invalid = entries.Where(x => x.DragTorque.IsSmaller(0)).ToList();
+			if (invalid.Count > 0) {
+				throw new VectoException("Drag torque has to be negative in input: {0}",
+					invalid.Select(x => x.MotorSpeed.AsRPM).Join());
 
+			}
             var duplicates = entries.GroupBy(x => x.MotorSpeed).Where(g => g.Count() > 1).Select(x => x.Key.AsRPM).ToList();
 			if (duplicates.Any()) {
 				throw new VectoException(

VectoCore/VectoCore/InputData/Reader/ComponentData/ElectricMotorMapReader.cs

@@ -14,12 +14,12 @@ namespace TUGraz.VectoCore.InputData.Reader.ComponentData
 
     public class ElectricMotorMapReader 
 	{
-		public static EfficiencyMap Create(Stream data, int count)
+		public static EfficiencyMap Create(Stream data, int count, ExecutionMode mode)
 		{
-			return Create(VectoCSVFile.ReadStream(data), count);
+			return Create(VectoCSVFile.ReadStream(data), count, mode);
 		}
 
-		public static EfficiencyMap Create(DataTable data, int count)
+		public static EfficiencyMap Create(DataTable data, int count, ExecutionMode mode)
 		{
 			var headerValid = HeaderIsValid(data.Columns);
 			if (!headerValid) {
@@ -39,6 +39,26 @@ namespace TUGraz.VectoCore.InputData.Reader.ComponentData
 			if (duplicates.Count > 0) {
 				throw new VectoException("Duplicate entries in EM power map: {0}", duplicates.Select(x => $"{x.Item1.AsRPM} rpm / {x.Item2}").Join());
 			}
+
+			var highEff = entries.Where(x => !x.Torque.IsEqual(0) && !x.MotorSpeed.IsEqual(0))
+				.Select(x => Tuple.Create(x,
+					x.Torque.IsGreater(0)
+						? x.MotorSpeed * x.Torque / x.PowerElectrical
+						: x.PowerElectrical / (x.MotorSpeed * x.Torque))).Where(x => x.Item2.IsGreater(1)).ToList();
+			if (highEff.Any()) {
+				if (mode == ExecutionMode.Declaration) {
+					throw new VectoException("Electric power map contains entries with efficiencies > 1! {1} entries: {0}",
+						highEff.Select(x =>
+							$"{x.Item1.MotorSpeed.AsRPM} rpm {x.Item1.Torque} => {x.Item1.PowerElectrical}").Join(),
+						highEff.Count);
+				}
+
+				LogManager.GetLogger(typeof(ElectricMotorMapReader).FullName).Debug(
+					"Electric power map contains entries with efficiencies > 1! {0}",
+					highEff.Select(x =>
+						$"{x.Item1.MotorSpeed.AsRPM} rpm {x.Item1.Torque} => {x.Item1.PowerElectrical}").Join());
+
+			}
             var entriesZero = GetEntriesAtZeroRpm(entries);
 
 			var delaunayMap = new DelaunayMap("ElectricMotorEfficiencyMap Mechanical to Electric");

VectoCore/VectoCore/InputData/Reader/ComponentData/IEPCDragCurveReader.cs

@@ -28,6 +28,11 @@ namespace TUGraz.VectoCore.InputData.Reader.ComponentData
 				MotorSpeed = x.ParseDouble(Fields.MotorSpeed).RPMtoRad() * ratio,
 				DragTorque = -x.ParseDouble(Fields.DragTorque).SI<NewtonMeter>() * count / ratio // / efficiency
 			}).OrderBy(x => x.MotorSpeed).ToList();
+			var invalid = entries.Where(x => x.DragTorque.IsSmaller(0)).ToList();
+			if (invalid.Count > 0) {
+				throw new VectoException("Drag torque has to be negative in input: {0}",
+					invalid.Select(x => $"{x.MotorSpeed.AsRPM} rpm").Join());
+			}
 			var duplicates = entries.GroupBy(x => x.MotorSpeed).Where(g => g.Count() > 1).Select(x => x.Key.AsRPM / ratio).ToList();
 			if (duplicates.Any()) {
 				throw new VectoException(

VectoCore/VectoCore/InputData/Reader/ComponentData/IEPCMapReader.cs

@@ -19,13 +19,13 @@ namespace TUGraz.VectoCore.InputData.Reader.ComponentData
 	public class IEPCMapReader
 	{
 		public static EfficiencyMap Create(Stream data, int count, double ratio,
-			ElectricMotorFullLoadCurve fullLoadCurve)
+			ElectricMotorFullLoadCurve fullLoadCurve, ExecutionMode mode)
 		{
-			return Create(VectoCSVFile.ReadStream(data), count, ratio, fullLoadCurve);
+			return Create(VectoCSVFile.ReadStream(data), count, ratio, fullLoadCurve, mode);
 		}
 
 		public static EfficiencyMap Create(DataTable data, int count, double ratio,
-			ElectricMotorFullLoadCurve fullLoadCurve)
+			ElectricMotorFullLoadCurve fullLoadCurve, ExecutionMode mode)
 		{
 			if (fullLoadCurve == null) {
 				throw new ArgumentNullException("Provide fullloadcurve for extrapolation");
@@ -43,7 +43,7 @@ namespace TUGraz.VectoCore.InputData.Reader.ComponentData
 				data.Columns[2].ColumnName = Fields.PowerElectrical;
 			}
 
-			var entries = GetEntries(data, ratio);
+			var entries = GetEntries(data, ratio, mode);
 			entries = ExtendEfficiencyMap(entries, fullLoadCurve);
 			var entriesZero = GetEntriesAtZeroRpm(entries);
 
@@ -282,7 +282,7 @@ namespace TUGraz.VectoCore.InputData.Reader.ComponentData
 				powerElectrical: row.ParseDouble(Fields.PowerElectrical).SI<Watt>());
 		}
 
-		internal static IList<EfficiencyMap.Entry> GetEntries(DataTable data, double ratio)
+		internal static IList<EfficiencyMap.Entry> GetEntries(DataTable data, double ratio, ExecutionMode mode)
 		{
 			var entries = (from DataRow row in data.Rows select CreateEntry(row, ratio)).OrderBy(x => x.MotorSpeed)
 				.ThenBy(x => x.Torque).ToList();
@@ -291,7 +291,25 @@ namespace TUGraz.VectoCore.InputData.Reader.ComponentData
 			if (duplicates.Count > 0) {
 				throw new VectoException("Duplicate entries in IEPC power map: {0}", duplicates.Select(x => $"{x.Item1.AsRPM / ratio} rpm / {x.Item2 * ratio}").Join());
 			}
+			var highEff = entries.Where(x => !x.Torque.IsEqual(0) && !x.MotorSpeed.IsEqual(0))
+                .Select(x => Tuple.Create(x,
+					x.Torque.IsGreater(0)
+						? x.MotorSpeed * x.Torque / x.PowerElectrical
+						: x.PowerElectrical / (x.MotorSpeed * x.Torque))).Where(x => x.Item2.IsGreater(1)).ToList();
+			if (highEff.Any()) {
+				if (mode == ExecutionMode.Declaration) {
+					throw new VectoException("Electric power map contains entries with efficiencies > 1! {1} entries: {0}",
+						highEff.Select(x =>
+							$"{x.Item1.MotorSpeed.AsRPM} rpm {x.Item1.Torque} => {x.Item1.PowerElectrical}").Join(),
+						highEff.Count);
+				}
+
+				LogManager.GetLogger(typeof(ElectricMotorMapReader).FullName).Debug(
+					"Electric power map contains entries with efficiencies > 1! {0}",
+					highEff.Select(x =>
+						$"{x.Item1.MotorSpeed.AsRPM} rpm {x.Item1.Torque} => {x.Item1.PowerElectrical}").Join());
 
+			}
             return entries;
 		}
 

VectoCore/VectoCore/InputData/Reader/DataObjectAdapter/EngineeringDataAdapter.cs

@@ -1010,7 +1010,7 @@ namespace TUGraz.VectoCore.InputData.Reader.DataObjectAdapter
 			}
 			var effMap = new Dictionary<uint, EfficiencyMap>();
 			foreach (var gear in gearList) {
-				effMap.Add(gear.Gear, ElectricMotorMapReader.Create(entry.PowerMap[(int)gear.Gear - 1].PowerMap, count));
+				effMap.Add(gear.Gear, ElectricMotorMapReader.Create(entry.PowerMap[(int)gear.Gear - 1].PowerMap, count, ExecutionMode.Engineering));
 			}
 			return new IEPCVoltageLevelData() {
 				Voltage = entry.VoltageLevel,
@@ -1026,7 +1026,7 @@ namespace TUGraz.VectoCore.InputData.Reader.DataObjectAdapter
 					
 				FullLoadCurve = fullLoadCurveCombined,
 				// DragCurve = ElectricMotorDragCurveReader.Create(entry.DragCurve, count),
-				EfficiencyMap = ElectricMotorMapReader.Create(entry.PowerMap.First().PowerMap, count), //PowerMap
+				EfficiencyMap = ElectricMotorMapReader.Create(entry.PowerMap.First().PowerMap, count, ExecutionMode.Engineering), //PowerMap
 			};
 		}
 
@@ -1223,7 +1223,7 @@ namespace TUGraz.VectoCore.InputData.Reader.DataObjectAdapter
 					IEPCFullLoadCurveReader.Create(entry.FullLoadCurve, count, gearRatioUsedForMeasurement.Ratio);
 				for (var i = 0u; i < entry.PowerMap.Count; i++) {
 					var ratio = iepc.Gears.First(x => x.GearNumber == i + 1).Ratio;
-					effMap.Add(i + 1, IEPCMapReader.Create(entry.PowerMap[(int)i].PowerMap, count, ratio, fldCurve));
+					effMap.Add(i + 1, IEPCMapReader.Create(entry.PowerMap[(int)i].PowerMap, count, ratio, fldCurve, ExecutionMode.Engineering));
 					//fullLoadCurves.Add(i + 1, IEPCFullLoadCurveReader.Create(entry.FullLoadCurve, count, ratio));
 				}
 				voltageLevels.Add(new IEPCVoltageLevelData() {

VectoCore/VectoCore/InputData/Reader/DataObjectAdapter/SimulationComponents/ElectricMachinesDataAdapter.cs

@@ -101,7 +101,7 @@ namespace TUGraz.VectoCore.InputData.Reader.DataObjectAdapter.SimulationComponen
 				} catch (Exception ex) {
 					throw new VectoException(
 						$"Could not create Voltage Level data for {entry.VoltageLevel} at position {powertrainPosition}!\n" +
-						$"{ex.Message}",
+						$"{ex.Message} {ex.InnerException?.Message?.Substring(0, Math.Min(256, ex.InnerException.Message.Length))}",
 						ex);
 				}
 			}
@@ -229,7 +229,7 @@ namespace TUGraz.VectoCore.InputData.Reader.DataObjectAdapter.SimulationComponen
 			}
 			var effMap = new Dictionary<uint, EfficiencyMap>();
 			foreach (var gear in gearList) {
-				effMap.Add(gear.Gear, ElectricMotorMapReader.Create(entry.PowerMap[(int)gear.Gear - 1].PowerMap, count));
+				effMap.Add(gear.Gear, ElectricMotorMapReader.Create(entry.PowerMap[(int)gear.Gear - 1].PowerMap, count, ExecutionMode.Declaration));
 			}
 			return new IHPCVoltageLevelData() {
 				Voltage = entry.VoltageLevel,
@@ -247,7 +247,7 @@ namespace TUGraz.VectoCore.InputData.Reader.DataObjectAdapter.SimulationComponen
 
 					FullLoadCurve = fullLoadCurveCombined,
 					// DragCurve = ElectricMotorDragCurveReader.Create(entry.DragCurve, count),
-					EfficiencyMap = ElectricMotorMapReader.Create(entry.PowerMap.First().PowerMap, count), //PowerMap
+					EfficiencyMap = ElectricMotorMapReader.Create(entry.PowerMap.First().PowerMap, count, ExecutionMode.Declaration), //PowerMap
 				};
 			} catch (Exception ex) {
 				throw new VectoException($"Invalid efficiency map at voltage level {entry.VoltageLevel}", ex);
@@ -282,7 +282,7 @@ namespace TUGraz.VectoCore.InputData.Reader.DataObjectAdapter.SimulationComponen
 					IEPCFullLoadCurveReader.Create(entry.FullLoadCurve, count, gearRatioUsedForMeasurement.Ratio);
 				for (var i = 0u; i < entry.PowerMap.Count; i++) {
 					var ratio = iepc.Gears.First(x => x.GearNumber == i + 1).Ratio;
-					effMap.Add(i + 1, IEPCMapReader.Create(entry.PowerMap[(int)i].PowerMap, count, ratio, fldCurve));
+					effMap.Add(i + 1, IEPCMapReader.Create(entry.PowerMap[(int)i].PowerMap, count, ratio, fldCurve, ExecutionMode.Declaration));
 					//fullLoadCurves.Add(i + 1, IEPCFullLoadCurveReader.Create(entry.FullLoadCurve, count, ratio));
 				}
 				voltageLevels.Add(new IEPCVoltageLevelData() {

VectoCore/VectoCore/Models/GenericModelData/GenericBusElectricMotorData.cs

@@ -165,7 +165,7 @@ namespace TUGraz.VectoCore.Models.GenericModelData
 				var electricMotorVoltageLevel = new ElectricMotorVoltageLevelData {
 					Voltage = voltageLevel.VoltageLevel,
 					FullLoadCurve = GetElectricMotorFullLoadCurve(voltageLevel, count, torqueLimits),
-					EfficiencyMap = ElectricMotorMapReader.Create(efficiencyMap, count)
+					EfficiencyMap = ElectricMotorMapReader.Create(efficiencyMap, count, ExecutionMode.Declaration)
 				};
 
 				result.Add(electricMotorVoltageLevel);

VectoCore/VectoCore/Models/GenericModelData/GenericBusIEPCData.cs

@@ -3,6 +3,7 @@ using System.Collections.Generic;
 using System.Data;
 using System.Linq;
 using TUGraz.VectoCommon.InputData;
+using TUGraz.VectoCommon.Models;
 using TUGraz.VectoCommon.Utils;
 using TUGraz.VectoCore.InputData.Reader.ComponentData;
 using TUGraz.VectoCore.Models.Declaration;
@@ -120,7 +121,7 @@ namespace TUGraz.VectoCore.Models.GenericModelData
 					_axleRatio, _gearRatioAtMeasurement.Value, GenericGearEfficiency, _axleEfficiency);
 				
 				var deNormalizedMap = DeNormalizeData(GetNormalizedEfficiencyMap(electricMachineType), ratedPoint, gearRatio);
-				result.Add((uint) gearEntry.Key, IEPCMapReader.Create(deNormalizedMap, count, gearRatio, fullLoadCurve));
+				result.Add((uint) gearEntry.Key, IEPCMapReader.Create(deNormalizedMap, count, gearRatio, fullLoadCurve, ExecutionMode.Declaration));
 			}
 
 			return result;

VectoCore/VectoCore/Models/GenericModelData/GenericBusIHPCData.cs

@@ -3,6 +3,7 @@ using System.Collections.Generic;
 using System.Data;
 using System.Linq;
 using TUGraz.VectoCommon.InputData;
+using TUGraz.VectoCommon.Models;
 using TUGraz.VectoCommon.Utils;
 using TUGraz.VectoCore.InputData.Reader.ComponentData;
 using TUGraz.VectoCore.Models.Declaration;
@@ -84,7 +85,7 @@ namespace TUGraz.VectoCore.Models.GenericModelData
 			var efficiencyMap = DeNormalizeData(normalizedMap, ratedPoint);
 
 			foreach (var gearData in gearboxData.Gears.OrderBy(x => x.Gear)) {
-				result.Add((uint)gearData.Gear, ElectricMotorMapReader.Create(efficiencyMap, count));
+				result.Add((uint)gearData.Gear, ElectricMotorMapReader.Create(efficiencyMap, count, ExecutionMode.Declaration));
 			}
 
 			return result;

VectoCore/VectoCoreTest/FileIO/JsonReadHybridTest.cs

@@ -74,7 +74,7 @@ namespace TUGraz.VectoCore.Tests.FileIO
 			Assert.AreEqual("-800", pwr.Rows[0][ElectricMotorMapReader.Fields.Torque]);
 			Assert.AreEqual("9844.9", pwr.Rows[0][ElectricMotorMapReader.Fields.PowerElectrical]);
 
-			var pwrMap = ElectricMotorMapReader.Create(pwr, 1);
+			var pwrMap = ElectricMotorMapReader.Create(pwr, 1, ExecutionMode.Engineering);
 			Assert.AreEqual(0, pwrMap.LookupElectricPower(-0.RPMtoRad(), -800.SI<NewtonMeter>()).ElectricalPower.Value(), 1e-3);
 			Assert.AreEqual(-298.4752, pwrMap.LookupElectricPower(1.RPMtoRad(), -800.SI<NewtonMeter>()).ElectricalPower.Value(), 1e-3);
 
@@ -107,7 +107,7 @@ namespace TUGraz.VectoCore.Tests.FileIO
 			Assert.AreEqual("-800", pwrLow.Rows[0][ElectricMotorMapReader.Fields.Torque]);
 			Assert.AreEqual("9844.9", pwrLow.Rows[0][ElectricMotorMapReader.Fields.PowerElectrical]);
 
-			var pwrMapLow = ElectricMotorMapReader.Create(pwrLow, 1);
+			var pwrMapLow = ElectricMotorMapReader.Create(pwrLow, 1, ExecutionMode.Engineering);
 			Assert.AreEqual(-0, pwrMapLow.LookupElectricPower(-0.RPMtoRad(), -800.SI<NewtonMeter>()).ElectricalPower.Value(), 1e-3);
 			Assert.AreEqual(-298.4752, pwrMapLow.LookupElectricPower(1.RPMtoRad(), -800.SI<NewtonMeter>()).ElectricalPower.Value(), 1e-3);
 
@@ -132,7 +132,7 @@ namespace TUGraz.VectoCore.Tests.FileIO
 			Assert.AreEqual("-800", pwrHi.Rows[0][ElectricMotorMapReader.Fields.Torque]);
 			Assert.AreEqual("8860.41", pwrHi.Rows[0][ElectricMotorMapReader.Fields.PowerElectrical]);
 
-			var pwrMap = ElectricMotorMapReader.Create(pwrHi, 1);
+			var pwrMap = ElectricMotorMapReader.Create(pwrHi, 1, ExecutionMode.Engineering);
 			Assert.AreEqual(0, pwrMap.LookupElectricPower(-0.RPMtoRad(), -800.SI<NewtonMeter>()).ElectricalPower.Value(), 1e-3);
 			Assert.AreEqual(-268.6277, pwrMap.LookupElectricPower(1.RPMtoRad(), -800.SI<NewtonMeter>()).ElectricalPower.Value(), 1e-3);
 
@@ -205,7 +205,7 @@ namespace TUGraz.VectoCore.Tests.FileIO
 			Assert.AreEqual("-800", pwr.Rows[0][ElectricMotorMapReader.Fields.Torque]);
 			Assert.AreEqual("9844.9", pwr.Rows[0][ElectricMotorMapReader.Fields.PowerElectrical]);
 
-			var pwrMap = ElectricMotorMapReader.Create(pwr, 2);
+			var pwrMap = ElectricMotorMapReader.Create(pwr, 2, ExecutionMode.Engineering);
 			Assert.AreEqual(0, pwrMap.LookupElectricPower(-0.RPMtoRad(), -800.SI<NewtonMeter>()).ElectricalPower.Value(), 1e-3);
 			Assert.AreEqual(-208.04255, pwrMap.LookupElectricPower(1.RPMtoRad(), -800.SI<NewtonMeter>()).ElectricalPower.Value(), 1e-3);
 

VectoCore/VectoCoreTest/InputData/IEPCMapReaderTest.cs

@@ -14,6 +14,7 @@ using System.Linq;
 using System.Reflection;
 
 using NUnit.Framework;
+using TUGraz.VectoCommon.Models;
 using TUGraz.VectoCommon.Utils;
 using TUGraz.VectoCore.Configuration;
 using TUGraz.VectoCore.InputData.Reader.ComponentData;
@@ -66,10 +67,10 @@ namespace TUGraz.VectoCore.Tests.InputData
 			powerMapData.Columns[2].ColumnName = IEPCMapReader.Fields.PowerElectrical;
 
 			var fld = IEPCFullLoadCurveReader.Create(fullLoadCurveData, 1, fldMeasuredRatio);
-			var powerMapInput = IEPCMapReader.GetEntries(powerMapData, ratio);
+			var powerMapInput = IEPCMapReader.GetEntries(powerMapData, ratio, ExecutionMode.Engineering);
 
 
-			var effMap = IEPCMapReader.Create(powerMapData, 1, ratio, fld);
+			var effMap = IEPCMapReader.Create(powerMapData, 1, ratio, fld, ExecutionMode.Engineering);
 #if TRACE
 			PrintMaps("FLD.png", 
 				new SeriesProperties<ElectricMotorFullLoadCurve.FullLoadEntry>() {

VectoCore/VectoCoreTest/Models/SimulationComponentData/ElectricMotorEfficienyMapTest.cs

@@ -4,6 +4,7 @@ using System.Data;
 using System.IO;
 using System.Linq;
 using NUnit.Framework;
+using TUGraz.VectoCommon.Models;
 using TUGraz.VectoCommon.Utils;
 using TUGraz.VectoCore.Configuration;
 using TUGraz.VectoCore.InputData.FileIO.JSON;
@@ -38,7 +39,7 @@ namespace TUGraz.VectoCore.Tests.Models.SimulationComponentData {
 
 			var pwr = inputProvider.VoltageLevels.First().PowerMap.First().PowerMap; //ToDo FK: maybe wrong selection
 			// var pwr = inputProvider.VoltageLevels.First().EfficiencyMap;
-			var pwrMap = ElectricMotorMapReader.Create(pwr, 1);
+			var pwrMap = ElectricMotorMapReader.Create(pwr, 1, ExecutionMode.Engineering);
 
 			var maxEmPwr = batPwr < 0
 				? fldMap.FullLoadDriveTorque(emSpeed.RPMtoRad())
@@ -103,7 +104,7 @@ namespace TUGraz.VectoCore.Tests.Models.SimulationComponentData {
 			
 			var pwr = inputProvider.VoltageLevels.First().PowerMap.First().PowerMap;//ToDo FK: maybe wrong selection
 			// var pwr = inputProvider.VoltageLevels.First().EfficiencyMap;
-			var pwrMap = ElectricMotorMapReader.Create(pwr, 1);
+			var pwrMap = ElectricMotorMapReader.Create(pwr, 1, ExecutionMode.Engineering);
 
 			var maxEmPwr = batPwr < 0
 				? fldMap.FullLoadDriveTorque(emSpeed.RPMtoRad())
@@ -120,7 +121,7 @@ namespace TUGraz.VectoCore.Tests.Models.SimulationComponentData {
 		public void TestInterpolationMethod_PowerMap(string filename, double etaMin, double etaMax)
 		{
 			var data = VectoCSVFile.Read(filename).ApplyFactor(ElectricMotorMapReader.Fields.PowerElectrical, 1000.0);
-			var emMap = ElectricMotorMapReader.Create(data, 1);
+			var emMap = ElectricMotorMapReader.Create(data, 1, ExecutionMode.Engineering);
 			
 			var efficiencies = new List<double>();
 			for (var n = 10.RPMtoRad(); n < 4000.RPMtoRad(); n += 10.RPMtoRad()) {