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improve turns fit calculation for bot window
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@gituser789
gituser789 committed Sep 5, 2024
1 parent 503c064 commit e0e0b86
Showing 1 changed file with 48 additions and 12 deletions.
60 changes: 48 additions & 12 deletions femmt/optimization/sto.py
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Original file line number Diff line number Diff line change
Expand Up @@ -127,6 +127,9 @@ def objective(trial: optuna.Trial, config: StoSingleInputConfig, target_and_fixe
core_inner_diameter = core["core_inner_diameter"]
window_w = core["window_w"]
window_h_bot = trial.suggest_float("window_h_bot", 0.3 * core["window_h"], core["window_h"])
trial.set_user_attr('core_inner_diameter', core_inner_diameter)
trial.set_user_attr('window_w', window_w)
trial.set_user_attr('window_h_bot', window_h_bot)

else:
# using arbitrary core sizes
Expand Down Expand Up @@ -159,9 +162,11 @@ def objective(trial: optuna.Trial, config: StoSingleInputConfig, target_and_fixe
# calculate total 2D-axi symmetric volume of the core:
# formula: number_turns_per_row = (available_width + primary_to_primary) / (wire_diameter + primary_to_primary)
available_width_top = window_w - config.insulations.iso_window_top_core_left - config.insulations.iso_window_top_core_right
possible_number_turns_per_row_top_window = int(
possible_number_turns_per_column_top_window = int(
(available_width_top + config.insulations.iso_primary_to_primary) / (primary_litz_wire_diameter + config.insulations.iso_primary_to_primary))
number_of_rows_needed = np.ceil(n_p_top / possible_number_turns_per_row_top_window)
if possible_number_turns_per_column_top_window < 1:
return float('nan'), float('nan')
number_of_rows_needed = np.ceil(n_p_top / possible_number_turns_per_column_top_window)
needed_height_top_wo_insulation = (number_of_rows_needed * primary_litz_wire_diameter + \
(number_of_rows_needed - 1) * config.insulations.iso_primary_to_primary)
window_h_top = needed_height_top_wo_insulation + config.insulations.iso_window_top_core_top + config.insulations.iso_window_top_core_bot
Expand All @@ -170,15 +175,38 @@ def objective(trial: optuna.Trial, config: StoSingleInputConfig, target_and_fixe
r_outer = fr.calculate_r_outer(core_inner_diameter, window_w)
volume = ff.calculate_cylinder_volume(cylinder_diameter=2 * r_outer, cylinder_height=core_total_height)

# detailed calculation for the winding window
# check the area for the primary winding
available_height_bot = window_h_bot - config.insulations.iso_window_bot_core_top - config.insulations.iso_window_bot_core_bot
possible_number_prim_turns_per_column_bot_window = int(
(available_height_bot + config.insulations.iso_primary_to_primary) / (primary_litz_wire_diameter + config.insulations.iso_primary_to_primary))
if possible_number_prim_turns_per_column_bot_window < 1:
return float('nan'), float('nan')
number_of_primary_columns_needed = np.ceil(n_p_bot / possible_number_prim_turns_per_column_bot_window)
needed_primary_width_bot_wo_insulation = (number_of_primary_columns_needed * primary_litz_wire_diameter + (number_of_primary_columns_needed - 1) * \
config.insulations.iso_primary_to_primary)
area_primary_bot = needed_primary_width_bot_wo_insulation * window_h_bot

# check the area for the secondary winding
possible_number_sec_turns_per_column_bot_window = int(
(available_height_bot + config.insulations.iso_secondary_to_secondary) / \
(secondary_litz_wire_diameter + config.insulations.iso_secondary_to_secondary))
if possible_number_sec_turns_per_column_bot_window < 1:
return float('nan'), float('nan')
number_of_secondary_columns_needed = np.ceil(n_s_bot / possible_number_sec_turns_per_column_bot_window)
needed_primary_width_bot_wo_insulation = (number_of_secondary_columns_needed * secondary_litz_wire_diameter + \
(number_of_secondary_columns_needed - 1) * config.insulations.iso_secondary_to_secondary)
area_secondary_bot = needed_primary_width_bot_wo_insulation * window_h_bot
area_insulation_prim_sec_bot = 2 * config.insulations.iso_primary_to_secondary * window_h_bot

total_area_windings_bot = area_primary_bot + area_secondary_bot + area_insulation_prim_sec_bot

window_bot_available_height = window_h_bot - config.insulations.iso_window_bot_core_top - config.insulations.iso_window_bot_core_bot
window_bot_available_width = window_w - config.insulations.iso_window_bot_core_left - config.insulations.iso_window_bot_core_right
window_bot_available_area = window_bot_available_height * window_bot_available_width

# turn area for a single turn is approximated as a rectangle
window_bot_turns_area = n_p_bot * primary_litz_wire_diameter ** 2 + n_s_bot * secondary_litz_wire_diameter ** 2

# as the window_h_top is adapted to the number of n_p_top, the top windings always fit into the top window.
if window_bot_turns_area > window_bot_available_area:
if total_area_windings_bot > window_bot_available_area:
print("Winding window too small for too many turns.")
return float('nan'), float('nan')

Expand Down Expand Up @@ -283,7 +311,6 @@ def objective(trial: optuna.Trial, config: StoSingleInputConfig, target_and_fixe
p_loss = p_hyst + winding_losses

# set additional attributes
trial.set_user_attr('n_s_bot', n_s_bot)
trial.set_user_attr('p_hyst', p_hyst)
trial.set_user_attr('p_hyst_top', p_top)
trial.set_user_attr('p_hyst_bot', p_bot)
Expand Down Expand Up @@ -569,11 +596,20 @@ def fem_simulations_from_reluctance_df(reluctance_df: pd.DataFrame, config: StoS
geo = fmt.MagneticComponent(component_type=fmt.ComponentType.IntegratedTransformer,
working_directory=working_directory, verbosity=fmt.Verbosity.ToConsole)

if reluctance_df["params_core_name"] is not None:
core_inner_diameter = reluctance_df["user_attrs_core_inner_diameter"][index]
window_w = reluctance_df["user_attrs_window_w"][index]
core_h_bot = reluctance_df["user_attrs_window_h_bot"][index]
else:
core_inner_diameter = reluctance_df["params_core_inner_diameter"][index]
window_w = reluctance_df["params_window_w"][index]
core_h_bot = reluctance_df["params_window_h_bot"][index]

# 2. set core parameters
core_dimensions = fmt.dtos.StackedCoreDimensions(core_inner_diameter=reluctance_df["params_core_inner_diameter"][index],
window_w=reluctance_df["params_window_w"][index],
core_dimensions = fmt.dtos.StackedCoreDimensions(core_inner_diameter=core_inner_diameter,
window_w=window_w,
window_h_top=reluctance_df['user_attrs_window_h_top'][index],
window_h_bot=reluctance_df["params_window_h_bot"][index])
window_h_bot=core_h_bot)
core = fmt.Core(core_type=fmt.CoreType.Stacked, core_dimensions=core_dimensions,
material=reluctance_df["params_material_name"][index], temperature=config.temperature,
frequency=target_and_fix_parameters.fundamental_frequency,
Expand Down Expand Up @@ -621,12 +657,12 @@ def fem_simulations_from_reluctance_df(reluctance_df: pd.DataFrame, config: StoS
primary_coil_turns = reluctance_df['params_n_p_top'][index]
print(f"{primary_coil_turns=}")
print(f"{reluctance_df['params_n_p_bot'][index]=}")
print(f"{reluctance_df['user_attrs_n_s_bot'][index]=}")
print(f"{reluctance_df['params_n_s_bot'][index]=}")

# 7. add conductor to vww and add winding window to MagneticComponent
vww_top.set_interleaved_winding(winding1, primary_coil_turns, winding2, 0, fmt.InterleavedWindingScheme.HorizontalAlternating)
vww_bot.set_interleaved_winding(winding1, reluctance_df['params_n_p_bot'][index], winding2,
int(reluctance_df['user_attrs_n_s_bot'][index]), fmt.InterleavedWindingScheme.HorizontalAlternating)
int(reluctance_df['params_n_s_bot'][index]), fmt.InterleavedWindingScheme.HorizontalAlternating)

geo.set_winding_windows([winding_window_top, winding_window_bot])

Expand Down

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