"""Executed thermal commissioning and failure cases using the supplied FE matrices.""" import copy,json,math import numpy as np import matplotlib;matplotlib.use('Agg') import matplotlib.pyplot as plt from scipy.sparse.linalg import factorized from solver import load,model from completion_util import ROOT,OUT,csv_file,check,table,finish def control(error,integral,control,dt): if not math.isfinite(error):return 0.,integral raw=control['Kp_W_K']*error+integral;power=float(np.clip(raw,0,control['maximum_power_W'])) if 0=control['maximum_power_W'] and error<0 or raw<=0 and error>0:integral+=control['Ki_W_Ks']*error*dt return power,integral def simulate(base,c,case,dt=None): dt=c['time_step_s'] if dt is None else dt if dt<=0 or c['horizon_s']=c['fault_time_s'];fault=case['fault'] if active and fault=='sensor_frozen': if frozen is None:frozen=actual_sensor measured=frozen if active and fault=='sensor_bias':measured+=c['low_sensor_bias_C'] if active and fault=='sensor_open':measured=float('nan');fault_latched=True if case['protected'] and requested_trip is None and (max(heater)>=c['heater_cutoff_C'] or max(surface)>=c['surface_cutoff_C']):requested_trip=now if requested_trip is not None and cutoff_time is None and now>=requested_trip+c['cutoff_delay_s']:cutoff_time=now power,integ=control(g['target_C']-measured,integ,g['controller'],dt) if active and fault=='relay_stuck':power=g['controller']['maximum_power_W'] if cutoff_time is not None or fault_latched:power=0. factors=np.ones(3) if active and fault=='heater_open':factors[0]=0. applied=power/3*factors in_band=bool(min(surface)>=g['target_C']-g['band_C'] and max(surface)<=g['target_C']+g['band_C']) if in_band and not fault_latched and cutoff_time is None: if ready_since is None:ready_since=now else:ready_since=None ready=ready_since is not None and now-ready_since>=c['readiness_hold_s'] if ready and first_ready is None:first_ready=now rows.append({'time_s':now,'surface_min_C':float(min(surface)),'surface_max_C':float(max(surface)),'heater_max_C':float(max(heater)),'actual_center_C':float(actual_sensor),'controller_sensor_C':None if not math.isfinite(measured) else float(measured),'applied_power_W':float(sum(applied)),'cutoff_latched':cutoff_time is not None,'sensor_fault_latched':fault_latched,'ready':ready}) if j==round(c['horizon_s']/dt):break f=np.zeros(len(theta));f[-3:]=applied;new=step(M@theta/dt+f);energy_in+=sum(applied)*dt;energy_out+=float(ones@(K@new))*dt;theta=new stored=float(ones@(M@theta));err=abs(energy_in-energy_out-stored)/max(energy_in,1) result={'case':case['name'],'fault':fault,'protected':case['protected'],'first_ready_s':first_ready,'final_ready':rows[-1]['ready'],'trip_request_s':requested_trip,'cutoff_s':cutoff_time,'sensor_fault_latched':fault_latched,'peak_surface_C':max(r['surface_max_C'] for r in rows),'peak_heater_C':max(r['heater_max_C'] for r in rows),'final_surface_min_C':rows[-1]['surface_min_C'],'final_surface_max_C':rows[-1]['surface_max_C'],'energy_input_J':float(energy_in),'energy_loss_J':energy_out,'stored_J':stored,'relative_energy_error':float(err)} return rows,result def main(): c=json.loads((ROOT/'completion-inputs.json').read_text());g=load();hist={};summaries=[];checks=[] for case in c['cases']: rows,r=simulate(g,c,case);hist[case['name']]=rows;summaries.append(r);csv_file(case['name']+'.csv',rows) checks.append(check('energy-'+case['name'],'Heat input equals stored plus lost energy','relative error < 1e-8',r['relative_energy_error'],r['relative_energy_error']<1e-8,'Implicit Euler FE balance including actual failed-heater power')) csv_file('fault-summary.csv',summaries);by={r['case']:r for r in summaries} checks.append(check('normal-readiness','Full modeled working area stays in band for 300 s','ready at end; no cutoff',{'ready':by['normal']['final_ready'],'cutoff':by['normal']['cutoff_s']},by['normal']['final_ready'] and by['normal']['cutoff_s'] is None,'Full surface node criterion, not center sensor alone')) for name in ['relay_stuck','sensor_frozen']: p=by[name+'_protected'];u=by[name+'_unprotected'];ok=p['cutoff_s'] is not None and p['peak_heater_C']<=c['screen_maximum_heater_C'] and p['peak_surface_C']<=c['screen_maximum_surface_C'] checks.append(check(name+'-protection','Independent cutoff limits the modeled fault excursion','cutoff operates; heater <=135 C and surface <=110 C',{'cutoff_s':p['cutoff_s'],'heater_C':p['peak_heater_C'],'surface_C':p['peak_surface_C']},ok,'A separate modeled contactor removes power even with the control output stuck')) checks.append(check(name+'-unsafe','The same fault without cutoff exceeds the screened temperature','surface >110 C',u['peak_surface_C'],u['peak_surface_C']>c['screen_maximum_surface_C'],'Counterfactual fault run; expected rejected condition')) p=by['poor_contact'];checks.append(check('poor-contact-cutoff','Poor contact is caught at the heater even if surface stays cooler','cutoff before 135 C heater',{'cutoff_s':p['cutoff_s'],'heater_C':p['peak_heater_C']},p['cutoff_s'] is not None and p['peak_heater_C']<=135,'Individual heater temperature monitoring in the model')) op=hist['sensor_open'];checks.append(check('open-sensor-failoff','An invalid controller sensor latches power off','all power = 0 after fault',max(r['applied_power_W'] for r in op if r['time_s']>=c['fault_time_s']),all(r['applied_power_W']==0 for r in op if r['time_s']>=c['fault_time_s']),'NaN sensor injection with explicit nonfinite guard')) checks.append(check('bias-quality-gate','A 5 C low-reading controller cannot falsely satisfy the full-surface criterion','not ready at end',by['sensor_bias_minus5']['final_ready'],not by['sensor_bias_minus5']['final_ready'],'Separate modeled surface grid checks the target band')) normal_cases=[r for r in summaries if r['case'] in ['normal','hot_ambient'] or r['case'].startswith('normal_grid_')] checks.append(check('selected-envelope','Six ambient/loss corner cases meet the selected operating conditions','all six ready at end with no cutoff', [{'case':r['case'],'ready':r['final_ready'],'cutoff':r['cutoff_s']} for r in normal_cases],len(normal_cases)==6 and all(r['final_ready'] and r['cutoff_s'] is None for r in normal_cases),'22/35 C ambient x 5/10/20 W/m2K top convection; bottom U2, contact1000, 60 W limit')) checks.append(check('heater-open-rejection','Loss of one heater cannot release an out-of-band process','not ready',by['heater_open']['final_ready'],not by['heater_open']['final_ready'],'Full-surface readiness interlock under an open heater')) checks.append(check('insulation-loss-rejection','Combined high top/bottom losses outside the selected envelope are rejected','not ready at end',by['high_losses']['final_ready'],not by['high_losses']['final_ready'],'Changed bottom U12 and top h20; the original temperature target is retained')) # Rerun a protected stuck-output case at half dt to bound cutoff timing discretization. case=next(x for x in c['cases'] if x['name']=='relay_stuck_protected');_,fine=simulate(g,c,case,dt=c['time_step_s']/2);coarse=by['relay_stuck_protected'];peak_delta=abs(coarse['peak_heater_C']-fine['peak_heater_C']);trip_delta=abs(coarse['cutoff_s']-fine['cutoff_s']) checks.append(check('cutoff-step-refinement','Halving dt preserves protected-fault peak and cutoff time','peak difference < 1 C; trip difference <= 4 s',{'peak_difference_C':peak_delta,'trip_difference_s':trip_delta},peak_delta<1 and trip_delta<=4,'2 s versus 1 s integration and sampled cutoff')) (OUT/'cutoff-refinement.json').write_text(json.dumps({'coarse':coarse,'fine':fine},indent=2)+'\n') fig,axes=plt.subplots(2,1,figsize=(10,7),sharex=True) for name,color,ls in [('normal','#4d7557','-'),('relay_stuck_unprotected','#9b4f38','--'),('relay_stuck_protected','#c28260','-'),('poor_contact','#6f607f','-')]: rr=hist[name];x=[r['time_s']/60 for r in rr];axes[0].plot(x,[r['surface_max_C'] for r in rr],label=name,color=color,ls=ls);axes[1].plot(x,[r['heater_max_C'] for r in rr],color=color,ls=ls) axes[0].axhspan(88,92,color='#a6bea0',alpha=.25);axes[0].axhline(c['surface_cutoff_C'],color='gray',ls=':');axes[1].axhline(c['heater_cutoff_C'],color='gray',ls=':');axes[0].set(ylabel='Maximum working surface (C)');axes[1].set(xlabel='Time (minutes)',ylabel='Maximum heater (C)');axes[0].legend(fontsize=8);fig.tight_layout();fig.savefig(OUT/'fault-transients.png',dpi=140);plt.close(fig) compact=[{k:r[k] for k in ['case','final_ready','cutoff_s','peak_surface_C','peak_heater_C','final_surface_min_C','final_surface_max_C']} for r in summaries] limits=['The same 2D thin-plate FE model underlies normal and fault cases. Through-thickness gradients, radiation separated from effective losses, adhesive behavior and actual wiring are outside this model.','Cutoff sensors, a separate contactor, threshold accuracy and a 2 s response are assumed. This is a completed theoretical protection study, not certified safety hardware or firmware.','The independent surface readiness check uses modeled surface temperatures. Real sensor placement, attachment errors, drift and calibration need measured data before a process qualification.','Faults are single modeled failures except the explicit unprotected counterfactual. Common-cause loss of all sensing/power interruption is not protected by a numerical assumption.','No physical heating, insulation fire assessment, electrical safety test, curing trial or measured warm-up result is claimed.'] sections=[('Selected operating conditions','

The selected reference assembly uses all three heaters, nominal 1000 W/(m2 K) contact, effective bottom U = 2 W/(m2 K), a 60 W power ceiling, and independent heater/surface cutoff monitoring. Six runs cover ambient 22/35 C crossed with top convection 5/10/20 W/(m2 K). All six finish with the entire working area in 88-92 C after a 300 s hold and without a protection trip. An open heater, poor contact, biased controller, and the U = 12 high-loss challenge are rejected operating states. Readiness is revoked whenever the full-surface band is lost.

'),('Decision','

The model reaches the full-surface band under the normal case. Poor heater contact, a stuck control output and a frozen controller sensor are examined with an independent power cutoff. Removing that protection produces excessive temperatures. A low-reading sensor can produce the wrong process temperature without reaching the cutoff; the full-surface readiness criterion rejects that case.

'),('Protection and test inputs',table([{'parameter':k,'value':v} for k,v in c.items() if k!='cases'])+'

The numerical protection latches when any heater reaches 125 C or the working surface reaches 105 C, then opens an independent power path after 2 s. It remains open for the rest of the run. A sensor-open condition latches the main output off immediately. Readiness requires every modeled working-area node to stay between 88 and 92 C for 300 s.

'),('Executed fault cases',table(compact)+'Working surface and heater temperatures in normal and fault cases'),('Equations and implementation','

Each step solves M (theta next - theta current) / dt + K theta next = f. The same supplied FE mass and conductance matrices are used. f contains the actual power at each heater, so an open heater contributes zero. A stuck output sets total requested power to 60 W. A separate modeled cutoff sets all actual heater powers to zero, independent of that output. The accumulated energy balance includes the powers that were actually applied.

'),('Bench exercise represented by the data','

The CSV records provide the complete cold start, fault injection at 600 s, trip request, delayed cutoff, cool-down and readiness state. The poor-contact case starts degraded. Hot-ambient and high-loss cases exercise boundary assumptions. The half-step rerun records cutoff timing and peak-temperature sensitivity. These are synthetic run logs, not filled-in measurement sheets.

')] finish('Heated platen fault and commissioning study',checks,sections,limits,['complete_validation.py','completion_util.py','completion-inputs.json','inputs.json','solver.py'],{'thermal_and_fault_cases':len(summaries),'selected_operating_cases':len(normal_cases),'energy_checks':len(summaries),'half_step_peak_change_C':peak_delta,'normal_ready_s':by['normal']['first_ready_s']}) if __name__=='__main__':main()