def damage_soderberg(m, R):
d = 0.
I = 0.25 * np.pi * R**4
y = R
sigma = m * y / I
print max(sigma)
c = rainflow.extract_cycles(sigma)
mean = np.array([])
alternate = np.array([])
m = np.array([])
for low, high, mult in c:
mean = np.append(mean, 0.5 * (high + low))
alternate = np.append(alternate, (high - low) / 2.)
m = np.append(m, mult)
Smax = 80.0 * 1.E6
ex = 4.
sig_eff = alternate * (Smax / (Smax - mean))
# sig_eff = (1.-mean*Smax)/alternate
Nf = (Smax / sig_eff)**ex
for i in range(len(mean)):
d += m[i] / Nf[i]
print d * 52560.0 * 20.
def test_extract_cycles(series, cycles, counts, approx):
result = list(rainflow.extract_cycles(series))
if approx:
expected = [(pytest.approx(rng), pytest.approx(mean), count, i, j)
for (rng, mean, count, i, j) in cycles]
else:
expected = cycles
assert result == expected
def count(self):
for spot in self.spotNames:
self.rainflowData[spot] = {'Cycle': [], 'Range': [], 'Mean': []}
for valley, peak, cycle in rainflow.extract_cycles(
self.dataInput[spot]):
rangeValue = peak - valley
meanValue = (peak + valley) / 2
self.rainflowData[spot]['Cycle'].append(cycle)
self.rainflowData[spot]['Range'].append(rangeValue)
self.rainflowData[spot]['Mean'].append(meanValue)
def _calc_damage(data):
stress_ranges = []
cycles = []
for low, high, mult in rainflow.extract_cycles(data, True, True):
cycles.append(mult)
amplitude = high - 0.5 * (high + low)
if amplitude > 0: stress_ranges.append(2 * amplitude)
N = sn_curve(stress_ranges, logA=math.log10(6e10), m=3, t=0, tref=25, k=0)
damage = sum(sorted(cycles / N))
return damage
def _calc_damage(data, sn_curve):
stress_ranges = []
cycles = []
for low, high, mult in rainflow.extract_cycles(data, True, True):
amplitude = high - 0.5 * (high + low)
if amplitude > 0:
cycles.append(mult)
stress_ranges.append(2 * amplitude)
N = sncurve(stress_ranges, **sn_curve)
damage = sum(sorted(cycles / N))
return damage
def test_order_of_remaining_halves(self):
cycle_ref = [0.5, 0.5, 0.5, 1.0, 0.5, 0.5, 0.5, 0.5, 0.5]
mean_ref = [-1.0, -0.5, -1.0, 1.0, 1.0, 0.5, 0.0, 1.0, -1.0]
cycles = []
means = []
for low, high, mult in rainflow.extract_cycles(self.series, True, True):
cycles.append(mult)
mean = 0.5 * (high + low)
means.append(mean)
self.assertEqual(cycles, cycle_ref)
self.assertEqual(means, mean_ref)
def count(self):
''' Rainflow counting spot by spot
'''
for spot in self.spots:
self.rainflowData[spot] = {'Cycle':collections.deque(),
'Range':collections.deque(),
'Mean':collections.deque()}
for valley, peak, cycle in rainflow.extract_cycles(self.dataInput.get(spot)['Records']):
rangeValue = peak - valley
meanValue = (peak+valley)/2
self.rainflowData[spot]['Cycle'].append(cycle)
self.rainflowData[spot]['Range'].append(rangeValue)
self.rainflowData[spot]['Mean'].append(meanValue)
def test_lows_and_highs_sorted(self):
self.assertTrue(
all(low <= high
for low, high, mult in rainflow.extract_cycles(self.series)))
def calc_degradation(self, opt_period, start_dttm, last_dttm):
""" calculate degradation percent based on yearly degradation and cycle degradation
Args:
opt_period: the index of the optimization that occurred before calling this function, None if
no optimization problem has been solved yet
start_dttm (DateTime): Start timestamp to calculate degradation. ie. the first datetime in the optimization
problem
last_dttm (DateTime): End timestamp to calculate degradation. ie. the last datetime in the optimization
problem
A percent that represented the energy capacity degradation
"""
# time difference between time stamps converted into years multiplied by yearly degrate rate
if self.incl_cycle_degrade:
cycle_degrade = 0
yearly_degradation = 0
if not isinstance(opt_period, str):
# calculate degradation due to cycling iff energy values are given
energy_series = self.variables_df.loc[start_dttm:last_dttm,
'ene']
# Find the effective energy capacity
eff_e_cap = self.degraded_energy_capacity()
#If using rainflow counting package uncomment following few lines
# use rainflow counting algorithm to get cycle counts
# cycle_counts = rainflow.count_cycles(energy_series, ndigits=4)
#
# aux_df = pd.DataFrame(cycle_counts, columns=['DoD', 'N_cycles'])
# aux_df['Opt window'] = opt_period
#
# # sort cycle counts into user inputed cycle life bins
# digitized_cycles = np.searchsorted(self.cycle_life['Cycle Depth Upper Limit'],[min(i[0]/eff_e_cap, 1) for i in cycle_counts], side='left')
# use rainflow extract function to get information on each cycle
cycle_extract = list(rainflow.extract_cycles(energy_series))
aux_df = pd.DataFrame(
cycle_extract,
columns=['rng', 'mean', 'count', 'i_start', 'i_end'])
aux_df['Opt window'] = opt_period
# sort cycle counts into user inputed cycle life bins
digitized_cycles = np.searchsorted(
self.cycle_life['Cycle Depth Upper Limit'],
[min(i[0] / eff_e_cap, 1) for i in cycle_extract],
side='left')
aux_df['Input_cycle_DoD_mapping'] = np.array(
self.cycle_life['Cycle Depth Upper Limit']
[digitized_cycles] * eff_e_cap)
aux_df['Cycle Life Value'] = np.array(
self.cycle_life['Cycle Life Value'][digitized_cycles])
self.counted_cycles.append(aux_df.copy())
# sum up number of cycles for all cycle counts in each bin
cycle_sum = self.cycle_life.loc[:, :]
cycle_sum.loc[:, 'cycles'] = 0
for i in range(len(cycle_extract)):
cycle_sum.loc[digitized_cycles[i],
'cycles'] += cycle_extract[i][2]
# sum across bins to get total degrade percent
# 1/cycle life value is degrade percent for each cycle
cycle_degrade = np.dot(
1 / cycle_sum['Cycle Life Value'],
cycle_sum.cycles) * (1 - self.eol_condition)
if start_dttm is not None and last_dttm is not None:
# add the yearly degradation linearly to the # of years from START_DTTM to (END_DTTM + dt)
days_in_year = 366 if is_leap_yr(start_dttm.year) else 365
portion_of_year = (
last_dttm + pd.Timedelta(self.dt, unit='h') -
start_dttm) / pd.Timedelta(days_in_year, unit='d')
yearly_degradation = self.yearly_degrade * portion_of_year
# add the degradation due to time passing and cycling for total degradation
degrade_percent = cycle_degrade + yearly_degradation
# record the degradation
# the total degradation after optimization OPT_PERIOD must also take into account the
# degradation that occurred before the battery was in operation (which we saved as SELF.DEGRADE_PERC)
self.degrade_data.loc[
opt_period,
'degradation progress %'] = degrade_percent + self.degrade_perc
self.degrade_perc += degrade_percent
soh_new = self.soh_initial - self.degrade_perc
self.soh = self.degrade_data.loc[opt_period,
'state of health %'] = soh_new
# apply degradation to technology (affects physical_constraints['ene_max_rated'] and control constraints)
eff_e_cap = self.degraded_energy_capacity()
TellUser.info(
f"BATTERY - {self.name}: effective energy capacity is now {truncate_float(eff_e_cap)} kWh "
+
f"({truncate_float(100*(1 - (self.ene_max_rated-eff_e_cap)/self.ene_max_rated), 7)}% of original)"
)
self.degrade_data.loc[
opt_period, 'effective energy capacity (kWh)'] = eff_e_cap
self.effective_soe_max = eff_e_cap * self.ulsoc
self.effective_soe_min = eff_e_cap * self.llsoc
def WeldFat(timestamp, _componentId, json_input, response):
"""Iterate cycles in the series.
Parameters
----------
timestamp (datetime.datetime):
_componentId (string): "e9fafc85-5f4d-422e-8988-6545890f202c"
jsonjson_obj (string):
Returns
------
res_dict dictionary as json
res_dict['cumulative_damage']
res_dict['safety_factor_life_per_bin']
res_dict['equivalent_stress_range']
res_dict['safety_factor_stress']
res_dict['rst'] : Fatigue result per bin as below
res_dict['rst'][bin]['life']
res_dict['rst'][bin]['log10_life']
res_dict['rst'][bin]['damage_per_bin']
res_dict['rst'][bin]['safety_factor_life_per_bin']
"""
# read json json_objs
json_obj = {}
json_obj = json.loads(json_input)
# Define unit conversion from user units to stress_unit_dict units
#stress_unit = json_obj['stress_unit']
stress_unit_dict = {
'mpa': 1.0,
'psi': 145.038,
'ksi': 0.145038
} #Mpa to user unit
#conv_stress = stress_unit_dict[stress_unit.lower()] #convert MPa to user unit
# Get S-N Curve definition parameters
if 'class' not in json_obj['fatigue_class']:
fat_class = 'User defined'
fat = json_obj['fatigue_class']['fat']
n_fat = json_obj['fatigue_class']['n_fat']
n_c = json_obj['fatigue_class']['n_c']
m_1 = json_obj['fatigue_class']['m_1']
m_2 = json_obj['fatigue_class']['m_2']
else:
fat_class = json_obj['fatigue_class']['class']
if fat_class in fatClassDict:
fat = fatClassDict[fat_class]['FAT'][0] * stress_unit_dict[
fatClassDict[fat_class]['FAT']
[1].lower()] #SN curve in MPa change to user unit
n_fat = fatClassDict[fat_class]['Nfat']
n_c = fatClassDict[fat_class]['Nc']
m_1 = fatClassDict[fat_class]['m1']
m_2 = fatClassDict[fat_class]['m2']
else:
response[
0] = fat_class + ' not found in fatClassDict - not catch json schema validator'
if 'fat_fact' not in json_obj['fatigue_class']:
fat_fact = 1.
else:
fat_fact = json_obj['fatigue_class']['fat_fact']
if 'N0' in fatClassDict[fat_class]:
n_0 = fatClassDict[fat_class]['N0']
else:
n_0 = 1
if 'm0' in fatClassDict[fat_class]:
m_0 = fatClassDict[fat_class]['m0']
else:
m_0 = 1
if 'Ncutoff' in fatClassDict[fat_class]:
n_cutoff = fatClassDict[fat_class]['Ncutoff']
else:
n_cutoff = 1
res_dict = {}
res_dict['stress_unit'] = json_obj['stress_unit']
# Save SN parameters for user check
res_dict['sn_parameters'] = {}
res_dict['sn_parameters']['class'] = fat_class
res_dict['sn_parameters']['fat'] = fat
res_dict['sn_parameters']['n_fat'] = n_fat
res_dict['sn_parameters']['n_c'] = n_c
res_dict['sn_parameters']['m_1'] = m_1
res_dict['sn_parameters']['m_2'] = m_2
res_dict['sn_parameters']['fat_fact'] = fat_fact
res_dict['sn_parameters']['n_0'] = n_0
res_dict['sn_parameters']['m_0'] = m_0
res_dict['sn_parameters']['n_cutoff'] = n_cutoff
# intermediate parameters
log10_sn_1 = log10(fat * fat_fact) + (log10(n_fat) - log10(n_0)) / m_1
sn_1 = 10**log10_sn_1
sn_0 = 10**(log10_sn_1 + log10(n_0) / m_0)
sn_c = 10**(log10(fat * fat_fact) - (log10(n_c) - log10(n_fat)) / m_1)
# added extraction of sn_cutoff to plot curve
sn_cutoff = 10**(log10(sn_c) - (log10(n_cutoff) - log10(n_c)) / m_2)
#plot sn-curve
sn_s = [sn_1, sn_0, sn_c, sn_cutoff]
log_sn_s = [log10(s) for s in sn_s]
n_s = [n_0, n_0, n_c, n_cutoff]
log_n_s = [log10(n) for n in n_s]
plt.plot(log_n_s, log_sn_s)
plt.savefig("deterministic_SN_curve")
plt.close()
# Get mean stress theory parameter
if 'mean_stress_theory' in json_obj:
mean_stress_theory = json_obj['mean_stress_theory']['theory']
if mean_stress_theory in ['Goodman', 'Gerber']:
r_m = json_obj['mean_stress_theory']['ultimate_limit']
r_y = 0.9 * r_m
elif mean_stress_theory == 'Soderberg':
r_m = 0.
r_y = json_obj['mean_stress_theory']['yield_limit']
else:
response[
0] = mean_stress_theory + ' not found in mean_stress_theory - not catch json schema validator'
# Calculate result per bin
#res_dict = {}
res_dict['cumulative_damage'] = 0.
res_dict['safety_factor_life_per_bin'] = 0.
res_dict['equivalent_stress_range'] = 0.
res_dict['safety_factor_stress'] = 0.
res_dict['result_per_bin'] = {}
# rainflow counting in the user unit
if 'stress_data' not in json_obj.keys() and 'serie_data' in json_obj.keys(
):
series = json_obj['serie_data']['series']
if series == []:
response[0] = 'serie ' + str(series) + ' not valid'
return
if 'nbins' in json_obj['serie_data'].keys():
max_range = max(series) - min(series)
if 'maxrange' in json_obj['serie_data']:
my_max_range = json_obj['serie_data']['maxrange']
max_range = my_max_range
if max_range < my_max_range:
pass
else:
response[
0] = 'Warning: serie max range larger than given max range'
nbins = json_obj['serie_data']['nbins']
binsize = max_range / nbins
counts_ix = defaultdict(int)
for i in range(nbins):
counts_ix[i] = 0
# Apply mean stress theory before assigning to bin
for (rng, mean, count, i_start,
i_end) in rainflow.extract_cycles(series):
if 'mean_stress_theory' in json_obj:
sn_0_user_unit = sn_0
rng = apply_mean_stress_theory(mean_stress_theory, mean,
rng, sn_0_user_unit, r_m,
r_y)
bin_index = int(abs(rng) / binsize)
# handle possibility of range equaliing max range
if bin_index == nbins:
bin_index = nbins - 1
counts_ix[bin_index] += count
# save count data to dictionary where key is the range
counts = dict(
((k + 1) * binsize, v) for (k, v) in counts_ix.items())
cycles_list = sorted(counts.items())
json_obj['stress_data'] = {}
for i in range(len(cycles_list)):
json_obj['stress_data'][i] = {
'rng': cycles_list[i][0],
'cycles': cycles_list[i][1],
'sm': 0.
}
if 'mean_stress_theory' in json_obj:
del json_obj['mean_stress_theory']
elif 'maxrange' in json_obj['serie_data'].keys(
) and not 'nbins' in json_obj['serie_data'].keys():
response[
0] = '"maxrange" and no "nbins" not currently handle - not catch json schema validator'
else:
json_obj['stress_data'] = {}
for (i, (rng, mean, count, i_start,
i_end)) in enumerate(rainflow.extract_cycles(series)):
json_obj['stress_data'][i] = {
'rng': rng,
'cycles': count,
'sm': mean
}
#res_dict['stress_data'] = json_obj['stress_data']
# Fatigue calculation in MPa unit
it = 0
for bin in json_obj['stress_data'].keys():
if it == 0:
cycles = json_obj['stress_data'][bin]['cycles']
rng = json_obj['stress_data'][bin]['rng']
if 'sm' in json_obj['stress_data'][bin]:
sm = json_obj['stress_data'][bin]['sm']
else:
sm = 0.
# init result dictionary
_rst_dic_per_bin = {}
_rst_dic_per_bin['rng'] = rng
_rst_dic_per_bin['mean'] = sm
_rst_dic_per_bin['corrected_rng'] = rng
_rst_dic_per_bin['cycles'] = cycles
_rst_dic_per_bin['life'] = 0.
_rst_dic_per_bin['log10_life'] = 0.
_rst_dic_per_bin['damage_per_bin'] = 0.
_rst_dic_per_bin['safety_factor_life_per_bin'] = 0.
if cycles != 0.:
# calculate s_nb
if cycles <= n_0:
s_nb = 10**(log10_sn_1 +
(log10(n_0) - log10(cycles)) / m_0)
elif cycles <= n_c:
s_nb = 10**(log10(sn_c) +
(log10(n_c) - log10(cycles)) / m_1)
else:
s_nb = 10**(log10(sn_c) -
(log10(cycles) - log10(n_c)) / m_2)
# mean stress theory
if 'mean_stress_theory' in json_obj and 'sm' in json_obj[
'stress_data'][bin]:
if rng > 1.5 * r_y:
response[
0] = 'The calculated Nominal stress range exceeds the 1.5*Yield Stress for the material. The fatigue calculations may not be valid. Please check the results carefully.'
if json_obj['stress_data'][bin]['sm'] != 0.:
mean_stress_theory = json_obj['mean_stress_theory'][
'theory']
rng = apply_mean_stress_theory(mean_stress_theory, sm,
rng, sn_0, r_m, r_y)
_rst_dic_per_bin['corrected_rng'] = rng
else:
_rst_dic_per_bin['corrected_rng'] = rng
else:
_rst_dic_per_bin['corrected_rng'] = rng
# Calculate life and store result
if rng > sn_0:
_rst_dic_per_bin['log10_life'] = -1.
_rst_dic_per_bin['life'] = 0.
_rst_dic_per_bin['damage_per_bin'] = 100.0
_rst_dic_per_bin['safety_factor_life_per_bin'] = 0.
elif rng > sn_1:
_rst_dic_per_bin['log10_life'] = log10(
n_0) - m_0 * (log10(rng) - log10_sn_1)
_rst_dic_per_bin['life'] = 10**_rst_dic_per_bin['log10_life']
elif rng > sn_c:
_rst_dic_per_bin['log10_life'] = log10(
n_c) - m_1 * (log10(rng) - log10(sn_c))
_rst_dic_per_bin['life'] = 10**_rst_dic_per_bin['log10_life']
elif rng > 0.:
_rst_dic_per_bin['log10_life'] = min(
log10(n_cutoff),
log10(n_c) + m_2 * (log10(sn_c) - log10(rng)))
_rst_dic_per_bin['life'] = 10**_rst_dic_per_bin['log10_life']
else:
_rst_dic_per_bin['log10_life'] = log10(n_cutoff)
_rst_dic_per_bin['life'] = n_cutoff
if _rst_dic_per_bin['life'] > 0:
_rst_dic_per_bin[
'damage_per_bin'] = cycles / _rst_dic_per_bin['life']
if _rst_dic_per_bin['damage_per_bin'] != 0.:
_rst_dic_per_bin[
'safety_factor_life_per_bin'] = 1 / _rst_dic_per_bin[
'damage_per_bin']
else:
_rst_dic_per_bin['safety_factor_life_per_bin'] = 1.
_rst_dic_per_bin['safety_factor_stress'] = min(
100.0, s_nb / max(1, rng))
# store results
res_dict['result_per_bin'][bin] = _rst_dic_per_bin
#it+=1
# Cumulated Damage
cum_damage = 0.
it = 0
for bin in json_obj['stress_data'].keys():
if it == 0:
cum_damage += res_dict['result_per_bin'][bin]['damage_per_bin']
it += 1
res_dict['cumulative_damage'] = cum_damage
if cum_damage > 1e-5:
res_dict['safety_factor_life_per_bin'] = 1. / cum_damage
n_seqv = cycles / cum_damage
else:
res_dict['safety_factor_life_per_bin'] = 1e5
n_seqv = n_cutoff
if n_seqv <= n_0:
s_eqv = 10**(log10_sn_1 + (log10(n_0) - log10(n_seqv)) / m_0)
elif n_seqv <= n_c:
s_eqv = 10**(log10(sn_c) + (log10(n_c) - log10(n_seqv)) / m_1)
elif n_seqv < n_cutoff:
s_eqv = 10**(log10(sn_c) - (log10(n_seqv) - log10(n_c)) / m_2)
else:
s_eqv = s_nb / 100.0
res_dict['equivalent_stress_range'] = s_eqv
res_dict['safety_factor_stress'] = min(100.0, s_nb / s_eqv)
#print(json.dumps(res_dict, indent=4, sort_keys=True))
dmg_list = []
for key, value in res_dict["result_per_bin"].items():
dmg_list.append(value["damage_per_bin"])
print("dmg per bin: ", dmg_list)
print("..........")
print("total damage: ", sum(dmg_list))
def test_extract_cycles(series, cycles, counts):
result = list(rainflow.extract_cycles(series))
assert result == cycles
def WeldFat(timestamp,_componentId, json_input):
"""Iterate cycles in the series.
Parameters
----------
timestamp (datetime.datetime):
_componentId (string): "e9fafc85-5f4d-422e-8988-6545890f202c"
jsonjson_obj (string):
Returns
------
res_dict dictionary as json
res_dict['cumulative_damage']
res_dict['safety_factor_life_per_bin']
res_dict['equivalent_stress_range']
res_dict['safety_factor_stress']
res_dict['rst'] : Fatigue result per bin as below
res_dict['rst'][bin]['life']
res_dict['rst'][bin]['log10_life']
res_dict['rst'][bin]['damage_per_bin']
res_dict['rst'][bin]['safety_factor_life_per_bin']
"""
# read json json_objs
json_obj = {}
json_obj = json.loads(json_input)
# Define unit conversion from user units to stress_unit_dict units
stress_unit = json_obj['stress_unit']
stress_unit_dict = {'mpa':1.0e6,'psi':6894.76,'ksi':6894757.29}
conv_stress = stress_unit_dict[stress_unit.lower()]
# Get S-N Curve definition parameters
if "class" not in json_obj["fatigue_class"]:
fat_class = "User defined"
fat = json_obj["fatigue_class"]["fat"]*conv_stress
n_fat = json_obj["fatigue_class"]["n_fat"]
n_c = json_obj["fatigue_class"]["n_c"]
m_1 = json_obj["fatigue_class"]["m_1"]
m_2 = json_obj["fatigue_class"]["m_2"]
else:
fat_class = json_obj["fatigue_class"]["class"]
fat = fatClassDict[fat_class]['FAT'][0]*stress_unit_dict[fatClassDict[fat_class]['FAT'][1].lower()]
n_fat = fatClassDict[fat_class]['Nfat']
n_c = fatClassDict[fat_class]['Nc']
m_1 = fatClassDict[fat_class]['m1']
m_2 = fatClassDict[fat_class]['m2']
if "fat_fact" not in json_obj["fatigue_class"]:
fat_fact = 1.
else:
fat_fact = json_obj["fatigue_class"]["fat_fact"]
if 'N0' in fatClassDict[fat_class]:
n_0 = fatClassDict[fat_class]['N0']
else:
n_0 = 1
if 'm0' in fatClassDict[fat_class]:
m_0 = fatClassDict[fat_class]['m0']
else:
m_0 = 1
if 'Ncutoff' in fatClassDict[fat_class]:
n_cutoff = fatClassDict[fat_class]['Ncutoff']
else:
n_cutoff = 1
# intermediate parameters
log10_sn_1 = log10(fat*fat_fact)+(log10(n_fat)-log10(n_0))/m_1
sn_1 = 10**(log10_sn_1)
sn_0 = 10**(log10_sn_1+log10(n_0)/m_0)
sn_c = 10**(log10(fat*fat_fact)-(log10(n_c)-log10(n_fat))/m_1)
# Get mean stress theory parameter
if "mean_stress_theory" in json_obj:
mean_stress_theory=json_obj['mean_stress_theory']['theory']
if mean_stress_theory in ['Goodman','Gerber']:
UTS = json_obj['mean_stress_theory']['ultimate_limit']*conv_stress
r_m = conv_stress*UTS
r_y = 0.9*r_m
elif mean_stress_theory == 'Soderberg':
SY = json_obj['mean_stress_theory']['yield_limit']*conv_stress
r_y = conv_stress*SY
#elif json_obj['mean_stress_theory'] == 'None':
# if json_obj['Method'] in ['nominalFatigue', 'hotSpotFatigue']:
# r_y = conv_stress*SY
# else:
# r_y = 0.0
# Calculate result per bin
res_dict = {}
res_dict['cumulative_damage'] = 0.
res_dict['safety_factor_life_per_bin'] = 0.
res_dict['equivalent_stress_range'] = 0.
res_dict['safety_factor_stress'] = 0.
res_dict['rst'] = {}
if 'stress_data' not in json_obj.keys() and 'serie_data' in json_obj.keys():
series=json_obj['serie_data']["series"]
if 'nbins' in json_obj['serie_data'].keys():
nbins = json_obj['serie_data']['nbins']
max_range = max(series) - min(series)
if 'maxrange' in json_obj['serie_data']:
my_max_range =json_obj['serie_data']['maxrange']
max_range = my_max_range
if max_range < my_max_range:#add error message?
pass
else:
print ("serie max range larger than given max range")
binsize = max_range / nbins
counts_ix = defaultdict(int)
for i in range(nbins):
counts_ix[i] = 0
# Apply mean stress theory before assigning to bin
for low, high, mult in rainflow.extract_cycles(series):
bin_index = int(abs(high - low) / binsize)
sm=0.5 * (high + low)
sa=high - low
if "mean_stress_theory" in json_obj: #does not handle sn_0
sa=apply_mean_stress_theory(mean_stress_theory,sm,sa,sn_0,r_m,r_y)
bin_index = int(abs(sa) / binsize)
# handle possibility of range equaliing max range
if bin_index == nbins:
bin_index = nbins - 1
counts_ix[bin_index] += mult
# save count data to dictionary where key is the range
counts = dict(((k+1)*binsize,v) for k,v in counts_ix.items())
cycles_list=sorted(counts.items())
#print (cycles_list)
json_obj['stress_data']={}
for i in range(len(cycles_list)):
json_obj['stress_data'][i]={'sa':cycles_list[i][0],'cycles':cycles_list[i][1],'sm':0.}
if "mean_stress_theory" in json_obj:
del json_obj["mean_stress_theory"]
else:
json_obj['stress_data']={}
for i,(low, high, mult) in enumerate(rainflow.extract_cycles(series)):
mean=0.5 * (high + low)
rng=high - low
json_obj['stress_data'][i]={'sa':rng,'cycles':mult,'sm':mean}
#print(json_obj['stress_data'])
for bin in json_obj['stress_data'].keys():
cycles = json_obj['stress_data'][bin]["cycles"]
if cycles !=0.:
# init result dictionary
_rst_dic_per_bin = {}
_rst_dic_per_bin['life'] = 0.0
_rst_dic_per_bin['log10_life'] = 0.0
_rst_dic_per_bin['damage_per_bin'] = 0.0
_rst_dic_per_bin['safety_factor_life_per_bin'] = 0.0
# calculate s_nb
if cycles <= n_0:
s_nb = 10**(log10_sn_1+(log10(n_0)-log10(cycles))/m_0)
elif cycles <= n_c:
s_nb = 10**(log10(sn_c)+(log10(n_c)-log10(cycles))/m_1)
else:
s_nb = 10**(log10(sn_c)-(log10(cycles)-log10(n_c))/m_2)
# mean stress theory
sa = json_obj['stress_data'][bin]["sa"]*conv_stress
if "mean_stress_theory" in json_obj and "sm" in json_obj['stress_data'][bin]:
mean_stress_theory=json_obj['mean_stress_theory']['theory']
sm = json_obj['stress_data'][bin]["sm"]*conv_stress
sa=apply_mean_stress_theory(mean_stress_theory,sm,sa,sn_0,r_m,r_y)
# Calculate life and store result
if sa > sn_0:
_rst_dic_per_bin['log10_life'] = -1.0
_rst_dic_per_bin['life'] = 0.0
_rst_dic_per_bin['damage_per_bin'] = 100.0
_rst_dic_per_bin['safety_factor_life_per_bin'] = 0.0
elif sa> sn_1:
_rst_dic_per_bin['log10_life'] = log10(n_0) - m_0*(log10(sa)-log10_sn_1)
_rst_dic_per_bin['life'] = 10**_rst_dic_per_bin['log10_life']
elif sa > sn_c:
_rst_dic_per_bin['log10_life'] = log10(n_c) - m_1*(log10(sa)-log10(sn_c))
_rst_dic_per_bin['life'] = 10**_rst_dic_per_bin['log10_life']
elif sa > 0.0:
_rst_dic_per_bin['log10_life'] = min(log10(n_cutoff),log10(n_c) + m_2*(log10(sn_c) - log10(sa)))
_rst_dic_per_bin['life'] = 10**_rst_dic_per_bin['log10_life']
else:
_rst_dic_per_bin['log10_life'] = log10(n_cutoff)
_rst_dic_per_bin['life'] = n_cutoff
if _rst_dic_per_bin['life']> 0:
_rst_dic_per_bin['damage_per_bin'] = cycles/_rst_dic_per_bin['life']
if _rst_dic_per_bin['damage_per_bin']!=0.:
_rst_dic_per_bin['safety_factor_life_per_bin'] = 1/_rst_dic_per_bin['damage_per_bin']
else:
_rst_dic_per_bin['safety_factor_life_per_bin'] = 1.
_rst_dic_per_bin['safety_factor_stress'] = min(100.0,s_nb/max(1,sa))
# store results
res_dict['rst'][bin]=_rst_dic_per_bin
#Cumulated Damage
cum_damage = 0.
for bin in json_obj['stress_data'].keys():
cum_damage += res_dict['rst'][bin]['damage_per_bin']
res_dict['cumulative_damage'] = cum_damage
if cum_damage > 1e-5:
res_dict['safety_factor_life_per_bin'] = 1.0/cum_damage
n_seqv = cycles/cum_damage
else:
res_dict['safety_factor_life_per_bin'] = 1e5
n_seqv = n_cutoff
if n_seqv <= n_0:
s_eqv = 10**(log10_sn_1+(log10(n_0)-log10(n_seqv))/m_0)
elif n_seqv <= n_c:
s_eqv = 10**(log10(sn_c)+(log10(n_c)-log10(n_seqv))/m_1)
elif n_seqv < n_cutoff:
s_eqv = 10**(log10(sn_c)-(log10(n_seqv)-log10(n_c))/m_2)
else:
s_eqv = s_nb/100.0
res_dict['equivalent_stress_range'] = s_eqv
res_dict['safety_factor_stress'] = min(100.0,s_nb/s_eqv)
#insert the result to the 'Result' database
data = formatTheResultForDB(res_dict)
#_resultTimeStamp = datetime.datetime.utcnow()
Result.add_data(timestamp, datetime.datetime.utcnow() , _componentId, data)
def test_extract_cycles_small_series(series, cycles):
assert list(rainflow.extract_cycles(series)) == cycles
def unpack_weldfat(json_input):
"""
Unpacks input json
to theano readable parameters
"""
#unpacking function:
stress_unit_dict = {
'mpa': 1.0,
'psi': 145.038,
'ksi': 0.145038
} #Mpa to user unit
json_obj = {}
json_obj = json.loads(json_input)
kwargs = {}
if 'class' not in json_obj['fatigue_class']:
fat_class = 'User defined'
#kwargs["fat_class"] = 'User defined'
kwargs["fat"] = json_obj['fatigue_class']['fat']
kwargs["n_fat"] = json_obj['fatigue_class']['n_fat']
kwargs["n_c"] = json_obj['fatigue_class']['n_c']
kwargs["m_1"] = json_obj['fatigue_class']['m_1']
kwargs["m_2"] = json_obj['fatigue_class']['m_2']
else:
fat_class = json_obj['fatigue_class']['class']
if fat_class in fatClassDict:
kwargs["fat"] = fatClassDict[fat_class]['FAT'][
0] * stress_unit_dict[fatClassDict[fat_class]['FAT'][1].lower(
)] #SN curve in MPa change to user unit
kwargs["n_fat"] = fatClassDict[fat_class]['Nfat']
kwargs["n_c"] = fatClassDict[fat_class]['Nc']
kwargs["m_1"] = fatClassDict[fat_class]['m1']
kwargs["m_2"] = fatClassDict[fat_class]['m2']
else:
response[
0] = fat_class + ' not found in fatClassDict - not catch json schema validator'
if 'fat_fact' not in json_obj['fatigue_class']:
kwargs["fat_fact"] = 1.
else:
kwargs["fat_fact"] = json_obj['fatigue_class']['fat_fact']
if 'N0' in fatClassDict[fat_class]:
kwargs["n_0"] = fatClassDict[fat_class]['N0']
else:
kwargs["n_0"] = 1
if 'm0' in fatClassDict[fat_class]:
kwargs["m_0"] = fatClassDict[fat_class]['m0']
else:
kwargs["m_0"] = 1
if 'Ncutoff' in fatClassDict[fat_class]:
kwargs["n_cutoff"] = fatClassDict[fat_class]['Ncutoff']
else:
kwargs["n_cutoff"] = 1
if 'mean_stress_theory' in json_obj:
kwargs["mean_stress_theory"] = json_obj['mean_stress_theory']
mean_stress_theory = kwargs['mean_stress_theory']['theory']
if mean_stress_theory in ['Goodman', 'Gerber']:
kwargs["r_m"] = kwargs['mean_stress_theory']['ultimate_limit']
kwargs["r_y"] = 0.9 * kwargs["r_m"]
if mean_stress_theory == "Goodman":
m_s_th = 1
else: #Gerber
m_s_th = 2
elif mean_stress_theory == 'Soderberg':
kwargs["r_m"] = 0.
kwargs["r_y"] = kwargs['mean_stress_theory']['yield_limit']
m_s_th = 3
else:
m_s_th = 0
kwargs["m_s_th"] = m_s_th
del kwargs["mean_stress_theory"]
if 'stress_data' not in json_obj.keys() and 'serie_data' in json_obj.keys(
):
series = json_obj['serie_data']['series']
if series == []:
response[0] = 'serie ' + str(series) + ' not valid'
return
if 'nbins' in json_obj['serie_data'].keys():
kwargs["max_range"] = max(series) - min(series)
if 'maxrange' in json_obj['serie_data']:
kwargs["my_max_range"] = json_obj['serie_data']['maxrange']
kwargs["max_range"] = kwargs["my_max_range"]
if kwargs["max_range"] < kwargs["my_max_range"]:
pass
else:
response[
0] = 'Warning: serie max range larger than given max range'
kwargs["nbins"] = json_obj['serie_data']['nbins']
kwargs["binsize"] = kwargs["max_range"] / kwargs["nbins"]
kwargs["counts_ix"] = defaultdict(int)
for i in range(kwargs["nbins"]):
kwargs["counts_ix"][i] = 0
# Apply mean stress theory before assigning to bin
for (rng, mean, count, i_start,
i_end) in rainflow.extract_cycles(series):
if 'mean_stress_theory' in json_obj:
kwargs["sn_0_user_unit"] = kwargs["sn_0"]
kwargs["rng"] = apply_mean_stress_theory(
kwargs["mean_stress_theory"], mean, rng,
kwargs["sn_0_user_unit"], kwargs["r_m"], kwargs["r_y"])
kwargs["bin_index"] = int(abs(rng) / kwargs["binsize"])
# handle possibility of range equaliing max range
if kwargs["bin_index"] == kwargs["nbins"]:
kwargs["bin_index"] = kwargs["nbins"] - 1
kwargs["counts_ix"][kwargs["bin_index"]] += count
# save count data to dictionary where key is the range
kwargs["counts"] = dict(((k + 1) * kwargs["binsize"], v)
for (k, v) in kwargs["counts_ix"].items())
kwargs["cycles_list"] = sorted(kwargs["counts"].items())
kwargs["stress_data"] = {}
for i in range(len(kwargs["cycles_list"])):
kwargs["stress_data"][i] = {
'rng': kwargs["cycles_list"][i][0],
'cycles': kwargs["cycles_list"][i][1],
'sm': 0.
}
if 'mean_stress_theory' in json_obj:
del json_obj['mean_stress_theory']
elif 'maxrange' in json_obj['serie_data'].keys(
) and not 'nbins' in json_obj['serie_data'].keys():
response[
0] = '"maxrange" and no "nbins" not currently handle - not catch json schema validator'
else:
kwargs['cycles'] = []
kwargs['rng'] = []
kwargs['sm'] = []
for (i, (rng, mean, count, i_start,
i_end)) in enumerate(rainflow.extract_cycles(series)):
kwargs["cycles"].append(count)
kwargs["rng"].append(rng)
kwargs["sm"].append(mean)
#print(json.dumps(kwargs, indent=4, sort_keys=True))
return kwargs