GUI: I limit field is the environment input-current limit, no hardcoded 20A
The 20A PSU ceiling was hardcoded and clamped user entries, which breaks benches with a different supply. Now the sweep I limit field IS the max input current allowed for the test environment: used verbatim as the supply CC limit and as the step-rejection / measured-backstop ceiling. Manual supply-current clamp removed; manual CC/CP load gate now checks against the I limit field value. PSU_MAX_CURRENT_A is reduced to INPUT_LIMIT_DEFAULT_A (initial field value only). Co-Authored-By: Claude Fable 5 <noreply@anthropic.com>
This commit is contained in:
janik
@@ -97,14 +97,15 @@ The GUI provides:
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launch auto-starts a log at `logs/data_<timestamp>.csv` (relative to the
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working directory); use Stop Log / Start Log to switch to a custom path
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- Console log panel (STM32 fault flags are reported here as they latch)
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- PSU capability guard: the HV supply can source at most 20 A
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(`PSU_MAX_CURRENT_A` in `gui.py`). Sweep steps whose estimated input draw
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`I_in = P_out / (0.90 * V_in)` exceeds that are rejected (skipped and
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- Input-current guard: the sweep "I limit" field is the maximum input
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current allowed for the test environment (set it to whatever the PSU on
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the bench can source; defaults to 20 A, no hardcoded ceiling). It is
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programmed as the supply CC limit, and sweep steps whose estimated input
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draw `I_in = P_out / (0.90 * V_in)` exceeds it are rejected (skipped and
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reported per voltage), regardless of the requested step range; a measured
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backstop additionally drops any point where the supply actually exceeded
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the limit and backs the load off. The programmed supply current limit
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(sweep "I limit" field and manual supply controls) is clamped to 20 A, and
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manual CC/CP load setpoints are checked against live Vin/Vout readings.
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the limit and backs the load off. Manual CC/CP load setpoints are checked
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against the same limit using live Vin/Vout readings.
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- Load range pinning: a mid-sweep auto-range transition on the Prodigit
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momentarily unloads the converter, so at sweep start the CC range is
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pinned to Range II for the whole run (auto-ranging restored after, with
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+25
-35
@@ -39,11 +39,13 @@ TELEM_DECIMATE = 4 # telemetry display decimation (full rate still recorded
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MIN_REDRAW_S = 0.4 # throttle canvas redraws
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STM_EMA_TAU_S = 2.0 # EMA time constant for displayed telemetry values
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# HV supply capability guard: the PSU can source at most this much current.
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# Load steps whose estimated input draw exceeds it are rejected, regardless
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# of what the sweep asks for. The estimate is conservative (low assumed
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# efficiency) so rejection kicks in before the PSU actually current-limits.
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PSU_MAX_CURRENT_A = 20.0
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# Input-current guard: the sweep "I limit" field holds the maximum input
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# current allowed for the test environment (whatever PSU is on the bench --
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# no hardcoded ceiling). Load steps whose estimated input draw exceeds it
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# are rejected, regardless of what the sweep asks for. The estimate is
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# conservative (low assumed efficiency) so rejection kicks in before the
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# PSU actually current-limits.
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INPUT_LIMIT_DEFAULT_A = 20.0 # initial I limit field value only
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VOUT_NOM_V = 48.0 # nominal converter output, fallback when unmeasured
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EFF_ASSUMED = 0.90 # conservative efficiency for input-current estimates
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@@ -667,7 +669,7 @@ class TestbenchGUI(tk.Tk):
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row.pack(fill=tk.X, pady=1)
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ttk.Label(row, text="I limit:", width=10).pack(side=tk.LEFT)
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self._svi_ilimit = ttk.Entry(row, width=7)
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self._svi_ilimit.insert(0, f"{PSU_MAX_CURRENT_A:g}")
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self._svi_ilimit.insert(0, f"{INPUT_LIMIT_DEFAULT_A:g}")
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self._svi_ilimit.pack(side=tk.LEFT, padx=2)
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ttk.Label(row, text="settle:").pack(side=tk.LEFT)
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self._svi_settle = ttk.Entry(row, width=5)
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@@ -1451,24 +1453,17 @@ class TestbenchGUI(tk.Tk):
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self._send_float(Cmd.SET_VOLTAGE, self._sup_voltage)
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def _set_supply_current(self) -> None:
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self._clamp_supply_current_entry()
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self._send_float(Cmd.SET_CURRENT, self._sup_current)
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def _clamp_supply_current_entry(self) -> None:
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"""Keep the programmed supply current within PSU capability."""
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def _input_limit_a(self) -> float | None:
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"""Max input current allowed for the test environment (I limit
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field). None when the field does not parse (gate inactive)."""
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try:
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val = float(self._sup_current.get())
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return float(self._svi_ilimit.get())
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except ValueError:
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return
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if val > PSU_MAX_CURRENT_A:
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self._console(
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f"Supply I {val:g}A clamped to PSU max "
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f"{PSU_MAX_CURRENT_A:g}A", "warn")
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self._sup_current.delete(0, tk.END)
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self._sup_current.insert(0, f"{PSU_MAX_CURRENT_A:g}")
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return None
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def _apply_supply(self) -> None:
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self._clamp_supply_current_entry()
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try:
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v = float(self._sup_voltage.get())
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i = float(self._sup_current.get())
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@@ -1490,18 +1485,20 @@ class TestbenchGUI(tk.Tk):
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self._load_value.config(foreground="red")
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self.after(1000, lambda: self._load_value.config(foreground=""))
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return
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# PSU capability gate (CC/CP; live readings when available)
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if mode in ("CC", "CP"):
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# Input-current gate (CC/CP; live readings when available), against
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# the user-set I limit for this test environment
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imax = self._input_limit_a()
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if mode in ("CC", "CP") and imax is not None:
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vin = self._latest_data.get("supply_V", 0.0)
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vout = self._latest_data.get("load_V", 0.0)
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if vout < 5.0:
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vout = VOUT_NOM_V
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if vin > 5.0:
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iin_est = _est_input_current(mode, val, vin, vout)
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if iin_est > PSU_MAX_CURRENT_A:
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if iin_est > imax:
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self._console(
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f"Load {mode}={val:g} rejected: est. input current "
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f"{iin_est:.1f}A > PSU max {PSU_MAX_CURRENT_A:g}A "
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f"{iin_est:.1f}A > I limit {imax:g}A "
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f"at Vin={vin:.1f}V / Vout={vout:.1f}V", "error")
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self._load_value.config(foreground="red")
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self.after(1000, lambda: self._load_value.config(foreground=""))
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@@ -1650,14 +1647,6 @@ class TestbenchGUI(tk.Tk):
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messagebox.showerror("Invalid Input", "Check sweep parameters.")
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return
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if params["current_limit"] > PSU_MAX_CURRENT_A:
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self._console(
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f"I limit {params['current_limit']:g}A clamped to PSU max "
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f"{PSU_MAX_CURRENT_A:g}A", "warn")
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params["current_limit"] = PSU_MAX_CURRENT_A
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self._svi_ilimit.delete(0, tk.END)
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self._svi_ilimit.insert(0, f"{PSU_MAX_CURRENT_A:g}")
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# Ask for output file
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default_name = time.strftime("sweep_vi_%Y%m%d_%H%M%S.csv")
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path = filedialog.asksaveasfilename(
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@@ -1808,9 +1797,10 @@ class TestbenchGUI(tk.Tk):
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"STM32 not linked - thermal pause guard inactive for this "
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"sweep", "warn")
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# PSU capability gate: never command an operating point whose
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# estimated input draw exceeds what the supply can source.
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psu_imax = min(current_limit, PSU_MAX_CURRENT_A)
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# Input-current gate: the I limit field IS the maximum input current
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# allowed for this test environment -- never command an operating
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# point whose estimated input draw exceeds it.
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psu_imax = current_limit
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vout_est = VOUT_NOM_V # refined from measured load voltage as we go
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first_v = v_start if v_step > 0 else max(v_start, v_stop)
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if _est_input_current(load_mode, l_start, first_v, vout_est) > psu_imax:
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@@ -1967,8 +1957,8 @@ class TestbenchGUI(tk.Tk):
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ll += l_step
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if rejected:
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self._console(
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f"V={v:.1f}V: rejected {rejected} step(s) - PSU "
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f"input limit {psu_imax:g}A / load range", "warn")
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f"V={v:.1f}V: rejected {rejected} step(s) - input "
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f"limit {psu_imax:g}A / load range", "warn")
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v += v_step
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finally:
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# Ramp load down gradually to avoid sudden transients
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