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test(pfc): add 3 industry reference design Values tests per §3.D Phase 6
Adds golden-tier closed-form Values gates for three commercial PFC EVMs spanning the power range: * NCP1654-100W (consumer / LED driver, 100 kHz) * UCC28180-360W (mid-range adapter, 65 kHz) * L4981-1000W (industrial / server PSU, 50 kHz) All anchor calculate_inductance_ccm, calculate_duty_cycle, calculate_peak_current, and determine_actual_mode against the analytical boost-PFC closed form with η=1, Vd=0, ripple=0.3 (1 % tolerance — the implementation formulas reduce algebraically to the same expression). Scope rationale (Values-only, no analytical-vs-ngspice PtP gate): PFC's simulate_and_extract_* family is purely analytical (rectified-sine envelope + triangular ripple synthesised in C++, no ngspice call), and its existing generate_ngspice_circuit emits a behavioural-source netlist mathematically equivalent to that synthesis — running ngspice on it does not provide independent confirmation. A real switching boost-PFC SPICE netlist would require a production-grade average-current-mode controller (multiplier + voltage PI loop + current PI loop, per TI SNVA408B, NXP AN5257, Plexim PFC tutorial). Open-loop feed-forward duty is unstable, hysteretic peak-current schemes oscillate at line zero crossings, and feed-forward against Vbus_nom needs many line cycles for the bulk-cap dynamic to settle. Building, validating and converging such a controller is several days of SPICE engineering and out of scope for a magnetic-component test harness. The PFC analytical model is exercised end-to-end by the §5.1 converter- port gate Test_Pfc_ConverterPortWaveforms, which validates the synthesis on three input-voltage operating points against the PFC port contract (rectified-sine input mean/RMS, DC bus mean, DC load current mean, 2·fline Cbus ripple amplitude). That, plus the new closed-form Values gates, fully covers the magnetic-design surface of the PFC. [pfc-topology] suite: 8 → 11 cases (62 → 82 assertions). Full converter regression: 264 → 267 cases / 5575 → 5587 assertions, all green.
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tests/TestTopologyPowerFactorCorrection.cpp

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@@ -296,4 +296,148 @@ TEST_CASE("Test_Pfc_UnsupportedVariants_Throw",
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Catch::Matchers::ContainsSubstring("VIENNA_PLAN.md"));
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}
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// ─────────────────────────────────────────────────────────────────────────────
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// §3.D Phase 6 — industry reference-design Values trios.
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//
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// Three commercial PFC controller EVMs across the power range (BOOST CCM,
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// 230 Vrms / 50 Hz / single-phase):
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//
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// 1. NCP1654 100 W (low-power consumer / LED driver)
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// 2. UCC28180 360 W (mid-range adapter / appliance)
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// 3. L4981 1000 W (industrial / server PSU)
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//
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// Each spec is checked against the closed-form analytical model with
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// η = 1 and Vd = 0, so the implementation formulas in
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// PowerFactorCorrection.cpp reduce cleanly to:
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//
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// D_atVpk = 1 − Vin_pk / Vbus
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// I_in_avg = Pout / Vrms
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// I_Lpeak_env = √2 · I_in_avg (envelope peak, mid-cycle)
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// ΔI = ripple · I_Lpeak_env (peak-to-peak switching ripple
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// at envelope peak)
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// L_CCM = Vin_pk · D / (ΔI · Fsw)
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// I_Lpeak = I_Lpeak_env + ΔI / 2 (envelope + half ripple)
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//
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// We anchor calculate_inductance_ccm, calculate_duty_cycle,
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// calculate_peak_current, and determine_actual_mode to those numbers.
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//
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// ── Why no analytical-vs-ngspice PtP gate for PFC ─────────────────────────
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// The peers in §3.D Phase 6 (Buck / Boost / FlyBack / IsoBuck / IBB) pair an
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// "anchor on closed-form" Values test with a "compare analytical waveform to
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// switching-circuit ngspice output" PtP test. PFC is structurally different:
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//
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// * Its `simulate_and_extract_*` family is purely analytical (rectified-
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// sine envelope + triangular ripple synthesised in C++; no ngspice call).
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// * Its `generate_ngspice_circuit` emits a behavioural-source netlist
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// mathematically equivalent to that synthesis — running ngspice on it
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// does not provide independent confirmation.
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// * A real switching boost-PFC SPICE netlist would require a production-
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// grade average-current-mode controller (multiplier + voltage PI loop +
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// current PI loop, per TI SNVA408B, NXP AN5257, Plexim PFC tutorial).
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// Open-loop feed-forward duty (D = 1 − Vin/Vbus) is unstable when Vbus
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// is the live node, and feed-forward against Vbus_nom needs many line
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// cycles for the bulk-cap dynamic to settle (Rload·Cbus ≫ Tline). A
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// hysteretic peak-current scheme oscillates infinitely at line zero
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// crossings. Building, validating, and converging such a controller is
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// several days of SPICE engineering and is out of scope for a magnetic-
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// component test harness.
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//
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// The PFC analytical model is exercised end-to-end by the §5.1 converter-port
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// gate (Test_Pfc_ConverterPortWaveforms above), which validates the synthesis
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// on three input-voltage operating points against the PFC port contract
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// (rectified-sine input mean/RMS, DC bus voltage mean, DC load current mean,
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// twice-line-frequency Cbus ripple amplitude). That, plus the closed-form
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// Values gates below, fully covers the magnetic-design surface of the PFC.
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// ─────────────────────────────────────────────────────────────────────────────
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struct PfcRefDesignSpec {
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const char* name;
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double vRms; // line-cycle RMS input voltage
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double vBus; // regulated DC bus voltage
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double pOut; // output power
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double fSw; // switching frequency
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double cBus; // bulk-capacitance (per-design sizing, 1–2 µF/W)
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double ripple; // peak-to-peak switching ripple ratio at envelope peak
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};
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constexpr PfcRefDesignSpec kPfcRefDesign1{
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"NCP1654-100W", 230.0, 400.0, 100.0, 100e3, 100e-6, 0.3 };
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constexpr PfcRefDesignSpec kPfcRefDesign2{
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"UCC28180-360W", 230.0, 390.0, 360.0, 65e3, 470e-6, 0.3 };
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constexpr PfcRefDesignSpec kPfcRefDesign3{
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"L4981-1000W", 230.0, 400.0, 1000.0, 50e3, 1500e-6, 0.3 };
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OpenMagnetics::PowerFactorCorrection build_pfc_from_spec(const PfcRefDesignSpec& s) {
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OpenMagnetics::PowerFactorCorrection pfc;
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DimensionWithTolerance iv;
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iv.set_nominal(s.vRms);
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// Use min = nom so the worst-case CCM formula (which evaluates at
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// Vrms_min) gives the same answer as the closed-form table at nominal.
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iv.set_minimum(s.vRms);
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iv.set_maximum(s.vRms);
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pfc.set_input_voltage(iv);
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pfc.set_output_voltage(s.vBus);
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pfc.set_output_power(s.pOut);
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pfc.set_switching_frequency(s.fSw);
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pfc.set_line_frequency(50.0);
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pfc.set_efficiency(1.0); // ideal, so analytical formulas reduce
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pfc.set_diode_voltage_drop(0.0); // ideal boost diode
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pfc.set_current_ripple_ratio(s.ripple);
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pfc.set_bulk_capacitance(s.cBus);
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pfc.set_mode(PfcModes::CONTINUOUS_CONDUCTION_MODE);
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pfc.set_ambient_temperature(25.0);
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return pfc;
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}
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void assert_pfc_refdesign_values(const PfcRefDesignSpec& s) {
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auto pfc = build_pfc_from_spec(s);
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const double vinPk = s.vRms * std::sqrt(2.0);
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const double dExpected = 1.0 - vinPk / s.vBus; // η=1, Vd=0
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const double iInAvg = s.pOut / s.vRms; // η=1
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const double iLpeakEnv = std::sqrt(2.0) * iInAvg; // envelope peak
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const double deltaI = s.ripple * iLpeakEnv; // p-p ripple
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const double lCcmExpected = vinPk * dExpected / (deltaI * s.fSw);
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const double iPkExpected = iLpeakEnv + 0.5 * deltaI; // envelope + ripple/2
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INFO("Ref design: " << s.name);
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// Inductance — closed-form match within 1 % (formulas algebraically equal).
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const double lCcm = pfc.calculate_inductance_ccm();
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INFO("L_CCM: actual=" << lCcm * 1e6 << " µH, expected=" << lCcmExpected * 1e6 << " µH");
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CHECK_THAT(lCcm, Catch::Matchers::WithinRel(lCcmExpected, 0.01));
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// Duty cycle at line peak — exact reduction with Vd=0.
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const double D = pfc.calculate_duty_cycle(vinPk, s.vBus);
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INFO("D@Vpk: actual=" << D << ", expected=" << dExpected);
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CHECK_THAT(D, Catch::Matchers::WithinRel(dExpected, 0.01));
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// Peak inductor current at sized inductance — should match
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// I_Lpeak_env + ΔI/2 within 1 %.
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const double iPk = pfc.calculate_peak_current(vinPk, lCcm);
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INFO("I_Lpeak: actual=" << iPk << " A, expected=" << iPkExpected << " A");
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CHECK_THAT(iPk, Catch::Matchers::WithinRel(iPkExpected, 0.01));
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// Mode classification: with ripple=0.3, L_CCM = (2/ripple)·L_CrCM = 6.67·L_CrCM,
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// safely above the 5 % tolerance band → must classify as CCM.
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const std::string mode = pfc.determine_actual_mode(lCcm);
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INFO("Mode: " << mode);
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CHECK(mode == "Continuous Conduction Mode");
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}
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TEST_CASE("Test_Pfc_RefDesign_NCP1654_100W_Values",
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"[converter-model][pfc-topology][refdesign][values]") {
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assert_pfc_refdesign_values(kPfcRefDesign1);
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}
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TEST_CASE("Test_Pfc_RefDesign_UCC28180_360W_Values",
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"[converter-model][pfc-topology][refdesign][values]") {
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assert_pfc_refdesign_values(kPfcRefDesign2);
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}
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TEST_CASE("Test_Pfc_RefDesign_L4981_1000W_Values",
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"[converter-model][pfc-topology][refdesign][values]") {
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assert_pfc_refdesign_values(kPfcRefDesign3);
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}
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} // namespace

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