Allow overshoot tanks during the first iterations

weight_and_balance_analysis/src/datapostprocessing.py

@@ -95,7 +95,10 @@ def data_postprocessing(paths_and_names, routing_dict, data_dict, runtime_output
     key_output_dict, method_specific_output_dict = routing_dict['func_user_method_data_output_preparation'](
         data_dict)
     # Extract tool level from routing dictionary.
-    tool_level = routing_dict['tool_level']
+    if data_dict['current_tool_level'] is None:
+        tool_level = routing_dict['tool_level']
+    else:
+        tool_level = str(data_dict['current_tool_level'])
 
     """Write data to aircraft exchange file."""
     # Extract root and path to aircraft exchange file.

weight_and_balance_analysis/src/tube_and_wing/standard/basic/methodbasic.py

@@ -45,7 +45,7 @@ def method_basic(paths_and_names, routing_dict, dict_ac_exchange, dict_mod_confi
     excel_file_path = paths_and_names['project_directory'] + \
         '/' + "Seats_positions.xlsx"
     airplane_seatings = pd.read_excel(excel_file_path)
-    DEBUG(msg="ToDo: Update this when acommodation and neutral point position are available.")
+    DEBUG(msg="ToDo: Update this when acommodation positions are available.")
 
     # Read fuselage and wing
     wing = read_wing(paths_and_names)
@@ -130,27 +130,29 @@ def method_basic(paths_and_names, routing_dict, dict_ac_exchange, dict_mod_confi
 
     # Maximum fuel mass + maximum fuel mass per tank
     maximum_fuel_mass, maximum_fuel_mass_per_tank, ferry_range_mass = calculate_maximum_fuel_mass(
-        tanks, operating_mass_empty, x_leading_edge_mac, mac)
+        tanks, operating_mass_empty, x_leading_edge_mac, mac, maximum_takeoff_mass, runtime_output)
     maximum_fuel_mass.print("Maximum fuel mass")
     ferry_range_mass.print("Ferry range mass")
 
+    # Maximum PL mass
+    maximum_payload_mass = calculate_maximum_payload_mass(
+        dict_ac_exchange["maximum_structural_payload_mass"],
+        main_components_mass_properties["fuselage"]).print("Maximimum payload mass")
+
     # Design payload mass
     design_payload_mass = calculate_design_payload_mass(
-        transport_task_data, main_components_mass_properties["fuselage"]).print("Design payload mass")
+        transport_task_data, main_components_mass_properties["fuselage"], maximum_payload_mass, runtime_output).print(
+            "Design payload mass")
 
     # Design fuel mass
     design_fuel_mass_takeoff, design_fuel_mass_midflight, design_fuel_mass_minimum_landing, \
-        design_fuel_mass_takeoff_per_tank, consumed_fuel, design_fuel_mass = \
+        design_fuel_mass_takeoff_per_tank, consumed_fuel, design_fuel_mass, design_fuel_mass_per_tank = \
         calculate_design_fuel_mass(
-            mission_information, maximum_takeoff_mass, operating_mass_empty, design_payload_mass, tanks)
+            mission_information, maximum_takeoff_mass, operating_mass_empty, design_payload_mass, tanks,
+            routing_dict, dict_ac_exchange)
     design_fuel_mass.path_to_element = "./analysis/masses_cg_inertia/design_fuel_mass"
     design_fuel_mass.print("Design fuel mass")
 
-    # Maximum PL mass
-    maximum_payload_mass = calculate_maximum_payload_mass(
-        dict_ac_exchange["maximum_structural_payload_mass"],
-        main_components_mass_properties["fuselage"]).print("Maximimum payload mass")
-
     # Maximum zero fuel mass
     maximum_zero_fuel_mass = calculate_maximum_zero_fuel_mass(
         [operating_mass_empty, maximum_payload_mass], inertia_method).print("Maximum zero fuel mass")
@@ -158,15 +160,20 @@ def method_basic(paths_and_names, routing_dict, dict_ac_exchange, dict_mod_confi
         maximum_zero_fuel_mass.center_of_gravity['x'] - x_leading_edge_mac) / mac * 100
 
     # Design mass
-    design_mass_takeoff = calculate_design_mass(
+    design_mass = calculate_design_mass(
         [operating_mass_empty, design_payload_mass,
-            design_fuel_mass_takeoff], inertia_method
-    ).print("Design mass takeoff")
-    design_mass = copy.copy(design_mass_takeoff)
+            design_fuel_mass], inertia_method
+    ).print("Design mass")
     design_mass.path_to_element = "./analysis/masses_cg_inertia/design_mass"
     design_mass.cg_mac = (
         design_mass.center_of_gravity['x'] - x_leading_edge_mac) / mac * 100
 
+    # Design mass takeoff
+    design_mass_takeoff = calculate_design_mass(
+        [operating_mass_empty, design_payload_mass,
+            design_fuel_mass_takeoff], inertia_method
+    ).print("Design mass takeoff")
+
     # Maximum takeoff mass
     maximum_takeoff_mass = copy.copy(design_mass)
     maximum_takeoff_mass.path_to_element = "./analysis/masses_cg_inertia/maximum_takeoff_mass"
@@ -295,7 +302,7 @@ def method_basic(paths_and_names, routing_dict, dict_ac_exchange, dict_mod_confi
     x_coord_back_front_cargo = x_coord_front_back_cargo[::-1]
 
     runtime_output.print("CARGO...")
-    DEBUG(msg="cargo = luggage mass per passenger, modify/extend later with palets / add additional cargo")
+    DEBUG(msg="The palets positions unknown. The cargo is loaded at the same locations as the seats positions.")
 
     cg_positions_over_mac_cargo_front_back, total_mass_cargo_front_back = \
         cg_change_cargo_loading_front_back(
@@ -344,9 +351,9 @@ def method_basic(paths_and_names, routing_dict, dict_ac_exchange, dict_mod_confi
     # Determine the CG curtailment:
 
     most_fwd_CG_over_mac = min([min(cg_positions_over_mac_refueling), min(cg_positions_over_mac_passengers_front_back),
-                                min(cg_positions_over_mac_cargo_front_back)])
+                                min(cg_positions_over_mac_cargo_front_back), min(cg_positions_over_mac_defueling)])
     most_aft_CG_over_mac = max([max(cg_positions_over_mac_refueling), max(cg_positions_over_mac_passengers_back_front),
-                                max(cg_positions_over_mac_cargo_back_front)])
+                                max(cg_positions_over_mac_cargo_back_front), max(cg_positions_over_mac_defueling)])
 
     most_fwd_CG = most_fwd_CG_over_mac * mac / 100 + x_leading_edge_mac
     most_aft_CG = most_aft_CG_over_mac * mac / 100 + x_leading_edge_mac
@@ -365,10 +372,14 @@ def method_basic(paths_and_names, routing_dict, dict_ac_exchange, dict_mod_confi
         corresponding_index = cg_positions_over_mac_passengers_front_back.index(
             most_fwd_CG_over_mac)
         corresponding_mass_most_fwd_CG = total_mass_passengers_front_back[corresponding_index]
-    else:
+    elif most_fwd_CG_over_mac in cg_positions_over_mac_cargo_front_back:
         corresponding_index = cg_positions_over_mac_cargo_front_back.index(
             most_fwd_CG_over_mac)
         corresponding_mass_most_fwd_CG = total_mass_cargo_front_back[corresponding_index]
+    else:
+        corresponding_index = cg_positions_over_mac_defueling.index(
+            most_fwd_CG_over_mac)
+        corresponding_mass_most_fwd_CG = total_mass_defueling[corresponding_index]
 
     runtime_output.print(
         f"Corresponding mass most fwd CG is of {corresponding_mass_most_fwd_CG:.2f} kg.")
@@ -382,10 +393,14 @@ def method_basic(paths_and_names, routing_dict, dict_ac_exchange, dict_mod_confi
         corresponding_index = cg_positions_over_mac_passengers_back_front.index(
             most_aft_CG_over_mac)
         corresponding_mass_most_aft_CG = total_mass_passengers_back_front[corresponding_index]
-    else:
+    elif most_aft_CG_over_mac in cg_positions_over_mac_cargo_back_front:
         corresponding_index = cg_positions_over_mac_cargo_back_front.index(
             most_aft_CG_over_mac)
         corresponding_mass_most_aft_CG = total_mass_cargo_back_front[corresponding_index]
+    else:
+        corresponding_index = cg_positions_over_mac_defueling.index(
+            most_fwd_CG_over_mac)
+        corresponding_mass_most_fwd_CG = total_mass_defueling[corresponding_index]
 
     runtime_output.print(
         f"Corresponding mass most aft CG is of {corresponding_mass_most_aft_CG:.2f} kg.")
@@ -488,6 +503,18 @@ def method_basic(paths_and_names, routing_dict, dict_ac_exchange, dict_mod_confi
         "Systems": systems
     }
 
+    # Check if the given tool_level from aircrat exchange file is None -> if true: -> initialize with 0.
+    if dict_ac_exchange['tool_level'] is None:
+        basic_output_dict['current_tool_level'] = 0
+    # Else if condition: Check if given tool_level from aircrat exchange is lower than the given own tool level
+    #  from module configuration file -> if true: Add 1 to current tool level from airaft exchange file.
+    elif dict_ac_exchange['tool_level'] < int(routing_dict['tool_level']):
+        basic_output_dict['current_tool_level'] = dict_ac_exchange['tool_level'] + 1
+    # Else condition: The given tool_level from aircrat exchange is equal to the given own tool level
+    else:
+        basic_output_dict['current_tool_level'] = int(
+            routing_dict['tool_level'])
+
     return basic_output_dict
 
 
@@ -833,7 +860,7 @@ def calculate_maximum_landing_mass_by_regression_rwth(maximum_takeoff_mass, iner
     return maximum_landing_mass
 
 
-def calculate_maximum_fuel_mass(tanks, ome, LE, mac):
+def calculate_maximum_fuel_mass(tanks, ome, LE, mac, mtom, runtime_output):
     """Calculation of maximum fuel mass
 
     Args:
@@ -883,6 +910,10 @@ def calculate_maximum_fuel_mass(tanks, ome, LE, mac):
     ferry_range_mass.cg_mac = (
         max_fuel_mass.center_of_gravity['x'] - LE) / mac * 100
 
+    if ferry_range_mass.mass >= mtom.mass:
+        runtime_output.warning(
+            "Attention: OEW + max_fuel_mass is higher than MTOW.")
+
     return max_fuel_mass, max_fuel_mass_per_tank, ferry_range_mass
 
 
@@ -973,7 +1004,7 @@ def calculate_fuel_mass_properties_evenly_distributed(tanks, fuel_mass, runtime_
     return fuel_mass_properties, fuel_mass_per_tank
 
 
-def calculate_fuel_mass_properties(tanks, fuel_mass):
+def calculate_fuel_mass_properties(tanks, fuel_mass, routing_dict, dict_ac_exchange):
     """
     Refuel tanks in the following priority order:
     1. Left and Right wing tanks (equally). These are also sorted based on the order defined before according
@@ -991,6 +1022,8 @@ def calculate_fuel_mass_properties(tanks, fuel_mass):
     Raises:
     ValueError: If the fuel mass exceeds the total tank capacity.
     """
+    import logging
+    runtime_output = logging.getLogger('module_logger')
 
     # Helper function to categorize tanks based on location string
     def categorize_tank_location(tank):
@@ -1019,7 +1052,7 @@ def calculate_fuel_mass_properties(tanks, fuel_mass):
         tank.energy / tank.gravimetric_density for tank in tanks)
 
     if fuel_mass > total_capacity:
-        raise ValueError(
+        runtime_output.critical(
             "Fuel mass to be filled up exceeds the total capacity of all tanks!")
 
     # Distribute fuel across left and right wing tanks first
@@ -1142,8 +1175,12 @@ def calculate_fuel_mass_properties(tanks, fuel_mass):
 
     # Check if there is still remaining fuel (should not happen unless there is a capacity error)
     if remaining_fuel > 0:
-        raise ValueError(
-            "Fuel mass calculation failed ... Not enough capacity in tanks!")
+        if int(dict_ac_exchange['tool_level']) < int(routing_dict['tool_level']):
+            runtime_output.warning(
+                "Fuel mass calculation failed ... Not enough capacity in tanks!")
+        else:
+            raise ValueError(
+                "Fuel mass calculation failed ... Not enough capacity in tanks!")
 
     fuel_mass_properties = MassPropertiesIO().initialize_zero()
     fuel_mass_properties.mass = sum(
@@ -1344,7 +1381,8 @@ def calculate_fuel_properties_defueling(tanks, fuel_to_remove, fuel_mass_per_tan
 
 
 def calculate_design_fuel_mass(mission_information=None, maximum_takeoff_mass=None,
-                               operating_mass_empty=None, design_payload_mass=None, tanks=None):
+                               operating_mass_empty=None, design_payload_mass=None, tanks=None,
+                               routing_dict=None, dict_ac_exchange=None):
     """Calculation of design fuel mass
 
     Args:
@@ -1377,14 +1415,14 @@ def calculate_design_fuel_mass(mission_information=None, maximum_takeoff_mass=No
         # distribute the fuel along the tanks and save the informations per tank
         # the refueling order is already saved in the sorted tanks
         # = (preparation for the calculation of the refueling-cg-shift)
-        design_fuel_mass, design_fuel_mass_takeoff_per_tank = calculate_fuel_mass_properties(
-            tanks, design_fuel_mass)
+        design_fuel_mass, design_fuel_mass_per_tank = calculate_fuel_mass_properties(
+            tanks, design_fuel_mass, routing_dict, dict_ac_exchange)
         design_fuel_mass_takeoff, design_fuel_mass_takeoff_per_tank = calculate_fuel_mass_properties(
-            tanks, design_fuel_mass_at_takeoff)
+            tanks, design_fuel_mass_at_takeoff, routing_dict, dict_ac_exchange)
         design_fuel_mass_midflight, _ = calculate_fuel_mass_properties(
-            tanks, design_fuel_mass_midflight)
+            tanks, design_fuel_mass_midflight, routing_dict, dict_ac_exchange)
         design_fuel_mass_landing_minimum, _ = calculate_fuel_mass_properties(
-            tanks, design_fuel_mass_landing_minimum)
+            tanks, design_fuel_mass_landing_minimum, routing_dict, dict_ac_exchange)
     else:
         contingency_fuel_factor = 0.05
         alternate_fuel_factor = 0.1
@@ -1404,16 +1442,17 @@ def calculate_design_fuel_mass(mission_information=None, maximum_takeoff_mass=No
         design_fuel_mass_takeoff, design_fuel_mass_takeoff_per_tank = calculate_fuel_mass_properties(
             tanks, design_fuel_mass_takeoff)
         design_fuel_mass_midflight, _ = calculate_fuel_mass_properties(
-            tanks, design_fuel_mass_midflight)
+            tanks, design_fuel_mass_midflight, routing_dict, dict_ac_exchange)
         design_fuel_mass_landing_minimum, _ = calculate_fuel_mass_properties(
-            tanks, design_fuel_mass_landing_minimum)
+            tanks, design_fuel_mass_landing_minimum, routing_dict, dict_ac_exchange)
         design_fuel_mass = design_fuel_mass_at_takeoff
+        design_fuel_mass_per_tank = design_fuel_mass_takeoff_per_tank
 
     return (design_fuel_mass_takeoff, design_fuel_mass_midflight, design_fuel_mass_landing_minimum,
-            design_fuel_mass_takeoff_per_tank, consumed_fuel_during_flight, design_fuel_mass)
+            design_fuel_mass_takeoff_per_tank, consumed_fuel_during_flight, design_fuel_mass, design_fuel_mass_per_tank)
 
 
-def calculate_design_payload_mass(transport_task_data, fuselage_mass_properties):
+def calculate_design_payload_mass(transport_task_data, fuselage_mass_properties, max_payload, runtime_output):
     """Design payload mass
 
     Args:
@@ -1427,9 +1466,17 @@ def calculate_design_payload_mass(transport_task_data, fuselage_mass_properties)
         "./analysis/masses_cg_inertia/design_payload_mass")
     design_payload_mass.mass = transport_task_data.combined_passenger_and_luggage_mass + \
         transport_task_data.additional_cargo_mass
+
+    if design_payload_mass.mass > max_payload.mass:
+        runtime_output.critical(
+            "Design payload mass exceeds the maximum allowed payload mass!")
+        raise ValueError(
+            "Design payload mass exceeds the maximum allowed payload mass!")
+
     # cargodeck + passenger_deck + additional cargo
     design_payload_mass.center_of_gravity = fuselage_mass_properties.center_of_gravity
     design_payload_mass.initialize_zero_inertia()
+    DEBUG(msg="The CG of the design payload is set at the fuselage CG.")
 
     return design_payload_mass
 
@@ -1473,8 +1520,8 @@ def cg_change_cargo_loading_front_back(initial_cg, initial_weight, x_coordinate_
     cg_positions.append(initial_mac_position)
 
     for row in range(len(x_coordinate_row)):
-        added_mass = transport_task_data.luggage_mass_per_passenger * \
-            transport_task_data.number_of_passengers / len(x_coordinate_row)
+        added_mass = (transport_task_data.luggage_mass_per_passenger * transport_task_data.number_of_passengers +
+                      transport_task_data.additional_cargo_mass) / len(x_coordinate_row)
 
         total_weight_new += added_mass
         total_moment_change += added_mass * (x_coordinate_row[row])
@@ -1574,6 +1621,7 @@ def calculate_maximum_payload_mass(maximum_structural_payload_mass, fuselage_acc
     # Use accomodation center_of_gravity
     maximum_payload_mass.center_of_gravity = fuselage_accomodation_mass_properties.center_of_gravity
     maximum_payload_mass.initialize_zero_inertia()
+    DEBUG(msg="The CG of the maximum payload is set at the fuselage CG.")
 
     return maximum_payload_mass
 
@@ -1626,7 +1674,7 @@ def calculate_mtow_max_payload(ome, maximum_payload_mass, wing, mtom, LE, mac):
     mtow_max_payload.center_of_gravity = (
         ome.mass * ome.center_of_gravity['x'] + fuel * wing.center_of_gravity['x'] +
         maximum_payload_mass.mass * maximum_payload_mass.center_of_gravity['x']) / mtow_max_payload.mass
-    # DEBUG(msg="Estimated CG (fuel CG set in wing CG)")
+    DEBUG(msg="Estimated CG of MTOM with max payload. (fuel CG set in wing CG, payload CG set in fuselage CG.)")
     mtow_max_payload.cg_mac = (
         mtow_max_payload.center_of_gravity - LE) / mac * 100.0
 
@@ -1643,7 +1691,7 @@ def calculate_mtow_max_fuel(ome, fuel_mass, wing, fuselage, mtom, LE, mac):
     mtow_max_fuel.mass = ome.mass + max_fuel + payload_mass
     mtow_max_fuel.center_of_gravity = (ome.mass * ome.center_of_gravity['x'] + max_fuel * wing.center_of_gravity['x'] +
                                        payload_mass * fuselage.center_of_gravity['x']) / mtow_max_fuel.mass
-    # DEBUG(msg="Estimated CG (fuel CG set in wing CG)")
+    DEBUG(msg="Estimated CG of MTOM with max fuel. (fuel CG set in wing CG, payload CG set in fuselage CG.)")
     mtow_max_fuel.cg_mac = (mtow_max_fuel.center_of_gravity - LE) / mac * 100.0
 
     return mtow_max_fuel
@@ -1865,7 +1913,7 @@ def read_operator_items(ac_exchange_file, fuselage_length):
             total_mass += operator_items[i].mass
             fuselage_operator_items_mass = total_mass
             i = i + 1
-    # DEBUG(msg="CGs of fuselage operator items missing in axml -> estimated here at 45% fuselage length")
+    DEBUG(msg="CGs of fuselage operator items estimated here at 45% fuselage length")
 
     systems_operator_nodes = ac_exchange_file.findall(
         "./component_design/systems/operator_items/operator_item[@ID]"

weight_and_balance_analysis/src/tube_and_wing/standard/general/methodhtmlreport.py

@@ -28,9 +28,9 @@ def method_html_report(paths_and_names, routing_dict, data_dict, method_specific
 
     # general aircraft masses
     aircraft_general_masses = [
-        ("Manufacturer Mass Empty", "MME",
+        ("Manufacturer Empty Mass", "MEM",
          data_dict["manufacturer_mass_empty"].mass),
-        ("Operating Mass Empty", "OME",
+        ("Operating Empty Mass", "OEM",
          data_dict["operating_mass_empty"].mass),
         ("Maximum Takeoff Mass", "MTOM",
          data_dict["maximum_takeoff_mass"].mass),
@@ -49,6 +49,7 @@ def method_html_report(paths_and_names, routing_dict, data_dict, method_specific
         ("Maximum Landing Mass", "MLM",
          data_dict["maximum_landing_mass"].mass),
         ("Design Payload Mass", "-", data_dict["design_payload_mass"].mass),
+        ("Design Fuel Mass", "-", data_dict["design_fuel_mass"].mass),
         ("Design Fuel Mass Takeoff", "-",
          data_dict["design_fuel_mass_takeoff"].mass),
         ("Design Fuel Mass Midflight", "-",

weight_and_balance_analysis/src/tube_and_wing/standard/general/methodplot.py

@@ -75,9 +75,9 @@ def method_plot(paths_and_names, routing_dict, data_dict, method_specific_output
 
     # Configure the plot
     ax.set_ylabel('Mass (kg)', color='#ecf0f1')
-    ax.set_title('Operating Mass Empty and its Components', color='#ecf0f1')
+    ax.set_title('Operating Empty Mass and its Components', color='#ecf0f1')
     ax.set_xticks(ind)
-    ax.set_xticklabels(['OME'] + components)
+    ax.set_xticklabels(['OEM'] + components)
 
     # Manually add legend entries for structure components and others
     handles, labels = ax.get_legend_handles_labels()
@@ -119,11 +119,11 @@ def method_plot(paths_and_names, routing_dict, data_dict, method_specific_output
         plt.plot(data_dict["Defueling CG change"],
                  data_dict["Defueling mass change"], 'm')  # Defueling
         legend_labels = ['Refueling', 'Pax from front', 'Pax from back', 'Cargo from front', 'Cargo from back',
-                         'Defueling', 'OME', 'MTOM', 'Neutral point Ma=0,83',
+                         'Defueling', 'OEM', 'MTOM', 'Neutral point Ma=0,83',
                          'Most fwd CG', 'Most aft CG', 'NP-5%']
     else:
         legend_labels = ['Refueling', 'Pax from front', 'Pax from back', 'Cargo from front', 'Cargo from back',
-                         'OME', 'MTOM', 'Neutral point Ma=0,83',
+                         'OEM', 'MTOM', 'Neutral point Ma=0,83',
                          'Most fwd CG', 'Most aft CG', 'NP-5%']
 
     N = np.arange(data_dict["Most forward CG mac position"] - 5, max(
@@ -184,7 +184,7 @@ def method_plot(paths_and_names, routing_dict, data_dict, method_specific_output
              data_dict["design_mass"].mass, 's')
 
     # Define legend labels and colors
-    legend_labels2 = ['OME', 'MZFM (max Payload)', 'max Payload + Fuel', 'max Fuel + Payload', 'max Fuel',
+    legend_labels2 = ['OEM', 'MZFM (max Payload)', 'max Payload + Fuel', 'max Fuel + Payload', 'max Fuel',
                       'Design Fuel + Design Payload']
     legend = plt.legend(legend_labels2, loc='lower right', fontsize='small')
     for text in legend.get_texts():

weight_and_balance_analysis/src/tube_and_wing/standard/usermethoddatapreparation.py

@@ -73,6 +73,7 @@ def user_method_data_input_preparation(routing_dict):
         "energy_carrier_density": [design_specification_path + 'energy_carriers/energy_carrier[@ID="0"]/density',
                                    float],
         "energy_carrier_type": [design_specification_path + 'energy_carriers/energy_carrier[@ID="0"]/type', str],
+        'tool_level': ['./analysis/masses_cg_inertia', 'tool_level'],
     }
 
     """Module configuration file."""

weight_and_balance_analysis/weight_and_balance_analysis_conf.xml

@@ -8,7 +8,7 @@
             <value>../projects/</value>
         </aircraft_exchange_file_directory>
         <own_tool_level description="Specify the tool level of this tool">
-            <value>2</value>
+            <value>3</value>
         </own_tool_level>
         <console_output description="Selector to specify the console output. Selector: mode_0 (Off) / mode_1 (only out/err/warn) / mode_2 (1 + info) / mode_3 (2 + debug)">
             <value>mode_1</value>