// // CableTests.swift // CableTests // // Created by Stefan Lange-Hegermann on 11.09.25. // import Testing @testable import Cable struct CableTests { // MARK: - Core Formula Verification /// Formula: A = (2 × I × L × ρ) / V_drop /// With ρ = 0.017 Ω·mm²/m, max voltage drop = 5% @Test func metricWireSizingUsesNearestStandardSize() async throws { // 10m, 5A, 12V → minCS = (2×5×10×0.017)/(12×0.05) = 2.833mm² → rounds up to 4.0mm² let crossSection = ElectricalCalculations.recommendedCrossSection( length: 10, current: 5, voltage: 12, unitSystem: .metric ) #expect(crossSection == 4.0) // V_drop = (2×5×10×0.017)/4.0 = 0.425V let voltageDrop = ElectricalCalculations.voltageDrop( length: 10, current: 5, voltage: 12, unitSystem: .metric ) #expect(abs(voltageDrop - 0.425) < 0.001) // 0.425/12 × 100 = 3.5417% let dropPercentage = ElectricalCalculations.voltageDropPercentage( length: 10, current: 5, voltage: 12, unitSystem: .metric ) #expect(abs(dropPercentage - 3.5417) < 0.001) // P_loss = I × V_drop = 5 × 0.425 = 2.125W let powerLoss = ElectricalCalculations.powerLoss( length: 10, current: 5, voltage: 12, unitSystem: .metric ) #expect(abs(powerLoss - 2.125) < 0.001) } /// Imperial test: length is always in meters (25 ft = 7.62 m), unitSystem controls AWG output @Test func imperialWireSizingMatchesExpectedGauge() async throws { let lengthInMeters = 25.0 * 0.3048 // 25 ft = 7.62 m let awg = ElectricalCalculations.recommendedCrossSection( length: lengthInMeters, current: 15, voltage: 120, unitSystem: .imperial ) // minCS = (2×15×7.62×0.017)/(120×0.05) = 0.648mm² → AWG 18 (0.823mm²) #expect(awg == 18.0) let voltageDrop = ElectricalCalculations.voltageDrop( length: lengthInMeters, current: 15, voltage: 120, unitSystem: .imperial ) // (2×15×7.62×0.017)/0.823 = 4.722V #expect(abs(voltageDrop - 4.722) < 0.01) let dropPercentage = ElectricalCalculations.voltageDropPercentage( length: lengthInMeters, current: 15, voltage: 120, unitSystem: .imperial ) // 4.722/120 × 100 = 3.935% #expect(abs(dropPercentage - 3.935) < 0.01) let powerLoss = ElectricalCalculations.powerLoss( length: lengthInMeters, current: 15, voltage: 120, unitSystem: .imperial ) // 15 × 4.722 = 70.83W #expect(abs(powerLoss - 70.83) < 0.05) } // MARK: - Fuse Sizing @Test func recommendedFuseRoundsUpToNearestStandardSize() async throws { // 7.2A × 1.25 = 9.0 → next fuse ≥ 9 = 10A #expect(ElectricalCalculations.recommendedFuse(forCurrent: 7.2) == 10.0) // 59A × 1.25 = 73.75 → ceil = 74 → next fuse ≥ 74 = 80A #expect(ElectricalCalculations.recommendedFuse(forCurrent: 59.0) == 80.0) } @Test func fuseAt125PercentOfCurrent() async throws { // 10A × 1.25 = 12.5 → ceil = 13 → next fuse = 15A #expect(ElectricalCalculations.recommendedFuse(forCurrent: 10.0) == 15.0) // 20A × 1.25 = 25 → next fuse = 25A #expect(ElectricalCalculations.recommendedFuse(forCurrent: 20.0) == 25.0) // 1A × 1.25 = 1.25 → ceil = 2 → next fuse = 2A #expect(ElectricalCalculations.recommendedFuse(forCurrent: 1.0) == 2.0) // 4A × 1.25 = 5 → next fuse = 5A #expect(ElectricalCalculations.recommendedFuse(forCurrent: 4.0) == 5.0) // 100A × 1.25 = 125 → next fuse = 125A #expect(ElectricalCalculations.recommendedFuse(forCurrent: 100.0) == 125.0) } @Test func fuseSelectsHalfAmpereSizes() async throws { // 5A × 1.25 = 6.25 → ceil = 7 → next fuse ≥ 7 = 7.5A #expect(ElectricalCalculations.recommendedFuse(forCurrent: 5.0) == 7.5) // 6A × 1.25 = 7.5 → ceil = 8 → next fuse ≥ 8 = 10A #expect(ElectricalCalculations.recommendedFuse(forCurrent: 6.0) == 10.0) } @Test func fuseForZeroCurrent() async throws { #expect(ElectricalCalculations.recommendedFuse(forCurrent: 0) == 1.0) } // MARK: - Metric Cross-Section Boundaries @Test func metricCrossSectionSelectsSmallestAdequateSize() async throws { // Very small load: 1m, 0.5A, 12V // minCS = (2×0.5×1×0.017)/(12×0.05) = 0.0283mm² → rounds up to 0.75mm² (smallest standard) let cs = ElectricalCalculations.recommendedCrossSection( length: 1, current: 0.5, voltage: 12, unitSystem: .metric ) #expect(cs == 0.75) } @Test func metricCrossSectionForHighCurrent() async throws { // 15m, 80A, 12V // minCS = (2×80×15×0.017)/(12×0.05) = 40.8/0.6 = 68mm² → rounds up to 70mm² let cs = ElectricalCalculations.recommendedCrossSection( length: 15, current: 80, voltage: 12, unitSystem: .metric ) #expect(cs == 70.0) } @Test func metricCrossSectionFor24VSystem() async throws { // 10m, 20A, 24V // minCS = (2×20×10×0.017)/(24×0.05) = 6.8/1.2 = 5.667mm² → rounds up to 6.0mm² let cs = ElectricalCalculations.recommendedCrossSection( length: 10, current: 20, voltage: 24, unitSystem: .metric ) #expect(cs == 6.0) } @Test func metricCrossSectionFor48VSystem() async throws { // 10m, 20A, 48V // minCS = (2×20×10×0.017)/(48×0.05) = 6.8/2.4 = 2.833mm² → rounds up to 4.0mm² let cs = ElectricalCalculations.recommendedCrossSection( length: 10, current: 20, voltage: 48, unitSystem: .metric ) #expect(cs == 4.0) } // MARK: - Imperial AWG Selection (including 1/0 through 4/0) @Test func imperialAWGLargeGauges() async throws { // Very high current should select large AWG sizes (represented as negative ints) // 10m, 100A, 12V → minCS = (2×100×10×0.017)/(12×0.05) = 34/0.6 = 56.67mm² // AWG: first awgCS ≥ 56.67 → 67.4 = 2/0 (represented as -2) let awg = ElectricalCalculations.recommendedCrossSection( length: 10, current: 100, voltage: 12, unitSystem: .imperial ) #expect(awg == -2.0) // Verify voltage drop uses the correct cross-section (67.4mm² for 2/0) let drop = ElectricalCalculations.voltageDrop( length: 10, current: 100, voltage: 12, unitSystem: .imperial, crossSection: awg ) // (2×100×10×0.017)/67.4 = 34/67.4 = 0.5045V #expect(abs(drop - 0.5045) < 0.01) } @Test func imperialAWG4over0ForExtremeCurrent() async throws { // 5m, 200A, 12V → minCS = (2×200×5×0.017)/(12×0.05) = 34/0.6 = 56.67mm² // Wait: (2×200×5×0.017)/0.6 = 34/0.6 = 56.67 → 67.4 (2/0) // 10m, 200A, 12V → minCS = (2×200×10×0.017)/(12×0.05) = 68/0.6 = 113.33mm² // AWG: first awgCS ≥ 113.33 → none! → returns last AWG = -4 (4/0, 107mm²) let awg = ElectricalCalculations.recommendedCrossSection( length: 10, current: 200, voltage: 12, unitSystem: .imperial ) #expect(awg == -4.0) } @Test func formatAWGDisplaysCorrectNotation() async throws { #expect(ElectricalCalculations.formatAWG(14) == "14") #expect(ElectricalCalculations.formatAWG(10) == "10") #expect(ElectricalCalculations.formatAWG(1) == "1") #expect(ElectricalCalculations.formatAWG(-1) == "1/0") #expect(ElectricalCalculations.formatAWG(-2) == "2/0") #expect(ElectricalCalculations.formatAWG(-3) == "3/0") #expect(ElectricalCalculations.formatAWG(-4) == "4/0") } @Test func imperialAWGForBoatLoad() async throws { // Typical boat scenario: 5m (≈16ft), 10A, 12V // minCS = (2×10×5×0.017)/(12×0.05) = 1.7/0.6 = 2.833mm² // AWG: first >= 2.833 → 3.31mm² = 12 AWG let awg = ElectricalCalculations.recommendedCrossSection( length: 5, current: 10, voltage: 12, unitSystem: .imperial ) #expect(awg == 12.0) } @Test func imperialAWGForHighCurrentLoad() async throws { // 3m, 50A, 12V // minCS = (2×50×3×0.017)/(12×0.05) = 5.1/0.6 = 8.5mm² // AWG: first >= 8.5 → 13.3mm² = 6 AWG let awg = ElectricalCalculations.recommendedCrossSection( length: 3, current: 50, voltage: 12, unitSystem: .imperial ) #expect(awg == 6.0) } // MARK: - Voltage Drop with Explicit Cross-Section @Test func voltageDropWithExplicitCrossSection_metric() async throws { // 5m, 10A, 12V, 2.5mm² // V_drop = (2×10×5×0.017)/2.5 = 1.7/2.5 = 0.68V let drop = ElectricalCalculations.voltageDrop( length: 5, current: 10, voltage: 12, unitSystem: .metric, crossSection: 2.5 ) #expect(abs(drop - 0.68) < 0.001) let pct = ElectricalCalculations.voltageDropPercentage( length: 5, current: 10, voltage: 12, unitSystem: .metric, crossSection: 2.5 ) // 0.68/12 × 100 = 5.667% #expect(abs(pct - 5.667) < 0.01) } @Test func voltageDropWithExplicitCrossSection_imperial() async throws { // 3m, 15A, 12V, AWG 10 (= 5.26mm²) // V_drop = (2×15×3×0.017)/5.26 = 1.53/5.26 = 0.2909V let drop = ElectricalCalculations.voltageDrop( length: 3, current: 15, voltage: 12, unitSystem: .imperial, crossSection: 10 // AWG 10 ) #expect(abs(drop - 0.2909) < 0.01) } // MARK: - Power Loss Verification @Test func powerLossEqualsCurrentTimesVoltageDrop() async throws { let length = 8.0 let current = 12.0 let voltage = 24.0 let drop = ElectricalCalculations.voltageDrop( length: length, current: current, voltage: voltage, unitSystem: .metric ) let loss = ElectricalCalculations.powerLoss( length: length, current: current, voltage: voltage, unitSystem: .metric ) // P_loss = I × V_drop #expect(abs(loss - current * drop) < 0.001) } // MARK: - Edge Cases @Test func zeroLengthProducesZeroDrop() async throws { let drop = ElectricalCalculations.voltageDrop( length: 0, current: 10, voltage: 12, unitSystem: .metric ) #expect(drop == 0) let loss = ElectricalCalculations.powerLoss( length: 0, current: 10, voltage: 12, unitSystem: .metric ) #expect(loss == 0) } @Test func zeroCurrentProducesZeroDrop() async throws { let drop = ElectricalCalculations.voltageDrop( length: 10, current: 0, voltage: 12, unitSystem: .metric ) #expect(drop == 0) } @Test func zeroVoltageReturnsZeroPercentage() async throws { let pct = ElectricalCalculations.voltageDropPercentage( length: 10, current: 5, voltage: 0, unitSystem: .metric ) #expect(pct == 0) } @Test func zeroVoltageReturnsZeroCrossSection() async throws { // With 0V, maxVoltageDrop = 0, guardAgainstZero returns 0 → smallest standard let cs = ElectricalCalculations.recommendedCrossSection( length: 10, current: 5, voltage: 0, unitSystem: .metric ) #expect(cs == 0.75) } // MARK: - Metric and Imperial Consistency @Test func metricAndImperialGiveSamePhysicalVoltageDrop() async throws { // Same physical setup: 10m cable, 15A, 12V // Metric: recommended cross-section in mm² // Imperial: recommended cross-section in AWG let lengthMeters = 10.0 let metricCS = ElectricalCalculations.recommendedCrossSection( length: lengthMeters, current: 15, voltage: 12, unitSystem: .metric ) let imperialAWG = ElectricalCalculations.recommendedCrossSection( length: lengthMeters, current: 15, voltage: 12, unitSystem: .imperial ) let metricDrop = ElectricalCalculations.voltageDrop( length: lengthMeters, current: 15, voltage: 12, unitSystem: .metric, crossSection: metricCS ) let imperialDrop = ElectricalCalculations.voltageDrop( length: lengthMeters, current: 15, voltage: 12, unitSystem: .imperial, crossSection: imperialAWG ) // Both should be within 5% voltage drop constraint #expect(metricDrop / 12 <= 0.05) #expect(imperialDrop / 12 <= 0.05) // Both drops should be positive #expect(metricDrop > 0) #expect(imperialDrop > 0) } // MARK: - Unit Convention: Length Always in Meters @Test func lengthParameterIsAlwaysMeters() async throws { // Passing the same meter value with both unit systems should give // the same underlying calculation, only differing in output format. let lengthMeters = 7.62 // = 25 feet let metricMinCS = ElectricalCalculations.recommendedCrossSection( length: lengthMeters, current: 15, voltage: 120, unitSystem: .metric ) let imperialAWG = ElectricalCalculations.recommendedCrossSection( length: lengthMeters, current: 15, voltage: 120, unitSystem: .imperial ) // Minimum raw cross-section: (2×15×7.62×0.017)/(120×0.05) = 0.648mm² // Metric: rounds to 0.75mm² (smallest standard ≥ 0.648) #expect(metricMinCS == 0.75) // Imperial: AWG 18 (0.823mm² ≥ 0.648) #expect(imperialAWG == 18.0) } // MARK: - Voltage Drop Constraint @Test func recommendedCrossSectionKeepsDropBelow5Percent() async throws { // Test several scenarios to verify the 5% constraint let scenarios: [(length: Double, current: Double, voltage: Double)] = [ (1, 1, 12), // minimal (5, 10, 12), // moderate boat load (10, 20, 24), // 24V system (15, 50, 12), // high current (3, 100, 48), // very high current, 48V (20, 5, 12), // long run, low current ] for s in scenarios { let cs = ElectricalCalculations.recommendedCrossSection( length: s.length, current: s.current, voltage: s.voltage, unitSystem: .metric ) let dropPct = ElectricalCalculations.voltageDropPercentage( length: s.length, current: s.current, voltage: s.voltage, unitSystem: .metric, crossSection: cs ) #expect(dropPct <= 5.0, "Drop \(dropPct)% exceeds 5% for \(s.length)m, \(s.current)A, \(s.voltage)V with \(cs)mm²") } } // MARK: - Formula Cross-Check: V_drop = I²R path @Test func voltageDropMatchesOhmsLaw() async throws { let length = 6.0 let current = 8.0 let crossSection = 4.0 // mm² let resistivity = 0.017 // R = (2 × L × ρ) / A = (2 × 6 × 0.017) / 4 = 0.051 Ω let resistance = (2 * length * resistivity) / crossSection // V = I × R = 8 × 0.051 = 0.408V let expectedDrop = current * resistance // P = I² × R = 64 × 0.051 = 3.264W let expectedPowerLoss = current * current * resistance let actualDrop = ElectricalCalculations.voltageDrop( length: length, current: current, voltage: 12, unitSystem: .metric, crossSection: crossSection ) let actualLoss = ElectricalCalculations.powerLoss( length: length, current: current, voltage: 12, unitSystem: .metric, crossSection: crossSection ) #expect(abs(actualDrop - expectedDrop) < 0.001) #expect(abs(actualLoss - expectedPowerLoss) < 0.001) } }