Errors: Repeated Corrector Convergence Failures in IDASolver at Specific Time Steps

[Norseips]

Hallo everyone,

I frequently encounter errors similar to those listed below when running my code, even after trying the suggestions from issue #1493 and adjusting some parameters.
These adjustments initially allowed the code to run smoothly on PyBaMM version 23.5 and CasADi version 3.6.3 without errors. However, after changing certain parameter values, I face consistent errors irrespective of the PyBaMM or CasADi version I use.

Here is a minimum working example that illustrates the issue:

import pybamm

model = pybamm.lithium_ion.DFN({"lithium plating": "partially reversible"})
param = pybamm.ParameterValues("OKane2022")
pybamm.set_logging_level("NOTICE")

cycle_number = 1000

degradation_experiments = [
    "Discharge at 1C until 2.5V",
    "Charge at 0.3C until 4.2V",
    "Hold at 4.2V until C/100",
] * cycle_number

param.update({"Ambient temperature [K]": 278.15})
solutions_degradation = {}
param.update({"Lithium plating kinetic rate constant [m.s-1]": 1E-8})
param.update({"Dead lithium decay constant [s-1]": 4E-7})

degradation_experiment = pybamm.Experiment(degradation_experiments)
sim_degradation = pybamm.Simulation(model, parameter_values=param, experiment=degradation_experiment)
safe_solver = pybamm.CasadiSolver(mode="safe")
sol_degradation = sim_degradation.solve(solver=safe_solver)

Errors with PyBaMM (24.1) and CasADi (3.6.5):

Using safe_solver = pybamm.CasadiSolver(mode="safe"), the code stops at cycle 1441/3000 with the following errors:

2024-04-24 17:49:00.747 - [NOTICE] callbacks.on_step_start(180): Cycle 1441/3000, step 1/1: Discharge at 1C until 2.5V
At t = 267.014 and h = 3.90134e-11, the corrector convergence failed repeatedly or with |h| = hmin.
At t = 45.806 and h = 1.58123e-09, the corrector convergence failed repeatedly or with |h| = hmin.
2024-04-24 17:49:01.790 - [ERROR] callbacks.on_experiment_error(224): Simulation error: Error in Function::call for 'F' [IdasInterface] at .../casadi/core/function.cpp:1432:
Error in Function::call for 'F' [IdasInterface] at .../casadi/core/function.cpp:361:
.../casadi/interfaces/sundials/idas_interface.cpp:596: IDASolve returned "IDA_CONV_FAIL". Consult IDAS documentation.
2024-04-24 17:49:01.934 - [NOTICE] callbacks.on_experiment_end(220): Finish experiment simulation, took 20 minutes, 53 seconds

Errors with PyBaMM (23.5) and CasADi (3.6.3):
The situation remains similar with safe_solver = pybamm.CasadiSolver(mode="safe"), where the code stops at cycle 910/3000 with errors like:

2024-04-24 18:29:54.019 - [NOTICE] callbacks.on_step_start(180): Cycle 910/3000, step 1/1: Discharge at 1C until 2.5V
At t = 285.773 and h = 3.43867e-11, the corrector convergence failed repeatedly or with |h| = hmin.
At t = 51.4407 and h = 4.71913e-10, the corrector convergence failed repeatedly or with |h| = hmin.
2024-04-24 18:29:55.091 - [ERROR] callbacks.on_experiment_error(224): Simulation error: Error in Function::call for 'F' [IdasInterface] at .../casadi/core/function.cpp:1401:
Error in Function::call for 'F' [IdasInterface] at .../casadi/core/function.cpp:330:
.../casadi/interfaces/sundials/idas_interface.cpp:596: IDASolve returned "IDA_CONV_FAIL". Consult IDAS documentation.
2024-04-24 18:29:55.201 - [NOTICE] callbacks.on_experiment_end(220): Finish experiment simulation, took 18 minutes, 2 seconds

I've also tried changing the CasadiSolver's mode to "fast" and using settings like dt_max=120 or rtol=1e-9, atol=1e-9 in safe_solver = pybamm.CasadiSolver(), but these adjustments did not significantly alter the outcome; the code still stops around the same cycle.

Does anyone know what might be causing this issue? Thank you in advance for your help!