RnD/EVOLV

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znetsixe 6d19038784 docs: initialize project wiki from production hardening session

12 pages covering architecture, findings, and metrics from the
rotatingMachine + machineGroupControl hardening work:

- Overview: node inventory, what works/doesn't, current scale
- Architecture: 3D pump curves, group optimization algorithm
- Findings: BEP-Gravitation proof (0.1% of optimum), NCog behavior,
  curve non-convexity, pump switching stability
- Metrics: test counts, power comparison table, performance numbers
- Knowledge graph: structured YAML with all data points and provenance
- Session log: 2026-04-07 production hardening
- Tools: query.py, search.sh, lint.sh

Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>

2026-04-07 16:36:08 +02:00

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2026-04-07 — Production Hardening

Scope

Full code review and hardening of rotatingMachine and machineGroupControl nodes for production readiness.

Key Discoveries

Efficiency rounding destroyed NCog/BEP — Math.round(Q/P * 100) / 100 in canonical units (m3/s and W) produces ratios ~1e-6 that all round to 0. All NCog, cog, and BEP calculations were non-functional. Fixed by removing rounding.
flowmovement unit mismatch — machineGroupControl computed flow in canonical (m3/s) and sent it directly to rotatingMachine which expected output units (m3/h). Every pump stayed at minimum flow. Fixed with _canonicalToOutputFlow().
emergencyStop case mismatch — "emergencyStop" vs config key "emergencystop". Emergency stop never worked. Fixed to lowercase.
Curve data anomalies — 3 flow values leaked into power columns in hidrostal-H05K-S03R.json at pressures 1600, 3200, 3300 mbar. Fixed with interpolated values.
C5 pump non-convexity — 5 data points per pressure level produces non-convex spline. The marginal-cost refinement loop closes the gap to brute-force optimum from 2.1% to 0.1%.

Changes Made

rotatingMachine (3 files, 7 test files)

Async input handler, null guards, listener cleanup, tick loop race fix
showCoG() implementation, efficiency variant fix, curve anomaly detection
43 new tests (76 total)

machineGroupControl (1 file, 2 test files)

_canonicalToOutputFlow() on all flowmovement calls
Absolute scaling bug, empty Qd block, empty-machines guards
Marginal-cost refinement loop in BEP-Gravitation
Missing flowmovement after startup in equalFlowControl

generalFunctions (1 file)

3 curve data fixes in hidrostal-H05K-S03R.json

Verification

90 tests passing across both nodes
machineGroupControl within 0.1% of brute-force global optimum (1000-step search)
Pump switching stable: 1-2 transitions across full demand range, no hysteresis
Optimization cost: 0.03-0.15ms per call (0.015% of tick budget)

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