6d19038784
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>
47 lines
2.2 KiB
Markdown
47 lines
2.2 KiB
Markdown
---
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title: "Session: Production Hardening rotatingMachine + machineGroupControl"
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created: 2026-04-07
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updated: 2026-04-07
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status: proven
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tags: [session, rotatingMachine, machineGroupControl, testing]
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---
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# 2026-04-07 — Production Hardening
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## Scope
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Full code review and hardening of rotatingMachine and machineGroupControl nodes for production readiness.
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## Key Discoveries
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1. **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.
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2. **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()`.
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3. **emergencyStop case mismatch** — `"emergencyStop"` vs config key `"emergencystop"`. Emergency stop never worked. Fixed to lowercase.
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4. **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.
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5. **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%.
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## Changes Made
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### rotatingMachine (3 files, 7 test files)
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- Async input handler, null guards, listener cleanup, tick loop race fix
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- showCoG() implementation, efficiency variant fix, curve anomaly detection
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- 43 new tests (76 total)
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### machineGroupControl (1 file, 2 test files)
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- `_canonicalToOutputFlow()` on all flowmovement calls
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- Absolute scaling bug, empty Qd block, empty-machines guards
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- Marginal-cost refinement loop in BEP-Gravitation
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- Missing flowmovement after startup in equalFlowControl
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### generalFunctions (1 file)
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- 3 curve data fixes in hidrostal-H05K-S03R.json
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## Verification
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- 90 tests passing across both nodes
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- machineGroupControl within 0.1% of brute-force global optimum (1000-step search)
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- Pump switching stable: 1-2 transitions across full demand range, no hysteresis
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- Optimization cost: 0.03-0.15ms per call (0.015% of tick budget)
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