diff --git a/src/specificClass.js b/src/specificClass.js index ba9e7a1..2f28fd3 100644 --- a/src/specificClass.js +++ b/src/specificClass.js @@ -265,7 +265,7 @@ class MachineGroup { calcRelativeDistanceFromPeak(currentEfficiency,maxEfficiency,minEfficiency){ let distance = 1; - if(currentEfficiency != null){ + if(currentEfficiency != null && maxEfficiency !== minEfficiency){ distance = this.interpolation.interpolate_lin_single_point(currentEfficiency,maxEfficiency, minEfficiency, 0, 1); } return distance; @@ -580,14 +580,40 @@ class MachineGroup { this.redistributeFlowBySlope(pumpInfos, flowDistribution, delta, directional); } + // Clamp and compute initial power + flowDistribution.forEach(entry => { + const info = pumpInfos.find(info => info.id === entry.machineId); + entry.flow = Math.min(info.maxFlow, Math.max(info.minFlow, entry.flow)); + }); + + // Marginal-cost refinement: shift flow from most expensive to cheapest + // pump using actual power evaluations. Converges regardless of curve convexity. + const mcDelta = Math.max(1e-6, (Qd / pumpInfos.length) * 0.005); + for (let refineIter = 0; refineIter < 50; refineIter++) { + const mcEntries = flowDistribution.map(entry => { + const info = pumpInfos.find(i => i.id === entry.machineId); + const pNow = info.machine.inputFlowCalcPower(entry.flow); + const pUp = info.machine.inputFlowCalcPower(Math.min(info.maxFlow, entry.flow + mcDelta)); + return { entry, info, mc: (pUp - pNow) / mcDelta }; + }); + let expensive = null, cheap = null; + for (const e of mcEntries) { + if (e.entry.flow > e.info.minFlow + mcDelta) { if (!expensive || e.mc > expensive.mc) expensive = e; } + if (e.entry.flow < e.info.maxFlow - mcDelta) { if (!cheap || e.mc < cheap.mc) cheap = e; } + } + if (!expensive || !cheap || expensive === cheap) break; + if (expensive.mc - cheap.mc < expensive.mc * 0.001) break; + const before = expensive.info.machine.inputFlowCalcPower(expensive.entry.flow) + cheap.info.machine.inputFlowCalcPower(cheap.entry.flow); + const after = expensive.info.machine.inputFlowCalcPower(expensive.entry.flow - mcDelta) + cheap.info.machine.inputFlowCalcPower(cheap.entry.flow + mcDelta); + if (after < before) { expensive.entry.flow -= mcDelta; cheap.entry.flow += mcDelta; } else { break; } + } + let totalPower = 0; totalFlow = 0; flowDistribution.forEach(entry => { - const info = pumpInfos.find(info => info.id === entry.machineId); - const flow = Math.min(info.maxFlow, Math.max(info.minFlow, entry.flow)); - entry.flow = flow; - totalFlow += flow; - totalPower += info.machine.inputFlowCalcPower(flow); + totalFlow += entry.flow; + const info = pumpInfos.find(i => i.id === entry.machineId); + totalPower += info.machine.inputFlowCalcPower(entry.flow); }); const totalCog = pumpInfos.reduce((sum, info) => sum + info.NCog, 0); @@ -645,12 +671,17 @@ class MachineGroup { async optimalControl(Qd, powerCap = Infinity) { try{ + if (Object.keys(this.machines).length === 0) { + this.logger.warn("No machines registered. Cannot execute optimal control."); + return; + } + //we need to force the pressures of all machines to be equal to the highest pressure measured in the group // this is to ensure a correct evaluation of the flow and power consumption const pressures = Object.entries(this.machines).map(([_machineId, machine]) => { return { - downstream: this._readChildMeasurement(machine, "pressure", "measured", POSITIONS.DOWNSTREAM, this.unitPolicy.canonical.pressure), - upstream: this._readChildMeasurement(machine, "pressure", "measured", POSITIONS.UPSTREAM, this.unitPolicy.canonical.pressure) + downstream: this._readChildMeasurement(machine, "pressure", "measured", POSITIONS.DOWNSTREAM, this.unitPolicy.canonical.pressure) || 0, + upstream: this._readChildMeasurement(machine, "pressure", "measured", POSITIONS.UPSTREAM, this.unitPolicy.canonical.pressure) || 0 }; }); @@ -682,7 +713,9 @@ class MachineGroup { }, {}); if( Qd <= 0 ) { - //if Qd is 0 turn all machines off and exit early + this.logger.debug("Flow demand <= 0, turning all machines off."); + await this.turnOffAllMachines(); + return; } if( Qd < dynamicTotals.flow.min && Qd > 0 ){ @@ -751,11 +784,11 @@ class MachineGroup { if(machineStates[machineId] === "idle" && flow > 0){ await machine.handleInput("parent", "execsequence", "startup"); - await machine.handleInput("parent", "flowmovement", flow); + await machine.handleInput("parent", "flowmovement", this._canonicalToOutputFlow(flow)); } if(machineStates[machineId] === "operational" && flow > 0 ){ - await machine.handleInput("parent", "flowmovement", flow); + await machine.handleInput("parent", "flowmovement", this._canonicalToOutputFlow(flow)); } })); } @@ -766,11 +799,13 @@ class MachineGroup { // Equalize pressure across all machines for machines that are not running. This is needed to ensure accurate flow and power predictions. equalizePressure(){ + if (Object.keys(this.machines).length === 0) return; + // Get current pressures from all machines const pressures = Object.entries(this.machines).map(([_machineId, machine]) => { return { - downstream: this._readChildMeasurement(machine, "pressure", "measured", POSITIONS.DOWNSTREAM, this.unitPolicy.canonical.pressure), - upstream: this._readChildMeasurement(machine, "pressure", "measured", POSITIONS.UPSTREAM, this.unitPolicy.canonical.pressure) + downstream: this._readChildMeasurement(machine, "pressure", "measured", POSITIONS.DOWNSTREAM, this.unitPolicy.canonical.pressure) || 0, + upstream: this._readChildMeasurement(machine, "pressure", "measured", POSITIONS.UPSTREAM, this.unitPolicy.canonical.pressure) || 0 }; }); @@ -977,9 +1012,10 @@ class MachineGroup { } else if (currentState === "idle" && flow > 0) { await machine.handleInput("parent", "execsequence", "startup"); + await machine.handleInput("parent", "flowmovement", this._canonicalToOutputFlow(flow)); } else if (currentState === "operational" && flow > 0) { - await machine.handleInput("parent", "flowmovement", flow); + await machine.handleInput("parent", "flowmovement", this._canonicalToOutputFlow(flow)); } })); } @@ -1126,18 +1162,19 @@ class MachineGroup { return; } - if (demandQ < this.absoluteTotals.flow.min) { - this.logger.warn(`Flow demand ${demandQ} is below minimum possible flow ${this.absoluteTotals.flow.min}. Capping to minimum flow.`); - demandQout = this.absoluteTotals.flow.min; - } else if (demandQout > this.absoluteTotals.flow.max) { - this.logger.warn(`Flow demand ${demandQ} is above maximum possible flow ${this.absoluteTotals.flow.max}. Capping to maximum flow.`); - demandQout = this.absoluteTotals.flow.max; - }else if(demandQout <= 0){ + if (demandQ <= 0) { this.logger.debug(`Turning machines off`); demandQout = 0; - //return early and turn all machines off this.turnOffAllMachines(); return; + } else if (demandQ < this.absoluteTotals.flow.min) { + this.logger.warn(`Flow demand ${demandQ} is below minimum possible flow ${this.absoluteTotals.flow.min}. Capping to minimum flow.`); + demandQout = this.absoluteTotals.flow.min; + } else if (demandQ > this.absoluteTotals.flow.max) { + this.logger.warn(`Flow demand ${demandQ} is above maximum possible flow ${this.absoluteTotals.flow.max}. Capping to maximum flow.`); + demandQout = this.absoluteTotals.flow.max; + } else { + demandQout = demandQ; } break; @@ -1244,6 +1281,13 @@ class MachineGroup { } } + _canonicalToOutputFlow(value) { + const from = this.unitPolicy.canonical.flow; + const to = this.unitPolicy.output.flow; + if (!from || !to || from === to) return value; + return convert(value).from(from).to(to); + } + _outputUnitForType(type) { switch (String(type || '').toLowerCase()) { case 'flow': diff --git a/test/integration/distribution-power-table.integration.test.js b/test/integration/distribution-power-table.integration.test.js new file mode 100644 index 0000000..ecdff33 --- /dev/null +++ b/test/integration/distribution-power-table.integration.test.js @@ -0,0 +1,227 @@ +/** + * machineGroupControl vs naive strategies — real pump curves + * + * Station: 2× hidrostal H05K-S03R + 1× hidrostal C5-D03R-SHN1 + * ΔP = 2000 mbar + * + * Compares the ACTUAL machineGroupControl optimalControl algorithm against + * naive baselines. All strategies must deliver exactly Qd. + */ +const test = require('node:test'); +const assert = require('node:assert/strict'); + +const MachineGroup = require('../../src/specificClass'); +const Machine = require('../../../rotatingMachine/src/specificClass'); + +const DIFF_MBAR = 2000; +const UP_MBAR = 500; +const DOWN_MBAR = UP_MBAR + DIFF_MBAR; + +const stateConfig = { + time: { starting: 0, warmingup: 0, stopping: 0, coolingdown: 0 }, + movement: { speed: 1200, mode: 'staticspeed', maxSpeed: 1800 } +}; + +function machineConfig(id, model) { + return { + general: { logging: { enabled: false, logLevel: 'error' }, name: id, id, unit: 'm3/h' }, + functionality: { softwareType: 'machine', role: 'rotationaldevicecontroller' }, + asset: { category: 'pump', type: 'centrifugal', model, supplier: 'hidrostal' }, + mode: { + current: 'auto', + allowedActions: { auto: ['execsequence', 'execmovement', 'flowmovement', 'statuscheck'] }, + allowedSources: { auto: ['parent', 'GUI'] } + }, + sequences: { + startup: ['starting', 'warmingup', 'operational'], + shutdown: ['stopping', 'coolingdown', 'idle'], + emergencystop: ['emergencystop', 'off'], + } + }; +} + +function groupConfig() { + return { + general: { logging: { enabled: false, logLevel: 'error' }, name: 'station' }, + functionality: { softwareType: 'machinegroup', role: 'groupcontroller' }, + scaling: { current: 'absolute' }, + mode: { current: 'optimalcontrol' } + }; +} + +function injectPressure(m) { + m.updateMeasuredPressure(UP_MBAR, 'upstream', { timestamp: Date.now(), unit: 'mbar', childName: 'up', childId: `up-${m.config.general.id}` }); + m.updateMeasuredPressure(DOWN_MBAR, 'downstream', { timestamp: Date.now(), unit: 'mbar', childName: 'dn', childId: `dn-${m.config.general.id}` }); +} + +/* ---- naive baselines (pumps OFF = 0 flow, 0 power) ---- */ + +function distribute(machines, running, rawDist, Qd) { + const dist = {}; + for (const id of Object.keys(machines)) dist[id] = 0; + for (const id of running) { + const m = machines[id]; + dist[id] = Math.min(m.predictFlow.currentFxyYMax, Math.max(m.predictFlow.currentFxyYMin, rawDist[id] || 0)); + } + for (let pass = 0; pass < 20; pass++) { + let rem = Qd - running.reduce((s, id) => s + dist[id], 0); + if (Math.abs(rem) < 1e-9) break; + for (const id of running) { + if (Math.abs(rem) < 1e-9) break; + const m = machines[id]; + const cap = rem > 0 ? m.predictFlow.currentFxyYMax - dist[id] : dist[id] - m.predictFlow.currentFxyYMin; + if (cap > 1e-9) { const t = Math.min(Math.abs(rem), cap); dist[id] += rem > 0 ? t : -t; rem += rem > 0 ? -t : t; } + } + } + return dist; +} + +function spillover(machines, Qd) { + const sorted = Object.keys(machines).sort((a, b) => machines[a].predictFlow.currentFxyYMax - machines[b].predictFlow.currentFxyYMax); + let running = [], maxCap = 0; + for (const id of sorted) { running.push(id); maxCap += machines[id].predictFlow.currentFxyYMax; if (maxCap >= Qd) break; } + const raw = {}; let rem = Qd; + for (const id of running) { raw[id] = rem; rem = Math.max(0, rem - machines[id].predictFlow.currentFxyYMax); } + const dist = distribute(machines, running, raw, Qd); + let p = 0, f = 0; + for (const id of running) { p += machines[id].inputFlowCalcPower(dist[id]); f += dist[id]; } + return { dist, power: p, flow: f, combo: running }; +} + +function equalAllOn(machines, Qd) { + const ids = Object.keys(machines); + const raw = {}; for (const id of ids) raw[id] = Qd / ids.length; + const dist = distribute(machines, ids, raw, Qd); + let p = 0, f = 0; + for (const id of ids) { p += machines[id].inputFlowCalcPower(dist[id]); f += dist[id]; } + return { dist, power: p, flow: f, combo: ids }; +} + +/* ---- test ---- */ + +test('machineGroupControl vs naive baselines — real curves, verified flow', async () => { + const mg = new MachineGroup(groupConfig()); + const machines = {}; + + for (const [id, model] of [['H05K-1','hidrostal-H05K-S03R'],['H05K-2','hidrostal-H05K-S03R'],['C5','hidrostal-C5-D03R-SHN1']]) { + const m = new Machine(machineConfig(id, model), stateConfig); + injectPressure(m); + mg.childRegistrationUtils.registerChild(m, 'downstream'); + machines[id] = m; + } + + const toH = (v) => +(v * 3600).toFixed(1); + const CANON_FLOW = 'm3/s'; + const CANON_POWER = 'W'; + + console.log(`\n=== STATION: 2×H05K + 1×C5 @ ΔP=${DIFF_MBAR} mbar ===`); + console.table(Object.entries(machines).map(([id, m]) => ({ + id, + 'min (m³/h)': toH(m.predictFlow.currentFxyYMin), + 'max (m³/h)': toH(m.predictFlow.currentFxyYMax), + 'BEP (m³/h)': toH(m.predictFlow.currentFxyYMin + (m.predictFlow.currentFxyYMax - m.predictFlow.currentFxyYMin) * m.NCog), + NCog: +m.NCog.toFixed(3), + }))); + + const minQ = Math.max(...Object.values(machines).map(m => m.predictFlow.currentFxyYMin)); + const maxQ = Object.values(machines).reduce((s, m) => s + m.predictFlow.currentFxyYMax, 0); + const demandPcts = [0.10, 0.25, 0.50, 0.75, 0.90]; + const rows = []; + + for (const pct of demandPcts) { + const Qd = minQ + (maxQ - minQ) * pct; + + // Reset all machines to idle, re-inject pressure + for (const m of Object.values(machines)) { + if (m.state.getCurrentState() !== 'idle') await m.handleInput('parent', 'execSequence', 'shutdown'); + injectPressure(m); + } + + // Run machineGroupControl optimalControl with absolute scaling + mg.setMode('optimalcontrol'); + mg.setScaling('absolute'); + mg.calcAbsoluteTotals(); + mg.calcDynamicTotals(); + await mg.handleInput('parent', Qd); + + // Read ACTUAL per-pump state (not the MGC summary which may be stale) + let mgcPower = 0, mgcFlow = 0; + const mgcCombo = []; + const mgcDist = {}; + for (const [id, m] of Object.entries(machines)) { + const state = m.state.getCurrentState(); + const flow = m.measurements.type('flow').variant('predicted').position('downstream').getCurrentValue(CANON_FLOW) || 0; + const power = m.measurements.type('power').variant('predicted').position('atequipment').getCurrentValue(CANON_POWER) || 0; + mgcDist[id] = { flow, power, state }; + if (state === 'operational' || state === 'warmingup' || state === 'accelerating') { + mgcCombo.push(id); + mgcPower += power; + mgcFlow += flow; + } + } + + // Naive baselines + const sp = spillover(machines, Qd); + const ea = equalAllOn(machines, Qd); + + const best = Math.min(mgcPower, sp.power, ea.power); + const delta = (v) => best > 0 ? `${(((v - best) / best) * 100).toFixed(1)}%` : ''; + + rows.push({ + demand: `${(pct * 100)}%`, + 'Qd (m³/h)': toH(Qd), + 'MGC kW': +(mgcPower / 1000).toFixed(1), + 'MGC flow': toH(mgcFlow), + 'MGC pumps': mgcCombo.join('+') || 'none', + 'Spill kW': +(sp.power / 1000).toFixed(1), + 'Spill flow': toH(sp.flow), + 'Spill pumps': sp.combo.join('+'), + 'EqAll kW': +(ea.power / 1000).toFixed(1), + 'EqAll flow': toH(ea.flow), + 'MGC Δ': delta(mgcPower), + 'Spill Δ': delta(sp.power), + 'EqAll Δ': delta(ea.power), + }); + } + + console.log('\n=== POWER + FLOW COMPARISON (★ = best, all must deliver Qd) ==='); + console.table(rows); + + // Per-pump detail at each demand level + for (const pct of demandPcts) { + const Qd = minQ + (maxQ - minQ) * pct; + + for (const m of Object.values(machines)) { + if (m.state.getCurrentState() !== 'idle') await m.handleInput('parent', 'execSequence', 'shutdown'); + injectPressure(m); + } + mg.setMode('optimalcontrol'); + mg.setScaling('absolute'); + mg.calcAbsoluteTotals(); + mg.calcDynamicTotals(); + await mg.handleInput('parent', Qd); + + const detail = Object.entries(machines).map(([id, m]) => { + const state = m.state.getCurrentState(); + const flow = m.measurements.type('flow').variant('predicted').position('downstream').getCurrentValue(CANON_FLOW) || 0; + const power = m.measurements.type('power').variant('predicted').position('atequipment').getCurrentValue(CANON_POWER) || 0; + return { + pump: id, + state, + 'flow (m³/h)': toH(flow), + 'power (kW)': +(power / 1000).toFixed(1), + }; + }); + console.log(`\n--- MGC per-pump @ ${(pct*100)}% (${toH(Qd)} m³/h) ---`); + console.table(detail); + } + + // Flow verification on naive strategies + for (const pct of demandPcts) { + const Qd = minQ + (maxQ - minQ) * pct; + const sp = spillover(machines, Qd); + const ea = equalAllOn(machines, Qd); + assert.ok(Math.abs(sp.flow - Qd) < Qd * 0.005, `Spillover flow mismatch at ${(pct*100)}%`); + assert.ok(Math.abs(ea.flow - Qd) < Qd * 0.005, `Equal-all flow mismatch at ${(pct*100)}%`); + } +}); diff --git a/test/integration/ncog-distribution.integration.test.js b/test/integration/ncog-distribution.integration.test.js new file mode 100644 index 0000000..4fb3acc --- /dev/null +++ b/test/integration/ncog-distribution.integration.test.js @@ -0,0 +1,442 @@ +/** + * Group Distribution Strategy Comparison Test + * + * Compares three flow distribution strategies for a group of pumps: + * 1. NCog/BEP-Gravitation (slope-weighted — favours pumps with flatter power curves) + * 2. Equal distribution (same flow to every pump) + * 3. Spillover (fill smallest pump first, overflow to next) + * + * For variable-speed centrifugal pumps, specific flow (Q/P) is monotonically + * decreasing per pump (affinity laws: P ∝ Q³), so NCog = 0 for all pumps. + * The real optimization value comes from the BEP-Gravitation algorithm's + * slope-based redistribution, which IS sensitive to curve shape differences. + * + * These tests verify that: + * - Asymmetric pumps produce different power slopes (the basis for optimization) + * - BEP-Gravitation uses less total power than naive strategies for mixed pumps + * - Equal pumps receive equal treatment under all strategies + * - Spillover creates a visibly different distribution than BEP-weighted + */ +const test = require('node:test'); +const assert = require('node:assert/strict'); + +const MachineGroup = require('../../src/specificClass'); +const Machine = require('../../../rotatingMachine/src/specificClass'); + +const baseCurve = require('../../../generalFunctions/datasets/assetData/curves/hidrostal-H05K-S03R.json'); + +/* ---- helpers ---- */ + +function deepClone(obj) { return JSON.parse(JSON.stringify(obj)); } + +function distortSeries(series, scale = 1, tilt = 0) { + const last = series.length - 1; + return series.map((v, i) => { + const gradient = last === 0 ? 0 : i / last - 0.5; + return Math.max(v * scale * (1 + tilt * gradient), 0); + }); +} + +function createSyntheticCurve(mods) { + const { flowScale = 1, powerScale = 1, flowTilt = 0, powerTilt = 0 } = mods; + const curve = deepClone(baseCurve); + Object.values(curve.nq).forEach(s => { s.y = distortSeries(s.y, flowScale, flowTilt); }); + Object.values(curve.np).forEach(s => { s.y = distortSeries(s.y, powerScale, powerTilt); }); + return curve; +} + +const stateConfig = { + time: { starting: 0, warmingup: 0, stopping: 0, coolingdown: 0 }, + movement: { speed: 1200, mode: 'staticspeed', maxSpeed: 1800 } +}; + +function createMachineConfig(id, label) { + return { + general: { logging: { enabled: false, logLevel: 'error' }, name: label, id, unit: 'm3/h' }, + functionality: { softwareType: 'machine', role: 'rotationaldevicecontroller' }, + asset: { category: 'pump', type: 'centrifugal', model: 'hidrostal-H05K-S03R', supplier: 'hidrostal' }, + mode: { + current: 'auto', + allowedActions: { auto: ['execsequence', 'execmovement', 'flowmovement', 'statuscheck'] }, + allowedSources: { auto: ['parent', 'GUI'] } + }, + sequences: { + startup: ['starting', 'warmingup', 'operational'], + shutdown: ['stopping', 'coolingdown', 'idle'], + emergencystop: ['emergencystop', 'off'], + } + }; +} + +function createGroupConfig(name) { + return { + general: { logging: { enabled: false, logLevel: 'error' }, name }, + functionality: { softwareType: 'machinegroup', role: 'groupcontroller' }, + scaling: { current: 'normalized' }, + mode: { current: 'optimalcontrol' } + }; +} + +/** + * Bootstrap with differential pressure (upstream + downstream) so the predict + * engine resolves a realistic fDimension and calcEfficiencyCurve produces + * a proper BEP peak — not a monotonic Q/P curve. + */ +function bootstrapGroup(name, machineSpecs, diffMbar, upstreamMbar = 800) { + const mg = new MachineGroup(createGroupConfig(name)); + const machines = {}; + for (const spec of machineSpecs) { + const m = new Machine(createMachineConfig(spec.id, spec.label), stateConfig); + if (spec.curveMods) m.updateCurve(createSyntheticCurve(spec.curveMods)); + // Set BOTH upstream and downstream so getMeasuredPressure computes differential + m.updateMeasuredPressure(upstreamMbar, 'upstream', { + timestamp: Date.now(), unit: 'mbar', childName: `pt-up-${spec.id}`, childId: `pt-up-${spec.id}` + }); + m.updateMeasuredPressure(upstreamMbar + diffMbar, 'downstream', { + timestamp: Date.now(), unit: 'mbar', childName: `pt-dn-${spec.id}`, childId: `pt-dn-${spec.id}` + }); + mg.childRegistrationUtils.registerChild(m, 'downstream'); + machines[spec.id] = m; + } + return { mg, machines }; +} + +/** Distribute flow weighted by each machine's NCog (BEP position). */ +function distributeByNCog(machines, Qd) { + const entries = Object.entries(machines); + let totalNCog = entries.reduce((s, [, m]) => s + (m.NCog || 0), 0); + + const distribution = {}; + for (const [id, m] of entries) { + const min = m.predictFlow.currentFxyYMin; + const max = m.predictFlow.currentFxyYMax; + const flow = totalNCog > 0 + ? ((m.NCog || 0) / totalNCog) * Qd + : Qd / entries.length; + distribution[id] = Math.min(max, Math.max(min, flow)); + } + + let totalPower = 0; + for (const [id, m] of entries) { + totalPower += m.inputFlowCalcPower(distribution[id]); + } + return { distribution, totalPower }; +} + +/** Compute power at a given flow for a machine using its inverse curve. */ +function powerAtFlow(machine, flow) { + return machine.inputFlowCalcPower(flow); +} + +/** Distribute by slope-weighting: flatter dP/dQ curves attract more flow. */ +function distributeBySlopeWeight(machines, Qd) { + const entries = Object.entries(machines); + // Estimate slope (dP/dQ) at midpoint for each machine + const pumpInfos = entries.map(([id, m]) => { + const min = m.predictFlow.currentFxyYMin; + const max = m.predictFlow.currentFxyYMax; + const mid = (min + max) / 2; + const delta = Math.max((max - min) * 0.05, 0.001); + const pMid = powerAtFlow(m, mid); + const pRight = powerAtFlow(m, Math.min(max, mid + delta)); + const slope = Math.abs((pRight - pMid) / delta); + return { id, m, min, max, slope: Math.max(slope, 1e-6) }; + }); + + // Weight = 1/slope: flatter curves get more flow + const totalWeight = pumpInfos.reduce((s, p) => s + (1 / p.slope), 0); + const distribution = {}; + let totalPower = 0; + + for (const p of pumpInfos) { + const weight = (1 / p.slope) / totalWeight; + const flow = Math.min(p.max, Math.max(p.min, Qd * weight)); + distribution[p.id] = flow; + totalPower += powerAtFlow(p.m, flow); + } + + return { distribution, totalPower }; +} + +/** Distribute equally. */ +function distributeEqual(machines, Qd) { + const entries = Object.entries(machines); + const flowEach = Qd / entries.length; + const distribution = {}; + let totalPower = 0; + for (const [id, m] of entries) { + const min = m.predictFlow.currentFxyYMin; + const max = m.predictFlow.currentFxyYMax; + const clamped = Math.min(max, Math.max(min, flowEach)); + distribution[id] = clamped; + totalPower += powerAtFlow(m, clamped); + } + return { distribution, totalPower }; +} + +/** Spillover: fill smallest pump to max first, then overflow to next. */ +function distributeSpillover(machines, Qd) { + const entries = Object.entries(machines) + .sort(([, a], [, b]) => a.predictFlow.currentFxyYMax - b.predictFlow.currentFxyYMax); + let remaining = Qd; + const distribution = {}; + let totalPower = 0; + for (const [id, m] of entries) { + const min = m.predictFlow.currentFxyYMin; + const max = m.predictFlow.currentFxyYMax; + const assigned = Math.min(max, Math.max(min, remaining)); + distribution[id] = assigned; + remaining = Math.max(0, remaining - assigned); + } + for (const [id, m] of entries) { + totalPower += powerAtFlow(m, distribution[id]); + } + return { distribution, totalPower }; +} + +/* ---- tests ---- */ + +test('NCog is meaningful (0 < NCog ≤ 1) with proper differential pressure', () => { + const { machines } = bootstrapGroup('ncog-basic', [ + { id: 'A', label: 'pump-A', curveMods: { flowScale: 1, powerScale: 1 } }, + ], 400); // 400 mbar differential + + const m = machines['A']; + assert.ok(Number.isFinite(m.NCog), `NCog should be finite, got ${m.NCog}`); + assert.ok(m.NCog > 0 && m.NCog <= 1, `NCog should be in (0,1], got ${m.NCog.toFixed(4)}`); + assert.ok(m.cog > 0, `cog (peak specific flow) should be positive, got ${m.cog}`); + assert.ok(m.cogIndex > 0, `BEP should not be at index 0 (that means monotonic Q/P with no real peak)`); +}); + +test('different curve shapes produce different NCog at same pressure', () => { + // powerTilt shifts the BEP position: positive tilt makes power steeper at high flow + // (BEP moves left), negative tilt makes it flatter at high flow (BEP moves right) + const { machines } = bootstrapGroup('ncog-shapes', [ + { id: 'early', label: 'early-BEP', curveMods: { flowScale: 1, powerScale: 1, powerTilt: 0.4 } }, + { id: 'late', label: 'late-BEP', curveMods: { flowScale: 1, powerScale: 1, powerTilt: -0.3 } }, + ], 400); + + const ncogEarly = machines['early'].NCog; + const ncogLate = machines['late'].NCog; + + assert.ok(ncogEarly > 0, `Early BEP NCog should be > 0, got ${ncogEarly.toFixed(4)}`); + assert.ok(ncogLate > 0, `Late BEP NCog should be > 0, got ${ncogLate.toFixed(4)}`); + assert.ok( + ncogLate > ncogEarly, + `Late BEP pump should have higher NCog (BEP further into flow range). ` + + `early=${ncogEarly.toFixed(4)}, late=${ncogLate.toFixed(4)}` + ); +}); + +test('NCog-weighted distribution differs from equal split for pumps with different BEPs', () => { + // Two pumps with different BEP positions (via powerTilt) + const { machines } = bootstrapGroup('ncog-vs-equal', [ + { id: 'early', label: 'early-BEP', curveMods: { flowScale: 1, powerScale: 1, powerTilt: 0.4 } }, + { id: 'late', label: 'late-BEP', curveMods: { flowScale: 1, powerScale: 1, powerTilt: -0.3 } }, + ], 400); + + const ncogA = machines['early'].NCog; + const ncogB = machines['late'].NCog; + assert.ok(ncogA > 0 && ncogB > 0, `Both NCog should be > 0 (early=${ncogA.toFixed(3)}, late=${ncogB.toFixed(3)})`); + assert.ok(ncogA !== ncogB, 'NCog values should differ'); + + const totalMax = machines['early'].predictFlow.currentFxyYMax + machines['late'].predictFlow.currentFxyYMax; + const Qd = totalMax * 0.5; + + const ncogResult = distributeByNCog(machines, Qd); + const equalResult = distributeEqual(machines, Qd); + + // NCog distributes proportionally to BEP position — late-BEP pump gets more flow + assert.ok( + ncogResult.distribution['late'] > ncogResult.distribution['early'], + `Late-BEP pump should get more flow under NCog. ` + + `early=${ncogResult.distribution['early'].toFixed(2)}, late=${ncogResult.distribution['late'].toFixed(2)}` + ); + + // Equal split gives same flow to both (they have same flow range, just different BEPs) + const equalDiff = Math.abs(equalResult.distribution['early'] - equalResult.distribution['late']); + const ncogDiff = Math.abs(ncogResult.distribution['early'] - ncogResult.distribution['late']); + assert.ok( + ncogDiff > equalDiff + Qd * 0.01, + `NCog distribution should be more asymmetric than equal split` + ); +}); + +test('asymmetric pumps have different power curve slopes', () => { + // A pump with low powerScale has a flatter power curve + const { machines } = bootstrapGroup('slope-check', [ + { id: 'flat', label: 'flat-power', curveMods: { flowScale: 1.2, powerScale: 0.7, flowTilt: 0.1 } }, + { id: 'steep', label: 'steep-power', curveMods: { flowScale: 0.8, powerScale: 1.4, flowTilt: -0.05 } }, + ], 400); + + // Compute slope at midpoint of each machine's range + const slopes = {}; + for (const [id, m] of Object.entries(machines)) { + const mid = (m.predictFlow.currentFxyYMin + m.predictFlow.currentFxyYMax) / 2; + const delta = (m.predictFlow.currentFxyYMax - m.predictFlow.currentFxyYMin) * 0.05; + const pMid = powerAtFlow(m, mid); + const pRight = powerAtFlow(m, mid + delta); + slopes[id] = (pRight - pMid) / delta; + } + + assert.ok(slopes['flat'] > 0 && slopes['steep'] > 0, 'Both slopes should be positive'); + assert.ok( + slopes['steep'] > slopes['flat'] * 1.3, + `Steep pump should have notably higher slope. flat=${slopes['flat'].toFixed(0)}, steep=${slopes['steep'].toFixed(0)}` + ); +}); + +test('slope-weighted distribution routes more flow to flatter pump', () => { + const { machines } = bootstrapGroup('slope-routing', [ + { id: 'flat', label: 'flat-power', curveMods: { flowScale: 1.2, powerScale: 0.7 } }, + { id: 'steep', label: 'steep-power', curveMods: { flowScale: 0.8, powerScale: 1.4 } }, + ], 400); + + const totalMax = machines['flat'].predictFlow.currentFxyYMax + machines['steep'].predictFlow.currentFxyYMax; + const Qd = totalMax * 0.5; + + const slopeResult = distributeBySlopeWeight(machines, Qd); + + assert.ok( + slopeResult.distribution['flat'] > slopeResult.distribution['steep'], + `Flat pump should get more flow. flat=${slopeResult.distribution['flat'].toFixed(2)}, steep=${slopeResult.distribution['steep'].toFixed(2)}` + ); +}); + +test('slope-weighted uses less power than equal split for asymmetric pumps', () => { + const { machines } = bootstrapGroup('power-compare', [ + { id: 'eff', label: 'efficient', curveMods: { flowScale: 1.2, powerScale: 0.7, flowTilt: 0.12 } }, + { id: 'std', label: 'standard', curveMods: { flowScale: 1, powerScale: 1 } }, + ], 400); + + const totalMax = machines['eff'].predictFlow.currentFxyYMax + machines['std'].predictFlow.currentFxyYMax; + const demandLevels = [0.3, 0.5, 0.7].map(p => { + const min = Math.max(machines['eff'].predictFlow.currentFxyYMin, machines['std'].predictFlow.currentFxyYMin); + return min + (totalMax - min) * p; + }); + + let slopeWins = 0; + const results = []; + + for (const Qd of demandLevels) { + const slopeResult = distributeBySlopeWeight(machines, Qd); + const equalResult = distributeEqual(machines, Qd); + const spillResult = distributeSpillover(machines, Qd); + + results.push({ + demand: Qd, + slopePower: slopeResult.totalPower, + equalPower: equalResult.totalPower, + spillPower: spillResult.totalPower, + }); + + if (slopeResult.totalPower <= equalResult.totalPower + 1) slopeWins++; + } + + assert.ok( + slopeWins >= 2, + `Slope-weighted should use ≤ power than equal in ≥ 2/3 cases.\n` + + results.map(r => + ` Qd=${r.demand.toFixed(1)}: slope=${r.slopePower.toFixed(1)}W, equal=${r.equalPower.toFixed(1)}W, spill=${r.spillPower.toFixed(1)}W` + ).join('\n') + ); +}); + +test('spillover produces visibly different distribution than slope-weighted for mixed sizes', () => { + const { machines } = bootstrapGroup('spillover-vs-slope', [ + { id: 'small', label: 'small-pump', curveMods: { flowScale: 0.6, powerScale: 0.55 } }, + { id: 'large', label: 'large-pump', curveMods: { flowScale: 1.5, powerScale: 1.2 } }, + ], 400); + + const totalMax = machines['small'].predictFlow.currentFxyYMax + machines['large'].predictFlow.currentFxyYMax; + const Qd = totalMax * 0.5; + + const slopeResult = distributeBySlopeWeight(machines, Qd); + const spillResult = distributeSpillover(machines, Qd); + + // Spillover fills the small pump first, slope-weight distributes by curve shape + const slopeDiff = Math.abs(slopeResult.distribution['small'] - spillResult.distribution['small']); + const percentDiff = (slopeDiff / Qd) * 100; + + assert.ok( + percentDiff > 1, + `Strategies should produce different distributions. ` + + `Slope small=${slopeResult.distribution['small'].toFixed(2)}, ` + + `Spill small=${spillResult.distribution['small'].toFixed(2)} (${percentDiff.toFixed(1)}% diff)` + ); +}); + +test('equal pumps get equal flow under all strategies', () => { + const { machines } = bootstrapGroup('equal-pumps', [ + { id: 'A', label: 'pump-A', curveMods: { flowScale: 1, powerScale: 1 } }, + { id: 'B', label: 'pump-B', curveMods: { flowScale: 1, powerScale: 1 } }, + ], 400); + + const totalMax = machines['A'].predictFlow.currentFxyYMax + machines['B'].predictFlow.currentFxyYMax; + const Qd = totalMax * 0.6; + + const slopeResult = distributeBySlopeWeight(machines, Qd); + const equalResult = distributeEqual(machines, Qd); + + const tolerance = Qd * 0.01; + + assert.ok( + Math.abs(slopeResult.distribution['A'] - slopeResult.distribution['B']) < tolerance, + `Slope-weighted should split equally for identical pumps. A=${slopeResult.distribution['A'].toFixed(2)}, B=${slopeResult.distribution['B'].toFixed(2)}` + ); + assert.ok( + Math.abs(equalResult.distribution['A'] - equalResult.distribution['B']) < tolerance, + `Equal should split equally. A=${equalResult.distribution['A'].toFixed(2)}, B=${equalResult.distribution['B'].toFixed(2)}` + ); + + // Power should be identical too + assert.ok( + Math.abs(slopeResult.totalPower - equalResult.totalPower) < 1, + `Equal pumps should produce same total power under any strategy` + ); +}); + +test('full MGC optimalControl uses ≤ power than priorityControl for mixed pumps', async () => { + const { mg, machines } = bootstrapGroup('mgc-full', [ + { id: 'eff', label: 'efficient', curveMods: { flowScale: 1.2, powerScale: 0.7, flowTilt: 0.1 } }, + { id: 'std', label: 'standard', curveMods: { flowScale: 1, powerScale: 1 } }, + { id: 'weak', label: 'weak', curveMods: { flowScale: 0.8, powerScale: 1.3, flowTilt: -0.08 } }, + ], 400); + + for (const m of Object.values(machines)) { + await m.handleInput('parent', 'execSequence', 'startup'); + } + + // Run optimalControl + mg.setMode('optimalcontrol'); + mg.setScaling('normalized'); + await mg.handleInput('parent', 50, Infinity); + const optPower = mg.measurements.type('power').variant('predicted').position('atequipment').getCurrentValue() || 0; + const optFlow = mg.measurements.type('flow').variant('predicted').position('atequipment').getCurrentValue() || 0; + + // Reset machines + for (const m of Object.values(machines)) { + await m.handleInput('parent', 'execSequence', 'shutdown'); + await m.handleInput('parent', 'execSequence', 'startup'); + } + + // Run priorityControl + mg.setMode('prioritycontrol'); + await mg.handleInput('parent', 50, Infinity, ['eff', 'std', 'weak']); + const prioPower = mg.measurements.type('power').variant('predicted').position('atequipment').getCurrentValue() || 0; + const prioFlow = mg.measurements.type('flow').variant('predicted').position('atequipment').getCurrentValue() || 0; + + assert.ok(optFlow > 0, `Optimal should deliver flow, got ${optFlow}`); + assert.ok(prioFlow > 0, `Priority should deliver flow, got ${prioFlow}`); + + // Compare efficiency (flow per unit power) + const optEff = optPower > 0 ? optFlow / optPower : 0; + const prioEff = prioPower > 0 ? prioFlow / prioPower : 0; + + assert.ok( + optEff >= prioEff * 0.95, + `Optimal efficiency should be ≥ priority (within 5% tolerance). ` + + `Opt: ${optFlow.toFixed(1)}/${optPower.toFixed(1)}=${optEff.toFixed(6)} | ` + + `Prio: ${prioFlow.toFixed(1)}/${prioPower.toFixed(1)}=${prioEff.toFixed(6)}` + ); +});