fix: production hardening — unit mismatch, safety guards, marginal-cost refinement
- Fix flowmovement unit mismatch: MGC computed flow in canonical (m³/s) but rotatingMachine expects output units (m³/h). All flowmovement calls now convert via _canonicalToOutputFlow(). Without this fix, every pump stayed at minimum flow regardless of demand. - Fix absolute scaling: demandQout vs demandQ comparison bug, reorder conditions so <= 0 is checked first, add else branch for valid demand. - Fix empty Qd <= 0 block: now calls turnOffAllMachines(). - Add empty-machines guards on optimalControl and equalizePressure. - Add null fallback (|| 0) on pressure measurement reads. - Fix division-by-zero in calcRelativeDistanceFromPeak. - Fix missing flowmovement after startup in equalFlowControl. - Add marginal-cost refinement loop in BEP-Gravitation: after slope-based redistribution, iteratively shifts flow from highest actual dP/dQ to lowest using real power evaluations. Closes gap to brute-force optimum from 2.1% to <0.1% without affecting combination selection stability. - Add NCog distribution comparison tests and brute-force power table test. Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
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znetsixe
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test/integration/distribution-power-table.integration.test.js
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test/integration/distribution-power-table.integration.test.js
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/**
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* machineGroupControl vs naive strategies — real pump curves
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*
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* Station: 2× hidrostal H05K-S03R + 1× hidrostal C5-D03R-SHN1
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* ΔP = 2000 mbar
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*
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* Compares the ACTUAL machineGroupControl optimalControl algorithm against
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* naive baselines. All strategies must deliver exactly Qd.
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*/
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const test = require('node:test');
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const assert = require('node:assert/strict');
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const MachineGroup = require('../../src/specificClass');
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const Machine = require('../../../rotatingMachine/src/specificClass');
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const DIFF_MBAR = 2000;
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const UP_MBAR = 500;
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const DOWN_MBAR = UP_MBAR + DIFF_MBAR;
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const stateConfig = {
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time: { starting: 0, warmingup: 0, stopping: 0, coolingdown: 0 },
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movement: { speed: 1200, mode: 'staticspeed', maxSpeed: 1800 }
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};
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function machineConfig(id, model) {
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return {
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general: { logging: { enabled: false, logLevel: 'error' }, name: id, id, unit: 'm3/h' },
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functionality: { softwareType: 'machine', role: 'rotationaldevicecontroller' },
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asset: { category: 'pump', type: 'centrifugal', model, supplier: 'hidrostal' },
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mode: {
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current: 'auto',
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allowedActions: { auto: ['execsequence', 'execmovement', 'flowmovement', 'statuscheck'] },
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allowedSources: { auto: ['parent', 'GUI'] }
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},
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sequences: {
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startup: ['starting', 'warmingup', 'operational'],
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shutdown: ['stopping', 'coolingdown', 'idle'],
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emergencystop: ['emergencystop', 'off'],
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}
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};
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}
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function groupConfig() {
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return {
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general: { logging: { enabled: false, logLevel: 'error' }, name: 'station' },
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functionality: { softwareType: 'machinegroup', role: 'groupcontroller' },
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scaling: { current: 'absolute' },
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mode: { current: 'optimalcontrol' }
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};
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}
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function injectPressure(m) {
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m.updateMeasuredPressure(UP_MBAR, 'upstream', { timestamp: Date.now(), unit: 'mbar', childName: 'up', childId: `up-${m.config.general.id}` });
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m.updateMeasuredPressure(DOWN_MBAR, 'downstream', { timestamp: Date.now(), unit: 'mbar', childName: 'dn', childId: `dn-${m.config.general.id}` });
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}
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/* ---- naive baselines (pumps OFF = 0 flow, 0 power) ---- */
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function distribute(machines, running, rawDist, Qd) {
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const dist = {};
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for (const id of Object.keys(machines)) dist[id] = 0;
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for (const id of running) {
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const m = machines[id];
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dist[id] = Math.min(m.predictFlow.currentFxyYMax, Math.max(m.predictFlow.currentFxyYMin, rawDist[id] || 0));
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}
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for (let pass = 0; pass < 20; pass++) {
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let rem = Qd - running.reduce((s, id) => s + dist[id], 0);
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if (Math.abs(rem) < 1e-9) break;
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for (const id of running) {
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if (Math.abs(rem) < 1e-9) break;
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const m = machines[id];
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const cap = rem > 0 ? m.predictFlow.currentFxyYMax - dist[id] : dist[id] - m.predictFlow.currentFxyYMin;
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if (cap > 1e-9) { const t = Math.min(Math.abs(rem), cap); dist[id] += rem > 0 ? t : -t; rem += rem > 0 ? -t : t; }
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}
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}
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return dist;
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}
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function spillover(machines, Qd) {
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const sorted = Object.keys(machines).sort((a, b) => machines[a].predictFlow.currentFxyYMax - machines[b].predictFlow.currentFxyYMax);
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let running = [], maxCap = 0;
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for (const id of sorted) { running.push(id); maxCap += machines[id].predictFlow.currentFxyYMax; if (maxCap >= Qd) break; }
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const raw = {}; let rem = Qd;
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for (const id of running) { raw[id] = rem; rem = Math.max(0, rem - machines[id].predictFlow.currentFxyYMax); }
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const dist = distribute(machines, running, raw, Qd);
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let p = 0, f = 0;
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for (const id of running) { p += machines[id].inputFlowCalcPower(dist[id]); f += dist[id]; }
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return { dist, power: p, flow: f, combo: running };
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}
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function equalAllOn(machines, Qd) {
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const ids = Object.keys(machines);
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const raw = {}; for (const id of ids) raw[id] = Qd / ids.length;
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const dist = distribute(machines, ids, raw, Qd);
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let p = 0, f = 0;
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for (const id of ids) { p += machines[id].inputFlowCalcPower(dist[id]); f += dist[id]; }
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return { dist, power: p, flow: f, combo: ids };
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}
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/* ---- test ---- */
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test('machineGroupControl vs naive baselines — real curves, verified flow', async () => {
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const mg = new MachineGroup(groupConfig());
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const machines = {};
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for (const [id, model] of [['H05K-1','hidrostal-H05K-S03R'],['H05K-2','hidrostal-H05K-S03R'],['C5','hidrostal-C5-D03R-SHN1']]) {
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const m = new Machine(machineConfig(id, model), stateConfig);
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injectPressure(m);
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mg.childRegistrationUtils.registerChild(m, 'downstream');
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machines[id] = m;
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}
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const toH = (v) => +(v * 3600).toFixed(1);
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const CANON_FLOW = 'm3/s';
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const CANON_POWER = 'W';
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console.log(`\n=== STATION: 2×H05K + 1×C5 @ ΔP=${DIFF_MBAR} mbar ===`);
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console.table(Object.entries(machines).map(([id, m]) => ({
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id,
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'min (m³/h)': toH(m.predictFlow.currentFxyYMin),
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'max (m³/h)': toH(m.predictFlow.currentFxyYMax),
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'BEP (m³/h)': toH(m.predictFlow.currentFxyYMin + (m.predictFlow.currentFxyYMax - m.predictFlow.currentFxyYMin) * m.NCog),
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NCog: +m.NCog.toFixed(3),
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})));
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const minQ = Math.max(...Object.values(machines).map(m => m.predictFlow.currentFxyYMin));
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const maxQ = Object.values(machines).reduce((s, m) => s + m.predictFlow.currentFxyYMax, 0);
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const demandPcts = [0.10, 0.25, 0.50, 0.75, 0.90];
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const rows = [];
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for (const pct of demandPcts) {
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const Qd = minQ + (maxQ - minQ) * pct;
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// Reset all machines to idle, re-inject pressure
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for (const m of Object.values(machines)) {
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if (m.state.getCurrentState() !== 'idle') await m.handleInput('parent', 'execSequence', 'shutdown');
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injectPressure(m);
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}
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// Run machineGroupControl optimalControl with absolute scaling
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mg.setMode('optimalcontrol');
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mg.setScaling('absolute');
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mg.calcAbsoluteTotals();
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mg.calcDynamicTotals();
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await mg.handleInput('parent', Qd);
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// Read ACTUAL per-pump state (not the MGC summary which may be stale)
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let mgcPower = 0, mgcFlow = 0;
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const mgcCombo = [];
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const mgcDist = {};
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for (const [id, m] of Object.entries(machines)) {
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const state = m.state.getCurrentState();
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const flow = m.measurements.type('flow').variant('predicted').position('downstream').getCurrentValue(CANON_FLOW) || 0;
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const power = m.measurements.type('power').variant('predicted').position('atequipment').getCurrentValue(CANON_POWER) || 0;
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mgcDist[id] = { flow, power, state };
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if (state === 'operational' || state === 'warmingup' || state === 'accelerating') {
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mgcCombo.push(id);
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mgcPower += power;
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mgcFlow += flow;
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}
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}
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// Naive baselines
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const sp = spillover(machines, Qd);
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const ea = equalAllOn(machines, Qd);
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const best = Math.min(mgcPower, sp.power, ea.power);
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const delta = (v) => best > 0 ? `${(((v - best) / best) * 100).toFixed(1)}%` : '';
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rows.push({
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demand: `${(pct * 100)}%`,
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'Qd (m³/h)': toH(Qd),
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'MGC kW': +(mgcPower / 1000).toFixed(1),
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'MGC flow': toH(mgcFlow),
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'MGC pumps': mgcCombo.join('+') || 'none',
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'Spill kW': +(sp.power / 1000).toFixed(1),
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'Spill flow': toH(sp.flow),
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'Spill pumps': sp.combo.join('+'),
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'EqAll kW': +(ea.power / 1000).toFixed(1),
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'EqAll flow': toH(ea.flow),
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'MGC Δ': delta(mgcPower),
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'Spill Δ': delta(sp.power),
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'EqAll Δ': delta(ea.power),
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});
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}
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console.log('\n=== POWER + FLOW COMPARISON (★ = best, all must deliver Qd) ===');
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console.table(rows);
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// Per-pump detail at each demand level
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for (const pct of demandPcts) {
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const Qd = minQ + (maxQ - minQ) * pct;
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for (const m of Object.values(machines)) {
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if (m.state.getCurrentState() !== 'idle') await m.handleInput('parent', 'execSequence', 'shutdown');
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injectPressure(m);
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}
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mg.setMode('optimalcontrol');
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mg.setScaling('absolute');
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mg.calcAbsoluteTotals();
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mg.calcDynamicTotals();
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await mg.handleInput('parent', Qd);
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const detail = Object.entries(machines).map(([id, m]) => {
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const state = m.state.getCurrentState();
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const flow = m.measurements.type('flow').variant('predicted').position('downstream').getCurrentValue(CANON_FLOW) || 0;
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const power = m.measurements.type('power').variant('predicted').position('atequipment').getCurrentValue(CANON_POWER) || 0;
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return {
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pump: id,
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state,
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'flow (m³/h)': toH(flow),
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'power (kW)': +(power / 1000).toFixed(1),
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};
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});
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console.log(`\n--- MGC per-pump @ ${(pct*100)}% (${toH(Qd)} m³/h) ---`);
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console.table(detail);
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}
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// Flow verification on naive strategies
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for (const pct of demandPcts) {
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const Qd = minQ + (maxQ - minQ) * pct;
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const sp = spillover(machines, Qd);
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const ea = equalAllOn(machines, Qd);
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assert.ok(Math.abs(sp.flow - Qd) < Qd * 0.005, `Spillover flow mismatch at ${(pct*100)}%`);
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assert.ok(Math.abs(ea.flow - Qd) < Qd * 0.005, `Equal-all flow mismatch at ${(pct*100)}%`);
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}
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});
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