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Author SHA1 Message Date
znetsixe
7eafd89f4e docs: add CLAUDE.md with S88 classification and superproject rule reference
References the flow-layout rule set in the EVOLV superproject
(.claude/rules/node-red-flow-layout.md) so Claude Code sessions working
in this repo know the S88 level, colour, and placement lane for this node.

Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
2026-04-14 07:47:23 +02:00
znetsixe
d55f401ab3 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>
2026-04-07 13:40:45 +02:00
znetsixe
ffb2072baa Merge commit '85797b5' into HEAD
# Conflicts:
#	src/nodeClass.js
#	src/specificClass.js
2026-03-31 18:17:41 +02:00
Rene De Ren
85797b5b8b Align machineGroupControl with current architecture 2026-03-12 16:43:29 +01:00
znetsixe
b337bf9eb7 updates 2026-03-11 11:12:52 +01:00
znetsixe
f8012c8bad update 2026-02-23 13:17:39 +01:00
znetsixe
ee38c8b581 before functional changes by codex 2026-02-19 17:38:05 +01:00
19 changed files with 1215 additions and 227 deletions

23
CLAUDE.md Normal file
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# machineGroupControl — Claude Code context
Coordinates multiple rotatingMachine or valve children.
Part of the [EVOLV](https://gitea.wbd-rd.nl/RnD/EVOLV) wastewater-automation platform.
## S88 classification
| Level | Colour | Placement lane |
|---|---|---|
| **Unit** | `#50a8d9` | L4 |
## Flow layout rules
When wiring this node into a multi-node demo or production flow, follow the
placement rule set in the **EVOLV superproject**:
> `.claude/rules/node-red-flow-layout.md` (in the EVOLV repo root)
Key points for this node:
- Place on lane **L4** (x-position per the lane table in the rule).
- Stack same-level siblings vertically.
- Parent/children sit on adjacent lanes (children one lane left, parent one lane right).
- Wrap in a Node-RED group box coloured `#50a8d9` (Unit).

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examples/README.md Normal file
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# machineGroupControl Example Flows
Import-ready Node-RED examples for machineGroupControl.
## Files
- basic.flow.json
- integration.flow.json
- edge.flow.json

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examples/basic.flow.json Normal file
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[
{"id":"machineGroupControl_basic_tab","type":"tab","label":"machineGroupControl basic","disabled":false,"info":"machineGroupControl basic example"},
{"id":"machineGroupControl_basic_node","type":"machineGroupControl","z":"machineGroupControl_basic_tab","name":"machineGroupControl basic","x":420,"y":180,"wires":[["machineGroupControl_basic_dbg"]]},
{"id":"machineGroupControl_basic_inj","type":"inject","z":"machineGroupControl_basic_tab","name":"basic trigger","props":[{"p":"topic","vt":"str"},{"p":"payload","vt":"str"}],"topic":"ping","payload":"1","payloadType":"str","x":160,"y":180,"wires":[["machineGroupControl_basic_node"]]},
{"id":"machineGroupControl_basic_dbg","type":"debug","z":"machineGroupControl_basic_tab","name":"machineGroupControl basic debug","active":true,"tosidebar":true,"console":false,"tostatus":false,"complete":"true","targetType":"full","x":660,"y":180,"wires":[]}
]

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examples/edge.flow.json Normal file
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[
{"id":"machineGroupControl_edge_tab","type":"tab","label":"machineGroupControl edge","disabled":false,"info":"machineGroupControl edge example"},
{"id":"machineGroupControl_edge_node","type":"machineGroupControl","z":"machineGroupControl_edge_tab","name":"machineGroupControl edge","x":420,"y":180,"wires":[["machineGroupControl_edge_dbg"]]},
{"id":"machineGroupControl_edge_inj","type":"inject","z":"machineGroupControl_edge_tab","name":"unknown topic","props":[{"p":"topic","vt":"str"},{"p":"payload","vt":"str"}],"topic":"doesNotExist","payload":"x","payloadType":"str","x":170,"y":180,"wires":[["machineGroupControl_edge_node"]]},
{"id":"machineGroupControl_edge_dbg","type":"debug","z":"machineGroupControl_edge_tab","name":"machineGroupControl edge debug","active":true,"tosidebar":true,"console":false,"tostatus":false,"complete":"true","targetType":"full","x":660,"y":180,"wires":[]}
]

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@@ -0,0 +1,6 @@
[
{"id":"machineGroupControl_int_tab","type":"tab","label":"machineGroupControl integration","disabled":false,"info":"machineGroupControl integration example"},
{"id":"machineGroupControl_int_node","type":"machineGroupControl","z":"machineGroupControl_int_tab","name":"machineGroupControl integration","x":420,"y":180,"wires":[["machineGroupControl_int_dbg"]]},
{"id":"machineGroupControl_int_inj","type":"inject","z":"machineGroupControl_int_tab","name":"registerChild","props":[{"p":"topic","vt":"str"},{"p":"payload","vt":"str"}],"topic":"registerChild","payload":"example-child-id","payloadType":"str","x":170,"y":180,"wires":[["machineGroupControl_int_node"]]},
{"id":"machineGroupControl_int_dbg","type":"debug","z":"machineGroupControl_int_tab","name":"machineGroupControl integration debug","active":true,"tosidebar":true,"console":false,"tostatus":false,"complete":"true","targetType":"full","x":680,"y":180,"wires":[]}
]

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@@ -18,6 +18,8 @@
defaults: { defaults: {
// Define default properties // Define default properties
name: { value: "" }, name: { value: "" },
processOutputFormat: { value: "process" },
dbaseOutputFormat: { value: "influxdb" },
// Logger properties // Logger properties
enableLog: { value: false }, enableLog: { value: false },
@@ -39,7 +41,7 @@
icon: "font-awesome/fa-cogs", icon: "font-awesome/fa-cogs",
label: function () { label: function () {
return this.positionIcon + " " + "machineGroup"; return (this.positionIcon || "") + " machineGroup";
}, },
oneditprepare: function() { oneditprepare: function() {
// Initialize the menu data for the node // Initialize the menu data for the node
@@ -74,6 +76,24 @@
<script type="text/html" data-template-name="machineGroupControl"> <script type="text/html" data-template-name="machineGroupControl">
<h3>Output Formats</h3>
<div class="form-row">
<label for="node-input-processOutputFormat"><i class="fa fa-random"></i> Process Output</label>
<select id="node-input-processOutputFormat" style="width:60%;">
<option value="process">process</option>
<option value="json">json</option>
<option value="csv">csv</option>
</select>
</div>
<div class="form-row">
<label for="node-input-dbaseOutputFormat"><i class="fa fa-database"></i> Database Output</label>
<select id="node-input-dbaseOutputFormat" style="width:60%;">
<option value="influxdb">influxdb</option>
<option value="json">json</option>
<option value="csv">csv</option>
</select>
</div>
<!-- Logger fields injected here --> <!-- Logger fields injected here -->
<div id="logger-fields-placeholder"></div> <div id="logger-fields-placeholder"></div>

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@@ -4,7 +4,7 @@
"description": "Control module machineGroupControl", "description": "Control module machineGroupControl",
"main": "mgc.js", "main": "mgc.js",
"scripts": { "scripts": {
"test": "node mgc.js" "test": "node --test test/basic/*.test.js test/integration/*.test.js test/edge/*.test.js"
}, },
"repository": { "repository": {
"type": "git", "type": "git",
@@ -24,4 +24,4 @@
"machineGroupControl": "mgc.js" "machineGroupControl": "mgc.js"
} }
} }
} }

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@@ -1,4 +1,4 @@
const { outputUtils, configManager } = require("generalFunctions"); const { outputUtils, configManager, convert } = require("generalFunctions");
const Specific = require("./specificClass"); const Specific = require("./specificClass");
class nodeClass { class nodeClass {
@@ -37,53 +37,60 @@ class nodeClass {
_loadConfig(uiConfig, node) { _loadConfig(uiConfig, node) {
const cfgMgr = new configManager(); const cfgMgr = new configManager();
this.defaultConfig = cfgMgr.getConfig(this.name); this.defaultConfig = cfgMgr.getConfig(this.name);
const flowUnit = this._resolveUnitOrFallback(uiConfig.unit, 'volumeFlowRate', 'm3/h', 'flow');
// Build config: base sections (no domain-specific config for group controller)
this.config = cfgMgr.buildConfig(this.name, uiConfig, node.id);
// Merge UI config over defaults
this.config = {
general: {
name: uiConfig.name,
id: node.id, // node.id is for the child registration process
unit: uiConfig.unit, // add converter options later to convert to default units (need like a model that defines this which units we are going to use and then conver to those standards)
logging: {
enabled: uiConfig.enableLog,
logLevel: uiConfig.logLevel,
},
},
functionality: {
positionVsParent: uiConfig.positionVsParent || "atEquipment", // Default to 'atEquipment' if not set
},
};
// Utility for formatting outputs // Utility for formatting outputs
this._output = new outputUtils(); this._output = new outputUtils();
} }
_resolveUnitOrFallback(candidate, expectedMeasure, fallbackUnit, label) {
const raw = typeof candidate === "string" ? candidate.trim() : "";
const fallback = String(fallbackUnit || "").trim();
if (!raw) {
return fallback;
}
try {
const desc = convert().describe(raw);
if (expectedMeasure && desc.measure !== expectedMeasure) {
throw new Error(`expected '${expectedMeasure}' but got '${desc.measure}'`);
}
return raw;
} catch (error) {
this.node?.warn?.(`Invalid ${label} unit '${raw}' (${error.message}). Falling back to '${fallback}'.`);
return fallback;
}
}
_updateNodeStatus() { _updateNodeStatus() {
//console.log('Updating node status...'); //console.log('Updating node status...');
const mg = this.source; const mg = this.source;
const mode = mg.mode; const mode = mg.mode;
const scaling = mg.scaling; const scaling = mg.scaling;
// Add safety checks for measurements // Add safety checks for measurements
const totalFlow = mg.measurements const totalFlow = mg.measurements
?.type("flow") ?.type("flow")
?.variant("predicted") ?.variant("predicted")
?.position("atequipment") ?.position("atequipment")
?.getCurrentValue('m3/h') || 0; ?.getCurrentValue(mg?.unitPolicy?.output?.flow || 'm3/h') || 0;
const totalPower = mg.measurements const totalPower = mg.measurements
?.type("power") ?.type("power")
?.variant("predicted") ?.variant("predicted")
?.position("atEquipment") ?.position("atEquipment")
?.getCurrentValue() || 0; ?.getCurrentValue(mg?.unitPolicy?.output?.power || 'kW') || 0;
// Calculate total capacity based on available machines with safety checks // Calculate total capacity based on available machines with safety checks
const availableMachines = Object.values(mg.machines || {}).filter((machine) => { const availableMachines = Object.values(mg.machines || {}).filter((machine) => {
// Safety check: ensure machine and machine.state exist // Safety check: ensure machine and machine.state exist
if (!machine || !machine.state || typeof machine.state.getCurrentState !== 'function') { if (!machine || !machine.state || typeof machine.state.getCurrentState !== 'function') {
console.warn(`Machine missing or invalid:`, machine?.config?.general?.id || 'unknown'); mg.logger?.warn(`Machine missing or invalid: ${machine?.config?.general?.id || 'unknown'}`);
return false; return false;
} }
const state = machine.state.getCurrentState(); const state = machine.state.getCurrentState();
const mode = machine.currentMode; const mode = machine.currentMode;
return !( return !(
@@ -195,67 +202,65 @@ class nodeClass {
this.node.on( this.node.on(
"input", "input",
async (msg, send, done) => { async (msg, send, done) => {
const mg = this.source; const mg = this.source;
const RED = this.RED; const RED = this.RED;
try {
switch (msg.topic) { switch (msg.topic) {
case "registerChild": case "registerChild": {
//console.log(`Registering child in mgc: ${msg.payload}`); const childId = msg.payload;
const childId = msg.payload; const childObj = RED.nodes.getNode(childId);
const childObj = RED.nodes.getNode(childId); if (!childObj || !childObj.source) {
mg.logger.warn(`registerChild skipped: missing child/source for id=${childId}`);
// Debug: Check what we're getting break;
//console.log(`Child object:`, childObj ? 'found' : 'NOT FOUND'); }
//console.log(`Child source:`, childObj?.source ? 'exists' : 'MISSING');
if (childObj?.source) {
//console.log(`Child source type:`, childObj.source.constructor.name);
//console.log(`Child has state:`, !!childObj.source.state);
}
mg.childRegistrationUtils.registerChild(
childObj.source,
msg.positionVsParent
);
// Debug: Check machines after registration
//console.log(`Total machines after registration:`, Object.keys(mg.machines || {}).length);
break;
case "setMode": mg.logger.debug(`Registering child: ${childId}, found: ${!!childObj}, source: ${!!childObj?.source}`);
mg.childRegistrationUtils.registerChild(childObj.source, msg.positionVsParent);
mg.logger.debug(`Total machines after registration: ${Object.keys(mg.machines || {}).length}`);
break;
}
case "setMode": {
const mode = msg.payload; const mode = msg.payload;
mg.setMode(mode); mg.setMode(mode);
break; break;
}
case "setScaling": case "setScaling": {
const scaling = msg.payload; const scaling = msg.payload;
mg.setScaling(scaling); mg.setScaling(scaling);
break; break;
}
case "Qd": case "Qd": {
const Qd = parseFloat(msg.payload); const Qd = parseFloat(msg.payload);
const sourceQd = "parent"; const sourceQd = "parent";
if (isNaN(Qd)) { if (isNaN(Qd)) {
return mg.logger.error(`Invalid demand value: ${Qd}`); mg.logger.error(`Invalid demand value: ${msg.payload}`);
break;
} }
try { try {
await mg.handleInput(sourceQd, Qd); await mg.handleInput(sourceQd, Qd);
msg.topic = mg.config.general.name; msg.topic = mg.config.general.name;
msg.payload = "done"; msg.payload = "done";
send(msg); send(msg);
} catch (e) { } catch (error) {
console.log(e); mg.logger.error(`Failed to process Qd: ${error.message}`);
} }
break; break;
}
default: default:
// Handle unknown topics if needed
mg.logger.warn(`Unknown topic: ${msg.topic}`); mg.logger.warn(`Unknown topic: ${msg.topic}`);
break; break;
} }
done(); } catch (error) {
mg.logger.error(`Input handler failure: ${error.message}`);
} }
if (typeof done === 'function') done();
}
); );
} }
@@ -266,7 +271,7 @@ class nodeClass {
this.node.on("close", (done) => { this.node.on("close", (done) => {
clearInterval(this._tickInterval); clearInterval(this._tickInterval);
clearInterval(this._statusInterval); clearInterval(this._statusInterval);
done(); if (typeof done === 'function') done();
}); });
} }
} }

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test/README.md Normal file
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# machineGroupControl Test Suite Layout
Required EVOLV layout:
- basic/
- integration/
- edge/
- helpers/
Baseline structure tests:
- basic/structure-module-load.basic.test.js
- integration/structure-examples.integration.test.js
- edge/structure-examples-node-type.edge.test.js

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const test = require('node:test');
const assert = require('node:assert/strict');
test('machineGroupControl module load smoke', () => {
assert.doesNotThrow(() => {
require('../../mgc.js');
});
});

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const test = require('node:test');
const assert = require('node:assert/strict');
const fs = require('node:fs');
const path = require('node:path');
const flow = JSON.parse(fs.readFileSync(path.resolve(__dirname, '../../examples/basic.flow.json'), 'utf8'));
test('basic example includes node type machineGroupControl', () => {
const count = flow.filter((n) => n && n.type === 'machineGroupControl').length;
assert.equal(count >= 1, true);
});

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/**
* 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)}%`);
}
});

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/**
* 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)}`
);
});

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const test = require('node:test');
const assert = require('node:assert/strict');
const fs = require('node:fs');
const path = require('node:path');
const dir = path.resolve(__dirname, '../../examples');
function loadJson(file) {
return JSON.parse(fs.readFileSync(path.join(dir, file), 'utf8'));
}
test('examples package exists for machineGroupControl', () => {
for (const file of ['README.md', 'basic.flow.json', 'integration.flow.json', 'edge.flow.json']) {
assert.equal(fs.existsSync(path.join(dir, file)), true, file + ' missing');
}
});
test('example flows are parseable arrays for machineGroupControl', () => {
for (const file of ['basic.flow.json', 'integration.flow.json', 'edge.flow.json']) {
const parsed = loadJson(file);
assert.equal(Array.isArray(parsed), true);
}
});