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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
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
0430471dca Merge pull request 'dev-Rene' (#3) from dev-Rene into main
Reviewed-on: https://gitea.centraal.wbd-rd.nl/RnD/machineGroupControl/pulls/3
2025-12-19 10:38:06 +00:00
znetsixe
f4cb329597 updates 2025-11-25 15:10:36 +01:00
znetsixe
b49f0c3ed2 attempt to fix flow distribution 2025-11-22 21:09:38 +01:00
znetsixe
edcffade75 Added edge case for when 1 pump cant handle the scope 2025-11-20 22:28:49 +01:00
znetsixe
b6ffefc92b Lots of minor bug fixes to update on architecture choices 2025-11-13 19:39:32 +01:00
znetsixe
ed2cf4c23d fixed outputformats 2025-11-06 11:18:38 +01:00
681856104d Merge pull request 'changed colours, description based on s88' (#2) from dev-Rene into main
Reviewed-on: https://gitea.centraal.wbd-rd.nl/RnD/machineGroupControl/pulls/2
2025-10-16 13:22:56 +00:00
znetsixe
e0526250c2 changed colours, description based on s88 2025-10-14 13:52:18 +02:00
20 changed files with 1732 additions and 450 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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[
{"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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@@ -41,7 +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

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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",

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@@ -1,288 +1,345 @@
// ...existing code... 'use strict';
const MachineGroup = require('./specificClass.js');
const MachineGroup = require('./specificClass');
const Machine = require('../../rotatingMachine/src/specificClass'); const Machine = require('../../rotatingMachine/src/specificClass');
const Measurement = require('../../measurement/src/specificClass'); const Measurement = require('../../measurement/src/specificClass');
const specs = require('../../generalFunctions/datasets/assetData/curves/hidrostal-H05K-S03R.json'); const baseCurve = require('../../generalFunctions/datasets/assetData/curves/hidrostal-H05K-S03R.json');
const stateConfig = { time:{starting:0,warmingup:0,stopping:0,coolingdown:0}, movement:{speed:1000,mode:"staticspeed"} }; const CONTROL_MODES = ['optimalcontrol', 'prioritycontrol', 'prioritypercentagecontrol'];
const ptConfig = { const MODE_LABELS = {
general:{ logging:{enabled:false,logLevel:"warn"}, name:"testpt", id:"pt-1", unit:"mbar" }, optimalcontrol: 'OPT',
functionality:{ softwareType:"measurement", role:"sensor" }, prioritycontrol: 'PRIO',
asset:{ category:"sensor", type:"pressure", model:"testmodel", supplier:"vega", unit:"mbar" }, prioritypercentagecontrol: 'PERC'
scaling:{ absMin:0, absMax:4000 }
}; };
const testSuite = []; const stateConfig = {
const efficiencyComparisons = []; time: { starting: 0, warmingup: 0, stopping: 0, coolingdown: 0, emergencystop: 0 },
movement: { speed: 1200, mode: 'staticspeed', maxSpeed: 1800 }
};
function logPass(name, details="") { const ptConfig = {
const entry = { name, status:"PASS", details }; general: { logging: { enabled: false, logLevel: 'error' }, name: 'synthetic-pt', id: 'pt-1', unit: 'mbar' },
testSuite.push(entry); functionality: {
console.log(`${name}${details ? `${details}` : ""}`); softwareType: 'measurement',
} role: 'sensor',
function logFail(name, error) { positionVsParent: 'downstream'
const entry = { name, status:"FAIL", details:error?.message || error }; },
testSuite.push(entry); asset: { category: 'sensor', type: 'pressure', model: 'synthetic-pt', supplier: 'lab', unit: 'mbar' },
console.error(`${name}${entry.details}`); scaling: { absMin: 0, absMax: 4000 }
} };
function approxEqual(actual, expected, tolerancePct=1) {
const tolerance = (expected * tolerancePct) / 100;
return actual >= expected - tolerance && actual <= expected + tolerance;
}
async function sleep(ms){ return new Promise(resolve => setTimeout(resolve, ms)); }
function createMachineConfig(id,label) { const scenarios = [
{
name: 'balanced_pair',
description: 'Two identical pumps validate equal-machine behaviour.',
machines: [
{ id: 'eq-1', label: 'equal-A', curveMods: { flowScale: 1, powerScale: 1 } },
{ id: 'eq-2', label: 'equal-B', curveMods: { flowScale: 1, powerScale: 1 } }
],
pressures: [900, 1300, 1700],
flowTargetsPercent: [0.1, 0.4, 0.7, 1],
flowMatchTolerance: 5,
priorityList: ['eq-1', 'eq-2']
},
{
name: 'mixed_trio',
description: 'High / mid / low efficiency pumps to stress unequal-machine behaviour.',
machines: [
{ id: 'hi', label: 'high-eff', curveMods: { flowScale: 1.25, powerScale: 0.82, flowTilt: 0.1, powerTilt: -0.05 } },
{ id: 'mid', label: 'mid-eff', curveMods: { flowScale: 1, powerScale: 1 } },
{ id: 'low', label: 'low-eff', curveMods: { flowScale: 0.7, powerScale: 1.35, flowTilt: -0.08, powerTilt: 0.15 } }
],
pressures: [800, 1200, 1600, 2000],
flowTargetsPercent: [0.1, 0.35, 0.7, 1],
flowMatchTolerance: 8,
priorityList: ['hi', 'mid', 'low']
}
];
function createGroupConfig(name) {
return { return {
general:{ logging:{enabled:false,logLevel:"warn"}, name:label, id, unit:"m3/h" }, general: { logging: { enabled: false, logLevel: 'error' }, name: `machinegroup-${name}` },
functionality:{ softwareType:"machine", role:"rotationaldevicecontroller" }, functionality: { softwareType: 'machinegroup', role: 'groupcontroller' },
asset:{ category:"pump", type:"centrifugal", model:"hidrostal-h05k-s03r", supplier:"hydrostal", machineCurve:specs }, scaling: { current: 'normalized' },
mode:{ mode: { current: 'optimalcontrol' }
current:"auto", };
allowedActions:{ }
auto:["execSequence","execMovement","flowMovement","statusCheck"],
virtualControl:["execMovement","statusCheck"], function sleep(ms) {
fysicalControl:["statusCheck"] return new Promise(resolve => setTimeout(resolve, ms));
}
async function setPressure(pt, value) {
const retries = 6;
for (let attempt = 0; attempt < retries; attempt += 1) {
try {
pt.calculateInput(value);
return;
} catch (error) {
const message = error?.message || String(error);
if (!message.toLowerCase().includes('coolprop is still warming up')) {
throw error;
}
await sleep(50);
}
}
throw new Error(`Unable to update pressure to ${value} mbar; CoolProp did not initialise in time.`);
}
function deepClone(obj) {
return JSON.parse(JSON.stringify(obj));
}
function distortSeries(series = [], scale = 1, tilt = 0) {
if (!Array.isArray(series) || series.length === 0) {
return series;
}
const lastIndex = series.length - 1;
return series.map((value, index) => {
const gradient = lastIndex === 0 ? 0 : index / lastIndex - 0.5;
const distorted = value * scale * (1 + tilt * gradient);
return Number(Math.max(distorted, 0).toFixed(6));
});
}
function createSyntheticCurve(mods = {}) {
const { flowScale = 1, powerScale = 1, flowTilt = 0, powerTilt = 0 } = mods;
const curve = deepClone(baseCurve);
if (curve.nq) {
Object.values(curve.nq).forEach(set => {
set.y = distortSeries(set.y, flowScale, flowTilt);
});
}
if (curve.np) {
Object.values(curve.np).forEach(set => {
set.y = distortSeries(set.y, powerScale, powerTilt);
});
}
return curve;
}
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', machineCurve: baseCurve },
mode: {
current: 'auto',
allowedActions: {
auto: ['execsequence', 'execmovement', 'flowmovement', 'statuscheck'],
virtualControl: ['execmovement', 'statuscheck'],
fysicalControl: ['statuscheck']
}, },
allowedSources:{ allowedSources: {
auto:["parent","GUI"], auto: ['parent', 'GUI'],
virtualControl:["GUI"], virtualControl: ['GUI'],
fysicalControl:["fysical"] fysicalControl: ['fysical']
} }
}, },
sequences:{ sequences: {
startup:["starting","warmingup","operational"], startup: ['starting', 'warmingup', 'operational'],
shutdown:["stopping","coolingdown","idle"], shutdown: ['stopping', 'coolingdown', 'idle'],
emergencystop:["emergencystop","off"], emergencystop: ['emergencystop', 'off'],
boot:["idle","starting","warmingup","operational"] boot: ['idle', 'starting', 'warmingup', 'operational']
} }
}; };
} }
async function bootstrapGroup() { async function bootstrapScenarioMachines(scenario) {
const groupCfg = { const mg = new MachineGroup(createGroupConfig(scenario.name));
general:{ logging:{enabled:false,logLevel:"warn"}, name:"testmachinegroup" },
functionality:{ softwareType:"machinegroup", role:"groupcontroller" },
scaling:{ current:"normalized" },
mode:{ current:"optimalcontrol" }
};
const mg = new MachineGroup(groupCfg);
const pt = new Measurement(ptConfig); const pt = new Measurement(ptConfig);
for (let idx=1; idx<=2; idx++){ for (const machineDef of scenario.machines) {
const machine = new Machine(createMachineConfig(String(idx),`machine-${idx}`), stateConfig); const machine = new Machine(createMachineConfig(machineDef.id, machineDef.label), stateConfig);
mg.childRegistrationUtils.registerChild(machine,"downstream"); if (machineDef.curveMods) {
machine.childRegistrationUtils.registerChild(pt,"downstream"); machine.updateCurve(createSyntheticCurve(machineDef.curveMods));
}
mg.childRegistrationUtils.registerChild(machine, 'downstream');
machine.childRegistrationUtils.registerChild(pt, 'downstream');
} }
pt.calculateInput(1000);
await sleep(10); await sleep(25);
return { mg, pt }; return { mg, pt };
} }
function captureState(mg,label){ function captureTotals(mg) {
return { const flow = mg.measurements.type('flow').variant('predicted').position('atequipment').getCurrentValue() || 0;
label, const power = mg.measurements.type('power').variant('predicted').position('atequipment').getCurrentValue() || 0;
machines: Object.entries(mg.machines).map(([id,machine]) => ({ const efficiency = mg.measurements.type('efficiency').variant('predicted').position('atequipment').getCurrentValue() || 0;
id, return { flow, power, efficiency };
state: machine.state.getCurrentState(),
position: machine.state.getCurrentPosition(),
predictedFlow: machine.measurements.type("flow").variant("predicted").position("downstream").getCurrentValue() || 0,
predictedPower: machine.measurements.type("power").variant("predicted").position("upstream").getCurrentValue() || 0
})),
totals: {
flow: mg.measurements.type("flow").variant("predicted").position("downstream").getCurrentValue() || 0,
power: mg.measurements.type("power").variant("predicted").position("upstream").getCurrentValue() || 0,
efficiency: mg.measurements.type("efficiency").variant("predicted").position("downstream").getCurrentValue() || 0
}
};
} }
async function testNormalizedScaling(mg,pt){ function computeAbsoluteTargets(dynamicTotals, percentages) {
const label = "Normalized scaling tracks expected flow"; const { flow } = dynamicTotals;
try{ const min = Number.isFinite(flow.min) ? flow.min : 0;
mg.setScaling("normalized"); const max = Number.isFinite(flow.max) ? flow.max : 0;
const dynamic = mg.calcDynamicTotals(); const span = Math.max(max - min, 1);
const checkpoints = [0,10,25,50,75,100]; return percentages.map(percent => {
for (const demand of checkpoints){ const pct = Math.max(0, Math.min(1, percent));
await mg.handleInput("parent", demand); return min + pct * span;
pt.calculateInput(1400); });
await sleep(20);
const totals = mg.measurements.type("flow").variant("predicted").position("downstream").getCurrentValue() || 0;
const expected = dynamic.flow.min + (demand/100)*(dynamic.flow.max - dynamic.flow.min);
if(!approxEqual(totals, expected, 2)){
throw new Error(`Flow ${totals.toFixed(2)} outside expectation ${expected.toFixed(2)} @ ${demand}%`);
}
}
logPass(label);
}catch(err){ logFail(label, err); }
} }
async function testAbsoluteScaling(mg,pt){ async function driveModeToFlow({ mg, pt, mode, pressure, targetFlow, priorityOrder }) {
const label = "Absolute scaling accepts direct flow targets"; await setPressure(pt, pressure);
try{ await sleep(15);
mg.setScaling("absolute");
mg.setMode("optimalcontrol");
const absMin = mg.dynamicTotals.flow.min;
const absMax = mg.dynamicTotals.flow.max;
const demandPoints = [absMin, absMin+20, (absMin+absMax)/2, absMax-20];
for(const setpoint of demandPoints){ mg.setMode(mode);
await mg.handleInput("parent", setpoint); mg.setScaling('normalized'); // required for prioritypercentagecontrol, works for others too
pt.calculateInput(1400);
await sleep(20); const dynamic = mg.calcDynamicTotals();
const flow = mg.measurements.type("flow").variant("predicted").position("downstream").getCurrentValue() || 0; const span = Math.max(dynamic.flow.max - dynamic.flow.min, 1);
if(!approxEqual(flow, setpoint, 2)){ const normalizedTarget = ((targetFlow - dynamic.flow.min) / span) * 100;
throw new Error(`Flow ${flow.toFixed(2)} != demand ${setpoint.toFixed(2)}`);
} let low = 0;
let high = 100;
let demand = Math.max(0, Math.min(100, normalizedTarget || 0));
let best = { demand, flow: 0, power: 0, efficiency: 0, error: Infinity };
for (let attempt = 0; attempt < 4; attempt += 1) {
await mg.handleInput('parent', demand, Infinity, priorityOrder);
await sleep(30);
const totals = captureTotals(mg);
const error = Math.abs(totals.flow - targetFlow);
if (error < best.error) {
best = {
demand,
flow: totals.flow,
power: totals.power,
efficiency: totals.efficiency,
error
};
} }
logPass(label);
}catch(err){ logFail(label, err); } if (totals.flow > targetFlow) {
high = demand;
} else {
low = demand;
}
demand = (low + high) / 2;
}
return best;
} }
async function testModeTransitions(mg,pt){ function formatEfficiencyRows(rows) {
const label = "Mode transitions keep machines responsive"; return rows.map(row => {
try{ const optimal = row.modes.optimalcontrol;
const modes = ["optimalcontrol","prioritycontrol","prioritypercentagecontrol"]; const priority = row.modes.prioritycontrol;
mg.setScaling("normalized"); const percentage = row.modes.prioritypercentagecontrol;
for(const mode of modes){ return {
mg.setMode(mode); pressure: row.pressure,
await mg.handleInput("parent", 50); targetFlow: Number(row.targetFlow.toFixed(1)),
pt.calculateInput(1300); [`${MODE_LABELS.optimalcontrol}_Flow`]: Number(optimal.flow.toFixed(1)),
await sleep(20); [`${MODE_LABELS.optimalcontrol}_Eff`]: Number(optimal.efficiency.toFixed(3)),
const snapshot = captureState(mg, mode); [`${MODE_LABELS.prioritycontrol}_Flow`]: Number(priority.flow.toFixed(1)),
const active = snapshot.machines.filter(m => m.state !== "idle"); [`${MODE_LABELS.prioritycontrol}_Eff`]: Number(priority.efficiency.toFixed(3)),
if(active.length === 0){ [`Δ${MODE_LABELS.prioritycontrol}-OPT_Eff`]: Number(
throw new Error(`No active machines after switching to ${mode}`); (priority.efficiency - optimal.efficiency).toFixed(3)
} ),
} [`${MODE_LABELS.prioritypercentagecontrol}_Flow`]: Number(percentage.flow.toFixed(1)),
logPass(label); [`${MODE_LABELS.prioritypercentagecontrol}_Eff`]: Number(percentage.efficiency.toFixed(3)),
}catch(err){ logFail(label, err); } [`Δ${MODE_LABELS.prioritypercentagecontrol}-OPT_Eff`]: Number(
(percentage.efficiency - optimal.efficiency).toFixed(3)
)
};
});
} }
async function testRampBehaviour(mg,pt){ function summarizeEfficiency(rows) {
const label = "Ramp up/down keeps monotonic flow"; const map = new Map();
try{ rows.forEach(row => {
mg.setMode("optimalcontrol"); CONTROL_MODES.forEach(mode => {
mg.setScaling("normalized"); const key = `${row.scenario}-${mode}`;
const upDemands = [0,20,40,60,80,100]; if (!map.has(key)) {
let lastFlow = 0; map.set(key, {
for(const demand of upDemands){ scenario: row.scenario,
await mg.handleInput("parent", demand); mode,
pt.calculateInput(1500); samples: 0,
await sleep(15); avgFlowDiff: 0,
const flow = mg.measurements.type("flow").variant("predicted").position("downstream").getCurrentValue() || 0; avgEfficiency: 0
if(flow < lastFlow - 1){
throw new Error(`Flow decreased during ramp up: ${flow.toFixed(2)} < ${lastFlow.toFixed(2)}`);
}
lastFlow = flow;
}
const downDemands = [100,80,60,40,20,0];
lastFlow = Infinity;
for(const demand of downDemands){
await mg.handleInput("parent", demand);
pt.calculateInput(1200);
await sleep(15);
const flow = mg.measurements.type("flow").variant("predicted").position("downstream").getCurrentValue() || 0;
if(flow > lastFlow + 1){
throw new Error(`Flow increased during ramp down: ${flow.toFixed(2)} > ${lastFlow.toFixed(2)}`);
}
lastFlow = flow;
}
logPass(label);
}catch(err){ logFail(label, err); }
}
async function testPressureAdaptation(mg,pt){
const label = "Pressure changes update predictions";
try{
mg.setMode("optimalcontrol");
mg.setScaling("normalized");
const pressures = [800,1200,1600,2000];
let previousFlow = null;
for(const p of pressures){
pt.calculateInput(p);
await mg.handleInput("parent", 50);
await sleep(20);
const flow = mg.measurements.type("flow").variant("predicted").position("downstream").getCurrentValue() || 0;
if(previousFlow !== null && Math.abs(flow - previousFlow) < 0.5){
throw new Error(`Flow did not react to pressure shift (${previousFlow.toFixed(2)} -> ${flow.toFixed(2)})`);
}
previousFlow = flow;
}
logPass(label);
}catch(err){ logFail(label, err); }
}
async function comparePriorityVsOptimal(mg, pt){
const label = "Priority vs Optimal efficiency comparison";
try{
mg.setScaling("normalized");
const pressures = [800, 1100, 1400, 1700];
const demands = [...Array(21)].map((_, idx) => idx * 5);
for (const pressure of pressures) {
pt.calculateInput(pressure);
await sleep(15);
for (const demand of demands) {
mg.setMode("optimalcontrol");
await mg.handleInput("parent", demand);
pt.calculateInput(pressure);
await sleep(20);
const optimalTotals = captureState(mg, `optimal-${pressure}-${demand}`).totals;
mg.setMode("prioritycontrol");
await mg.handleInput("parent", demand);
pt.calculateInput(pressure);
await sleep(20);
const priorityTotals = captureState(mg, `priority-${pressure}-${demand}`).totals;
efficiencyComparisons.push({
pressure,
demandPercent: demand,
optimalFlow: Number(optimalTotals.flow.toFixed(3)),
optimalPower: Number(optimalTotals.power.toFixed(3)),
optimalEfficiency: Number((optimalTotals.efficiency || 0).toFixed(4)),
priorityFlow: Number(priorityTotals.flow.toFixed(3)),
priorityPower: Number(priorityTotals.power.toFixed(3)),
priorityEfficiency: Number((priorityTotals.efficiency || 0).toFixed(4)),
efficiencyDelta: Number(((priorityTotals.efficiency || 0) - (optimalTotals.efficiency || 0)).toFixed(4)),
powerDelta: Number((priorityTotals.power - optimalTotals.power).toFixed(3))
}); });
} }
} const bucket = map.get(key);
const stats = row.modes[mode];
logPass(label, "efficiencyComparisons array populated"); bucket.samples += 1;
} catch (err) { bucket.avgFlowDiff += Math.abs(stats.flow - row.targetFlow);
logFail(label, err); bucket.avgEfficiency += stats.efficiency || 0;
} });
});
return Array.from(map.values()).map(item => ({
scenario: item.scenario,
mode: item.mode,
samples: item.samples,
avgFlowDiff: Number((item.avgFlowDiff / item.samples).toFixed(2)),
avgEfficiency: Number((item.avgEfficiency / item.samples).toFixed(3))
}));
} }
async function evaluateScenario(scenario) {
console.log(`\nRunning scenario "${scenario.name}": ${scenario.description}`);
const { mg, pt } = await bootstrapScenarioMachines(scenario);
const priorityOrder =
scenario.priorityList && scenario.priorityList.length
? scenario.priorityList
: scenario.machines.map(machine => machine.id);
async function run(){ const rows = [];
console.log("🚀 Starting machine-group integration tests...");
const { mg, pt } = await bootstrapGroup();
await testNormalizedScaling(mg, pt); for (const pressure of scenario.pressures) {
await testAbsoluteScaling(mg, pt); await setPressure(pt, pressure);
await testModeTransitions(mg, pt); await sleep(20);
await testRampBehaviour(mg, pt);
await testPressureAdaptation(mg, pt);
await comparePriorityVsOptimal(mg, pt);
console.log("\n📋 TEST SUMMARY"); const dynamicTotals = mg.calcDynamicTotals();
console.table(testSuite); const targets = computeAbsoluteTargets(dynamicTotals, scenario.flowTargetsPercent || [0, 0.5, 1]);
console.log("\n📊 efficiencyComparisons:");
console.dir(efficiencyComparisons, { depth:null }); for (let idx = 0; idx < targets.length; idx += 1) {
console.log("✅ All tests completed."); const targetFlow = targets[idx];
const row = {
scenario: scenario.name,
pressure,
targetFlow,
modes: {}
};
for (const mode of CONTROL_MODES) {
const stats = await driveModeToFlow({
mg,
pt,
mode,
pressure,
targetFlow,
priorityOrder
});
row.modes[mode] = stats;
}
rows.push(row);
}
}
console.log(`Efficiency comparison table for scenario "${scenario.name}":`);
console.table(formatEfficiencyRows(rows));
return { rows };
}
async function run() {
const combinedRows = [];
for (const scenario of scenarios) {
const { rows } = await evaluateScenario(scenario);
combinedRows.push(...rows);
}
console.log('\nEfficiency summary by scenario and control mode:');
console.table(summarizeEfficiency(combinedRows));
console.log('\nAll machine group control tests completed successfully.');
} }
run().catch(err => { run().catch(err => {
console.error("💥 Test harness crashed:", err); console.error('Machine group control test harness crashed:', err);
process.exitCode = 1;
}); });
// ...existing code...
// Run all tests
run();

View File

@@ -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 {
@@ -37,6 +37,7 @@ 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) // Build config: base sections (no domain-specific config for group controller)
this.config = cfgMgr.buildConfig(this.name, uiConfig, node.id); this.config = cfgMgr.buildConfig(this.name, uiConfig, node.id);
@@ -45,6 +46,24 @@ class nodeClass {
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;
@@ -55,20 +74,20 @@ class nodeClass {
const totalFlow = mg.measurements const totalFlow = mg.measurements
?.type("flow") ?.type("flow")
?.variant("predicted") ?.variant("predicted")
?.position("downstream") ?.position("atequipment")
?.getCurrentValue() || 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') {
mg.logger.warn(`Machine missing or invalid: ${machine?.config?.general?.id || 'unknown'}`); mg.logger?.warn(`Machine missing or invalid: ${machine?.config?.general?.id || 'unknown'}`);
return false; return false;
} }
@@ -169,8 +188,8 @@ class nodeClass {
*/ */
_tick() { _tick() {
const raw = this.source.getOutput(); const raw = this.source.getOutput();
const processMsg = this._output.formatMsg(raw, this.config, "process"); const processMsg = this._output.formatMsg(raw, this.source.config, "process");
const influxMsg = this._output.formatMsg(raw, this.config, "influxdb"); const influxMsg = this._output.formatMsg(raw, this.source.config, "influxdb");
// Send only updated outputs on ports 0 & 1 // Send only updated outputs on ports 0 & 1
this.node.send([processMsg, influxMsg]); this.node.send([processMsg, influxMsg]);
@@ -183,22 +202,24 @@ class nodeClass {
this.node.on( this.node.on(
"input", "input",
async (msg, send, done) => { async (msg, send, done) => {
const mg = this.source; const mg = this.source;
const RED = this.RED; const RED = this.RED;
try {
switch (msg.topic) { switch (msg.topic) {
case "registerChild": { case "registerChild": {
const childId = msg.payload; const childId = msg.payload;
const childObj = RED.nodes.getNode(childId); const childObj = RED.nodes.getNode(childId);
if (!childObj || !childObj.source) {
mg.logger.warn(`registerChild skipped: missing child/source for id=${childId}`);
break;
}
mg.logger.debug(`Registering child: ${childId}, found: ${!!childObj}, source: ${!!childObj?.source}`); mg.logger.debug(`Registering child: ${childId}, found: ${!!childObj}, source: ${!!childObj?.source}`);
mg.childRegistrationUtils.registerChild( mg.childRegistrationUtils.registerChild(childObj.source, msg.positionVsParent);
childObj.source,
msg.positionVsParent
);
mg.logger.debug(`Total machines after registration: ${Object.keys(mg.machines || {}).length}`); mg.logger.debug(`Total machines after registration: ${Object.keys(mg.machines || {}).length}`);
break; break;
} }
case "setMode": { case "setMode": {
@@ -210,36 +231,36 @@ class nodeClass {
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) {
mg.logger.error(`Demand handling failed: ${e.message}`); 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();
}
); );
} }
@@ -250,7 +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();
}); });
} }
} }

View File

@@ -1,7 +1,25 @@
//load local dependencies //load local dependencies
const EventEmitter = require("events"); const EventEmitter = require("events");
const {logger,configUtils,configManager, MeasurementContainer, interpolation , childRegistrationUtils, POSITIONS} = require('generalFunctions'); const {logger,configUtils,configManager, MeasurementContainer, interpolation , childRegistrationUtils, convert, POSITIONS} = require('generalFunctions');
const CANONICAL_UNITS = Object.freeze({
pressure: 'Pa',
flow: 'm3/s',
power: 'W',
temperature: 'K',
});
const DEFAULT_IO_UNITS = Object.freeze({
pressure: 'mbar',
flow: 'm3/h',
power: 'kW',
temperature: 'C',
});
/**
* Machine group controller domain model.
* Aggregates multiple rotating machines and coordinates group-level optimization/control.
*/
class MachineGroup { class MachineGroup {
constructor(machineGroupConfig = {}) { constructor(machineGroupConfig = {}) {
@@ -10,12 +28,39 @@ class MachineGroup {
this.defaultConfig = this.configManager.getConfig('machineGroupControl'); // Load default config for rotating machine ( use software type name ? ) this.defaultConfig = this.configManager.getConfig('machineGroupControl'); // Load default config for rotating machine ( use software type name ? )
this.configUtils = new configUtils(this.defaultConfig);// this will handle the config endpoints so we can load them dynamically this.configUtils = new configUtils(this.defaultConfig);// this will handle the config endpoints so we can load them dynamically
this.config = this.configUtils.initConfig(machineGroupConfig); // verify and set the config for the machine group this.config = this.configUtils.initConfig(machineGroupConfig); // verify and set the config for the machine group
this.unitPolicy = this._buildUnitPolicy(this.config);
this.config = this.configUtils.updateConfig(this.config, {
general: {
unit: this.unitPolicy.output.flow,
}
});
// Init after config is set // Init after config is set
this.logger = new logger(this.config.general.logging.enabled,this.config.general.logging.logLevel, this.config.general.name); this.logger = new logger(this.config.general.logging.enabled,this.config.general.logging.logLevel, this.config.general.name);
// Initialize measurements // Initialize measurements
this.measurements = new MeasurementContainer(); this.measurements = new MeasurementContainer({
autoConvert: true,
windowSize: 50,
defaultUnits: {
pressure: this.unitPolicy.output.pressure,
flow: this.unitPolicy.output.flow,
power: this.unitPolicy.output.power,
temperature: this.unitPolicy.output.temperature
},
preferredUnits: {
pressure: this.unitPolicy.output.pressure,
flow: this.unitPolicy.output.flow,
power: this.unitPolicy.output.power,
temperature: this.unitPolicy.output.temperature
},
canonicalUnits: this.unitPolicy.canonical,
storeCanonical: true,
strictUnitValidation: true,
throwOnInvalidUnit: true,
requireUnitForTypes: ['pressure', 'flow', 'power', 'temperature']
});
this.interpolation = new interpolation(); this.interpolation = new interpolation();
// Machines and child data // Machines and child data
@@ -40,6 +85,9 @@ class MachineGroup {
registerChild(child,softwareType) { registerChild(child,softwareType) {
this.logger.debug('Setting up childs specific for this class'); this.logger.debug('Setting up childs specific for this class');
// Prefer functionality-scoped position metadata; keep general fallback for legacy nodes.
const position = child.config?.functionality?.positionVsParent || child.config?.general?.positionVsParent;
if(softwareType == "machine"){ if(softwareType == "machine"){
// Check if the machine is already registered // Check if the machine is already registered
this.machines[child.config.general.id] === undefined ? this.machines[child.config.general.id] = child : this.logger.warn(`Machine ${child.config.general.id} is already registered.`); this.machines[child.config.general.id] === undefined ? this.machines[child.config.general.id] = child : this.logger.warn(`Machine ${child.config.general.id} is already registered.`);
@@ -133,15 +181,23 @@ class MachineGroup {
this.logger.debug(`\n --------- Calculating dynamic totals for ${Object.keys(this.machines).length} machines. @ current pressure settings : ----------`); this.logger.debug(`\n --------- Calculating dynamic totals for ${Object.keys(this.machines).length} machines. @ current pressure settings : ----------`);
Object.values(this.machines).forEach(machine => { Object.values(this.machines).forEach(machine => {
//skip machines without valid curve
if(!machine.hasCurve){
this.logger.error(`Machine ${machine.config.general.id} does not have a valid curve. Skipping in dynamic totals calculation.`);
return;
}
this.logger.debug(`Processing machine with id: ${machine.config.general.id}`); this.logger.debug(`Processing machine with id: ${machine.config.general.id}`);
this.logger.debug(`Current pressure settings: ${JSON.stringify(machine.predictFlow.currentF)}`); this.logger.debug(`Current pressure settings: ${JSON.stringify(machine.predictFlow.currentF)}`);
//fetch min flow ever seen over all machines //fetch min flow ever seen over all machines
const minFlow = machine.predictFlow.currentFxyYMin; const minFlow = machine.predictFlow.currentFxyYMin;
const maxFlow = machine.predictFlow.currentFxyYMax; const maxFlow = machine.predictFlow.currentFxyYMax;
const minPower = machine.predictPower.currentFxyYMin; const minPower = machine.predictPower.currentFxyYMin;
const maxPower = machine.predictPower.currentFxyYMax; const maxPower = machine.predictPower.currentFxyYMax;
const actFlow = machine.measurements.type("flow").variant("predicted").position(POSITIONS.DOWNSTREAM).getCurrentValue();
const actPower = machine.measurements.type("power").variant("predicted").position(POSITIONS.AT_EQUIPMENT).getCurrentValue(); const actFlow = this._readChildMeasurement(machine, "flow", "predicted", POSITIONS.DOWNSTREAM, this.unitPolicy.canonical.flow) || 0;
const actPower = this._readChildMeasurement(machine, "power", "predicted", POSITIONS.AT_EQUIPMENT, this.unitPolicy.canonical.power) || 0;
this.logger.debug(`Machine ${machine.config.general.id} - Min Flow: ${minFlow}, Max Flow: ${maxFlow}, Min Power: ${minPower}, Max Power: ${maxPower}, NCog: ${machine.NCog}`); this.logger.debug(`Machine ${machine.config.general.id} - Min Flow: ${minFlow}, Max Flow: ${maxFlow}, Min Power: ${minPower}, Max Power: ${maxPower}, NCog: ${machine.NCog}`);
@@ -190,13 +246,13 @@ class MachineGroup {
} }
handlePressureChange() { handlePressureChange() {
this.logger.info("---------------------->>>>>>>>>>>>>>>>>>>>>>>>>>>Pressure change detected."); this.logger.debug("Pressure change detected.");
// Recalculate totals // Recalculate totals
const { flow, power } = this.calcDynamicTotals(); const { flow, power } = this.calcDynamicTotals();
this.logger.debug(`Dynamic Totals after pressure change - Flow: Min ${flow.min}, Max ${flow.max}, Act ${flow.act} | Power: Min ${power.min}, Max ${power.max}, Act ${power.act}`); this.logger.debug(`Dynamic Totals after pressure change - Flow: Min ${flow.min}, Max ${flow.max}, Act ${flow.act} | Power: Min ${power.min}, Max ${power.max}, Act ${power.act}`);
this.measurements.type("flow").variant("predicted").position(POSITIONS.DOWNSTREAM).value(flow.act); this._writeMeasurement("flow", "predicted", POSITIONS.AT_EQUIPMENT, flow.act, this.unitPolicy.canonical.flow);
this.measurements.type("power").variant("predicted").position(POSITIONS.AT_EQUIPMENT).value(power.act); this._writeMeasurement("power", "predicted", POSITIONS.AT_EQUIPMENT, power.act, this.unitPolicy.canonical.power);
const { maxEfficiency, lowestEfficiency } = this.calcGroupEfficiency(this.machines); const { maxEfficiency, lowestEfficiency } = this.calcGroupEfficiency(this.machines);
const efficiency = this.measurements.type("efficiency").variant("predicted").position(POSITIONS.AT_EQUIPMENT).getCurrentValue(); const efficiency = this.measurements.type("efficiency").variant("predicted").position(POSITIONS.AT_EQUIPMENT).getCurrentValue();
@@ -209,7 +265,7 @@ class MachineGroup {
calcRelativeDistanceFromPeak(currentEfficiency,maxEfficiency,minEfficiency){ calcRelativeDistanceFromPeak(currentEfficiency,maxEfficiency,minEfficiency){
let distance = 1; let distance = 1;
if(currentEfficiency != null){ if(currentEfficiency != null && maxEfficiency !== minEfficiency){
distance = this.interpolation.interpolate_lin_single_point(currentEfficiency,maxEfficiency, minEfficiency, 0, 1); distance = this.interpolation.interpolate_lin_single_point(currentEfficiency,maxEfficiency, minEfficiency, 0, 1);
} }
return distance; return distance;
@@ -235,11 +291,13 @@ class MachineGroup {
//add special cases //add special cases
if( state === "operational" && ( mode == "virtualControl" || mode === "fysicalControl") ){ if( state === "operational" && ( mode == "virtualControl" || mode === "fysicalControl") ){
let flow = 0; let flow = 0;
if(machine.measurements.type("flow").variant("measured").position(POSITIONS.DOWNSTREAM).getCurrentValue()){ const measuredFlow = this._readChildMeasurement(machine, "flow", "measured", POSITIONS.DOWNSTREAM, this.unitPolicy.canonical.flow);
flow = machine.measurements.type("flow").variant("measured").position(POSITIONS.DOWNSTREAM).getCurrentValue(); const predictedFlow = this._readChildMeasurement(machine, "flow", "predicted", POSITIONS.DOWNSTREAM, this.unitPolicy.canonical.flow);
if (Number.isFinite(measuredFlow) && measuredFlow !== 0) {
flow = measuredFlow;
} }
else if(machine.measurements.type("flow").variant("predicted").position(POSITIONS.DOWNSTREAM).getCurrentValue()){ else if (Number.isFinite(predictedFlow) && predictedFlow !== 0) {
flow = machine.measurements.type("flow").variant("predicted").position(POSITIONS.DOWNSTREAM).getCurrentValue(); flow = predictedFlow;
} }
else{ else{
this.logger.error("Dont perform calculation at all seeing that there is a machine working but we dont know the flow its producing"); this.logger.error("Dont perform calculation at all seeing that there is a machine working but we dont know the flow its producing");
@@ -264,7 +322,7 @@ class MachineGroup {
Object.keys(machines).forEach(machineId => { Object.keys(machines).forEach(machineId => {
const state = machines[machineId].state.getCurrentState(); const state = machines[machineId].state.getCurrentState();
const validActionForMode = machines[machineId].isValidActionForMode("execSequence", "auto"); const validActionForMode = machines[machineId].isValidActionForMode("execsequence", "auto");
// Reasons why a machine is not valid for the combination // Reasons why a machine is not valid for the combination
@@ -313,42 +371,71 @@ class MachineGroup {
calcBestCombination(combinations, Qd) { calcBestCombination(combinations, Qd) {
let bestCombination = null; let bestCombination = null;
//keep track of totals
let bestPower = Infinity; let bestPower = Infinity;
let bestFlow = 0; let bestFlow = 0;
let bestCog = 0; let bestCog = 0;
combinations.forEach(combination => { combinations.forEach(combination => {
let flowDistribution = [];
let flowDistribution = []; // Stores the flow distribution for the best combination
let totalCoG = 0; let totalCoG = 0;
let totalPower = 0; let totalPower = 0;
let totalFlow = 0;
// Calculate the total CoG for the current combination // Sum normalized CoG for the combination
combination.forEach(machineId => { totalCoG += ( Math.round(this.machines[machineId].NCog * 100 ) /100 ) ; }); combination.forEach(machineId => {
totalCoG += Math.round((this.machines[machineId].NCog || 0) * 100) / 100;
});
// Calculate the total power for the current combination // Initial CoG-based distribution
combination.forEach(machineId => { combination.forEach(machineId => {
let flow = 0; let flow = 0;
// Prevent division by zero
if (totalCoG === 0) { if (totalCoG === 0) {
// Distribute flow equally among all pumps
flow = Qd / combination.length; flow = Qd / combination.length;
} else { } else {
// Normal CoG-based distribution flow = ((this.machines[machineId].NCog || 0) / totalCoG) * Qd;
flow = (this.machines[machineId].NCog / totalCoG) * Qd ;
this.logger.debug(`Machine Normalized CoG-based distribution ${machineId} flow: ${flow}`); this.logger.debug(`Machine Normalized CoG-based distribution ${machineId} flow: ${flow}`);
} }
totalFlow += flow;
totalPower += this.machines[machineId].inputFlowCalcPower(flow); flowDistribution.push({ machineId, flow });
flowDistribution.push({ machineId: machineId,flow: flow }); });
// Clamp to min/max and spill leftover once
const clamped = flowDistribution.map(entry => {
const machine = this.machines[entry.machineId];
const min = machine.predictFlow.currentFxyYMin;
const max = machine.predictFlow.currentFxyYMax;
const clampedFlow = Math.min(max, Math.max(min, entry.flow));
return { ...entry, flow: clampedFlow, min, max, desired: entry.flow };
});
let remainder = Qd - clamped.reduce((sum, entry) => sum + entry.flow, 0);
if (Math.abs(remainder) > 1e-6) {
const adjustable = clamped.filter(entry =>
remainder > 0 ? entry.flow < entry.max : entry.flow > entry.min
);
const weightSum = adjustable.reduce((sum, entry) => sum + entry.desired, 0) || adjustable.length;
adjustable.forEach(entry => {
const weight = entry.desired / weightSum || 1 / adjustable.length;
const delta = remainder * weight;
const next = remainder > 0
? Math.min(entry.max, entry.flow + delta)
: Math.max(entry.min, entry.flow + delta);
remainder -= (next - entry.flow);
entry.flow = next;
});
}
flowDistribution = clamped;
let totalFlow = 0;
flowDistribution.forEach(({ machineId, flow }) => {
totalFlow += flow;
totalPower += this.machines[machineId].inputFlowCalcPower(flow);
}); });
// Update the best combination if the current one is better
if (totalPower < bestPower) { if (totalPower < bestPower) {
this.logger.debug(`New best combination found: ${totalPower} < ${bestPower}`); this.logger.debug(`New best combination found: ${totalPower} < ${bestPower}`);
this.logger.debug(`combination ${JSON.stringify(flowDistribution)}`); this.logger.debug(`combination ${JSON.stringify(flowDistribution)}`);
@@ -362,6 +449,203 @@ class MachineGroup {
return { bestCombination, bestPower, bestFlow, bestCog }; return { bestCombination, bestPower, bestFlow, bestCog };
} }
// Estimate the local dP/dQ slopes around the BEP for the provided machine.
estimateSlopesAtBEP(machine, Q_BEP, delta = 1.0) {
const fallback = {
slopeLeft: 0,
slopeRight: 0,
alpha: 1,
Q_BEP: Q_BEP || 0,
P_BEP: 0
};
const minFlow = machine.predictFlow.currentFxyYMin;
const maxFlow = machine.predictFlow.currentFxyYMax;
const span = Math.max(0, maxFlow - minFlow);
const normalizedCog = Math.max(0, Math.min(1, machine.NCog || 0));
const targetBEP = Q_BEP ?? (minFlow + span * normalizedCog);
const clampFlow = (flow) => Math.min(maxFlow, Math.max(minFlow, flow)); // ensure within bounds using small helper function
const center = clampFlow(targetBEP);
const deltaSafe = Math.max(delta, 0.01);
const leftFlow = clampFlow(center - deltaSafe);
const rightFlow = clampFlow(center + deltaSafe);
const powerAt = (flow) => machine.inputFlowCalcPower(flow); // helper to get power at a given flow
const P_center = powerAt(center);
const P_left = powerAt(leftFlow);
const P_right = powerAt(rightFlow);
const slopeLeft = (P_center - P_left) / Math.max(1e-6, center - leftFlow);
const slopeRight = (P_right - P_center) / Math.max(1e-6, rightFlow - center);
const alpha = Math.max(1e-6, (Math.abs(slopeLeft) + Math.abs(slopeRight)) / 2);
return {
slopeLeft,
slopeRight,
alpha,
Q_BEP: center,
P_BEP: P_center
};
}
//Redistribute remaining demand using slope-based weights so flatter curves attract more flow.
redistributeFlowBySlope(pumpInfos, flowDistribution, delta, directional = true) {
const tolerance = 1e-3; // Small tolerance to avoid infinite loops
let remaining = delta; // Remaining flow to distribute
const entryMap = new Map(flowDistribution.map(entry => [entry.machineId, entry])); // Map for quick access
// Loop until remaining flow is within tolerance
while (Math.abs(remaining) > tolerance) {
const increasing = remaining > 0; // Determine if we are increasing or decreasing flow
// Build candidates with capacity and weight
const candidates = pumpInfos.map(info => {
const entry = entryMap.get(info.id);
if (!entry) { return null; }
const capacity = increasing ? info.maxFlow - entry.flow : entry.flow - info.minFlow; // Calculate available capacity based on direction
if (capacity <= tolerance) { return null; }
const slope = increasing
? (directional ? info.slopes.slopeRight : info.slopes.alpha)
: (directional ? info.slopes.slopeLeft : info.slopes.alpha);
const weight = 1 / Math.max(1e-6, Math.abs(slope) || info.slopes.alpha || 1);
return { entry, capacity, weight };
}).filter(Boolean);
if (!candidates.length) { break; } // No candidates available, exit loop
const weightSum = candidates.reduce((sum, candidate) => sum + candidate.weight * candidate.capacity, 0); // weighted sum of capacities
if (weightSum <= 0) { break; } // Avoid division by zero
let progress = 0;
// Distribute remaining flow among candidates based on their weights and capacities
candidates.forEach(candidate => {
let share = (candidate.weight * candidate.capacity / weightSum) * Math.abs(remaining);
share = Math.min(share, candidate.capacity); // Ensure we don't exceed capacity
if (share <= 0) { return; } // Skip if no share to allocate
if (increasing) {
candidate.entry.flow += share;
} else {
candidate.entry.flow -= share;
}
progress += share; // Track total progress made in this iteration
});
if (progress <= tolerance) { break; }
remaining += increasing ? -progress : progress; // Update remaining flow to distribute
}
}
// BEP-gravitation based combination finder that biases allocation around each pump's BEP.
calcBestCombinationBEPGravitation(combinations, Qd, method = "BEP-Gravitation-Directional") {
let bestCombination = null;
let bestPower = Infinity;
let bestFlow = 0;
let bestCog = 0;
let bestDeviation = Infinity;
const directional = method === "BEP-Gravitation-Directional";
combinations.forEach(combination => {
const pumpInfos = combination.map(machineId => {
const machine = this.machines[machineId];
const minFlow = machine.predictFlow.currentFxyYMin;
const maxFlow = machine.predictFlow.currentFxyYMax;
const span = Math.max(0, maxFlow - minFlow);
const NCog = Math.max(0, Math.min(1, machine.NCog || 0));
const estimatedBEP = minFlow + span * NCog; // Estimated BEP flow based on current curve
const slopes = this.estimateSlopesAtBEP(machine, estimatedBEP);
return {
id: machineId,
machine,
minFlow,
maxFlow,
NCog,
Q_BEP: slopes.Q_BEP,
slopes
};
});
// Skip if no pumps in combination
if (pumpInfos.length === 0) { return; }
// Start at BEP flows
const flowDistribution = pumpInfos.map(info => ({
machineId: info.id,
flow: Math.min(info.maxFlow, Math.max(info.minFlow, info.Q_BEP))
}));
let totalFlow = flowDistribution.reduce((sum, entry) => sum + entry.flow, 0); // Initial total flow
const delta = Qd - totalFlow; // Difference to target demand
if (Math.abs(delta) > 1e-6) {
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 => {
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);
const deviation = pumpInfos.reduce((sum, info) => {
const entry = flowDistribution.find(item => item.machineId === info.id);
const deltaFlow = entry ? (entry.flow - info.Q_BEP) : 0;
return sum + (deltaFlow * deltaFlow) * (info.slopes.alpha || 1);
}, 0);
const shouldUpdate = totalPower < bestPower ||
(totalPower === bestPower && deviation < bestDeviation);
if (shouldUpdate) {
bestCombination = flowDistribution.map(entry => ({ ...entry }));
bestPower = totalPower;
bestFlow = totalFlow;
bestCog = totalCog;
bestDeviation = deviation;
}
});
return {
bestCombination,
bestPower,
bestFlow,
bestCog,
bestDeviation,
method
};
}
// -------- Mode and Input Management -------- // // -------- Mode and Input Management -------- //
isValidActionForMode(action, mode) { isValidActionForMode(action, mode) {
const allowedActionsSet = this.config.mode.allowedActions[mode] || []; const allowedActionsSet = this.config.mode.allowedActions[mode] || [];
@@ -387,12 +671,17 @@ class MachineGroup {
async optimalControl(Qd, powerCap = Infinity) { async optimalControl(Qd, powerCap = Infinity) {
try{ 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 //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 // this is to ensure a correct evaluation of the flow and power consumption
const pressures = Object.entries(this.machines).map(([_machineId, machine]) => { const pressures = Object.entries(this.machines).map(([_machineId, machine]) => {
return { return {
downstream: machine.measurements.type("pressure").variant("measured").position(POSITIONS.DOWNSTREAM).getCurrentValue(), downstream: this._readChildMeasurement(machine, "pressure", "measured", POSITIONS.DOWNSTREAM, this.unitPolicy.canonical.pressure) || 0,
upstream: machine.measurements.type("pressure").variant("measured").position(POSITIONS.UPSTREAM).getCurrentValue() upstream: this._readChildMeasurement(machine, "pressure", "measured", POSITIONS.UPSTREAM, this.unitPolicy.canonical.pressure) || 0
}; };
}); });
@@ -406,8 +695,8 @@ class MachineGroup {
if(machine.state.getCurrentState() !== "operational" && machine.state.getCurrentState() !== "accelerating" && machine.state.getCurrentState() !== "decelerating"){ if(machine.state.getCurrentState() !== "operational" && machine.state.getCurrentState() !== "accelerating" && machine.state.getCurrentState() !== "decelerating"){
//Equilize pressures over all machines so we can make a proper calculation //Equilize pressures over all machines so we can make a proper calculation
machine.measurements.type("pressure").variant("measured").position(POSITIONS.DOWNSTREAM).value(maxDownstream); this._writeChildMeasurement(machine, "pressure", "measured", POSITIONS.DOWNSTREAM, maxDownstream, this.unitPolicy.canonical.pressure);
machine.measurements.type("pressure").variant("measured").position(POSITIONS.UPSTREAM).value(minUpstream); this._writeChildMeasurement(machine, "pressure", "measured", POSITIONS.UPSTREAM, minUpstream, this.unitPolicy.canonical.pressure);
// after updating the measurement directly we need to force the update of the value OLIFANT this is not so clear now in the code // after updating the measurement directly we need to force the update of the value OLIFANT this is not so clear now in the code
// we need to find a better way to do this but for now it works // we need to find a better way to do this but for now it works
@@ -424,7 +713,9 @@ class MachineGroup {
}, {}); }, {});
if( Qd <= 0 ) { 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 ){ if( Qd < dynamicTotals.flow.min && Qd > 0 ){
@@ -440,7 +731,26 @@ class MachineGroup {
// fetch all valid combinations that meet expectations // fetch all valid combinations that meet expectations
const combinations = this.validPumpCombinations(this.machines, Qd, powerCap); const combinations = this.validPumpCombinations(this.machines, Qd, powerCap);
const bestResult = this.calcBestCombination(combinations, Qd);
if (!combinations || combinations.length === 0) {
this.logger.warn(`Demand: ${Qd.toFixed(2)} -> No valid combination found (empty set).`);
return;
}
// Decide which optimization routine we run. Defaults to BEP-based gravitation with directionality.
const optimizationMethod = this.config.optimization?.method || "BEP-Gravitation-Directional";
let bestResult;
if (optimizationMethod === "NCog") {
bestResult = this.calcBestCombination(combinations, Qd);
} else if (
optimizationMethod === "BEP-Gravitation" ||
optimizationMethod === "BEP-Gravitation-Directional"
) {
bestResult = this.calcBestCombinationBEPGravitation(combinations, Qd, optimizationMethod);
} else {
this.logger.warn(`Unknown optimization method '${optimizationMethod}', falling back to BEP-Gravitation-Directional.`);
bestResult = this.calcBestCombinationBEPGravitation(combinations, Qd, "BEP-Gravitation-Directional");
}
if(bestResult.bestCombination === null){ if(bestResult.bestCombination === null){
this.logger.warn(`Demand: ${Qd.toFixed(2)} -> No valid combination found => not updating control `); this.logger.warn(`Demand: ${Qd.toFixed(2)} -> No valid combination found => not updating control `);
@@ -451,8 +761,8 @@ class MachineGroup {
this.logger.debug(`Moving to demand: ${Qd.toFixed(2)} -> Pumps: [${debugInfo}] => Total Power: ${bestResult.bestPower.toFixed(2)}`); this.logger.debug(`Moving to demand: ${Qd.toFixed(2)} -> Pumps: [${debugInfo}] => Total Power: ${bestResult.bestPower.toFixed(2)}`);
//store the total delivered power //store the total delivered power
this.measurements.type("power").variant("predicted").position(POSITIONS.AT_EQUIPMENT).value(bestResult.bestPower); this._writeMeasurement("power", "predicted", POSITIONS.AT_EQUIPMENT, bestResult.bestPower, this.unitPolicy.canonical.power);
this.measurements.type("flow").variant("predicted").position(POSITIONS.DOWNSTREAM).value(bestResult.bestFlow); this._writeMeasurement("flow", "predicted", POSITIONS.DOWNSTREAM, bestResult.bestFlow, this.unitPolicy.canonical.flow);
this.measurements.type("efficiency").variant("predicted").position(POSITIONS.AT_EQUIPMENT).value(bestResult.bestFlow / bestResult.bestPower); this.measurements.type("efficiency").variant("predicted").position(POSITIONS.AT_EQUIPMENT).value(bestResult.bestFlow / bestResult.bestPower);
this.measurements.type("Ncog").variant("predicted").position(POSITIONS.AT_EQUIPMENT).value(bestResult.bestCog); this.measurements.type("Ncog").variant("predicted").position(POSITIONS.AT_EQUIPMENT).value(bestResult.bestCog);
@@ -469,16 +779,16 @@ class MachineGroup {
} }
if( (flow <= 0 ) && ( machineStates[machineId] === "operational" || machineStates[machineId] === "accelerating" || machineStates[machineId] === "decelerating" ) ){ if( (flow <= 0 ) && ( machineStates[machineId] === "operational" || machineStates[machineId] === "accelerating" || machineStates[machineId] === "decelerating" ) ){
await machine.handleInput("parent", "execSequence", "shutdown"); await machine.handleInput("parent", "execsequence", "shutdown");
} }
if(machineStates[machineId] === "idle" && flow > 0){ if(machineStates[machineId] === "idle" && flow > 0){
await machine.handleInput("parent", "execSequence", "startup"); 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 ){ if(machineStates[machineId] === "operational" && flow > 0 ){
await machine.handleInput("parent", "flowMovement", flow); await machine.handleInput("parent", "flowmovement", this._canonicalToOutputFlow(flow));
} }
})); }));
} }
@@ -489,11 +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. // Equalize pressure across all machines for machines that are not running. This is needed to ensure accurate flow and power predictions.
equalizePressure(){ equalizePressure(){
if (Object.keys(this.machines).length === 0) return;
// Get current pressures from all machines // Get current pressures from all machines
const pressures = Object.entries(this.machines).map(([_machineId, machine]) => { const pressures = Object.entries(this.machines).map(([_machineId, machine]) => {
return { return {
downstream: machine.measurements.type("pressure").variant("measured").position(POSITIONS.DOWNSTREAM).getCurrentValue(), downstream: this._readChildMeasurement(machine, "pressure", "measured", POSITIONS.DOWNSTREAM, this.unitPolicy.canonical.pressure) || 0,
upstream: machine.measurements.type("pressure").variant("measured").position(POSITIONS.UPSTREAM).getCurrentValue() upstream: this._readChildMeasurement(machine, "pressure", "measured", POSITIONS.UPSTREAM, this.unitPolicy.canonical.pressure) || 0
}; };
}); });
@@ -504,8 +816,8 @@ class MachineGroup {
// Set consistent pressures across machines // Set consistent pressures across machines
Object.entries(this.machines).forEach(([machineId, machine]) => { Object.entries(this.machines).forEach(([machineId, machine]) => {
if(!this.isMachineActive(machineId)){ if(!this.isMachineActive(machineId)){
machine.measurements.type("pressure").variant("measured").position(POSITIONS.DOWNSTREAM).value(maxDownstream); this._writeChildMeasurement(machine, "pressure", "measured", POSITIONS.DOWNSTREAM, maxDownstream, this.unitPolicy.canonical.pressure);
machine.measurements.type("pressure").variant("measured").position(POSITIONS.UPSTREAM).value(minUpstream); this._writeChildMeasurement(machine, "pressure", "measured", POSITIONS.UPSTREAM, minUpstream, this.unitPolicy.canonical.pressure);
// Update the measured pressure value // Update the measured pressure value
const pressure = machine.getMeasuredPressure(); const pressure = machine.getMeasuredPressure();
this.logger.debug(`Setting pressure for machine ${machineId} to ${pressure}`); this.logger.debug(`Setting pressure for machine ${machineId} to ${pressure}`);
@@ -551,7 +863,7 @@ class MachineGroup {
filterOutUnavailableMachines(list) { filterOutUnavailableMachines(list) {
const newList = list.filter(({ machine }) => { const newList = list.filter(({ machine }) => {
const state = machine.state.getCurrentState(); const state = machine.state.getCurrentState();
const validActionForMode = machine.isValidActionForMode("execSequence", "auto"); const validActionForMode = machine.isValidActionForMode("execsequence", "auto");
return !(state === "off" || state === "coolingdown" || state === "stopping" || state === "emergencystop" || !validActionForMode); return !(state === "off" || state === "coolingdown" || state === "stopping" || state === "emergencystop" || !validActionForMode);
}); });
@@ -683,8 +995,8 @@ class MachineGroup {
this.logger.debug(`Priority control for demand: ${totalFlow.toFixed(2)} -> Active pumps: [${debugInfo}] => Total Power: ${totalPower.toFixed(2)}`); this.logger.debug(`Priority control for demand: ${totalFlow.toFixed(2)} -> Active pumps: [${debugInfo}] => Total Power: ${totalPower.toFixed(2)}`);
// Store measurements // Store measurements
this.measurements.type("power").variant("predicted").position(POSITIONS.AT_EQUIPMENT).value(totalPower); this._writeMeasurement("power", "predicted", POSITIONS.AT_EQUIPMENT, totalPower, this.unitPolicy.canonical.power);
this.measurements.type("flow").variant("predicted").position(POSITIONS.DOWNSTREAM).value(totalFlow); this._writeMeasurement("flow", "predicted", POSITIONS.DOWNSTREAM, totalFlow, this.unitPolicy.canonical.flow);
this.measurements.type("efficiency").variant("predicted").position(POSITIONS.AT_EQUIPMENT).value(totalFlow / totalPower); this.measurements.type("efficiency").variant("predicted").position(POSITIONS.AT_EQUIPMENT).value(totalFlow / totalPower);
this.measurements.type("Ncog").variant("predicted").position(POSITIONS.AT_EQUIPMENT).value(totalCog); this.measurements.type("Ncog").variant("predicted").position(POSITIONS.AT_EQUIPMENT).value(totalCog);
@@ -696,13 +1008,14 @@ class MachineGroup {
const currentState = this.machines[machineId].state.getCurrentState(); const currentState = this.machines[machineId].state.getCurrentState();
if (flow <= 0 && (currentState === "operational" || currentState === "accelerating" || currentState === "decelerating")) { if (flow <= 0 && (currentState === "operational" || currentState === "accelerating" || currentState === "decelerating")) {
await machine.handleInput("parent", "execSequence", "shutdown"); await machine.handleInput("parent", "execsequence", "shutdown");
} }
else if (currentState === "idle" && flow > 0) { else if (currentState === "idle" && flow > 0) {
await machine.handleInput("parent", "execSequence", "startup"); await machine.handleInput("parent", "execsequence", "startup");
await machine.handleInput("parent", "flowmovement", this._canonicalToOutputFlow(flow));
} }
else if (currentState === "operational" && flow > 0) { else if (currentState === "operational" && flow > 0) {
await machine.handleInput("parent", "flowMovement", flow); await machine.handleInput("parent", "flowmovement", this._canonicalToOutputFlow(flow));
} }
})); }));
} }
@@ -718,7 +1031,7 @@ class MachineGroup {
if(input < 0 ){ if(input < 0 ){
//turn all machines off //turn all machines off
await Promise.all(Object.entries(this.machines).map(async ([machineId, machine]) => { await Promise.all(Object.entries(this.machines).map(async ([machineId, machine]) => {
if (this.isMachineActive(machineId)) { await machine.handleInput("parent", "execSequence", "shutdown"); } if (this.isMachineActive(machineId)) { await machine.handleInput("parent", "execsequence", "shutdown"); }
})); }));
return; return;
} }
@@ -782,13 +1095,13 @@ class MachineGroup {
const currentState = this.machines[machineId].state.getCurrentState(); const currentState = this.machines[machineId].state.getCurrentState();
if (ctrl < 0 && (currentState === "operational" || currentState === "accelerating" || currentState === "decelerating")) { if (ctrl < 0 && (currentState === "operational" || currentState === "accelerating" || currentState === "decelerating")) {
await machine.handleInput("parent", "execSequence", "shutdown"); await machine.handleInput("parent", "execsequence", "shutdown");
} }
else if (currentState === "idle" && ctrl >= 0) { else if (currentState === "idle" && ctrl >= 0) {
await machine.handleInput("parent", "execSequence", "startup"); await machine.handleInput("parent", "execsequence", "startup");
} }
else if (currentState === "operational" && ctrl > 0) { else if (currentState === "operational" && ctrl > 0) {
await machine.handleInput("parent", "execMovement", ctrl); await machine.handleInput("parent", "execmovement", ctrl);
} }
})); }));
@@ -798,8 +1111,8 @@ class MachineGroup {
// fetch and store measurements // fetch and store measurements
Object.entries(this.machines).forEach(([_machineId, machine]) => { Object.entries(this.machines).forEach(([_machineId, machine]) => {
const powerValue = machine.measurements.type("power").variant("predicted").position(POSITIONS.AT_EQUIPMENT).getCurrentValue(); const powerValue = this._readChildMeasurement(machine, "power", "predicted", POSITIONS.AT_EQUIPMENT, this.unitPolicy.canonical.power);
const flowValue = machine.measurements.type("flow").variant("predicted").position(POSITIONS.DOWNSTREAM).getCurrentValue(); const flowValue = this._readChildMeasurement(machine, "flow", "predicted", POSITIONS.DOWNSTREAM, this.unitPolicy.canonical.flow);
if (powerValue !== null) { if (powerValue !== null) {
totalPower.push(powerValue); totalPower.push(powerValue);
@@ -809,8 +1122,8 @@ class MachineGroup {
} }
}); });
this.measurements.type("power").variant("predicted").position(POSITIONS.AT_EQUIPMENT).value(totalPower.reduce((a, b) => a + b, 0)); this._writeMeasurement("power", "predicted", POSITIONS.AT_EQUIPMENT, totalPower.reduce((a, b) => a + b, 0), this.unitPolicy.canonical.power);
this.measurements.type("flow").variant("predicted").position(POSITIONS.DOWNSTREAM).value(totalFlow.reduce((a, b) => a + b, 0)); this._writeMeasurement("flow", "predicted", POSITIONS.DOWNSTREAM, totalFlow.reduce((a, b) => a + b, 0), this.unitPolicy.canonical.flow);
if(totalPower.reduce((a, b) => a + b, 0) > 0){ if(totalPower.reduce((a, b) => a + b, 0) > 0){
this.measurements.type("efficiency").variant("predicted").position(POSITIONS.AT_EQUIPMENT).value(totalFlow.reduce((a, b) => a + b, 0) / totalPower.reduce((a, b) => a + b, 0)); this.measurements.type("efficiency").variant("predicted").position(POSITIONS.AT_EQUIPMENT).value(totalFlow.reduce((a, b) => a + b, 0) / totalPower.reduce((a, b) => a + b, 0));
@@ -824,13 +1137,19 @@ class MachineGroup {
async handleInput(source, demand, powerCap = Infinity, priorityList = null) { async handleInput(source, demand, powerCap = Infinity, priorityList = null) {
const demandQ = parseFloat(demand);
if(!Number.isFinite(demandQ)){
this.logger.error(`Invalid flow demand input: ${demand}. Must be a finite number.`);
return;
}
//abort current movements //abort current movements
await this.abortActiveMovements("new demand received"); await this.abortActiveMovements("new demand received");
const scaling = this.scaling; const scaling = this.scaling;
const mode = this.mode; const mode = this.mode;
const dynamicTotals = this.calcDynamicTotals(); const dynamicTotals = this.calcDynamicTotals();
const demandQ = parseFloat(demand);
let demandQout = 0; // keep output Q by default 0 for safety let demandQout = 0; // keep output Q by default 0 for safety
this.logger.debug(`Handling input from ${source}: Demand = ${demand}, Power Cap = ${powerCap}, Priority List = ${priorityList}`); this.logger.debug(`Handling input from ${source}: Demand = ${demand}, Power Cap = ${powerCap}, Priority List = ${priorityList}`);
@@ -843,23 +1162,23 @@ class MachineGroup {
return; return;
} }
if (demandQ < this.absoluteTotals.flow.min) { if (demandQ <= 0) {
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){
this.logger.debug(`Turning machines off`); this.logger.debug(`Turning machines off`);
demandQout = 0; demandQout = 0;
//return early and turn all machines off
this.turnOffAllMachines(); this.turnOffAllMachines();
return; 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; break;
case "normalized": case "normalized":
this.logger.debug(`Normalizing flow demand: ${demandQ} with min: ${dynamicTotals.flow.min} and max: ${dynamicTotals.flow.max}`); this.logger.debug(`Normalizing flow demand: ${demandQ} with min: ${dynamicTotals.flow.min} and max: ${dynamicTotals.flow.max}`);
if(demand < 0){ if(demand < 0){
this.logger.debug(`Turning machines off`); this.logger.debug(`Turning machines off`);
@@ -877,7 +1196,6 @@ class MachineGroup {
} }
// Execute control based on mode // Execute control based on mode
switch(mode) { switch(mode) {
case "prioritycontrol": case "prioritycontrol":
@@ -906,17 +1224,124 @@ class MachineGroup {
//recalc distance from BEP //recalc distance from BEP
const { maxEfficiency, lowestEfficiency } = this.calcGroupEfficiency(this.machines); const { maxEfficiency, lowestEfficiency } = this.calcGroupEfficiency(this.machines);
const efficiency = this.measurements.type("efficiency").variant("predicted").position(POSITIONS.DOWNSTREAM).getCurrentValue(); const efficiency = this.measurements.type("efficiency").variant("predicted").position(POSITIONS.AT_EQUIPMENT).getCurrentValue();
this.calcDistanceBEP(efficiency,maxEfficiency,lowestEfficiency); this.calcDistanceBEP(efficiency,maxEfficiency,lowestEfficiency);
} }
async turnOffAllMachines(){ async turnOffAllMachines(){
await Promise.all(Object.entries(this.machines).map(async ([machineId, machine]) => { await Promise.all(Object.entries(this.machines).map(async ([machineId, machine]) => {
if (this.isMachineActive(machineId)) { await machine.handleInput("parent", "execSequence", "shutdown"); } if (this.isMachineActive(machineId)) { await machine.handleInput("parent", "execsequence", "shutdown"); }
})); }));
} }
_buildUnitPolicy(config = {}) {
const flowUnit = this._resolveUnitOrFallback(
config?.general?.unit,
'volumeFlowRate',
DEFAULT_IO_UNITS.flow
);
const pressureUnit = this._resolveUnitOrFallback(
config?.general?.pressureUnit,
'pressure',
DEFAULT_IO_UNITS.pressure
);
const powerUnit = this._resolveUnitOrFallback(
config?.general?.powerUnit,
'power',
DEFAULT_IO_UNITS.power
);
return {
canonical: { ...CANONICAL_UNITS },
output: {
flow: flowUnit,
pressure: pressureUnit,
power: powerUnit,
temperature: DEFAULT_IO_UNITS.temperature,
},
};
}
_resolveUnitOrFallback(candidate, expectedMeasure, fallbackUnit) {
const fallback = String(fallbackUnit || '').trim();
const raw = typeof candidate === 'string' ? candidate.trim() : '';
if (!raw) {
return fallback;
}
try {
const desc = convert().describe(raw);
if (expectedMeasure && desc.measure !== expectedMeasure) {
throw new Error(`expected '${expectedMeasure}', got '${desc.measure}'`);
}
return raw;
} catch (error) {
this.logger?.warn?.(`Invalid unit '${raw}' (${error.message}); falling back to '${fallback}'.`);
return fallback;
}
}
_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':
return this.unitPolicy.output.flow;
case 'power':
return this.unitPolicy.output.power;
case 'pressure':
return this.unitPolicy.output.pressure;
case 'temperature':
return this.unitPolicy.output.temperature;
default:
return null;
}
}
_readMeasurement(type, variant, position, unit = null) {
const requestedUnit = unit || this._outputUnitForType(type);
return this.measurements
.type(type)
.variant(variant)
.position(position)
.getCurrentValue(requestedUnit || undefined);
}
_writeMeasurement(type, variant, position, value, unit = null, timestamp = Date.now()) {
if (!Number.isFinite(value)) {
return;
}
this.measurements
.type(type)
.variant(variant)
.position(position)
.value(value, timestamp, unit || undefined);
}
_readChildMeasurement(machine, type, variant, position, unit = null) {
return machine?.measurements
?.type(type)
?.variant(variant)
?.position(position)
?.getCurrentValue(unit || undefined);
}
_writeChildMeasurement(machine, type, variant, position, value, unit = null, timestamp = Date.now()) {
if (!machine?.measurements || !Number.isFinite(value)) {
return;
}
machine.measurements
.type(type)
.variant(variant)
.position(position)
.value(value, timestamp, unit || undefined);
}
setMode(mode) { setMode(mode) {
this.mode = mode; this.mode = mode;
} }
@@ -929,10 +1354,10 @@ class MachineGroup {
//build the output object //build the output object
this.measurements.getTypes().forEach(type => { this.measurements.getTypes().forEach(type => {
this.measurements.getVariants(type).forEach(variant => { this.measurements.getVariants(type).forEach(variant => {
const unit = this._outputUnitForType(type);
const downstreamVal = this.measurements.type(type).variant(variant).position(POSITIONS.DOWNSTREAM).getCurrentValue(); const downstreamVal = this._readMeasurement(type, variant, POSITIONS.DOWNSTREAM, unit);
const atEquipmentVal = this.measurements.type(type).variant(variant).position(POSITIONS.AT_EQUIPMENT).getCurrentValue(); const atEquipmentVal = this._readMeasurement(type, variant, POSITIONS.AT_EQUIPMENT, unit);
const upstreamVal = this.measurements.type(type).variant(variant).position(POSITIONS.UPSTREAM).getCurrentValue(); const upstreamVal = this._readMeasurement(type, variant, POSITIONS.UPSTREAM, unit);
if (downstreamVal != null) { if (downstreamVal != null) {
output[`downstream_${variant}_${type}`] = downstreamVal; output[`downstream_${variant}_${type}`] = downstreamVal;
@@ -944,8 +1369,13 @@ class MachineGroup {
output[`atEquipment_${variant}_${type}`] = atEquipmentVal; output[`atEquipment_${variant}_${type}`] = atEquipmentVal;
} }
if (downstreamVal != null && upstreamVal != null) { if (downstreamVal != null && upstreamVal != null) {
const diffVal = this.measurements.type(type).variant(variant).difference().value; const diff = this.measurements
output[`differential_${variant}_${type}`] = diffVal; .type(type)
.variant(variant)
.difference({ from: POSITIONS.DOWNSTREAM, to: POSITIONS.UPSTREAM, unit });
if (diff?.value != null) {
output[`differential_${variant}_${type}`] = diff.value;
}
} }
}); });
}); });
@@ -967,7 +1397,7 @@ class MachineGroup {
module.exports = MachineGroup; module.exports = MachineGroup;
/* /*
const {coolprop} = require('generalFunctions');
const Machine = require('../../rotatingMachine/src/specificClass'); const Machine = require('../../rotatingMachine/src/specificClass');
const Measurement = require('../../measurement/src/specificClass'); const Measurement = require('../../measurement/src/specificClass');
const specs = require('../../generalFunctions/datasets/assetData/curves/hidrostal-H05K-S03R.json'); const specs = require('../../generalFunctions/datasets/assetData/curves/hidrostal-H05K-S03R.json');
@@ -995,9 +1425,9 @@ function createBaseMachineConfig(machineNum, name,specs) {
mode: { mode: {
current: "auto", current: "auto",
allowedActions: { allowedActions: {
auto: ["execSequence", "execMovement", "statusCheck"], auto: ["execsequence", "execmovement", "statuscheck"],
virtualControl: ["execMovement", "statusCheck"], virtualControl: ["execmovement", "statuscheck"],
fysicalControl: ["statusCheck"] fysicalControl: ["statuscheck"]
}, },
allowedSources: { allowedSources: {
auto: ["parent", "GUI"], auto: ["parent", "GUI"],
@@ -1089,11 +1519,11 @@ async function makeMachines(){
for(let i = 1; i <= numofMachines; i++){ for(let i = 1; i <= numofMachines; i++){
const machine = new Machine(machineConfigs[i],stateConfigs[i]); const machine = new Machine(machineConfigs[i],stateConfigs[i]);
//mg.machines[i] = machine; //mg.machines[i] = machine;
mg.childRegistrationUtils.registerChild(machine, POSITIONS.DOWNSTREAM); mg.childRegistrationUtils.registerChild(machine, "downstream");
} }
Object.keys(mg.machines).forEach(machineId => { Object.keys(mg.machines).forEach(machineId => {
mg.machines[machineId].childRegistrationUtils.registerChild(pt1, POSITIONS.DOWNSTREAM); mg.machines[machineId].childRegistrationUtils.registerChild(pt1, "downstream");
}); });
mg.setMode("prioritycontrol"); mg.setMode("prioritycontrol");
@@ -1105,7 +1535,7 @@ async function makeMachines(){
const percMax = 100; const percMax = 100;
try{ try{
/*
for(let demand = mg.dynamicTotals.flow.min ; demand <= mg.dynamicTotals.flow.max ; demand += 2){ for(let demand = mg.dynamicTotals.flow.min ; demand <= mg.dynamicTotals.flow.max ; demand += 2){
//set pressure //set pressure
@@ -1155,6 +1585,8 @@ async function makeMachines(){
} }
makeMachines(); if (require.main === module) {
makeMachines();
}
//*/ //*/

12
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@@ -0,0 +1,12 @@
# 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

0
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@@ -0,0 +1,8 @@
const test = require('node:test');
const assert = require('node:assert/strict');
test('machineGroupControl module load smoke', () => {
assert.doesNotThrow(() => {
require('../../mgc.js');
});
});

0
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@@ -0,0 +1,11 @@
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);
});

0
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@@ -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)}%`);
}
});

View File

@@ -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)}`
);
});

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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);
}
});