machineGroupControl/test/integration/demand-cycle-walkthrough.integration.test.js

// MGC demand-cycle walkthrough — drive the machine group through a
// configurable demand sweep and print a clean per-step snapshot of every
// pump's state, ctrl%, flow and power. This is a diagnostic test, not a
// strict invariant guard: it asserts only the basics (no stuck states,
// total flow tracks demand) and prints a readable table for visual
// inspection.
//
// Knobs (env vars):
//   STEP_PERCENT   — demand step in percent           (default 10)
//   DWELL_MS       — wait per step for movement       (default 800)
//   HEAD_MBAR      — pump head in mbar                (default 1100)
//   N_PUMPS        — number of identical pumps        (default 3)
//   LOG_DEBUG=1    — enable verbose domain logging    (default off)
//
// Run:
//   node --test nodes/machineGroupControl/test/integration/demand-cycle-walkthrough.integration.test.js
//   STEP_PERCENT=5 DWELL_MS=400 node --test ...
//   LOG_DEBUG=1 node --test ...        # firehose mode

const test = require('node:test');
const assert = require('node:assert/strict');

const MachineGroup = require('../../src/specificClass');
const Machine = require('../../../rotatingMachine/src/specificClass');

const STEP_PERCENT = parseFloat(process.env.STEP_PERCENT || '10');
const DWELL_MS     = parseInt(process.env.DWELL_MS     || '800', 10);
const HEAD_MBAR    = parseFloat(process.env.HEAD_MBAR  || '1100');
const N_PUMPS      = parseInt(process.env.N_PUMPS      || '3', 10);
const LOG_DEBUG    = process.env.LOG_DEBUG === '1';

const HEAD_MBAR_UP   = 0;
const HEAD_MBAR_DOWN = HEAD_MBAR;

const logCfg = { enabled: LOG_DEBUG, logLevel: LOG_DEBUG ? 'debug' : 'error' };

const stateConfig = {
  general: { logging: logCfg },
  state: { current: 'idle' },
  // Fast ramp so each step settles within DWELL_MS.
  movement: { mode: 'staticspeed', speed: 200, maxSpeed: 200, interval: 50 },
  // Zero sequence-step durations — startup/shutdown are instantaneous so
  // the per-step delta is purely the optimizer's response, not waiting
  // for the FSM.
  time: { starting: 0, warmingup: 0, stopping: 0, coolingdown: 0 },
};

function machineConfig(id) {
  return {
    general: { logging: logCfg, name: id, id, unit: 'm3/h' },
    functionality: { softwareType: 'machine', role: 'rotationaldevicecontroller' },
    asset: { model: 'hidrostal-H05K-S03R', unit: 'm3/h' },
    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: logCfg, name: 'mgc', id: 'mgc' },
    functionality: { softwareType: 'machinegroup', role: 'groupcontroller', positionVsParent: 'atEquipment' },
    mode:    { current: 'optimalcontrol' },     // production mode
    // No scaling config: post-refactor MGC has no scaling state. handleInput
    // takes canonical m³/s. Test converts pct → m³/s before dispatch (mirrors
    // what the set.demand handler does for bare-number payloads).
  };
}

function buildGroup() {
  const mgc = new MachineGroup(groupConfig());
  const ids = Array.from({ length: N_PUMPS }, (_, i) => `pump_${String.fromCharCode(97 + i)}`);
  const pumps = ids.map(id => new Machine(machineConfig(id), stateConfig));
  for (const m of pumps) {
    m.updateMeasuredPressure(HEAD_MBAR_UP, 'upstream', {
      timestamp: Date.now(), unit: 'mbar', childName: 'up', childId: `up-${m.config.general.id}` });
    m.updateMeasuredPressure(HEAD_MBAR_DOWN, 'downstream', {
      timestamp: Date.now(), unit: 'mbar', childName: 'dn', childId: `dn-${m.config.general.id}` });
    mgc.childRegistrationUtils.registerChild(m, 'downstream');
  }
  mgc.calcAbsoluteTotals();
  mgc.calcDynamicTotals();
  return { mgc, pumps };
}

const sleep = (ms) => new Promise(r => setTimeout(r, ms));

// States where the pump is not actually producing flow/power. When the FSM
// is parked in any of these, predictFlow.outputY / predictPower.outputY
// still reflect the curve floor at the current operating point — that is
// useful for the optimizer but misleading in this walkthrough table. Show
// zeros instead so each row's per-pump column matches the optimizer's
// chosen split and ΣQ matches Qd.
const NON_RUNNING = new Set(['idle', 'off', 'stopping', 'coolingdown', 'emergencystop']);

function snapshot(pump) {
  const state = pump.state.getCurrentState();
  const ctrl  = Number(pump.state.getCurrentPosition?.() ?? 0);
  const running = !NON_RUNNING.has(state);
  const flow  = running ? Number(pump.predictFlow?.outputY  ?? 0) * 3600 : 0;   // m³/s → m³/h
  const power = running ? Number(pump.predictPower?.outputY ?? 0) / 1000 : 0;   // W   → kW
  return { state, ctrl, flow, power };
}

function fmt(x, w, d = 1) { return Number.isFinite(x) ? x.toFixed(d).padStart(w) : '   n/a'.padStart(w); }

function printHeader(pumps) {
  const head = ['cmd%'.padStart(5), 'Qd m³/h'.padStart(9)];
  for (const p of pumps) {
    head.push('|', `${p.config.general.id}`.padEnd(8), 'state'.padEnd(13), 'ctrl%'.padStart(6),
              'Q m³/h'.padStart(7), 'kW'.padStart(6));
  }
  head.push('|', 'ΣQ m³/h'.padStart(8), 'ΣkW'.padStart(6));
  const line = head.join(' ');
  console.log(line);
  console.log('─'.repeat(line.length));
}

function printRow(pct, demandQout_m3h, pumps) {
  const snaps = pumps.map(snapshot);
  const totalQ = snaps.reduce((s, x) => s + x.flow,  0);
  const totalP = snaps.reduce((s, x) => s + x.power, 0);
  const cells = [fmt(pct, 5), fmt(demandQout_m3h, 9)];
  for (let i = 0; i < pumps.length; i++) {
    const s = snaps[i];
    cells.push('|', ''.padEnd(8), s.state.padEnd(13), fmt(s.ctrl, 6), fmt(s.flow, 7), fmt(s.power, 6));
  }
  cells.push('|', fmt(totalQ, 8), fmt(totalP, 6));
  console.log(cells.join(' '));
  return { totalQ, totalP, snaps };
}

test(`MGC demand-cycle walkthrough — head=${HEAD_MBAR} mbar, ${N_PUMPS} pumps, step=${STEP_PERCENT}%`, async () => {
  const { mgc, pumps } = buildGroup();

  // Bring all pumps to operational up-front so the very first row of the
  // table reflects the optimizer's response, not "the FSM is still
  // booting".
  for (const m of pumps) await m.handleInput('parent', 'execsequence', 'startup');
  for (let i = 0; i < 50 && pumps.some(p => p.state.getCurrentState() !== 'operational'); i++) await sleep(20);
  for (const p of pumps) {
    assert.equal(p.state.getCurrentState(), 'operational',
      `pre-condition: pump ${p.config.general.id} should be operational; got ${p.state.getCurrentState()}`);
  }

  const dyn = mgc.calcDynamicTotals();
  const flowMin_m3h = dyn.flow.min * 3600;
  const flowMax_m3h = dyn.flow.max * 3600;
  const sample = pumps[0].groupPredictFlow ?? pumps[0].predictFlow;
  const perPumpMin_m3h = sample.currentFxyYMin * 3600;
  const perPumpMax_m3h = sample.currentFxyYMax * 3600;

  console.log('');
  console.log(`MGC station envelope at head ${HEAD_MBAR} mbar (${N_PUMPS} pumps):`);
  console.log(`  per-pump: ${perPumpMin_m3h.toFixed(1)} .. ${perPumpMax_m3h.toFixed(1)} m³/h`);
  console.log(`  station: ${flowMin_m3h.toFixed(1)} .. ${flowMax_m3h.toFixed(1)} m³/h`);
  console.log(`  0% → ${flowMin_m3h.toFixed(1)} m³/h, 100% → ${flowMax_m3h.toFixed(1)} m³/h`);
  console.log(`  (demand < 0 turns ALL pumps off; 0 = minimum-control floor)`);
  console.log('');
  printHeader(pumps);

  // Build demand sweep: 0..100% up, then 100..0% down, then -1 (all-off sentinel).
  const upSteps = [];
  for (let pct = 0; pct <= 100 + 1e-9; pct += STEP_PERCENT) upSteps.push(Math.min(pct, 100));
  const downSteps = upSteps.slice(0, -1).reverse();         // skip the duplicate 100
  const sequence = [...upSteps, ...downSteps, -1];

  let stuckSeen = 0;
  for (const pct of sequence) {
    // Post-refactor handleInput takes canonical m³/s; the percent → m³/s
    // mapping the set.demand handler does is replicated here in test.
    if (pct < 0) {
      await mgc.turnOffAllMachines();
    } else {
      const flowMin_m3s = flowMin_m3h / 3600;
      const flowMax_m3s = flowMax_m3h / 3600;
      const canonical = flowMin_m3s + (pct / 100) * (flowMax_m3s - flowMin_m3s);
      await mgc.handleInput('parent', canonical);
    }
    await sleep(DWELL_MS);

    // pct < 0 → all off (Qd = 0); pct >= 0 → linear interpolation across [min, max].
    const demandQout_m3h = pct < 0
      ? 0
      : (flowMax_m3h - flowMin_m3h) * (pct / 100) + flowMin_m3h;

    const { totalQ, snaps } = printRow(pct, demandQout_m3h, pumps);

    // Loose invariants:
    //  - demand > 0% → station total flow within 10% of optimizer's chosen
    //    Qout (allow slack: optimizer may pick a smaller combo for
    //    efficiency, in which case totalQ falls below demand only inside
    //    the per-pump curve envelope; we ONLY check above feasibility).
    //  - no pump should sit in a residue state ('accelerating' /
    //    'decelerating') AFTER the dwell — that's the deadlock symptom
    //    the abort-deadlock test guards against.
    for (const s of snaps) {
      if (s.state === 'accelerating' || s.state === 'decelerating') stuckSeen += 1;
    }

    if (pct < 0) {
      // Strict negative demand turns ALL pumps off (the explicit "all off" signal).
      for (const s of snaps) {
        assert.ok(['idle', 'off', 'stopping', 'coolingdown'].includes(s.state),
          `demand ${pct}% but pump still in '${s.state}' (totalQ=${totalQ.toFixed(2)})`);
      }
    }
  }

  console.log('');
  console.log(`Stuck-state observations across ${sequence.length} steps: ${stuckSeen}`);
  assert.equal(stuckSeen, 0,
    `${stuckSeen} pump×step observations parked in accelerating/decelerating after dwell — ` +
    `would indicate the abort-deadlock regression has returned (state.js post-abort residue).`);
});