machineGroupControl/test/integration/distribution-power-table.integration.test.js

/**
 * 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: { model, 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: { 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)}%`);
  }
});