machineGroupControl/src/groupcontrol.test.js

'use strict';

const MachineGroup = require('./specificClass');
const Machine = require('../../rotatingMachine/src/specificClass');
const Measurement = require('../../measurement/src/specificClass');
const baseCurve = require('../../generalFunctions/datasets/assetData/curves/hidrostal-H05K-S03R.json');

const CONTROL_MODES = ['optimalcontrol', 'prioritycontrol', 'prioritypercentagecontrol'];
const MODE_LABELS = {
  optimalcontrol: 'OPT',
  prioritycontrol: 'PRIO',
  prioritypercentagecontrol: 'PERC'
};

const stateConfig = {
  time: { starting: 0, warmingup: 0, stopping: 0, coolingdown: 0, emergencystop: 0 },
  movement: { speed: 1200, mode: 'staticspeed', maxSpeed: 1800 }
};

const ptConfig = {
  general: { logging: { enabled: false, logLevel: 'error' }, name: 'synthetic-pt', id: 'pt-1', unit: 'mbar' },
  functionality: {
    softwareType: 'measurement',
    role: 'sensor',
    positionVsParent: 'downstream'
  },
  asset: { category: 'sensor', type: 'pressure', model: 'synthetic-pt', supplier: 'lab', unit: 'mbar' },
  scaling: { absMin: 0, absMax: 4000 }
};

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 {
    general: { logging: { enabled: false, logLevel: 'error' }, name: `machinegroup-${name}` },
    functionality: { softwareType: 'machinegroup', role: 'groupcontroller' },
    scaling: { current: 'normalized' },
    mode: { current: 'optimalcontrol' }
  };
}

function sleep(ms) {
  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: {
        auto: ['parent', 'GUI'],
        virtualControl: ['GUI'],
        fysicalControl: ['fysical']
      }
    },
    sequences: {
      startup: ['starting', 'warmingup', 'operational'],
      shutdown: ['stopping', 'coolingdown', 'idle'],
      emergencystop: ['emergencystop', 'off'],
      boot: ['idle', 'starting', 'warmingup', 'operational']
    }
  };
}

async function bootstrapScenarioMachines(scenario) {
  const mg = new MachineGroup(createGroupConfig(scenario.name));
  const pt = new Measurement(ptConfig);

  for (const machineDef of scenario.machines) {
    const machine = new Machine(createMachineConfig(machineDef.id, machineDef.label), stateConfig);
    if (machineDef.curveMods) {
      machine.updateCurve(createSyntheticCurve(machineDef.curveMods));
    }
    mg.childRegistrationUtils.registerChild(machine, 'downstream');
    machine.childRegistrationUtils.registerChild(pt, 'downstream');
  }

  await sleep(25);
  return { mg, pt };
}

function captureTotals(mg) {
  const flow = mg.measurements.type('flow').variant('predicted').position('atequipment').getCurrentValue() || 0;
  const power = mg.measurements.type('power').variant('predicted').position('atequipment').getCurrentValue() || 0;
  const efficiency = mg.measurements.type('efficiency').variant('predicted').position('atequipment').getCurrentValue() || 0;
  return { flow, power, efficiency };
}

function computeAbsoluteTargets(dynamicTotals, percentages) {
  const { flow } = dynamicTotals;
  const min = Number.isFinite(flow.min) ? flow.min : 0;
  const max = Number.isFinite(flow.max) ? flow.max : 0;
  const span = Math.max(max - min, 1);
  return percentages.map(percent => {
    const pct = Math.max(0, Math.min(1, percent));
    return min + pct * span;
  });
}

async function driveModeToFlow({ mg, pt, mode, pressure, targetFlow, priorityOrder }) {
  await setPressure(pt, pressure);
  await sleep(15);

  mg.setMode(mode);
  mg.setScaling('normalized'); // required for prioritypercentagecontrol, works for others too

  const dynamic = mg.calcDynamicTotals();
  const span = Math.max(dynamic.flow.max - dynamic.flow.min, 1);
  const normalizedTarget = ((targetFlow - dynamic.flow.min) / span) * 100;

  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
      };
    }

    if (totals.flow > targetFlow) {
      high = demand;
    } else {
      low = demand;
    }
    demand = (low + high) / 2;
  }

  return best;
}

function formatEfficiencyRows(rows) {
  return rows.map(row => {
    const optimal = row.modes.optimalcontrol;
    const priority = row.modes.prioritycontrol;
    const percentage = row.modes.prioritypercentagecontrol;
    return {
      pressure: row.pressure,
      targetFlow: Number(row.targetFlow.toFixed(1)),
      [`${MODE_LABELS.optimalcontrol}_Flow`]: Number(optimal.flow.toFixed(1)),
      [`${MODE_LABELS.optimalcontrol}_Eff`]: Number(optimal.efficiency.toFixed(3)),
      [`${MODE_LABELS.prioritycontrol}_Flow`]: Number(priority.flow.toFixed(1)),
      [`${MODE_LABELS.prioritycontrol}_Eff`]: Number(priority.efficiency.toFixed(3)),
      [`Δ${MODE_LABELS.prioritycontrol}-OPT_Eff`]: Number(
        (priority.efficiency - optimal.efficiency).toFixed(3)
      ),
      [`${MODE_LABELS.prioritypercentagecontrol}_Flow`]: Number(percentage.flow.toFixed(1)),
      [`${MODE_LABELS.prioritypercentagecontrol}_Eff`]: Number(percentage.efficiency.toFixed(3)),
      [`Δ${MODE_LABELS.prioritypercentagecontrol}-OPT_Eff`]: Number(
        (percentage.efficiency - optimal.efficiency).toFixed(3)
      )
    };
  });
}

function summarizeEfficiency(rows) {
  const map = new Map();
  rows.forEach(row => {
    CONTROL_MODES.forEach(mode => {
      const key = `${row.scenario}-${mode}`;
      if (!map.has(key)) {
        map.set(key, {
          scenario: row.scenario,
          mode,
          samples: 0,
          avgFlowDiff: 0,
          avgEfficiency: 0
        });
      }
      const bucket = map.get(key);
      const stats = row.modes[mode];
      bucket.samples += 1;
      bucket.avgFlowDiff += Math.abs(stats.flow - row.targetFlow);
      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);

  const rows = [];

  for (const pressure of scenario.pressures) {
    await setPressure(pt, pressure);
    await sleep(20);

    const dynamicTotals = mg.calcDynamicTotals();
    const targets = computeAbsoluteTargets(dynamicTotals, scenario.flowTargetsPercent || [0, 0.5, 1]);

    for (let idx = 0; idx < targets.length; idx += 1) {
      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 => {
  console.error('Machine group control test harness crashed:', err);
  process.exitCode = 1;
});