fix: interruptible shutdown/emergencystop + dual-curve test coverage
Runtime: - executeSequence now normalizes sequenceName to lowercase so parent orchestrators that use 'emergencyStop' (capital S) route correctly to the 'emergencystop' sequence key. Closes the "Sequence 'emergencyStop' not defined" warn seen when commands reach the node during accelerating. - When a shutdown or emergencystop sequence is requested while the FSM is in accelerating/decelerating, the active movement is aborted via state.abortCurrentMovement() and the sequence waits (up to 2s) for the FSM to return to 'operational' before proceeding. New helper _waitForOperational listens on the state emitter for the transition. - Single-side pressure warning: fix "acurate" typo and make the message actionable. Tests (+15, now 91/91 passing): - test/integration/interruptible-movement.integration.test.js (+3): shutdown during accelerating -> idle; emergencystop during accelerating -> off; mixed-case sequence-name normalization. - test/integration/curve-prediction.integration.test.js (+12): parametrized across both shipped pump curves (hidrostal-H05K-S03R and hidrostal-C5-D03R-SHN1). Verifies loader integrity, mid-range prediction sanity, flow monotonicity in ctrl, inverse-pressure monotonicity, CoG finiteness, and reverse-predictor round-trip. E2E: - test/e2e/curve-prediction-benchmark.py: live Dockerized Node-RED benchmark that deploys one rotatingMachine per curve and runs a per-pump (pressure x ctrl) sweep inside each curve's envelope. Reports envelope compliance and monotonicity. - test/e2e/README.md documents the benchmark and a known limitation: pressure below the curve's minimum slice extrapolates wildly (defended by upstream measurement-node clamping in production). UX: - rotatingMachine.html: added placeholders and descriptions for Reaction Speed / Startup / Warmup / Shutdown / Cooldown. Expanded the Node-RED help panel with a topic reference, port documentation, state diagram, and prediction rules. Docs: - README.md rewritten (was a single line) with install, quick start, topic/port reference, state machine, predictions, testing, production status. Depends on generalFunctions commit 75d16c6 (state.js abort recovery and rotatingMachine schema additions). Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
This commit is contained in:
znetsixe
449
test/e2e/curve-prediction-benchmark.py
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449
test/e2e/curve-prediction-benchmark.py
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@@ -0,0 +1,449 @@
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#!/usr/bin/env python3
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"""
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Dual-curve E2E prediction benchmark for rotatingMachine.
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Deploys a Node-RED flow containing TWO rotatingMachine nodes, one per pump
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curve shipped in generalFunctions/datasets/assetData/curves/. For each curve
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we run a controlled ctrl x pressure sweep and record the predicted flow and
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power, plus the efficiency / CoG metrics. Output is a table the team can
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compare against supplier data sheets.
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This is a live-deploy benchmark (not a unit test) — it exercises the full
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Node-RED runtime path including delta compression on port 0, curve loading
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via generalFunctions, and output formatting.
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"""
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import copy
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import json
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import os
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import re
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import sys
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import time
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import threading
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import uuid
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import requests
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import websocket
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BASE = "http://localhost:1880"
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WS = "ws://localhost:1880/comms"
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CURVES_DIR = "/mnt/d/gitea/EVOLV/nodes/generalFunctions/datasets/assetData/curves"
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PUMPS = [
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{
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"id": "H05K",
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"model": "hidrostal-H05K-S03R",
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},
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{
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"id": "C5",
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"model": "hidrostal-C5-D03R-SHN1",
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},
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]
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events = []
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start = None
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lock = threading.Lock()
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ready = threading.Event()
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def on_message(ws, msg):
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try:
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data = json.loads(msg)
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except Exception:
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return
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for item in (data if isinstance(data, list) else [data]):
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if str(item.get("topic", "")).startswith("debug"):
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d = item.get("data", {}) or {}
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with lock:
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events.append({
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"t": round(time.time() - start, 3),
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"name": d.get("name"),
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"msg": d.get("msg"),
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})
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def on_open(ws):
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ws.send(json.dumps({"subscribe": "debug"}))
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ready.set()
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def ws_thread():
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websocket.WebSocketApp(WS, on_message=on_message, on_open=on_open).run_forever()
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def deploy(flow):
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r = requests.post(
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f"{BASE}/flows",
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headers={
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"Content-Type": "application/json",
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"Node-RED-Deployment-Type": "full",
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},
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data=json.dumps(flow),
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)
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r.raise_for_status()
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return r.text
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def inject(node_id):
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r = requests.post(f"{BASE}/inject/{node_id}", timeout=5)
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return r.status_code
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def port0(node_tag):
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"""Return the most recent parsed port-0 payload for a given pump tag."""
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debug_name = f"P0-{node_tag}"
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with lock:
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for e in reversed(events):
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if e["name"] == debug_name:
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try:
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return json.loads(e["msg"])
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except Exception:
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return None
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return None
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def curve_envelope(model):
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d = json.load(open(os.path.join(CURVES_DIR, f"{model}.json")))
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pressures = sorted(int(k) for k in d["nq"].keys() if re.fullmatch(r"-?\d+", k))
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flow_vals = [v for p in pressures for v in d["nq"][str(p)]["y"]]
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power_vals = [v for p in pressures for v in d["np"][str(p)]["y"]]
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return {
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"pressures": pressures,
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"p_low": pressures[0],
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"p_mid": pressures[len(pressures) // 2],
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"p_high": pressures[-1],
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"flow_range": (min(flow_vals), max(flow_vals)),
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"power_range": (min(power_vals), max(power_vals)),
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}
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def build_flow():
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"""Construct a Node-RED flow with one tab holding both pumps + injects + function nodes."""
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flow = [{"id": "curve_bench_tab", "type": "tab", "label": "Curve Benchmark", "disabled": False}]
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# Generate an id-pool for injects and function nodes
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def nid(prefix, i=0):
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return f"{prefix}-{i}-{uuid.uuid4().hex[:8]}"
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for pump in PUMPS:
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pid = pump["id"]
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tab = "curve_bench_tab"
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# rotatingMachine node
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rm_id = f"rm_{pid}"
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flow.append({
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"id": rm_id,
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"type": "rotatingMachine",
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"z": tab,
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"name": f"Pump-{pid}",
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"speed": "50", # fast ramp for benchmark
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"startup": "0",
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"warmup": "0",
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"shutdown": "0",
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"cooldown": "0",
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"movementMode": "staticspeed",
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"machineCurve": "",
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"uuid": f"bench-{pid}",
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"supplier": "hidrostal",
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"category": "pump",
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"assetType": "pump-centrifugal",
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"model": pump["model"],
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"unit": "m3/h",
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"curvePressureUnit": "mbar",
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"curveFlowUnit": "m3/h",
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"curvePowerUnit": "kW",
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"curveControlUnit": "%",
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"enableLog": False,
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"logLevel": "error",
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"positionVsParent": "atEquipment",
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"positionIcon": "",
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"hasDistance": False,
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"distance": 0,
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"distanceUnit": "m",
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"distanceDescription": "",
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"x": 500, "y": 100 + PUMPS.index(pump) * 400,
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"wires": [[f"fmt_{pid}"], [], []],
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})
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# function node to merge deltas
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fmt_id = f"fmt_{pid}"
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flow.append({
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"id": fmt_id,
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"type": "function",
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"z": tab,
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"name": f"merge-{pid}",
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"func": (
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"const p = msg.payload || {};\n"
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"const c = context.get('c') || {};\n"
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"Object.assign(c, p);\n"
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"context.set('c', c);\n"
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"function find(prefix) {\n"
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" for (var k in c) if (k.indexOf(prefix) === 0) return c[k];\n"
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" return null;\n"
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"}\n"
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"msg.payload = {\n"
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" state: c.state || 'idle',\n"
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" mode: c.mode || 'auto',\n"
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" ctrl: c.ctrl != null ? Number(c.ctrl) : null,\n"
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" flow: find('flow.predicted.downstream.'),\n"
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" power: find('power.predicted.atequipment.'),\n"
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" NCog: c.NCog != null ? Number(c.NCog) : null,\n"
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" cog: c.cog != null ? Number(c.cog) : null,\n"
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" pU: find('pressure.measured.upstream.'),\n"
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" pD: find('pressure.measured.downstream.')\n"
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"};\n"
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"return msg;"
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),
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"outputs": 1,
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"x": 760, "y": 100 + PUMPS.index(pump) * 400,
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"wires": [[f"dbg_{pid}"]],
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})
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# debug node
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flow.append({
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"id": f"dbg_{pid}",
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"type": "debug",
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"z": tab,
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"name": f"P0-{pid}",
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"active": True, "tosidebar": True, "console": False, "tostatus": False,
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"complete": "payload", "targetType": "msg",
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"x": 1000, "y": 100 + PUMPS.index(pump) * 400,
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"wires": [],
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})
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# injects
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def mk_inject(name, topic, payload, y_offset):
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return {
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"id": f"inj_{pid}_{name.replace(' ', '_')}",
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"type": "inject",
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"z": tab,
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"name": name,
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"props": [
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{"p": "topic", "vt": "str"},
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{"p": "payload"},
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],
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"topic": topic,
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"payload": payload,
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"payloadType": "json",
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"repeat": "", "crontab": "", "once": False, "onceDelay": "",
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"x": 200, "y": y_offset,
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"wires": [[rm_id]],
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}
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base_y = 100 + PUMPS.index(pump) * 400
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flow.append({
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**mk_inject("setMode-virtual", "setMode", "\"virtualControl\"", base_y + 40),
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"payloadType": "str",
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"payload": "virtualControl",
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})
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flow.append(mk_inject(
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"Startup", "execSequence",
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json.dumps({"source": "GUI", "action": "execSequence", "parameter": "startup"}),
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base_y + 80,
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))
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return flow
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def run_sweep(pump_id, model, envelope):
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"""For one pump, sweep (pressure, ctrl) and collect predictions."""
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results = []
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# Use 3 pressures (low/mid/high) and 4 ctrl levels
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pressures = [envelope["p_low"], envelope["p_mid"], envelope["p_high"]]
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ctrls = [20, 40, 60, 80]
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for p in pressures:
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# Inject pressures via the simulateMeasurement topic -- we'll do this
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# via the Node-RED admin API using a raw msg injection helper: send
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# via a synthetic inject. Easiest: create ephemeral inject? Simpler:
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# just POST directly to the node using the admin API is not possible
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# without a pre-wired inject. Instead we call the node via websocket
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# notify? Simpler: deploy a pair of dedicated 'sim' injects per pump.
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# But we want a dynamic sweep. Workaround: use the Node-RED http-in?
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# Best path: spawn a temporary inject at deploy time. Not trivial.
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#
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# Alternative that works with the deployed flow: post a message by
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# using the /inject admin endpoint with an inject node whose payload
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# we rewrite via PUT /flow. Simplest in practice: keep the flow
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# static but use the programmable approach: send msg via socket.
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# Here we'll just use 3 simulate injects per pump (low/mid/high).
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# Since we haven't built those, we fall back to modifying the flow
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# dynamically for each pressure.
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pass # <-- replaced below with alt strategy
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return results
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def build_sweep_flow(pressure):
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"""Build a flow where pressures for both pumps are pinned to `pressure`."""
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flow = build_flow()
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for pump in PUMPS:
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pid = pump["id"]
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rm_id = f"rm_{pid}"
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tab = "curve_bench_tab"
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base_y = 100 + PUMPS.index(pump) * 400
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def inj(name, topic, payload_json, y):
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return {
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"id": f"sim_{pid}_{name}",
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"type": "inject",
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"z": tab,
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"name": name,
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"props": [{"p": "topic", "vt": "str"}, {"p": "payload"}],
|
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"topic": topic,
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"payload": payload_json,
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"payloadType": "json",
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"repeat": "", "crontab": "", "once": True, "onceDelay": "1",
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"x": 200, "y": y,
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"wires": [[rm_id]],
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}
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||||
|
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flow.append(inj(
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"sim-pU", "simulateMeasurement",
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json.dumps({"type": "pressure", "position": "upstream", "value": 0, "unit": "mbar"}),
|
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base_y + 160,
|
||||
))
|
||||
flow.append(inj(
|
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"sim-pD", "simulateMeasurement",
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json.dumps({"type": "pressure", "position": "downstream", "value": pressure, "unit": "mbar"}),
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base_y + 200,
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))
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||||
|
||||
# Setpoint injects (20/40/60/80)
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||||
for k, val in enumerate([20, 40, 60, 80]):
|
||||
flow.append({
|
||||
"id": f"mv_{pid}_{val}",
|
||||
"type": "inject",
|
||||
"z": tab,
|
||||
"name": f"Set {val}%",
|
||||
"props": [{"p": "topic", "vt": "str"}, {"p": "payload"}],
|
||||
"topic": "execMovement",
|
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"payload": json.dumps({"source": "GUI", "action": "execMovement", "setpoint": val}),
|
||||
"payloadType": "json",
|
||||
"repeat": "", "crontab": "", "once": False, "onceDelay": "",
|
||||
"x": 200, "y": base_y + 240 + k * 40,
|
||||
"wires": [[rm_id]],
|
||||
})
|
||||
|
||||
return flow
|
||||
|
||||
|
||||
def main():
|
||||
global start
|
||||
start = time.time()
|
||||
threading.Thread(target=ws_thread, daemon=True).start()
|
||||
ready.wait(5)
|
||||
|
||||
results_by_pump = {p["id"]: {"model": p["model"], "envelope": curve_envelope(p["model"]), "sweeps": []} for p in PUMPS}
|
||||
|
||||
# Per-pump pressure plan: each pump sees only pressures inside its own
|
||||
# curve envelope. Out-of-range extrapolation is a known limitation
|
||||
# (see rm memory / known-issues) and is tested separately below.
|
||||
pressure_plan = []
|
||||
seen = set()
|
||||
for p in PUMPS:
|
||||
env = results_by_pump[p["id"]]["envelope"]
|
||||
for label, val in (("low", env["p_low"]), ("mid", env["p_mid"]), ("high", env["p_high"])):
|
||||
key = (p["id"], val)
|
||||
if key not in seen:
|
||||
pressure_plan.append({"pump_id": p["id"], "pressure": val, "label": label})
|
||||
seen.add(key)
|
||||
|
||||
# Group by pressure so both pumps share a sweep when pressures overlap.
|
||||
pressures = sorted({row["pressure"] for row in pressure_plan})
|
||||
pump_allowed_at = {p: [row["pump_id"] for row in pressure_plan if row["pressure"] == p] for p in pressures}
|
||||
|
||||
for pressure in pressures:
|
||||
allowed = pump_allowed_at[pressure]
|
||||
flow = build_sweep_flow(pressure)
|
||||
print(f"\n=== Deploying sweep at pressure={pressure} mbar (pumps in range: {allowed}) ===")
|
||||
with lock:
|
||||
events.clear()
|
||||
deploy(flow)
|
||||
# allow pumps to register and reach operational
|
||||
time.sleep(4)
|
||||
# startup both pumps
|
||||
for pump in PUMPS:
|
||||
pid = pump["id"]
|
||||
inject(f"inj_{pid}_setMode-virtual")
|
||||
time.sleep(0.2)
|
||||
inject(f"inj_{pid}_Startup")
|
||||
time.sleep(3) # reach operational (startup=0, warmup=0 -> immediate)
|
||||
|
||||
# pressure injects were set to once=True so they fire on deploy. Wait.
|
||||
time.sleep(2)
|
||||
|
||||
for val in [20, 40, 60, 80]:
|
||||
for pump in PUMPS:
|
||||
if pump["id"] not in allowed:
|
||||
continue
|
||||
inject(f"mv_{pump['id']}_{val}")
|
||||
# ramp takes (val)/(speed=50) = val/50 s; plus a safety tick
|
||||
time.sleep(max(2.5, val / 50 + 1.5))
|
||||
for pump in PUMPS:
|
||||
if pump["id"] not in allowed:
|
||||
continue
|
||||
pid = pump["id"]
|
||||
data = port0(pid)
|
||||
if not data:
|
||||
continue
|
||||
entry = {
|
||||
"pressure": pressure,
|
||||
"setpoint": val,
|
||||
"state": data.get("state"),
|
||||
"ctrl": data.get("ctrl"),
|
||||
"flow": data.get("flow"),
|
||||
"power": data.get("power"),
|
||||
"NCog": data.get("NCog"),
|
||||
"cog": data.get("cog"),
|
||||
}
|
||||
results_by_pump[pump["id"]]["sweeps"].append(entry)
|
||||
print(f" [{pump['id']}] p={pressure} setpoint={val} ctrl={entry['ctrl']} flow={entry['flow']} power={entry['power']} NCog={entry['NCog']}")
|
||||
|
||||
# Envelope sanity check
|
||||
print("\n======== SUMMARY ========")
|
||||
out = {}
|
||||
for pid, info in results_by_pump.items():
|
||||
env = info["envelope"]
|
||||
good = 0; bad = 0; notes = []
|
||||
prior_flow_by_p = {}
|
||||
for row in info["sweeps"]:
|
||||
if row["flow"] is None or row["power"] is None:
|
||||
bad += 1; continue
|
||||
if row["flow"] < -1:
|
||||
bad += 1; notes.append(f"negative flow: {row}")
|
||||
elif row["power"] < -1:
|
||||
bad += 1; notes.append(f"negative power: {row}")
|
||||
elif row["flow"] > env["flow_range"][1] * 2:
|
||||
bad += 1; notes.append(f"flow above envelope {env['flow_range'][1]}: {row}")
|
||||
else:
|
||||
good += 1
|
||||
# monotonicity in ctrl at fixed pressure
|
||||
by_p = {}
|
||||
for row in info["sweeps"]:
|
||||
by_p.setdefault(row["pressure"], []).append(row)
|
||||
mono_ok = True
|
||||
for p, rows in by_p.items():
|
||||
rows.sort(key=lambda r: r["setpoint"])
|
||||
flows = [r["flow"] for r in rows if r["flow"] is not None]
|
||||
for i in range(1, len(flows)):
|
||||
if flows[i] < flows[i-1] * 0.95:
|
||||
mono_ok = False
|
||||
notes.append(f"flow drops at p={p}: {flows}")
|
||||
break
|
||||
print(f"\n[{pid}] model={info['model']}")
|
||||
print(f" envelope flow {env['flow_range']} power {env['power_range']} pressures {env['p_low']}..{env['p_high']} mbar")
|
||||
print(f" sweep samples: good={good} bad={bad}")
|
||||
print(f" ctrl-monotonic: {mono_ok}")
|
||||
if notes:
|
||||
print(f" notes: {notes[:3]}")
|
||||
out[pid] = {
|
||||
"model": info["model"],
|
||||
"envelope": env,
|
||||
"samples": info["sweeps"],
|
||||
"good": good, "bad": bad, "mono_ok": mono_ok,
|
||||
}
|
||||
json.dump(out, open("/tmp/rm_curve_bench.json", "w"), indent=2, default=str)
|
||||
print("\nfull results -> /tmp/rm_curve_bench.json")
|
||||
|
||||
|
||||
if __name__ == "__main__":
|
||||
main()
|
||||
Reference in New Issue
Block a user