docs: initialize project wiki from production hardening session
12 pages covering architecture, findings, and metrics from the
rotatingMachine + machineGroupControl hardening work:
- Overview: node inventory, what works/doesn't, current scale
- Architecture: 3D pump curves, group optimization algorithm
- Findings: BEP-Gravitation proof (0.1% of optimum), NCog behavior,
curve non-convexity, pump switching stability
- Metrics: test counts, power comparison table, performance numbers
- Knowledge graph: structured YAML with all data points and provenance
- Session log: 2026-04-07 production hardening
- Tools: query.py, search.sh, lint.sh
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
2026-04-07 16:36:08 +02:00
---
title: "Session: Production Hardening rotatingMachine + machineGroupControl"
created: 2026-04-07
updated: 2026-04-07
status: proven
tags: [session, rotatingMachine, machineGroupControl, testing]
---
wiki: audit + archive stale pages; refresh Home for 2026-05-11 wave
- Archived 20 pre-refactor pages to wiki/Archive/ with standard banners:
- All 6 architecture/ pages (old _loadConfig/_setupSpecificClass internals,
pre-refactor S88 hierarchy, deployment blueprint)
- All 3 sessions/ logs (Apr-07 + Apr-13 session summaries)
- findings/open-issues-2026-03.md (issues 1-5 all resolved by refactor)
- concepts/generalfunctions-api.md (missing BaseDomain/BaseNodeAdapter)
- concepts/sources-readme.md (empty PDF placeholder, never populated)
- manuals/nodes/rotatingMachine.md + measurement.md (superseded by per-repo wikis)
- Top-level SCHEMA.md, index.md, log.md, metrics.md, overview.md,
knowledge-graph.yaml (all Apr-07 snapshot, pre-refactor)
- Kept wiki/concepts/ domain pages (ASM, PID, pump-affinity, settling, etc.)
- Kept wiki/findings/ proven results (BEP, NCog, curve-non-convexity, stability)
- Kept wiki/manuals/node-red/* (FlowFuse + Node-RED runtime docs, still current)
- Kept wiki/tools/* (utility scripts)
- Updated wiki/Archive.md index with 20 rows
- Fixed wiki/Home.md: Tier 6 was wrongly marked done; corrected to pending;
Tier 9 updated to reflect 2026-05-11 in-progress wave
Co-Authored-By: Claude Opus 4.7 (1M context) <noreply@anthropic.com>
2026-05-11 21:07:48 +02:00
> **⚠️ ARCHIVED — pre-refactor (Tier 1–
>
> This page describes the architecture before the platform refactor.
> The current page is the per-node wiki on **[gitea.wbd-rd.nl/RnD](https://gitea.wbd-rd.nl/RnD)** or **[Home](../Home)**.
>
> Kept for historical reference only. **Do not update.**
docs: initialize project wiki from production hardening session
12 pages covering architecture, findings, and metrics from the
rotatingMachine + machineGroupControl hardening work:
- Overview: node inventory, what works/doesn't, current scale
- Architecture: 3D pump curves, group optimization algorithm
- Findings: BEP-Gravitation proof (0.1% of optimum), NCog behavior,
curve non-convexity, pump switching stability
- Metrics: test counts, power comparison table, performance numbers
- Knowledge graph: structured YAML with all data points and provenance
- Session log: 2026-04-07 production hardening
- Tools: query.py, search.sh, lint.sh
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
2026-04-07 16:36:08 +02:00
# 2026-04-07 — Production Hardening
## Scope
Full code review and hardening of rotatingMachine and machineGroupControl nodes for production readiness.
## Key Discoveries
1. **Efficiency rounding destroyed NCog/BEP ** — `Math.round(Q/P * 100) / 100` in canonical units (m3/s and W) produces ratios ~1e-6 that all round to 0. All NCog, cog, and BEP calculations were non-functional. Fixed by removing rounding.
2. **flowmovement unit mismatch ** — machineGroupControl computed flow in canonical (m3/s) and sent it directly to rotatingMachine which expected output units (m3/h). Every pump stayed at minimum flow. Fixed with `_canonicalToOutputFlow()` .
3. **emergencyStop case mismatch ** — `"emergencyStop"` vs config key `"emergencystop"` . Emergency stop never worked. Fixed to lowercase.
4. **Curve data anomalies ** — 3 flow values leaked into power columns in hidrostal-H05K-S03R.json at pressures 1600, 3200, 3300 mbar. Fixed with interpolated values.
5. **C5 pump non-convexity ** — 5 data points per pressure level produces non-convex spline. The marginal-cost refinement loop closes the gap to brute-force optimum from 2.1% to 0.1%.
## Changes Made
### rotatingMachine (3 files, 7 test files)
- Async input handler, null guards, listener cleanup, tick loop race fix
- showCoG() implementation, efficiency variant fix, curve anomaly detection
- 43 new tests (76 total)
### machineGroupControl (1 file, 2 test files)
- `_canonicalToOutputFlow()` on all flowmovement calls
- Absolute scaling bug, empty Qd block, empty-machines guards
- Marginal-cost refinement loop in BEP-Gravitation
- Missing flowmovement after startup in equalFlowControl
### generalFunctions (1 file)
- 3 curve data fixes in hidrostal-H05K-S03R.json
## Verification
- 90 tests passing across both nodes
- machineGroupControl within 0.1% of brute-force global optimum (1000-step search)
- Pump switching stable: 1-2 transitions across full demand range, no hysteresis
- Optimization cost: 0.03-0.15ms per call (0.015% of tick budget)
