b8cb889d87
- 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- manuals/nodes/rotatingMachine.md + measurement.md (superseded by per-repo wikis)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>
55 lines
2.5 KiB
Markdown
55 lines
2.5 KiB
Markdown
---
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title: "Session: Production Hardening rotatingMachine + machineGroupControl"
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created: 2026-04-07
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updated: 2026-04-07
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status: proven
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tags: [session, rotatingMachine, machineGroupControl, testing]
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---
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> **⚠️ ARCHIVED — pre-refactor (Tier 1–4, 2026-05)**
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>
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> This page describes the architecture before the platform refactor.
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> The current page is the per-node wiki on **[gitea.wbd-rd.nl/RnD](https://gitea.wbd-rd.nl/RnD)** or **[Home](../Home)**.
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>
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> Kept for historical reference only. **Do not update.**
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# 2026-04-07 — Production Hardening
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## Scope
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Full code review and hardening of rotatingMachine and machineGroupControl nodes for production readiness.
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## Key Discoveries
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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.
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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()`.
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3. **emergencyStop case mismatch** — `"emergencyStop"` vs config key `"emergencystop"`. Emergency stop never worked. Fixed to lowercase.
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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.
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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%.
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## Changes Made
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### rotatingMachine (3 files, 7 test files)
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- Async input handler, null guards, listener cleanup, tick loop race fix
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- showCoG() implementation, efficiency variant fix, curve anomaly detection
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- 43 new tests (76 total)
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### machineGroupControl (1 file, 2 test files)
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- `_canonicalToOutputFlow()` on all flowmovement calls
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- Absolute scaling bug, empty Qd block, empty-machines guards
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- Marginal-cost refinement loop in BEP-Gravitation
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- Missing flowmovement after startup in equalFlowControl
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### generalFunctions (1 file)
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- 3 curve data fixes in hidrostal-H05K-S03R.json
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## Verification
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- 90 tests passing across both nodes
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- machineGroupControl within 0.1% of brute-force global optimum (1000-step search)
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- Pump switching stable: 1-2 transitions across full demand range, no hysteresis
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- Optimization cost: 0.03-0.15ms per call (0.015% of tick budget)
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