fix: allow gentle negative HOLD floor to fix steady-state overshoot
Testing the windup-fix rework live against sude/sud_0030.json surfaced a
distinct bug: a HOLD overshoot from grain-fill-in cooling never decayed -
process_pid()'s pid_outer_y floor clamped to exactly 0.0, so pid_inner
fought the pot's own ambient loss to hold the overshot temperature flat
instead of declining back to setpoint (see docs/overshoot2.png).
Replace the hardcoded 0.0 floor with a configurable Outer.y_hold_min
(default 0.0, backward compatible), set to -0.1 in config.json, both
.tpl templates, and the demo scripts - small enough to avoid
reintroducing the bb5af3c limit cycle while letting HOLD request a
gentle decline matching passive ambient cooling.
Adds TestHoldOvershootRecoversToSetpoint and documents the finding in
docs/overshoot_hold_windup.md's Follow-up section and
components/pid/TODO.md. Confirmed against a live sud_0030 re-run, not
just the unit test.
Co-Authored-By: Claude Sonnet 5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01M2ierBoxW3v7nUbDw3M2pE
This commit is contained in:
@@ -99,6 +99,25 @@ git history for `temp_controller.py`/`temp_controller_smith.py`).
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cases) was added under `tests/components/pid/` — see the "No automated
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tests" item above.
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- [x] **HOLD overshoot was a permanent steady-state offset, not just a
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transient windup.** Found testing the rework against a real Sud run
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(`sude/sud_0030.json`): a grain-fill-in disturbance during a `HOLD`
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overshot by ~0.4°C (under the `HoldCool` threshold, so the FSM stayed in
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`HOLD`) and then never converged back — `temp_ist` sat in a 55.3-55.4°C
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band for the rest of the 20-minute hold instead of returning to 55.0.
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Cause: `process_pid()`'s HOLD-state floor on `pid_outer_y` clamped to
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exactly `0.0`, so once overshot, `heatrate_soll` = 0 ("hold flat") and
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`pid_inner` actively fought the pot's own ambient loss to keep the
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overshot temperature flat instead of declining back to setpoint. Fixed:
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the floor is now a configurable `Outer.y_hold_min` (default `0.0`,
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backward compatible), set to `-0.1` in `config.json`/both `.tpl`
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templates, letting HOLD request a gentle decline that roughly matches
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passive ambient cooling without reopening the `bb5af3c` limit cycle
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(fully unclamped negative). See the "Follow-up" section in
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`docs/overshoot_hold_windup.md` and
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`TestHoldOvershootRecoversToSetpoint` in
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`tests/components/pid/test_temp_controller_closed_loop.py`.
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- [ ] **`kalman.py` is now dead code in production.** Neither
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`temp_controller.py` nor `temp_controller_smith.py` uses `Kalman`
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anymore; the only remaining references are
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