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
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@@ -21,6 +21,7 @@ class TempControllerBase(TempControllerFsm, APid):
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self.params = None
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self._inner_heat_params = None
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self._inner_hold_params = None
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self._outer_hold_y_min = 0.0
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self.y = -1
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# Heat-rate pre-filter state (option A) - None until first process() tick
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self.last_theta_ist = None
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@@ -32,6 +33,11 @@ class TempControllerBase(TempControllerFsm, APid):
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self.thresholds = {**DEFAULT_THRESHOLDS, **params.get('Thresholds', {})}
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self.beta = params.get('beta', 0.05)
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self.pid_outer.set_params(params['Outer'])
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# How far into "actively cool" pid_outer is allowed to reach during
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# HOLD - see the floor in process_pid() below. Defaults to 0.0
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# (old flat-clamp behaviour) so configs that don't set it are
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# unaffected.
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self._outer_hold_y_min = params['Outer'].get('y_hold_min', 0.0)
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self._inner_heat_params = params['Inner']['Heat']
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self._inner_hold_params = params['Inner']['Hold']
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self.pid_inner_cool.set_params(params['Inner']['Cool'])
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@@ -135,14 +141,21 @@ class TempControllerBase(TempControllerFsm, APid):
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def process_pid(self, theta_err, hold_scale=1.0):
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self.pid_outer.process(theta_err, -self.theta_ist, hold_scale)
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# In HOLD state, clamp pid_outer's output to [0, 1]: a small temperature
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# overshoot makes pid_outer.y go negative, which would invert heatrate_soll
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# and drive pid_inner's power to 0, causing a limit cycle (power on →
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# overshoot → power off → coast down → repeat). Clamping to 0 lets the
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# outer loop reduce the inner setpoint to zero but no further.
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# In HOLD state, floor pid_outer's output at Outer.y_hold_min (<= 0)
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# rather than letting it swing all the way to -1: a large negative
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# heatrate_soll asks for a decline far steeper than the pot's own
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# ambient heat loss can deliver, so pid_inner pins power at 0 for an
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# extended stretch, undershoots, and swings back hard - a ~110s
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# limit cycle (see git history for this clamp). A small negative
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# floor instead lets HOLD ask for a gentle decline that roughly
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# matches passive cooling, so a small overshoot coasts back down to
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# setpoint instead of sitting in a permanent flat-clamp dead zone
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# (the outer loop otherwise commands "stay flat" forever, and
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# pid_inner actively fights the pot's own ambient loss to hold that
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# flat line - see docs/overshoot_hold_windup.md).
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pid_outer_y = self.pid_outer.get_y()
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if self.state == States.HOLD:
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pid_outer_y = max(0.0, pid_outer_y)
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pid_outer_y = max(self._outer_hold_y_min, pid_outer_y)
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self.heatrate_soll = self.heatrate_soll_set * pid_outer_y
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heatrate_err = self.heatrate_soll - self.heatrate_ist
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