docs: note active-cooler architecture assessment in pid TODO

Captures the answer to "would the cascade/FSM design still hold up with
a real active cooler instead of heat-only + passive loss": PID/plant
model already generalize (symmetric y range, sign-agnostic plant math,
existing COOL state/pid_inner_cool), but the actor-level max(0, y)
clamp in tasks/heater.py is the one thing making today's tuning
mismatches free - removing it exposes both Outer.y_hold_min and
pid_inner_cool as live, untuned negative-power paths.

Co-Authored-By: Claude Sonnet 5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01M2ierBoxW3v7nUbDw3M2pE
This commit is contained in:
2026-07-06 08:26:25 +02:00
co-authored by Claude Sonnet 5
parent 2d032bf9b2
commit 6d17419067
+37
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@@ -118,6 +118,43 @@ git history for `temp_controller.py`/`temp_controller_smith.py`).
`TestHoldOvershootRecoversToSetpoint` in `TestHoldOvershootRecoversToSetpoint` in
`tests/components/pid/test_temp_controller_closed_loop.py`. `tests/components/pid/test_temp_controller_closed_loop.py`.
- [ ] **Architecture isn't ready for a real active cooler yet, only a
heat-only actuator.** Asked (not yet built): would the cascade/FSM
design still hold up if an active cooler (compressor/chiller, some
finite cooling power) replaced "heater off + passive ambient loss"?
Mostly yes at the PID/plant-model level: `Pid.y_min`/`y_max` are
already symmetric `-1.0`/`1.0` (`pid.py:12-13`), `Pot.set_power()`/
`process()` are sign-agnostic so the simulator already models negative
power correctly, and the FSM already has a dedicated `COOL` state with
its own PID instance (`pid_inner_cool`, `temp_controller_fsm.py:35-39`)
whose comment explicitly anticipates this ("the actuator ... is
responsible for clamping the resulting negative power to whatever it's
actually capable of").
The gap is at the actuator boundary: today `y` only ever reaches one
consumer, `tasks/heater.py:59`'s `self.power_actor = max(0, ... * y)`,
which silently discards every negative command — that's what's made
tuning mismatches free so far. A real cooler needs (a) a second
actuator/device class consuming the negative half instead of that
`max(0, ...)` clamp — there's no `Cooler`/chiller abstraction anywhere
yet (`grep -rniE "cooler|chiller|compressor"` across all `.py` is
empty, fully greenfield), and `heater_hendi.py:80`'s `set_power` only
clamps to a max, not a min, so feeding it a negative value today would
call `setPowerWatts(negative)` on real hardware with undefined result;
and (b) its own power ceiling, since one normalized `y` scaled by one
`get_power_max()` breaks once heater and cooler have different max
power.
Biggest risk once that clamp is removed: two separate paths start
issuing real negative-power commands that were previously harmless -
HOLD's `Outer.y_hold_min` floor (via `Inner.Hold`, see the steady-state
overshoot item above) and the pre-existing `pid_inner_cool` (via
`Inner.Cool`) - and neither has been tuned against actual active-cooling
dynamics (compressor lag, min-on-time). `Inner.Cool` in the demo
configs is literally a copy of `Inner.Heat`'s gains, never validated
independently. So adding a real cooler is a wiring task (new actuator
class, per-actuator power scaling) plus a re-tuning task (`Inner.Cool`,
and re-checking the `HoldCool`/`CoolHold` thresholds in
`temp_controller_fsm.py:14-17`), not just wiring.
- [ ] **`kalman.py` is now dead code in production.** Neither - [ ] **`kalman.py` is now dead code in production.** Neither
`temp_controller.py` nor `temp_controller_smith.py` uses `Kalman` `temp_controller.py` nor `temp_controller_smith.py` uses `Kalman`
anymore; the only remaining references are anymore; the only remaining references are