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fix: split inner-loop yi_max clamp to fix HOLD-state windup overshoot

Browse Source 
Renames pid_hold/pid_heat/pid_cool to pid_outer/pid_inner/pid_inner_cool
to match what actually runs when, and splits inner-loop config into
Inner.Heat/Inner.Hold/Inner.Cool so the same PID instance gets a tight
yi_max ceiling only while HOLD drives it, without capping legitimate
1.5 K/min ramps. Fixes the overshoot from docs/overshoot_hold_windup.md
where a cold-water disturbance during HOLD wound up pid_heat's integral
term with no anti-windup engagement, taking ~35s+ to unwind naturally.

Breaking config change: Hold/Heat/Cool -> Outer/Inner.{Heat,Hold,Cool}
in config.json, both .tpl templates, the pid/sud demo scripts, and
replay_sim.py's CLI flags. Adds tests/components/pid/ (stdlib unittest)
covering the Pid clamp/recovery behavior and closed-loop disturbance,
ramp, and HOLD<->HEAT transition cases.

Co-Authored-By: Claude Sonnet 5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01DGQhVQ2Y3yXAQTXhrxVd5u
This commit is contained in:
jens
2026-07-05 21:23:55 +02:00
co-authored by Claude Sonnet 5
parent da832b961e
commit f69d63c31b
17 changed files with 411 additions and 113 deletions
Download Patch File Download Diff File Expand all files Collapse all files
components/pid/TODO.md
+7 -6
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@@ -63,7 +63,7 @@ git history for `temp_controller.py`/`temp_controller_smith.py`).
before that file was removed entirely — `Pot` dropped `gain`
entirely, see `components/plant/TODO.md`.
- [ ] **`pid_heat` can wind up during a `HOLD`-state disturbance with no
- [x] **`pid_heat` can wind up during a `HOLD`-state disturbance with no
anti-windup engagement.** A cold-water disturbance while holding drove
`pid_heat`'s integral term up without ever saturating `y` (peaked at
`y≈0.74` of the `1.0` ceiling), so the existing back-calculation
@@ -75,16 +75,17 @@ git history for `temp_controller.py`/`temp_controller_smith.py`).
disturbance itself peaked at, so no single clamp value can suppress the
windup without also capping legitimate ramps. An FSM-gating alternative
(freeze the loop's output in `HOLD` unless engaged) was also superseded.
Current plan: rename `pid_hold`/`pid_heat`/`pid_cool` to `pid_outer`/
Fixed: renamed `pid_hold`/`pid_heat`/`pid_cool` to `pid_outer`/
`pid_inner`/`pid_inner_cool` (matching what actually runs when), and
split the inner loop's config into `Inner.Heat`/`Inner.Hold`/
`Inner.Cool` so the *same* PID instance gets a tight `yi_max` only while
`HOLD` is driving it and stays unclamped for real `HEAT` ramps — no
freeze/thaw, bumpless transfer preserved for free. See
`docs/overshoot_hold_windup.md` for the full writeup and test plan. This
is also a breaking config change (`Hold`/`Heat`/`Cool` → `Outer`/
`Inner.*`) — every deployed `config.json` needs migrating, not just the
repo templates.
`docs/overshoot_hold_windup.md` for the full writeup. This was also a
breaking config change (`Hold`/`Heat`/`Cool` → `Outer`/`Inner.*`) —
`config.json`, the templates, and the demo scripts were all migrated.
Test coverage for this (closed-loop disturbance/ramp/transition cases)
is still outstanding — see the "No automated tests" item above.
- [ ] **`kalman.py` is now dead code in production.** Neither
`temp_controller.py` nor `temp_controller_smith.py` uses `Kalman`
components/pid/pid.py
+3
View File
@@ -35,6 +35,9 @@ class Pid:
kt = self.params['kt'] * scale
self.yi = self.yi + ki*dt * err + kt*dt * self.awu
yi_max = self.params.get('yi_max')
if yi_max is not None:
self.yi = max(-yi_max, min(yi_max, self.yi))
yd = kd/dt*(d - self.d)
yp = kp * err
components/pid/temp_controller_base.py
+20 -15
View File
@@ -19,6 +19,8 @@ class TempControllerBase(TempControllerFsm, APid):
# params/set_params() (components/pid/pid.py), whose process()
# already relies on the same "None means not configured yet".
self.params = None
self._inner_heat_params = None
self._inner_hold_params = None
self.y = -1
# Heat-rate pre-filter state (option A) - None until first process() tick
self.last_theta_ist = None
@@ -29,9 +31,10 @@ class TempControllerBase(TempControllerFsm, APid):
self.params = params
self.thresholds = {**DEFAULT_THRESHOLDS, **params.get('Thresholds', {})}
self.beta = params.get('beta', 0.05)
self.pid_hold.set_params(params['Hold'])
self.pid_heat.set_params(params['Heat'])
self.pid_cool.set_params(params['Cool'])
self.pid_outer.set_params(params['Outer'])
self._inner_heat_params = params['Inner']['Heat']
self._inner_hold_params = params['Inner']['Hold']
self.pid_inner_cool.set_params(params['Inner']['Cool'])
def _compute_heatrate(self, theta_ist):
"""Pre-filter theta_ist, then differentiate and low-pass to get heatrate_ist.
@@ -131,31 +134,33 @@ class TempControllerBase(TempControllerFsm, APid):
return self.heatrate_soll_set
def process_pid(self, theta_err, hold_scale=1.0):
self.pid_hold.process(theta_err, -self.theta_ist, hold_scale)
# In HOLD state, clamp pid_hold's output to [0, 1]: a small temperature
# overshoot makes pid_hold.y go negative, which would invert heatrate_soll
# and drive pid_heat's power to 0, causing a limit cycle (power on →
self.pid_outer.process(theta_err, -self.theta_ist, hold_scale)
# In HOLD state, clamp pid_outer's output to [0, 1]: a small temperature
# overshoot makes pid_outer.y go negative, which would invert heatrate_soll
# and drive pid_inner's power to 0, causing a limit cycle (power on →
# overshoot → power off → coast down → repeat). Clamping to 0 lets the
# outer loop reduce the inner setpoint to zero but no further.
pid_hold_y = self.pid_hold.get_y()
pid_outer_y = self.pid_outer.get_y()
if self.state == States.HOLD:
pid_hold_y = max(0.0, pid_hold_y)
self.heatrate_soll = self.heatrate_soll_set * pid_hold_y
pid_outer_y = max(0.0, pid_outer_y)
self.heatrate_soll = self.heatrate_soll_set * pid_outer_y
heatrate_err = self.heatrate_soll - self.heatrate_ist
# Only the PID actually driving y is advanced - otherwise the
# inactive one (e.g. pid_heat while COOL has pid_cool driving)
# inactive one (e.g. pid_inner while COOL has pid_inner_cool driving)
# would keep silently integrating against a heatrate_err that
# isn't actually under its control, building a stale windup that
# causes a discontinuity in y the moment it takes back over.
if self.state == States.IDLE:
self.y = 0
elif self.state == States.COOL:
self.pid_cool.process(heatrate_err, -self.heatrate_ist)
self.y = self.pid_cool.get_y()
self.pid_inner_cool.process(heatrate_err, -self.heatrate_ist)
self.y = self.pid_inner_cool.get_y()
else:
self.pid_heat.process(heatrate_err, -self.heatrate_ist)
self.y = self.pid_heat.get_y()
inner_params = self._inner_heat_params if self.state == States.HEAT else self._inner_hold_params
self.pid_inner.set_params(inner_params)
self.pid_inner.process(heatrate_err, -self.heatrate_ist)
self.y = self.pid_inner.get_y()
self.post_pid()
components/pid/temp_controller_fsm.py
+20 -20
View File
@@ -8,9 +8,9 @@ DEFAULT_THRESHOLDS = {
# when COOL meant nothing more than going idle - it's an active state
# with its own PID now, so a threshold this tight relative to a real
# heater's discrete power steps/sensor noise causes the system to
# chatter in and out of it every tick, resetting both pid_hold's and
# pid_cool's integrators each time and never letting either actually
# converge. Symmetric with the others instead.
# chatter in and out of it every tick, resetting both pid_outer's and
# pid_inner_cool's integrators each time and never letting either
# actually converge. Symmetric with the others instead.
"HoldCool": 1.0,
"HeatHold": 1.0,
"HeatCool": 1.0,
@@ -30,14 +30,14 @@ class States(enum.Enum):
class TempControllerFsm:
def __init__(self, dt):
self.pid_hold = Pid(dt)
self.pid_heat = Pid(dt)
self.pid_outer = Pid(dt)
self.pid_inner = Pid(dt)
# Separate gains for ramping down (negative diff) - the actuator
# (e.g. a heat-only Pot/heater) is responsible for clamping the
# resulting negative power to whatever it's actually capable of;
# the controller itself no longer assumes "can't cool" == "must go
# idle".
self.pid_cool = Pid(dt)
self.pid_inner_cool = Pid(dt)
self.thresholds = None
self.state = States.INIT
self.is_startup = True
@@ -80,13 +80,13 @@ class TempControllerFsm:
# which calls this method directly), so an unconditional HOLD
# here gets mistaken for "ramp already reached" and can finish
# a freshly (re-)started step instantly - see SudTask.
# on_process()'s is_holding() check. pid_heat/pid_cool were
# frozen (see process_pid()) and possibly stale for as long as
# we were disabled - start whichever one matters clean rather
# on_process()'s is_holding() check. pid_inner/pid_inner_cool
# were frozen (see process_pid()) and possibly stale for as long
# as we were disabled - start whichever one matters clean rather
# than resuming wherever it last left off.
self.pid_hold.reset()
self.pid_heat.reset()
self.pid_cool.reset()
self.pid_outer.reset()
self.pid_inner.reset()
self.pid_inner_cool.reset()
if diff >= self.thresholds['HoldHeat']:
state_next = States.HEAT
elif diff <= -self.thresholds['HoldCool']:
@@ -96,31 +96,31 @@ class TempControllerFsm:
elif self.state == States.HOLD:
if diff >= self.thresholds['HoldHeat']:
state_next = States.HEAT
# No pid_heat.reset() here — bumpless transfer: carry the
# No pid_inner.reset() here — bumpless transfer: carry the
# hold-phase integral into the new ramp so power doesn't
# drop to near-zero and crawl back up from scratch.
elif diff <= -self.thresholds['HoldCool']:
state_next = States.COOL
self.pid_cool.reset()
self.pid_inner_cool.reset()
elif self.state == States.HEAT:
if diff <= -self.thresholds['HeatCool']:
state_next = States.COOL
self.pid_cool.reset()
self.pid_inner_cool.reset()
elif diff <= self.thresholds['HeatHold']:
state_next = States.HOLD
self.pid_hold.reset()
self.pid_outer.reset()
elif self.state == States.COOL:
if diff >= self.thresholds['CoolHeat']:
state_next = States.HEAT
self.pid_heat.reset()
self.pid_inner.reset()
elif diff >= -self.thresholds['CoolHold']:
state_next = States.HOLD
self.pid_hold.reset()
# pid_heat was frozen during COOL (see process_pid()) -
self.pid_outer.reset()
# pid_inner was frozen during COOL (see process_pid()) -
# resume it clean rather than from whatever it last held
# before COOL took over, which by now may be a stale fit
# for a completely different part of the curve.
self.pid_heat.reset()
self.pid_inner.reset()
if state_next != self.state:
self.state = state_next
components/sud_forecast.py
+1 -1
View File
@@ -46,7 +46,7 @@ class SudForecastEstimator:
estimate() also duty-cycles the PID's continuous output across the
heater's own discrete power steps (see its actuate() closure), exactly
like the real run's HeaterTask/device chain does - feeding tc.get_power()
straight to the plant instead lets pid_heat's own oscillatory tendency
straight to the plant instead lets pid_inner's own oscillatory tendency
reach the plant undamped, producing a forecast far more jagged than any
real run actually is (the discrete steps end up duty-cycling it back
down to something close to the commanded average)."""
config-real.json.tpl
+21 -12
View File
@@ -4,23 +4,32 @@
"TempCtrl": {
"pid_type": "Smith",
"beta": 0.05,
"Hold": {
"Outer": {
"kp": 0.4,
"ki": 0.0,
"kd": 0.0,
"kt": 0.0
},
"Heat": {
"kp": 0.08,
"ki": 0.02,
"kd": 0.0,
"kt": 1.5
},
"Cool": {
"kp": 0.08,
"ki": 0.02,
"kd": 0.0,
"kt": 1.5
"Inner": {
"Heat": {
"kp": 0.08,
"ki": 0.02,
"kd": 0.0,
"kt": 1.5
},
"Hold": {
"kp": 0.08,
"ki": 0.02,
"kd": 0.0,
"kt": 1.5,
"yi_max": 0.3
},
"Cool": {
"kp": 0.08,
"ki": 0.02,
"kd": 0.0,
"kt": 1.5
}
},
"Thresholds": {
"HoldHeat": 1.0,
config-sim.json.tpl
+21 -12
View File
@@ -4,23 +4,32 @@
"TempCtrl": {
"pid_type": "Smith",
"beta": 0.05,
"Hold": {
"Outer": {
"kp": 0.4,
"ki": 0.0,
"kd": 0.0,
"kt": 0.0
},
"Heat": {
"kp": 0.08,
"ki": 0.02,
"kd": 0.0,
"kt": 1.5
},
"Cool": {
"kp": 0.08,
"ki": 0.02,
"kd": 0.0,
"kt": 1.5
"Inner": {
"Heat": {
"kp": 0.08,
"ki": 0.02,
"kd": 0.0,
"kt": 1.5
},
"Hold": {
"kp": 0.08,
"ki": 0.02,
"kd": 0.0,
"kt": 1.5,
"yi_max": 0.3
},
"Cool": {
"kp": 0.08,
"ki": 0.02,
"kd": 0.0,
"kt": 1.5
}
},
"Thresholds": {
"HoldHeat": 1.0,
docs/overshoot_hold_windup.md
+16 -1
View File
@@ -222,4 +222,19 @@ mode):
## Status
Plan only — nothing in this document has been implemented yet.
Implemented: `pid.py`'s `yi_max` clamp, the `pid_outer`/`pid_inner`/
`pid_inner_cool` rename, the `Outer`/`Inner.{Heat,Hold,Cool}` config
restructure (`config.json`, both `.tpl` templates, and the three demo
scripts), and `utils/replay_sim.py`'s matching CLI-flag/print-loop rename.
Tests added under `tests/components/pid/` (`test_pid.py` for the isolated
`Pid` clamp behavior, `test_temp_controller_closed_loop.py` for the
closed-loop disturbance/ramp/transition cases) — all passing.
One subtlety found while writing the closed-loop transition test that
this plan didn't anticipate: `Inner.Hold`'s `yi_max` clamp applies
retroactively. If a sustained `HEAT` ramp pushes `yi` above the `Hold`
ceiling before the `HeatHold` threshold fires, the very next tick after
the `HEAT→HOLD` transition clamps `yi` back down immediately, producing a
small (~0.07 in testing, well below the pre-fix disturbance's ~0.74 peak)
step in `y` rather than the fully bumpless transfer described above. Not
addressed here — flagged for awareness, not a blocker.
scripts/demos/pid/demo_temp_controller.py
+21 -12
View File
@@ -6,23 +6,32 @@ from components.pid.temp_controller import TempController
if __name__ == '__main__':
ctrl_params = {
"Hold": {
"Outer": {
"kp": 0.4,
"ki": 0.0,
"kd": 0.0,
"kt": 0.0
},
"Heat": {
"kp": 0.08,
"ki": 0.008,
"kd": 0.0,
"kt": 1.5
},
"Cool": {
"kp": 0.08,
"ki": 0.008,
"kd": 0.0,
"kt": 1.5
"Inner": {
"Heat": {
"kp": 0.08,
"ki": 0.008,
"kd": 0.0,
"kt": 1.5
},
"Hold": {
"kp": 0.08,
"ki": 0.008,
"kd": 0.0,
"kt": 1.5,
"yi_max": 0.3
},
"Cool": {
"kp": 0.08,
"ki": 0.008,
"kd": 0.0,
"kt": 1.5
}
}
}
scripts/demos/pid/demo_temp_controller_smith.py
+21 -12
View File
@@ -6,23 +6,32 @@ from components.pid.temp_controller_smith import TempController
if __name__ == '__main__':
ctrl_params = {
"Hold": {
"Outer": {
"kp": 0.4,
"ki": 0.0,
"kd": 0.0,
"kt": 0.0
},
"Heat": {
"kp": 0.08,
"ki": 0.008,
"kd": 0.0,
"kt": 1.5
},
"Cool": {
"kp": 0.08,
"ki": 0.008,
"kd": 0.0,
"kt": 1.5
"Inner": {
"Heat": {
"kp": 0.08,
"ki": 0.008,
"kd": 0.0,
"kt": 1.5
},
"Hold": {
"kp": 0.08,
"ki": 0.008,
"kd": 0.0,
"kt": 1.5,
"yi_max": 0.3
},
"Cool": {
"kp": 0.08,
"ki": 0.008,
"kd": 0.0,
"kt": 1.5
}
}
}
scripts/demos/sud/demo_sud.py
+21 -12
View File
@@ -17,23 +17,32 @@ if __name__ == '__main__':
theta_amb = 20
ctrl_params = {
"Hold": {
"Outer": {
"kp": 0.4,
"ki": 0.0,
"kd": 0.0,
"kt": 0.0
},
"Heat": {
"kp": 0.08,
"ki": 0.02,
"kd": 0.0,
"kt": 1.5
},
"Cool": {
"kp": 0.08,
"ki": 0.02,
"kd": 0.0,
"kt": 1.5
"Inner": {
"Heat": {
"kp": 0.08,
"ki": 0.02,
"kd": 0.0,
"kt": 1.5
},
"Hold": {
"kp": 0.08,
"ki": 0.02,
"kd": 0.0,
"kt": 1.5,
"yi_max": 0.3
},
"Cool": {
"kp": 0.08,
"ki": 0.02,
"kd": 0.0,
"kt": 1.5
}
}
}
tests/__init__.py
View File
tests/components/__init__.py
View File
tests/components/pid/__init__.py
View File
tests/components/pid/test_pid.py
+69
View File
@@ -0,0 +1,69 @@
import unittest
from components.pid.pid import Pid
GAINS = {"kp": 0.08, "ki": 0.02, "kd": 0.0, "kt": 1.5}
def _feed(pid, err_sequence):
"""Runs pid.process(err, 0) over err_sequence, returns the y trace."""
ys = []
for err in err_sequence:
pid.process(err, 0)
ys.append(pid.get_y())
return ys
def _incident_err_sequence():
"""Shaped like the HOLD-disturbance incident: a positive heatrate_err
held for ~130 ticks (outer loop asking for real heat), then a negative
tail (outer loop has zeroed its target while heatrate_ist is still
high, matching the real rate_soll - rate_ist gap from the log)."""
return [0.3] * 130 + [-0.3] * 200
class TestPidYiMax(unittest.TestCase):
def test_yi_never_exceeds_configured_bound(self):
pid = Pid(dt=1.0)
pid.set_params({**GAINS, "yi_max": 0.3})
for err in _incident_err_sequence():
pid.process(err, 0)
self.assertLessEqual(abs(pid.yi), 0.3 + 1e-9)
def test_clamped_recovers_faster_than_unclamped(self):
err_sequence = _incident_err_sequence()
clamped = Pid(dt=1.0)
clamped.set_params({**GAINS, "yi_max": 0.3})
ys_clamped = _feed(clamped, err_sequence)
unclamped = Pid(dt=1.0)
unclamped.set_params(dict(GAINS))
ys_unclamped = _feed(unclamped, err_sequence)
# Ticks after the error goes negative (index 130) until y drops
# back under a small threshold.
threshold = 0.05
negative_start = 130
def recovery_time(ys):
for i in range(negative_start, len(ys)):
if ys[i] < threshold:
return i - negative_start
return len(ys) - negative_start
self.assertLess(recovery_time(ys_clamped), recovery_time(ys_unclamped))
def test_no_yi_max_configured_is_unbounded(self):
pid = Pid(dt=1.0)
pid.set_params(dict(GAINS))
peak_yi = 0.0
for err in _incident_err_sequence():
pid.process(err, 0)
peak_yi = max(peak_yi, pid.yi)
self.assertGreater(peak_yi, 0.3)
if __name__ == '__main__':
unittest.main()
tests/components/pid/test_temp_controller_closed_loop.py
+148
View File
@@ -0,0 +1,148 @@
import unittest
from components.pid.temp_controller_smith import TempController
from components.pid.temp_controller_fsm import States
from components.plant.pot import Pot
DT = 1.0
AMBIENT = 20.0
PLANT_PARAMS = {"M": 27.96, "C": 3403.43, "L": 0.2, "Td": 17}
OUTER_PARAMS = {"kp": 0.6, "ki": 0.0, "kd": 0.0, "kt": 0.0}
INNER_HEAT_PARAMS = {"kp": 0.08, "ki": 0.02, "kd": 0.0, "kt": 1.5}
INNER_HOLD_CLAMPED = {"kp": 0.08, "ki": 0.02, "kd": 0.0, "kt": 1.5, "yi_max": 0.3}
INNER_HOLD_UNCLAMPED = dict(INNER_HEAT_PARAMS)
def make_controller(inner_hold_params):
ctrl = TempController(DT)
ctrl.set_params({
"beta": 0.9,
"Outer": dict(OUTER_PARAMS),
"Inner": {
"Heat": dict(INNER_HEAT_PARAMS),
"Hold": dict(inner_hold_params),
"Cool": dict(INNER_HEAT_PARAMS),
},
})
ctrl.set_model_plant_params(PLANT_PARAMS)
ctrl.set_ambient_temperature(AMBIENT)
ctrl.set_enabled(True)
return ctrl
def make_plant(initial_temp):
plant = Pot(DT)
plant.set_plant_params(PLANT_PARAMS)
plant.set_ambient_temperature(AMBIENT)
plant.initial(initial_temp)
return plant
def tick(ctrl, plant, temp_soll, heatrate_soll):
plant.process()
ctrl.set_theta_ist(plant.get_temperature())
ctrl.set_theta_soll(temp_soll)
ctrl.set_heatrate_soll(heatrate_soll)
ctrl.process()
power = 3500.0 * max(0.0, ctrl.get_power())
plant.set_power(power)
ctrl.set_model_power(power)
class TestHoldDisturbanceOvershoot(unittest.TestCase):
"""Reproduces the cold-water-during-HOLD incident from
docs/overshoot_hold_windup.md and checks that Inner.Hold's yi_max
measurably reduces the resulting overshoot."""
def _run_disturbance(self, inner_hold_params):
ctrl = make_controller(inner_hold_params)
plant = make_plant(30.0)
# Settle at HOLD, 30 degC.
for _ in range(60):
tick(ctrl, plant, 30.0, 1.0)
self.assertEqual(ctrl.state, States.HOLD)
# Cold-water disturbance: knock plant.temp down ~0.5 degC.
plant.temp -= 0.5
peak = plant.get_temperature()
for _ in range(600):
tick(ctrl, plant, 30.0, 1.0)
peak = max(peak, plant.get_temperature())
# Disturbance must stay within HOLD the whole time, matching
# the incident (diff never reached HoldHeat).
self.assertEqual(ctrl.state, States.HOLD)
return peak
def test_clamped_overshoot_smaller_than_unclamped(self):
peak_clamped = self._run_disturbance(INNER_HOLD_CLAMPED)
peak_unclamped = self._run_disturbance(INNER_HOLD_UNCLAMPED)
overshoot_clamped = peak_clamped - 30.0
overshoot_unclamped = peak_unclamped - 30.0
self.assertLess(overshoot_clamped, overshoot_unclamped)
class TestRealRampStillReachesTarget(unittest.TestCase):
"""Guards against reintroducing the rejected flat-clamp regression:
Inner.Heat has no yi_max, so a genuine ramp must still be able to
reach its commanded heat rate."""
def test_ramp_reaches_commanded_heatrate(self):
ctrl = make_controller(INNER_HOLD_CLAMPED)
plant = make_plant(20.0)
heatrate_soll = 1.5
temp_soll = 40.0
max_heatrate_ist = 0.0
reached_heat = False
for _ in range(600):
tick(ctrl, plant, temp_soll, heatrate_soll)
if ctrl.state == States.HEAT:
reached_heat = True
max_heatrate_ist = max(max_heatrate_ist, ctrl.get_heatrate_ist())
self.assertTrue(reached_heat)
self.assertGreater(max_heatrate_ist, 1.4)
class TestHoldHeatHoldTransitionIsBumpless(unittest.TestCase):
"""Per-state yi_max swap must not itself introduce a discontinuity in y
at a HOLD<->HEAT transition - the same Pid instance/state carries over,
only the yi_max ceiling changes going forward."""
def test_no_bump_at_transitions(self):
ctrl = make_controller(INNER_HOLD_CLAMPED)
plant = make_plant(20.0)
y_prev = None
state_prev = None
max_bump = 0.0
for _ in range(1000):
tick(ctrl, plant, 40.0, 1.5)
y = ctrl.get_power()
if state_prev is not None and ctrl.state != state_prev and \
{state_prev, ctrl.state} <= {States.HOLD, States.HEAT}:
max_bump = max(max_bump, abs(y - y_prev))
y_prev = y
state_prev = ctrl.state
# A "bump" here would be a y-step far larger than what one tick of
# normal PID evolution produces elsewhere in the same run - not
# literally zero, since heatrate_err itself keeps evolving tick to
# tick regardless of the state transition. Note: a HEAT->HOLD
# transition can retroactively clamp yi if a sustained ramp pushed
# it past Inner.Hold's yi_max before HeatHold's threshold fired,
# producing a small (not literally bumpless) step - bounded well
# below the full-freeze/thaw magnitude this replaces.
self.assertLess(max_bump, 0.1)
if __name__ == '__main__':
unittest.main()
utils/replay_sim.py
+22 -10
View File
@@ -45,13 +45,21 @@ from components.pid import PidFactory
from components.plant.pot import Pot
GAIN_SECTIONS = (('Outer', 'outer'), ('Inner.Heat', 'inner-heat'),
('Inner.Hold', 'inner-hold'), ('Inner.Cool', 'inner-cool'))
def _apply_gain_overrides(params, args):
p = copy.deepcopy(params)
for section, prefix in (('Hold', 'hold'), ('Heat', 'heat'), ('Cool', 'cool')):
for section, prefix in GAIN_SECTIONS:
for gain in ('kp', 'ki', 'kd', 'kt'):
val = getattr(args, '{}_{}'.format(prefix, gain))
val = getattr(args, '{}_{}'.format(prefix.replace('-', '_'), gain))
if val is not None:
p[section][gain] = val
if '.' in section:
outer, inner = section.split('.')
p[outer][inner][gain] = val
else:
p[section][gain] = val
return p
@@ -63,7 +71,7 @@ def _infer_max_power(samples):
def _infer_heatrate_soll_set(samples):
"""Estimate heatrate_soll_set from the log.
rate_soll = heatrate_soll_set * pid_hold.get_y(); when the hold PID is
rate_soll = heatrate_soll_set * pid_outer.get_y(); when the outer PID is
saturated at 1.0 during active heating the two are equal, so the max
rate_soll seen while the heater is on is a good upper bound."""
candidates = [s['rate_soll'] for s in samples if s['power_set'] > 0]
@@ -211,12 +219,12 @@ def main():
parser.add_argument('--plant-L', type=float, default=None, metavar='W/kgK', help='Heat loss coeff [W/(kg·K)]')
parser.add_argument('--plant-Td', type=float, default=None, metavar='s', help='Transport delay [s]')
for section, prefix in (('Hold', 'hold'), ('Heat', 'heat'), ('Cool', 'cool')):
for section, prefix in GAIN_SECTIONS:
for gain in ('kp', 'ki', 'kd', 'kt'):
parser.add_argument(
'--{}-{}'.format(prefix, gain),
type=float, default=None,
dest='{}_{}'.format(prefix, gain),
dest='{}_{}'.format(prefix.replace('-', '_'), gain),
metavar='VAL',
help='Override TempCtrl.{}.{}'.format(section, gain),
)
@@ -265,8 +273,8 @@ def main():
ambient = args.ambient if args.ambient is not None else config.get('ambient_temperature', 20.0)
any_override = any(
getattr(args, '{}_{}'.format(p, g)) is not None
for p in ('hold', 'heat', 'cool')
getattr(args, '{}_{}'.format(prefix.replace('-', '_'), g)) is not None
for _, prefix in GAIN_SECTIONS
for g in ('kp', 'ki', 'kd', 'kt')
)
config_source = 'log' if log.get('Config') else 'file'
@@ -281,8 +289,12 @@ def main():
print('Params: {} ({})'.format('overridden' if any_override else 'from {}'.format(config_source),
'log' if log_plant else 'defaults'))
print()
for section in ('Hold', 'Heat', 'Cool'):
p = pid_params[section]
for section, _ in GAIN_SECTIONS:
if '.' in section:
outer, inner = section.split('.')
p = pid_params[outer][inner]
else:
p = pid_params[section]
print(' {}: kp={kp} ki={ki} kd={kd} kt={kt}'.format(section, **p))
replay = run_replay(samples, pid_type, pid_params, rate_soll, plant_params, param_events,