The previous hotfix's disconnect()-on-comm-error path can now fire
during server/brewpi.py's own final best-effort hardware-release
cleanup (finally: block's heater.close()/stirrer.activate(False)),
which runs after the event loop has already stopped - previously
nothing about hardware teardown touched an AttributeChange-tracked
field, so this path was dormant. asyncio.create_task() there raises
RuntimeError: no running event loop, crashing the shutdown sequence.
Adds fire_and_forget() (tasks/task.py) - asyncio.create_task() that
silently drops the message instead of raising when there's no loop to
schedule on - and uses it for the Connected/FirmwareVersion broadcasts.
SudTask.check_connections() also now no-ops entirely without a running
loop, since self.sud.stop() cascades into further unguarded
create_task() calls (on_state_changed, heater_task.shutdown(), ...)
that a stopped loop can't help with anyway.
Reproduced and verified fixed directly against HeaterTask/HeaterHendi
with no event loop running (mirrors the exact server/brewpi.py
shutdown-time call path that crashed on the brewpi Pi).
Co-Authored-By: Claude Sonnet 5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01YaPLuRPpyjWcwhMvCvpHCL
Live-testing on the brewpi Pi found that a connected-but-unresponsive
device (e.g. the hendi sitting in its ungraceful-disconnect lockout, see
docs/hendi_lockout_findings.md) crashed the whole server: activate() -
called both from HeaterTask's `with device.open():` and from a client's
Connect/Disconnect command - raised uncaught, escaping the gathered task
and killing the entire asyncio.gather in TaskManager.start().
activate()/is_activated()/process() on both real actors now catch comm
exceptions and self-heal via disconnect() (the same path a genuine
unplug already takes), instead of letting the exception propagate.
Co-Authored-By: Claude Sonnet 5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01YaPLuRPpyjWcwhMvCvpHCL
Heater and Stirrer can be real serial hardware (hendi, Pololu1376), but
there was no connection concept at all - the constructors opened the
port and crashed the whole server if the device was missing, with no
way to see connection status or firmware version and no way to
reconnect without a restart.
Adds an observable Connectable mixin (components/connectable.py) shared
by AHeater/AStirrer; real devices defer opening the serial port to an
explicit connect(), auto-connect on server startup, and surface
Connected/FirmwareVersion/Simulated plus manual Connect/Disconnect over
the web GUI. Heating/stirring and Sud Start are all gated on connection
state, and a disconnect mid-brew force-stops the run via the same path
as a manual Stop.
Co-Authored-By: Claude Sonnet 5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01YaPLuRPpyjWcwhMvCvpHCL
TempSensorSim/TempSensor_max31865's temperature() now stores its
reading on self.temp, so ATemperatureSensor's inherited AttributeChange
(previously never triggered by anything) actually fires. TempSensorTask
no longer keeps its own shadow copy of the reading - it registers its
websocket-push callback on self.sensor directly and just drives the
read each tick; server/brewpi.py's TC-feeding registration moved from
sensor_task to sensor for the same reason.
Priming read happens before registering the callback (not after) since
all tasks are built synchronously at module level, before the asyncio
event loop starts - registering first would fire on_temp_changed's
asyncio.create_task() with no running loop.
Co-Authored-By: Claude Sonnet 5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01GpePKZiEZWbGo9HrfuML6U
Moves components/actor/HendiCtrl.srec (v1.12) alongside the v1.14/
v1.15 images gathered during lockout testing, all under one versioned
naming scheme (hendi_ctrl_0112/0114/0115.srec) instead of scattered
across the repo root and components/actor/.
Co-Authored-By: Claude Sonnet 5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01GpePKZiEZWbGo9HrfuML6U
Confirmed on hardware: 15s idle while remote-enabled with the heater
on and powered auto-suspends (R? and S? both drop to 0). P? does not
read literal 0 though - it lands on 4095, the raw register's max value
past the calibrated curve's low end, not the digit 0. Any check
expecting P?=="0" to confirm zero power would be wrong on this
firmware; S? is the correct check.
Co-Authored-By: Claude Sonnet 5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01GpePKZiEZWbGo9HrfuML6U
HendiCtrl.cmd() previously raised a bare "Communication error" for any
non-OK response, discarding the firmware's actual reply. It now
includes the raw echo/answer bytes, and --debug prints every
request/response. Using this, the rejected R1 during lockout turned
out to be an explicit "ERR:Invalid state" reply, not a timeout.
Also flashed and retested v1.16: plain reconnect (no --reset) now
recovers from the lockout reliably (4/4 trials), fixing the
intermittent behavior seen on v1.15.
Co-Authored-By: Claude Sonnet 5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01GpePKZiEZWbGo9HrfuML6U
--reset still reliably clears the lockout on v1.15, same as v1.14. A
plain reconnect without --reset now succeeds intermittently (1 of 3
trials) where it always failed before, but that's unreliable enough to
flag as a remaining race condition rather than a fix.
Co-Authored-By: Claude Sonnet 5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01GpePKZiEZWbGo9HrfuML6U
Firmware v1.14 makes --reset (DTR/RTS toggle) reliably clear the
ungraceful-disconnect lockout, unlike v1.12. A plain reconnect without
--reset still fails on both versions, so recovery is specifically tied
to the reset line, not just a fresh connection.
Co-Authored-By: Claude Sonnet 5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01GpePKZiEZWbGo9HrfuML6U
--trigger-error-state deliberately reproduces the Hendi's
ungraceful-disconnect lockout (remoteEnable(True) without a matching
disable) so it can be tested on demand. --reset toggles the reset
line, but per hardware testing it does NOT clear that lockout - only
the device's physical knob/power cycle does.
Co-Authored-By: Claude Sonnet 5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01GpePKZiEZWbGo9HrfuML6U
hendiCtrl.py is now import-only. The new CLI app exposes serial
port/baudrate, version/capability info, converter test, heater test,
and firmware update as separate flags, instead of one fixed script.
Co-Authored-By: Claude Sonnet 5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01GpePKZiEZWbGo9HrfuML6U
Covers the last two commits: tick-counted t/_elapsed() semantics and why
PlantParams must be stamped with each logger's own (not Sud.elapsed
universally), plus the log_latest.json/log_latest_sud.json fixed-name
copies and the caveat that the two aren't guaranteed to be in sync.
Co-Authored-By: Claude Sonnet 5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01JFDeoTKBDkXRhPfnyDEoBt
log_plant_params() stored whatever elapsed it was handed - always
Sud.elapsed - regardless of which logger's own Samples.t timeline it
needed to match. SudLogTask._elapsed() is Sud.elapsed, so its PlantParams
lined up fine, but ServerLogTask._elapsed() is a separate tick counter
since server startup - using Sud.elapsed there put PlantParams.t on a
different scale than its own Samples.t entirely, causing
utils/replay_sim.py to apply grain/water-mass changes at the wrong point
when replaying a server-session log (spotted by comparing its output for
log_latest.json vs log_latest_sud.json from the same session).
Fixed by dropping the elapsed parameter - log_plant_params(params) now
stamps with self._elapsed(), so each logger always uses its own correct
timeline. Cascades into SudTask.set_on_plant_params()'s callback signature
and its wiring in server/brewpi.py.
Co-Authored-By: Claude Sonnet 5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01JFDeoTKBDkXRhPfnyDEoBt
Alongside the dated log files, ServerLogTask/SudLogTask now also write
(and overwrite) a fixed-name copy on every write() - logs/log_latest.json
and logs/log_latest_sud.json - so a dashboard/tail-style consumer can
point at one unchanging path instead of tracking the current run's
timestamped filename.
Also switches SudLogTask's own dated/latest filenames from .log to .json,
matching what they've always actually contained. This incidentally fixes
utils/analyze_log.py's two-argument CLI form, which already assumed a
.json extension for sud logs.
Co-Authored-By: Claude Sonnet 5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01JFDeoTKBDkXRhPfnyDEoBt
sim_warp_factor was scaling DT_TASK unconditionally, including against real
hardware, and was leaking into recorded sample timestamps via wall-clock
time - both violate its intended meaning (a reciprocal scale on task wait
time only). Clamp it to 1.0 whenever Heater.type isn't "sim", and track
elapsed time via tick-counted accumulators (Sud.elapsed for SudLogTask, a
matching one for ServerLogTask) instead of time.monotonic().
Sud/server logs now also carry HeaterPowers, the effective SimWarpFactor,
the raw Doc, a correct Name, and ForecastAnchors (one entry per real
_reanchor_forecast() trigger) - enough for utils/analyze_log.py to rebuild
a SudForecastEstimator and replay the exact same splice-per-transition
forecast correction offline that a live client sees, replacing the old
(always-dead) forecast_*.json sidecar lookup.
Two bugs found and fixed along the way:
- ServerLogTask's periodic wall-clock checkpoint had no way to know a
SudLogTask run had just ended, so it would immediately re-write the
just-completed log with PlantParams/ForecastAnchors cleared back to
empty. Gated the checkpoint on _should_sample().
- _reanchor_forecast() truncated the old forecast against real elapsed
time, which can end up numerically less than the old forecast's own
(very wrong) speculative timestamps once a WAIT_USER confirmation runs
long - leaving a "ghost" segment instead of a clean cut. Truncate
against forecast_step_starts[index] instead, which lives in the same
coordinate space as the forecast being cut.
Co-Authored-By: Claude Sonnet 5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01JFDeoTKBDkXRhPfnyDEoBt
deploy/install.sh and deploy/brewpi.service existed but were never
mentioned in the README - the only documented deployment path was the
older virtualenvwrapper-based server/brewpi.sh. Also ties in the
SIGTERM handling fix, since systemctl stop is exactly the path it
protects.
Co-Authored-By: Claude Sonnet 5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01TvgC7oy9MxaA4ZQxXqkNdS
Both loggers previously only wrote their JSON log on their end trigger
(shutdown / Stop-or-DONE), losing the whole session/run's data on a
hard crash or power loss. Add a log_interval (config.json, default
300s) that rewrites the same file whole every N seconds in between.
Co-Authored-By: Claude Sonnet 5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01TvgC7oy9MxaA4ZQxXqkNdS
systemctl stop/restart send SIGTERM, whose default disposition kills
the process immediately - skipping the shutdown finally: block that
cancels tasks and forces both actors safe via their activate(False).
Route SIGTERM through the same KeyboardInterrupt path SIGINT already
uses, and add stirrer.activate(False) alongside the existing
heater.close() as a belt-and-suspenders fallback.
Co-Authored-By: Claude Sonnet 5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01TvgC7oy9MxaA4ZQxXqkNdS
The Logging & analysis section and a couple of cross-references still
described the old SudLogTask (forecast_*.json pairing) that predated
the ServerLogTask refactor and the just-reintroduced per-run SudLogTask.
Also documents the state_pump() task's role in reconnect behavior.
Co-Authored-By: Claude Sonnet 5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01TvgC7oy9MxaA4ZQxXqkNdS
SudLogTask reuses ServerLogTask's sample format but only records while
a Sud run is active: starts on Play (fresh start only, not a Pause
resume) and writes logs/log_{date_time}_{sud_name}.log on Stop or
natural completion.
Co-Authored-By: Claude Sonnet 5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01TvgC7oy9MxaA4ZQxXqkNdS
Each connection used to run its own handler_send loop consuming from
the shared dispatcher queue. With zero clients connected (e.g. an
iPad that silently drops on sleep), nothing drained the queue, so
state updates piled up unbounded and got replayed as a burst on
reconnect. Now one pump task drains the queue continuously regardless
of connection count, and reconnecting clients resync from
global_state instead of a backlog.
Co-Authored-By: Claude Sonnet 5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01TvgC7oy9MxaA4ZQxXqkNdS
HeaterTask.shutdown() switched the heater to open-loop when a brew
ended, but nothing switched it back when a new Sud was started. The
browser happened to send {ClosedLoop: true} as part of its UI setup,
so its connect-and-start path worked; PyQt (and any other client that
doesn't send that message) left the heater in open-loop and the TC
never drove it.
Add SudTask._on_start / set_on_start() hook, HeaterTask.start_closed_loop()
(mirror of shutdown()), and wire them in brewpi.py so the server
switches to closed-loop and broadcasts the new state to all clients the
moment any client starts a brew.
Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>
server/brewpi.py: pass physics DT to ServerLogTask (not wall-clock DT_TASK)
so logs carry the correct integration timestep; log startup plant params as
the first PlantParams event so replay_sim can reconstruct them even when no
Sud is ever loaded (previously fell back to hardcoded defaults, causing ~3°C
temperature offset in replay).
tasks/server_log.py: accept and embed dt in log JSON; switch
log_plant_params() to wall-clock monotonic time (same base as sample t),
since the elapsed argument was simulated time and not comparable.
utils/replay_sim.py: switch to open-loop replay (plant driven by logged
power_eff, not sim controller output); use PidFactory so Smith vs Normal
controller type is honoured; set Td=0 in replay plant for Smith mode (logged
temp_ist is already Smith-corrected); feed Smith predictor's internal model
with real power; apply embedded PlantParams mid-run; prefer embedded dt over
sample-based fallback; clamp sim power ≥ 0; replace meaningless sim-power
trace in power subplot with power_set vs power_eff from the log.
Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>
SudLogTask is removed; ServerLogTask now covers the full server session
and gains PlantParams tracking (log_plant_params callback wired from
SudTask.set_on_plant_params) so step transitions are still captured in
the log.
Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>
ServerLogTask now embeds the full config in its JSON output, matching
SudLogTask — so replay_sim and analyze_log work on server logs without
needing a separate config file.
replay_sim.py switches from two positional args (date_time, sud_name) to
a single log file path, with config and plant params resolved from the
log's embedded "Config"/"PlantParams" sections when present and falling
back to config.json / hardcoded defaults for older logs.
Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>
Each log_*.json now carries a "Config" key (the full server config) and
a "PlantParams" list of {t, params} entries — one per step transition —
so offline analysis tools have the PID gains and plant model that were
active at every point of the run without having to cross-reference a
separate config file.
Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>
During hold, a small temperature overshoot causes pid_hold.y to go
slightly negative, inverting heatrate_soll and driving pid_heat's
power to 0. With no power the pot coasts back down, pid_hold goes
positive again, power builds back up, overshoot repeats — a ~110s
limit cycle visible as pumping in the power trace.
Clamping pid_hold.y to [0, 1] in HOLD state lets the outer loop
reduce the inner rate setpoint to zero (stop adding heat) but not
invert it (actively demand cooling), breaking the limit cycle while
preserving normal HEAT/COOL cascade behaviour.
Note: Hold.kt must remain 0 when Hold.ki=0 — a non-zero kt drains
pid_hold.yi during ramp saturation, suppressing heatrate_soll at the
start of each hold phase and leaking into the next ramp via the
bumpless HOLD→HEAT transfer.
Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>
Two root causes for the visible power dip at every ramp-to-ramp
step boundary:
1. One-tick cascade delay: heatrate_soll was computed from
pid_hold.get_y() before pid_hold.process() ran in that tick,
so the first tick of a new ramp used the stale hold-phase
output (≈0) as the rate setpoint, driving pid_heat to near
zero. Fix: move heatrate_soll computation inside process_pid(),
after pid_hold.process().
2. Cold-start reset: pid_heat.reset() at HOLD→HEAT discarded
the hold-phase integral, so pid_heat had to ramp up from
zero on every new step. Fix: remove the reset (bumpless
transfer) — the hold-phase integral is a warm starting point
that carries the baseline hold power into the new ramp.
Together these eliminate the ~1s dip to near-zero and replace
the slow 20–30s integral ramp-up with an immediate start at
roughly hold-level power, climbing monotonically to the target.
Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>
Pot config (water_mass, volumen) sent in System message at startup.
app.js stores potConfig and uses it in updatePotVisualization/
updateStatusLine when sudEmpty, showing startup fill level and
"No schedule – N L water" without requiring a sud to be loaded first.
Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>
Sud._parse_data now falls through to pot_config for all hardware keys
(mass, material, L, Td) — EMPTY_SUD no longer shadows them. brewpi.py
seeds pot/tc plant params from Pot.water_mass on startup so the
simulated plant is configured before any sud is loaded.
Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>
Pot hardware constants (mass, material, L, Td) moved from sude/*.json
to config.json's Pot section; Sud/SudForecastEstimator accept pot_config
as baseline, per-brew pot sections may still override. Controller key
removed; pid_type moved into TempCtrl.
Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>
PlantFactory.create() no longer takes plant_name; sim vs real is derived
from Heater.type. StirrerFactory is wired from Stirrer.type. HeaterFactory
registry key lowercased to "hendi" to match config. Controller.plant_name
removed from both config templates.
Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>
PlantFactory.create() now accepts sensor_config dict; extracts type and
kwargs, falls back to sigma=0.05/temp_offset=-0.15 defaults. brewpi.py
passes config.get('TempSensor', {}). Templates updated with full
TempSensor sections.
Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>
Replaces the opaque variance/√12 formula with two explicit noise components:
sigma (default 0.05 °C) — white Gaussian noise, calibrated against the
20260628T184903 Sud-0010 log (detrended hold-phase tick-to-tick std ≈ 0.053 °C).
stirrer_sigma / stirrer_tau — optional AR(1) low-frequency component for
stirrer-induced fluctuations (off by default); steady-state std equals
stirrer_sigma, correlation time equals stirrer_tau ticks.
plant_factory.py updated to use sigma=0.05 instead of the old variance=0.01
(which gave std ≈ 0.003 °C — far too quiet).
Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>
The two-argument form (date_time sud_name) is unchanged. When called
with a single argument it is treated as a direct path to any log_*.json
(e.g. a server-session log without a Sud name); the forecast panel is
shown only if a matching forecast_*.json exists alongside it.
Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>
Adds ServerLogTask (tasks/server_log.py) which records temp/power samples
from startup to shutdown regardless of Sud state, in the same Name/Samples
JSON format as SudLogTask so analyze_log.py and replay_sim.py can consume
it directly. The file is written on graceful exit (Ctrl-C) from brewpi.py's
finally block, just before the heater is closed.
Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>
On KeyboardInterrupt, brewpi.py cancels all asyncio tasks (letting
HeaterTask's `with device.open()` finally block run), then calls
heater.close() as belt-and-suspenders before closing the event loop.
On shutdown HeaterHendi.activate(False) now sets the switch to 0 instead
of disabling remote control, so the Hendi stays in remote mode at 0 W
rather than dropping back to its local panel state. HendiCtrl.close()
does the same (setSwitch(0)) then closes the serial port.
Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>
Adds a configurable IIR pre-filter (beta, default 0.05, τ≈19 s at dt=1 s)
applied to theta_ist before the derivative, so stirrer-induced temperature
noise is attenuated before being amplified by differentiation rather than
after. The shared filter/derivative/post-filter logic is factored into
TempControllerBase._compute_heatrate(); both Normal and Smith subclasses
call it, replacing their duplicated inline rate blocks.
beta is read from TempCtrl.beta in the config (default 0.05 if absent) and
added to config-sim.json.tpl and config-real.json.tpl.
Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>
jensandClaude Sonnet 5