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
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
TempController(Smith).__init__ no longer takes model_params/theta_amb -
set_model_plant_params() and the existing set_ambient_temperature() must be
called instead (mirrors components/plant/pot.py's own Pot constructor
refactor). temp_controller.py's now-pointless model_params/theta_amb
constructor placeholders (kept only for "compatibility" with Smith) are
dropped too.
Both TempController variants now raise a clear RuntimeError from process()
itself if set_params() wasn't called, instead of letting it surface deep
inside Pid.process() as an opaque "'NoneType' object is not subscriptable".
Smith additionally checks its internal models via Pot.is_configured() (new)
and raises if set_model_plant_params()/set_ambient_temperature() weren't
called either.
Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01DkkuG48uHFCGKe6dPSERFk
Mirrors components/pid/pid.py's own Pid.set_params() pattern: params/
thresholds start out None, and set_params() configures pid_hold/pid_heat/
pid_cool from them. process()/process_fsm() fail naturally (TypeError on
None) if called before set_params() - same as Pid.process() already does -
rather than a new bespoke check. Updates all callers (server/brewpi.py,
SudForecastEstimator, and the pid/sud demo scripts) to call set_params()
right after construction.
Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01DkkuG48uHFCGKe6dPSERFk
Pot.__init__ now only takes dt; set_plant_params() and set_ambient_temperature()
must be called before process(), which now raises RuntimeError if either is
missing instead of silently computing on whatever the constructor happened to
default to. set_ambient_temperature() only seeds the plant's starting
temperature the first time it's called, so changing ambient mid-run still
can't clobber an in-progress simulated temperature. Updates all callers
(server/brewpi.py, TempController(Smith)'s two internal models,
SudForecastEstimator, and the plant/pid/sud demo scripts) to call the setters
right after construction.
Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01DkkuG48uHFCGKe6dPSERFk
IDLE conflated two unrelated things: "controller disabled" and "needs
to cool, which this heat-only actuator fakes via zero output." Split
them apart:
- IDLE now means disabled only - the FSM forces it whenever
enabled=False, regardless of the temperature gap, and process_pid()
zeroes y for it same as before.
- New COOL state (mirroring HEAT) takes over the negative-diff case,
with its own pid_cool (separate "Cool" gains, alongside Hold/Heat)
instead of reusing pid_rate. Its output can legitimately be negative
- it's the actuator (tasks/heater.py's actor(), already max(0, ...))
that clamps it to 0 because *this* plant (Pot) can only heat. A
plant with real cooling capability could one day honor it directly.
- Thresholds renamed accordingly (HoldIdle->HoldCool, HeatIdle->
HeatCool, new CoolHold/CoolHeat); config.json/.sim/.templ and the
hand-rolled ctrl_params in scripts/demos/pid/ and demo_sud.py
updated with a "Cool" params section (mirrors "Heat" for now, since
there's no real cooling actuator to tune against yet).
Also fixes a regression in demo_sud.py/the other PID demos: none of
them ever called set_enabled(True), so since enabled defaults to
False they never drove the heater at all - only caught because this
change's demo_sud.py re-run got stuck in RAMPING forever.
brewpi.py passed a literal 20 as theta_amb to Pot, and
temp_controller_smith.py's two internal Pot models (and every demo's
Pot/TempController instantiation) silently relied on Pot's default of
20 instead. Add a top-level ambient_temperature key to
config.json(.templ/.sim), thread it through brewpi.py into both the
real plant and the Smith predictor's models via a new theta_amb param
on TempController, and make the demos pass it explicitly too.
Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>
temp_controller_smith.py still relied on Kalman filtering and Pot's old
get_temperature_intermediate(), both removed by the recent Pot/Kalman
simplification. Rebuild it using two Pot model copies (zero-delay and
delayed) and the same backward-difference heat rate as temp_controller.py,
combined into the classic Smith correction:
theta_ist = theta_model_fast + (theta_plant - theta_model_delay).
Also fix set_model_power() never being called, so the internal model
actually receives the controller's power output, and fill in
demo_temp_controller_smith.py to exercise it end-to-end with an extra
plot of plant vs. fast-model vs. delayed-model temperature.
Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>
temp_controller.py, temp_controller_smith.py, and kalman.py imported
matplotlib at module level just to support eyeballed-plot __main__
blocks, coupling the live server's import graph to a GUI plotting lib
it never uses at runtime. Relocate those demos (and kalman_eval.py) to
scripts/demos/pid/ and strip the now-unused imports/__main__ blocks
from the production files.
Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>
jensandClaude Sonnet 5