Commit Graph
264 Commits
Author SHA1 Message Date
jensandClaude Sonnet 5 c60fdff74d docs: check off set_model_power gap in PID design backlog
Already fixed in 2f2067d (no-op stub on TempControllerBase, 2026-06-25)
but the TODO entry was never marked done.

Co-Authored-By: Claude Sonnet 5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01F4oEE99rkKVU8L8tkzXWdG
2026-07-11 12:17:13 +02:00
jens 9f262c48d0 log: match Sud's step Heating/Reached lines to requested format
"{descr}({number}) Heating"/"Reached" instead of the reverse
"Heating/Reached to Step {number} ({descr})" ordering.
2026-07-10 22:53:37 +02:00
jens 280f74edaa log: rename Sud's step-entry log line to describe the ramp phase
Every step ramps toward its target first (see _advance()'s own
comment) - "Heating to Step N (...)" names that phase instead of the
generic "Entering step".
2026-07-10 22:37:16 +02:00
jens ce5eb3bc23 log: Sud lifecycle transitions and stirrer/heater connect state
Logs load/start/pause/continue/stop/entering-step/wait-user/finished
on Sud (components/sud.py) and connected/disconnected on
StirrerTask/HeaterTask, using the self.log added earlier.

SudForecastEstimator.estimate() (components/sud_forecast.py) drives its
own throwaway Sud through an entire schedule in a tight loop (no real
waiting) to predict its duration, and re-runs that on every real step
transition too - since it's still a Sud, it logged through the exact
same "Sud" logger as the real, server-driven one, making an instant
internal forecast run indistinguishable in the log from an actual
brew. Gave it its own "SudForecastEstimator" logger, silenced to
WARNING by default, so only the real Sud's transitions show up.
2026-07-10 22:28:01 +02:00
jens a1864a5257 log: route task/component status output through logging, not print()
AttributeChange (the common base of every ATask and component ABC) now
sets self.log = logging.getLogger(type(self).__name__), so components
no longer need to hand-type their own name into each message. Wired
logging.basicConfig() in server/brewpi.py with a bare "%(name)s:
%(message)s" formatter - Tee (see prior commit) still supplies the
"<date>T<time>:" prefix, so lines read "<date>T<time>:<component>:
<message>" without double-stamping, and third-party loggers
(websockets, asyncio) now get the same formatting for free.

Converted the print() call sites that were standing in for this in
tasks/ and components/ (leaving __main__ demo blocks and explicit
debug-dump helpers alone).
2026-07-10 22:00:04 +02:00
jensandClaude Sonnet 5 a19d2504fb stirrer: decode and report Pololu SMC status errors instead of guessing
Adds StatusError flags for the STATUS register and get_status_errors();
go() now reports if a fail-safe (safe-start violation or other error)
persists after GO instead of failing silently. _on_process uses the
same decoding to log any active error and only auto-recovers on a
safe-start violation, rather than the old narrow status & limit_status
heuristic.

Co-Authored-By: Claude Sonnet 5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01EU3NTwLygh8jkrnqPoHNXF
2026-07-07 19:36:11 +02:00
jensandClaude Sonnet 5 5a75d15416 docs: note grounding y_hold_min in passive-cooling capacity in pid TODO
Captures the idea of computing the HOLD-state negative floor from the
Smith controller's internal Pot model (L*(theta_ist-theta_amb)/C) instead
of the fixed -0.1 heuristic, plus the caveat that the Normal controller
has no internal plant model to draw the same estimate from.

Co-Authored-By: Claude Sonnet 5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01M2ierBoxW3v7nUbDw3M2pE
2026-07-06 08:30:40 +02:00
jensandClaude Sonnet 5 6d17419067 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
2026-07-06 08:26:25 +02:00
jensandClaude Sonnet 5 2d032bf9b2 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
2026-07-06 08:19:10 +02:00
jensandClaude Sonnet 5 11c3d92f25 docs: refresh windup writeup to past tense, link architecture diagram
overshoot_hold_windup.md read like a live plan ("not yet implemented")
even though the fix had already shipped; reworks it into a past-tense
record with corrected line numbers and test descriptions matching what
was actually built. Fixes a stale pid_heat reference in
temp_control_calibration.md.

TODO.md's windup item still claimed test coverage was "outstanding"
from before the test suite was added; corrects that and the "No
automated tests" item above it to reflect current coverage. Both docs
now link docs/fsm_states.png (durable) and the Claude Artifact URL
(session-scoped) for the cascade architecture diagram.

Co-Authored-By: Claude Sonnet 5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01DGQhVQ2Y3yXAQTXhrxVd5u
2026-07-05 22:08:19 +02:00
jensandClaude Sonnet 5 f69d63c31b fix: split inner-loop yi_max clamp to fix HOLD-state windup overshoot
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
2026-07-05 21:23:55 +02:00
jensandClaude Sonnet 5 de11b849d8 docs: revise pid_heat windup plan to pid_outer/pid_inner rename + Inner.Hold split
Supersedes the earlier flat yi_max clamp / FSM-gating ideas: same inner
PID instance switches its active param set (Inner.Heat vs Inner.Hold)
by state instead of freezing, giving bumpless transfer for free and a
tight yi_max that only applies while HOLD is driving it.

Co-Authored-By: Claude Sonnet 5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01KefnwbGDM8CGrhb4sFhVq9
2026-07-04 12:48:59 +02:00
jensandClaude Sonnet 5 13bb011099 docs: plan HOLD-state pid_heat windup fix from overshoot investigation
Records the root cause of the cold-water overshoot in docs/overshoot.png
(integral windup in pid_heat with no anti-windup engagement, since y never
saturated) and the refined fix plan: gate pid_heat by FSM state instead of
a flat yi_max clamp, which was rejected after the numbers showed it would
also cripple legitimate high-rate ramps.

Co-Authored-By: Claude Sonnet 5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01KefnwbGDM8CGrhb4sFhVq9
2026-07-04 12:31:58 +02:00
jensandClaude Sonnet 5 4b9a144b62 fix: temp sensor read failures could crash startup or permanently kill the task
Same bug class as the earlier heater fix: TempSensorTask.on_process()
called self.sensor.temperature() every tick with no exception handling
at all, and the constructor even called it once synchronously at
startup to prime the value. A read failure there would either crash
the whole server before the event loop started, or permanently kill
TempSensorTask's coroutine mid-run - nothing restarts a dead ATask, so
the sensor would never be read again for the rest of the process's
life.

TempSensor_max31865.temperature() now catches read failures and calls
a new reopen() (closes/reopens the spidev handle - the closest
equivalent to unplug/replug for a bus peripheral) instead of raising,
holding the last-known-good reading meanwhile. reopen() itself never
raises either, learned from HendiCtrl.disconnect() previously letting
a failure escape the same way. Belt-and-suspenders guards added at the
TempSensorTask level too, matching HeaterTask/StirrerTask.

Verified against a fake spidev: a read failure no longer raises,
reopen() is attempted automatically, and readings resume once the bus
responds again - even when reopen() itself also fails.

Co-Authored-By: Claude Sonnet 5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01YaPLuRPpyjWcwhMvCvpHCL
2026-07-03 21:45:21 +02:00
jensandClaude Sonnet 5 671e0c2474 fix: heater task permanently died after a mid-brew unplug, never recovered
Root cause (from the brewpi Pi's log): HendiCtrl.disconnect() only
caught HendiException (a protocol-level NAK), but a genuine unplug
fails deep inside pyserial itself - flushInput()/readline() raise
termios.error/OSError on the now-dead fd. That escaped disconnect()
uncaught (skipping self.ser.close() too), then kept propagating up
through every caller that invoked disconnect() from its own except
handler (HeaterHendi.process()/activate(), AHeater.open()'s
context-manager exit), all the way out of HeaterTask.on_process()'s
coroutine entirely. Nothing restarts a dead ATask, so the heater's
process()/duty-cycle loop was gone for the rest of the process's
life - reconnecting afterward changed `connected` back to True but
nothing was left running to ever call process() again.

Fixes:
- HendiCtrl.disconnect() now catches broadly and always closes the
  port, matching Pololu1376.disconnect()'s already-correct pattern.
- HeaterTask/StirrerTask.on_process() gain an outer retry loop as a
  safety net: even an unanticipated exception now logs, marks
  disconnected, and re-enters rather than permanently killing the
  task.

Verified by reproducing the exact failure (comm error raising a raw
OSError, not HendiException) against a fake device - the task now
survives and resumes process()ing once reconnected.

Co-Authored-By: Claude Sonnet 5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01YaPLuRPpyjWcwhMvCvpHCL
2026-07-03 21:21:44 +02:00
jensandClaude Sonnet 5 7b162cf1f5 refactor: drop firmware-version display, move Enable toggle to Controller
Firmware version is already printed to the log at connect() time
(HendiCtrl/Pololu1376) - remove the live GUI/websocket firmware
reporting entirely (Connectable, HeaterHendi/StirrerPololu1376,
Heater/StirrerTask, web GUI) as redundant.

Also move the Heater panel's Closed-loop checkbox into the Controller
panel and rename it "Enable" - the Controller panel now shows a
live Enabled (green) / Disabled (gray) status badge next to its
heading, matching the Connected/Disconnected badges on the Heater/
Stirrer panels.

Co-Authored-By: Claude Sonnet 5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01YaPLuRPpyjWcwhMvCvpHCL
2026-07-03 20:23:55 +02:00
jensandClaude Sonnet 5 0877e7754b fix: guard HeaterHendi/StirrerPololu1376 activate() against comm errors
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
2026-07-03 19:39:07 +02:00
jensandClaude Sonnet 5 f20e617d81 feat: add connect/disconnect status for real heater/stirrer hardware
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
2026-07-03 19:18:59 +02:00
jensandClaude Sonnet 5 698c019581 refactor: make ATemperatureSensor's temp observable directly on the sensor
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
2026-07-02 22:03:50 +02:00
jensandClaude Sonnet 5 75a886950c refactor: collect hendi firmware images under firmware/hendi_ctrl/
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
2026-07-02 18:58:32 +02:00
jensandClaude Sonnet 5 5bc278e875 feat: add --debug tracing to hendi_ctrl_app.py, document v1.16 fix
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
2026-07-02 18:44:00 +02:00
jensandClaude Sonnet 5 5522b9c491 refactor: move hendiCtrl.py's main() into scripts/hendi_ctrl_app.py
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
2026-07-02 17:02:21 +02:00
jens 1bcabb0ccc added firmware info to hendi and motor driver 2026-07-02 16:33:37 +02:00
jensandClaude Sonnet 4.6 bb5af3c0ed fix: clamp pid_hold output to [0,1] in HOLD state to break limit cycle
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>
2026-06-30 21:13:30 +02:00
jensandClaude Sonnet 4.6 b3923fb1c0 fix: smooth HOLD→HEAT power transition (bumpless transfer + cascade timing)
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>
2026-06-30 20:33:12 +02:00
jensandClaude Sonnet 4.6 d0a137e39e config: seed plant params from Pot.water_mass at server startup
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>
2026-06-30 19:45:13 +02:00
jensandClaude Sonnet 4.6 5142fcbf3d refactor: move pot hardware params and pid_type out of per-brew docs
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>
2026-06-30 19:41:04 +02:00
jensandClaude Sonnet 4.6 0495e177c4 refactor: replace plant_name with per-component type keys in config
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>
2026-06-30 19:31:39 +02:00
jensandClaude Sonnet 4.6 0156e689ca config: wire TempSensor section from config.json to TempSensorSim
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>
2026-06-30 19:27:04 +02:00
jensandClaude Sonnet 4.6 ca1953c9ee sensor: model real temp sensor noise in TempSensorSim
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>
2026-06-30 19:17:48 +02:00
jens 801e9809a6 hendiCtrl: fixed graceful close 2026-06-30 18:59:33 +02:00
jensandClaude Sonnet 4.6 5751d26873 server: graceful Ctrl-C shutdown; HendiCtrl closes connection cleanly
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>
2026-06-30 18:26:54 +02:00
jens 29dd5267a9 - fixed hendiCtrl exceptions 2026-06-30 17:05:43 +02:00
jensandClaude Sonnet 4.6 5be1d4e862 pid: option A heat-rate pre-filter (beta IIR before differentiation)
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>
2026-06-30 17:02:14 +02:00
jens 8ca4e4d803 fixed duplicate class declaration 2026-06-30 16:38:51 +02:00
jens 6547478d00 HendiCtrl: better Exceptions 2026-06-30 16:22:06 +02:00
jensandClaude Sonnet 4.6 c6e9258351 Rename config templates: .templ → -sim.json.tpl, config_real.json → -real.json.tpl
Consistent naming: config-sim.json.tpl and config-real.json.tpl.
Update README and TODO references accordingly.

Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01SH2D4LRuCnhLSzoYerAfJX
2026-06-28 20:23:29 +02:00
jensandClaude Sonnet 4.6 8c845ed5c5 Fix crash: rename shadowing 'pot' variable in forecast closure
In estimate()'s on_step_changed closure, the new 'pot = step.get("pot", {})'
local variable shadowed the outer 'pot' (Pot plant instance), causing
pot.set_plant_params() to be called on a plain dict and crash on load.
Renamed to 'step_pot' to avoid the collision.

Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01T52JH848ojhXXHn1bAzdC3
2026-06-26 08:02:53 +02:00
jensandClaude Sonnet 4.6 e2e3baab08 Refactor sud JSON pot params under a nested 'pot' key
Top-level pot_mass/pot_material/L/Td/grain_mass/water_mass and their
per-step overrides are now grouped under a 'pot' sub-object, matching
the structure already applied to sud_0010.json's parent level. Updated
all sude/*.json files and the parsing/consuming code in components/sud.py,
tasks/sud.py, components/sud_forecast.py, and scripts/demos/sud/demo_sud.py.

Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01T52JH848ojhXXHn1bAzdC3
2026-06-26 07:31:27 +02:00
jensandClaude Sonnet 4.6 44541220f9 Fix FSM regression: swap TempControllerBase base class order
With TempControllerBase(APid, TempControllerFsm), APid.is_holding()
(abstract stub returning None) shadowed TempControllerFsm.is_holding()
in the MRO, so tc.is_holding() always returned None. The forecast
simulation never called sud.temp_reached() and always hit MAX_TICKS.

Swapping to TempControllerBase(TempControllerFsm, APid) puts the
concrete FSM methods before APid's abstract stubs in the MRO.

Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01Tqxrk8uj4M3w3d3eXm3xK8
2026-06-25 21:22:52 +02:00
jensandClaude Sonnet 4.6 42d7776a85 Extract FSM logic from TempControllerBase into TempControllerFsm
States, DEFAULT_THRESHOLDS, the three PIDs, FSM state vars, process_fsm(),
on_state_entered(), set_enabled(), and is_holding() move to a new
TempControllerFsm class in temp_controller_fsm.py. TempControllerBase
inherits from both APid and TempControllerFsm; States is re-exported so
existing imports in temp_controller_smith.py are unaffected.

Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01Tqxrk8uj4M3w3d3eXm3xK8
2026-06-25 20:50:20 +02:00
jensandClaude Sonnet 4.6 f7355270c8 Extract shared factory dispatch into ComponentFactory base class
All four name-dispatch factories repeated the same if/elif lazy-import
pattern. Replace with a ComponentFactory base class holding a callable
registry and a _lazy() helper for the common import-and-construct case.
PlantFactory is an orchestrator, not a dispatcher, and is left as-is.

Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01Tqxrk8uj4M3w3d3eXm3xK8
2026-06-25 20:44:43 +02:00
jensandClaude Sonnet 4.6 6e696f44e4 Add set_ambient_temperature and set_model_plant_params stubs to TempControllerBase
Same pattern as set_model_power: these methods only existed on the Smith
controller, forcing five hasattr guards at call sites. No-op stubs on the
base class give all controllers a stable interface; Smith overrides them.
Remove the now-redundant hasattr guards.

Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01Tqxrk8uj4M3w3d3eXm3xK8
2026-06-25 20:22:33 +02:00
jensandClaude Sonnet 4.6 2f2067d2b9 Add set_model_power no-op stub to TempControllerBase
The Normal controller had no set_model_power(), causing callers to
guard with hasattr() instead of relying on a stable interface. Adding a
no-op stub to the base class means all controllers have the method;
TempControllerSmith overrides it to actually update its internal model.
Remove the now-redundant hasattr guards at both call sites.

Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01Tqxrk8uj4M3w3d3eXm3xK8
2026-06-25 20:19:33 +02:00
jensandClaude Sonnet 4.6 740fe8eee9 Remove debug prints from HeaterFactory
print(**kwargs) crashes at runtime since print doesn't accept
arbitrary keyword arguments. Both debug lines were leftover scaffolding.

Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01Tqxrk8uj4M3w3d3eXm3xK8
2026-06-25 20:17:42 +02:00
jensandClaude Sonnet 4.6 35d33530ef Fix step-1-skipped-on-restart race and Progress tab step number mismatch
Re-enabling the temp controller landed unconditionally in HOLD and
relied on the next tick to correct it, but SudTask.on_process() reads
is_holding() synchronously in the same call chain that pushes a fresh
step's setpoint - so a restart could finish a hold-less step instantly
instead of actually ramping. Resolve the FSM against the real gap right
away instead. Also fix the status bar showing one step number below
what the Progress tab's plates show for the same step.

Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_0189FkmyJkY77HqsNomr1DwV
2026-06-24 23:30:37 +02:00
jensandClaude Sonnet 4.6 e49af8a347 Add a Progress tab: one step plate per schedule step, stacked
A glance at the Automatic tab's forecast plot couldn't show where the
brew actually stands within its own schedule - just a curve. The new
Progress tab stacks one StepPlate per step instead: an LED for its
status (off/done/active-ramping/active-holding), its resolved target
temp, masses and ramp rate, plus, for whichever step is currently
active, live actual temp and stirrer state (frozen at their last
value once that step finishes) and a forecast-based remaining-time
countdown.

The countdown needs to know where each step actually begins in the
forecast's timeline, which the server didn't track before -
SudForecastEstimator.estimate() now returns per-step start times
alongside t/theta, and SudTask threads them through send_forecast()/
_reanchor_forecast() the same way (including the same generation-guard
against the concurrent-call race) as a new 'StepStarts' field on the
'Forecast' message.

Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_019qvu5giu7gvRCyEWzf2Vpx
2026-06-24 17:15:14 +02:00
jens 0be8ffcbe0 Revert "Run the Pot simulation from server startup, not just once a Sud loads"
This reverts commit 63fa093a8a.
2026-06-24 16:09:49 +02:00
jensandClaude Sonnet 4.6 17e8386002 Generalize Sud forecast reanchoring to every step boundary
Reanchoring used to only happen when a user confirmed a WAIT_USER
step, so anything the schedule advanced through on its own (a ramp
reaching target, a hold timing out) left the forecast showing a
stale, increasingly wrong prediction once reality diverged from it.
_reanchor_forecast() now fires from on_step_changed() on every real
transition, splicing in a fresh simulation anchored at the real
current temperature/elapsed time instead.

Also fixes two bugs surfaced while testing that change:
- estimate()'s early-return for an empty/not-yet-loaded schedule still
  returned the old 4-tuple shape, crashing every connection before a
  Sud was ever Loaded.
- send_forecast() and _reanchor_forecast() can run concurrently (e.g.
  a fresh Start triggers both at once), and whichever resumed second
  after its own worker-thread simulation would blindly splice its tail
  onto whatever the other had already written, producing a spurious
  connecting line across the plot. Both now carry a generation counter
  and discard their result if a newer call has since committed.

Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_019qvu5giu7gvRCyEWzf2Vpx
2026-06-24 10:50:17 +02:00
jens ead900b7b1 Build the heater/pot/sensor rig as one unit, picked by plant_name alone
heater_name/sensor_name/plant_name were three independent config keys,
each picked via its own factory - in practice sim and real hardware
are never actually mixed and matched, so this could (nonsensically)
disagree, e.g. a real heater paired with a simulated sensor.

Add PlantFactory (components/plant/plant_factory.py): plant_name alone
now builds the whole rig together. "sim" gets HeaterSim/Pot (the
modeled plant, as before)/TempSensorSim. Anything else gets
HeaterHendi/PotReal/TempSensor_max31865 - PotReal is a new, deliberately
unmodeled Pot for the real, physical kettle (components/plant/pot_real.py):
the real temperature comes straight from the real sensor, not from a
model, so it just accepts and ignores set_plant_params()/
set_ambient_temperature()/initial() and reports no temperature of its
own, satisfying PotTask/SudTask's interface with nothing to actually
simulate.

heater_name/sensor_name are gone from config.json.templ; server/brewpi.py
delegates to HeaterFactory/TempSensorFactory lazily from inside
PlantFactory, same as before, so real hardware's spidev/pyserial deps
still aren't needed just to import the module.
2026-06-23 20:22:51 +02:00