diff --git a/goodwe_controller/DECISIONS/SAFETY-81-load-too-high.md b/goodwe_controller/DECISIONS/SAFETY-81-load-too-high.md new file mode 100644 index 0000000..bb56bc2 --- /dev/null +++ b/goodwe_controller/DECISIONS/SAFETY-81-load-too-high.md @@ -0,0 +1,47 @@ +# SAFETY-81 — no false "Load too high for battery" alarms + +**Status: 2026-09-29, owner go for the card. The 10 W tolerance is this PR's choice, for review.** + +## Defect + +The SAFETY-79 test (SAFETY-79-test-report.md, F1/F2) saw 6 false alarms in 7. +The alarm fired whenever `decide()` clamped its floor to the rating +(`saturated`). Three things set that while the quarter landed on target: + +- **Double count.** `decide()` sizes from the held meter reading plus the + battery reading. When the meter sample predates the battery's last increase, + the increase is counted twice. It happens under noise, and at each quarter + start, where the battery is back while the held sample is still the spike. +- **The aim, not the cap.** `saturated` is graded against cap − margin, so at + margin 50 noise needs 50 W less to trip it (F2). +- **Last seconds.** The gain 900 / remaining turns a few W over the aim into + thousands of W wanted, with the battery far from its rating. + +## Decision + +The alarm needs `saturated` and `peakguard.load_too_high()`: with the battery +at full power from now on, the quarter still ends more than `ALARM_MISS_W` +(10 W) over the real limit (`ceiling_w`). That is the miss itself, without the +gain. The battery reading it uses is the lower of this cycle's and the last +one's. At most one alarm per quarter, because near the threshold the test +flickers with the meter. + +**Why 10 W:** at margin 0 the guard itself lands up to +5.7 W over (SAFETY-79 +test, check 5), and those misses are real but tiny; the alarm would fire in +the last second of most guarded quarters. The margin (default 50) is the fix +for them. Cost: a real miss of 10 W or less is not alarmed. + +**Cost:** a load that climbs slowly through the band between the aim and the +cap alarms when the quarter will end over the cap, not at the aim (10 s later +in `ramp6500`). A step overload alarms in the same cycle as before; a real +overload shows on the meter before the battery moves, so the lower reading +costs it nothing. A quarter already over that the battery cannot win back +still alarms (test_peakguard.py's saturated fixture). + +## Not changed: the 1 s spike itself + +The cycle after a quarter boundary and before the new quarter's first meter +sample still sees 0 s left, files no claim, and an Off battery drops to 0 W for +one cycle. That is the same edge tick as OPT-15 F1, so it is left to OPT-15. +Control is unchanged here: every command in `tools/safety81_sim.py` is +byte-identical to 5a4cdc2 (test_safety81.py part 1). diff --git a/goodwe_controller/DOCS.md b/goodwe_controller/DOCS.md index 2da5da8..47386dc 100644 --- a/goodwe_controller/DOCS.md +++ b/goodwe_controller/DOCS.md @@ -1739,7 +1739,8 @@ control action and goes to the action log and the status page. A *saturated* guard — asking for everything the inverter has while the quarter is still projected over — raises one notification (`goodwe_peak_saturated`), because that is the one state where the money will be spent and shedding load is the only -thing left that changes the bill. +thing left that changes the bill. SAFETY-81 keeps a 1 s meter spike, noise and +a quarter's last seconds from raising it: see `peakguard.load_too_high()`. **And it sizes a price-driven charge, not only a forced discharge (SAFETY-45).** The same arithmetic read the other way answers *"how hard may this site charge @@ -3211,9 +3212,11 @@ reason code `OUTPUT_CLAMP`. **Load too high for battery.** The capacity-peak guard (SAFETY-07) asks for everything the inverter can discharge and the running 15-minute average is still projected over the peak limit, so the month's billed peak -(capaciteitstarief) goes up. In shadow mode the guard's projection is made on a -plant that did not respond (SAFETY-47), and the text says so. See *The -capacity-peak guard*. +(capaciteitstarief) goes up. It fires only when, with the battery at full +power, the period will still end more than 10 W over the real limit (not the +margin's aim), and at most once per period (SAFETY-81). In shadow mode the +guard's projection is made on a plant that did not respond (SAFETY-47), and +the text says so. See *The capacity-peak guard*. **Battery stopped limiting the peak.** The peak guard may not discharge below `peak_soc_floor` (label “Peak reserve”, SAFETY-24). It also stops when the diff --git a/goodwe_controller/app/main.py b/goodwe_controller/app/main.py index ac2962b..954cacc 100644 --- a/goodwe_controller/app/main.py +++ b/goodwe_controller/app/main.py @@ -922,6 +922,10 @@ class Controller: "peak_margin_w", peakguard.PEAK_OPTION_DEFAULTS["peak_margin_w"])) self._peak_engaged = False self._peak_saturated = False + # SAFETY-81: what the alarm is graded on, beside the guard's decision. + self._peak_proj = None + self._peak_batt_prev = None + self._peak_alarm_block = None self._peak_floor_limited = False self._maint_shape_suspended = False # OPT-11. Battery modes, off by default so an install that has not @@ -3712,8 +3716,10 @@ class Controller: # is not measured on that path, and the honest report is NOT COVERED - # the same answer, for the same reason, that the status page already # gives for SAFETY-18 on a transport that cannot see `unchanged_s`. + self._peak_proj = (None if not self.p1_enabled + else self.peak.project(self.p1.averager, now)) self.peak_guard = None if not self.p1_enabled else peakguard.decide( - self.peak.project(self.p1.averager, now), + self._peak_proj, # ⚠️ THE SITE SUM. The guard sizes a floor from what the battery is # ALREADY removing from the meter, and the meter sees every # inverter. One unit's power here would size the floor from a @@ -4816,15 +4822,34 @@ class Controller: available to it. That is the one state where the money is going to be spent and a human is the only remaining actuator. + SAFETY-81: `g.saturated` alone is not enough. It is graded against the + aim, and a 1 s meter spike, noise or the last seconds of a quarter set + it while the quarter lands on target; `peakguard.load_too_high()` must + agree too. The battery reading it gets is the lower of this cycle's and + the last one's - see there. + Edge-triggered, and de-asserting arms it again - the same shape as FreezeWatchdog's `evaluate()`, and for the same reason: one notification - per episode, not one per cycle. + per episode, not one per cycle. SAFETY-81: and at most one per quarter. """ g = self.peak_guard - saturated = bool(g is not None and g.saturated) + batt, prev = self.site_batt_w, self._peak_batt_prev + self._peak_batt_prev = batt + if batt is not None and prev is not None: + batt = min(float(batt), float(prev)) + saturated = bool( + g is not None and g.saturated and self._peak_proj is not None + and peakguard.load_too_high( + self._peak_proj, batt_w=batt, ceiling_w=g.ceiling_w, + achievable_w=self.site_rating_w)) was, self._peak_saturated = self._peak_saturated, saturated if not saturated or was: return + # SAFETY-81: at most once per quarter. Near its threshold the test + # above flickers with the meter, and each flicker would re-alarm. + if self._peak_proj.block_start == self._peak_alarm_block: + return + self._peak_alarm_block = self._peak_proj.block_start self.log_event("PEAK_GUARD_SATURATED - " + g.reason, hint=messages.hint("peak_saturated")) _LOG.error( diff --git a/goodwe_controller/app/peakguard.py b/goodwe_controller/app/peakguard.py index e21a7ac..15df274 100644 --- a/goodwe_controller/app/peakguard.py +++ b/goodwe_controller/app/peakguard.py @@ -866,6 +866,37 @@ def decide(projection, *, batt_w, cap_w, margin_w, reading, achievable_w, soc, if saturated else ""))) +# SAFETY-81. A quarter must end this many W over the real limit before +# "Load too high for battery" fires. Above the guard's own landing error at +# margin 0 (up to +5.7 W, SAFETY-79 test check 5), which margin 0 accepts. +ALARM_MISS_W = 10.0 + + +def load_too_high(projection, *, batt_w, ceiling_w, achievable_w) -> bool: + """SAFETY-81. May "Load too high for battery" fire? Only if, with the + battery at full power from now on, the quarter still ends more than + `ALARM_MISS_W` over the real limit (`ceiling_w`, not the aim). + + This is the miss itself, in W of the quarter average, so it does not have + `decide()`'s gain (900 / remaining): near a quarter's end that gain turns + a watt over the aim into thousands of W wanted. + + The load is the held meter reading plus `batt_w`. The caller passes the + lower of this cycle's and the last cycle's battery reading, so a meter + sample taken before the battery's last increase is not counted twice + (DECISIONS/SAFETY-81-load-too-high.md). A real overload shows on the meter + before the battery moves, so that filter costs it no cycle. + """ + remaining = QUARTER_S - float(projection.elapsed_s) + if batt_w is None or remaining <= 0.0: + return False + rest = float(projection.held_w) + float(batt_w) - float(achievable_w) + done_ws = (QUARTER_S * float(projection.projected_w) + - max(float(projection.held_w), 0.0) * remaining) + ends_w = (done_ws + max(rest, 0.0) * remaining) / QUARTER_S + return ends_w - float(ceiling_w) > ALARM_MISS_W + + def charge_headroom_w(decision) -> float | None: """SAFETY-45. The hardest this SITE may charge without putting the billed quarter over the ceiling, in W, positive - or None when nothing measured it. diff --git a/goodwe_controller/test_safety81.py b/goodwe_controller/test_safety81.py new file mode 100644 index 0000000..64da0fa --- /dev/null +++ b/goodwe_controller/test_safety81.py @@ -0,0 +1,117 @@ +"""Runnable check for SAFETY-81, no false "Load too high for battery" alarms. +`python3 test_safety81.py` + +Drives the REAL Controller through tools/safety81_sim.py (a 1 s cycle on a +plant shaped like the SAFETY-79 rig, one sample in ten late). +DECISIONS/SAFETY-81-load-too-high.md has the record. + +1. Every command is byte-identical to release/1.0 5a4cdc2. +2. No alarm on the quarter-edge spike, the last seconds, noise (margin 50 + and 0) or a burst the quarter absorbs. +3. Real overloads still alarm, as fast as on 5a4cdc2. +4. peakguard.load_too_high() on its own. + +Mutations (MUTATION.md, purged copies) are listed in the pull request. +""" + +import os +import sys +from types import SimpleNamespace + +HERE = os.path.dirname(os.path.abspath(__file__)) +sys.path.insert(0, os.path.join(HERE, "tools")) + +import safety81_sim as sim # noqa: E402 +from app.peakguard import load_too_high # noqa: E402 + +fails = [] + + +def check(name, cond): + print(f" {'ok ' if cond else 'FAIL'} {name}") + if not cond: + fails.append(name) + + +# Printed by `python3 tools/safety81_sim.py` on release/1.0 5a4cdc2 (the tool +# copied in, nothing else changed), in the CI image: (alarm times, digest). +BASE = { + "const4500": ([2699.0], "6ba6b8634f0df9526adc04f03c82db7d083973268deda0d1f07c5519bc2e5e9d"), + "const4500_m0": ([2699.0], "2bede28f3ea6ba9294be134c9b9733e43d22a7c24deac3bf8210bbbbe09b2039"), + "sine4500": ([2699.0], "bf70c2c23a0eede40c34478d1354b7daa1858e0a0f920693e2dd15fb5046120f"), + "edge4600": ([2.0, 902.0, 1802.0, 2699.0], "3cc0c6fec0c70f138530955babc2b416fe7307373037c1b2e927b6ccdaad3a4d"), + "edge4600_m0": ([2.0, 902.0, 1802.0, 2699.0], "ba9ba2c042ee42b043315b996ece38b3478dc9866aaf833256c9c29c02f0fe9f"), + "burst_end": ([881.0, 1781.0, 2681.0], "5f70e1eb4244820f1d44b494cb80e51f1a4486dee03357c9a8e8f7d371c5d9af"), + "noise5000_m50": ([292.0, 2551.0, 2698.0], "48b446e1a78e6d6032b31cb68a4eadb0f74e3aec4cc1e184162e9c65449bfdc5"), + "noise5000_m0": ([292.0, 2552.0, 2698.0], "1a0527dee6c2b03dc95a90b4682858c7bf5edf7205c2aced249112f04328c960"), + "step6500": ([1201.0, 1801.0], "95e5c90e4a6814526cb4f3bea76286063b449d86a420f888c014531fb6e913a3"), + "miss5560": ([1201.0, 1801.0], "cd991cfe1685750598236701a5a2f2f0342d66645609c536d42ab7ba07216e6c"), + "ramp6500": ([1296.0, 1801.0], "8db7675535f1a01abf38bd6bfb996a6fe57711d3ecca53541bb1c0870748c46b"), + "step7500_reserve": ([], "21eb9c07a4582f47f347084d1c75a28a5d767bc068bc3f74f32433d3239e9ccb"), +} +RUN = {k: sim.run(**v)[:2] for k, v in sim.SCENARIOS.items()} + +# ============================================================================ # +print("1. every command byte-identical to release/1.0 5a4cdc2") +check("the same scenarios as 5a4cdc2", set(RUN) == set(BASE)) +for k, (alarms, digest) in RUN.items(): + check(f"{k}: digest {digest[:12]}", digest == BASE[k][1]) + +# ============================================================================ # +print("2. no false alarm (5a4cdc2's are listed)") +for k in ("edge4600", "edge4600_m0", "const4500", "const4500_m0", "sine4500", + "noise5000_m50", "noise5000_m0", "burst_end"): + check(f"{k}: none (5a4cdc2: {BASE[k][0]})", RUN[k][0] == []) + +# ============================================================================ # +print("3. real overloads still alarm, as fast as 5a4cdc2") +for k in ("step6500", "miss5560"): + print(f" {k}: load steps up at 1200 s; alarms at {RUN[k][0]}, " + f"5a4cdc2 {BASE[k][0]}") + check(f"{k}: the same second as 5a4cdc2, and again only at the next " + f"quarter (at most once per quarter)", RUN[k][0] == BASE[k][0]) +# By design: until 1306 s this quarter would end at most ALARM_MISS_W over the +# real 3500 W cap; 5a4cdc2 alarmed when it crossed the aim (cap - 50). +print(f" ramp6500: alarms at {RUN['ramp6500'][0]}, " + f"5a4cdc2 {BASE['ramp6500'][0]}") +check("ramp6500: alarms once the quarter will end over the real cap by " + "more than ALARM_MISS_W", + RUN["ramp6500"][0] == [1306.0, 1801.0]) +check("step7500 under the peak reserve: not this alarm (the guard is not " + "allowed to discharge)", RUN["step7500_reserve"][0] == []) + +# ============================================================================ # +print("4. load_too_high()") + + +def proj(elapsed, done_avg, held): + """A projection `elapsed` s in, averaging `done_avg` so far.""" + r = 900.0 - elapsed + return SimpleNamespace(elapsed_s=elapsed, held_w=held, + projected_w=(done_avg * elapsed + max(held, 0) * r) + / 900.0) + + +def ltl(p, batt, cap=3500.0, rail=2000.0): + return load_too_high(p, batt_w=batt, ceiling_w=cap, achievable_w=rail) + + +check("load 6000 W vs 3500 + 2000: yes", ltl(proj(300, 3450, 4000), 2000)) +check("already over, the battery can carry the load but not catch up: yes", + ltl(proj(450, 7200, 7200), 0, rail=5000)) +check("the last second, a 7 W miss (under ALARM_MISS_W): no", + not ltl(proj(899, 3509, 2500), 1000)) +check("a miss of exactly ALARM_MISS_W: no", + not ltl(proj(450, 3520, 3500), 2000)) +check("...and 1 W more: yes", ltl(proj(450, 3522, 3500), 2000)) +check("over cap + battery, but the quarter lands under the cap: no", + not ltl(proj(880, 3450, 4000), 2000)) +check("...and when it does not: yes", ltl(proj(700, 3450, 4000), 2000)) +check("no battery reading: no", not ltl(proj(300, 3450, 5000), None)) +check("no seconds left: no", not ltl(proj(900, 4000, 5000), 2000)) + +print() +if fails: + print(f"FAILED: {len(fails)} check(s)") + sys.exit(1) +print("all checks passed") diff --git a/goodwe_controller/tools/safety81_sim.py b/goodwe_controller/tools/safety81_sim.py new file mode 100644 index 0000000..f91d07b --- /dev/null +++ b/goodwe_controller/tools/safety81_sim.py @@ -0,0 +1,203 @@ +#!/usr/bin/env python3 +"""SAFETY-81: when does "Load too high for battery" fire? + + python3 tools/safety81_sim.py # alarms and a control digest per run + +The REAL Controller (read_inputs + cycle) at a 1 s cycle, on a plant shaped +like the SAFETY-79 test rig: one battery switched Off (so only the peak guard +makes it give, max 2000 W), a 3500 W cap, and a P1 meter that publishes +0.3 s before each cycle. The battery reaches a new command 0.5 s after it is +written. One meter sample in ten arrives late (the add-on still holds the one +before), so the held meter reading can predate the battery's last change: +the double count behind the rig's false alarms. The cycle on a quarter +boundary, before the new quarter's first sample, files no peak claim, which +is the rig's 1 s grid spike at each quarter change. Each run returns the +alarm times and a digest of every command, so the same runs show both what +changed and what did not. +""" + +import asyncio +import hashlib +import os +import random +import sys +import tempfile +import time +from datetime import timedelta + +sys.path.insert(0, os.path.dirname(os.path.abspath(__file__))) + +import opt11_identity as rig # noqa: E402 +import app.main as m # noqa: E402 +from app import packmode # noqa: E402 +from app.main import Controller # noqa: E402 +from app.p1 import make_sample, split_signed # noqa: E402 +from app.store import unit_key # noqa: E402 + +TICK = 1.0 +SAMPLE_LEAD_S = 0.3 # the meter publishes this long before each cycle +RESPONSE_S = 0.5 # a new command reaches the battery this much later +LATE_P = 0.1 # share of meter samples that arrive late +ALARM = "goodwe_peak_saturated" + + +def constant(w): + return lambda t: w + + +def noisy(mean, amp, seed=81): + """`mean` +/- `amp`, a new uniform value every second.""" + rnd = random.Random(seed) + table = {} + + def f(t): + k = int(t) + if k not in table: + table[k] = mean + rnd.uniform(-amp, amp) + return table[k] + return f + + +def sine(mean, amp, period=120.0, noise=50.0): + import math + n = noisy(0.0, noise, seed=79) + return lambda t: mean + amp * math.sin(2 * math.pi * t / period) + n(t) + + +def step(before, after, at): + return lambda t: before if t < at else after + + +def ramp(before, after, at, secs): + return lambda t: before + (after - before) * min(max(t - at, 0.0) / secs, 1.0) + + +class _Plant: + """One battery that reaches its command RESPONSE_S after the write.""" + + def __init__(self, load, rating, soc): + self.load, self.rating, self.soc = load, rating, soc + self.t = 0.0 + self.hist = [(-1e9, 0.0)] # (time the command takes effect, W) + self.notes = [] + self.meter = 0.0 # the last meter reading delivered + + def batt(self, at): + w = 0.0 + for when, v in self.hist: + if when <= at: + w = v + return max(-self.rating, min(self.rating, float(round(w)))) + + def grid(self, at): + return self.load(at) - self.batt(at) + + async def limits(self, e): + return (-5000.0, 5000.0, 1.0) + + async def call(self, domain, service, data): + if service == "create": + self.notes.append((self.t, data.get("notification_id"))) + return True + + async def number(self, e, invert=False): + if e in ("sensor.grid", "sensor.net"): + return self.meter + if e.startswith("sensor.soc"): + return self.soc + if e.startswith("sensor.batt"): + return self.batt(self.t) + return None + + async def set_number(self, e, v): + self.hist.append((self.t + RESPONSE_S, float(v))) + return True + + +def run(load, *, margin=50, dur=2700.0, rating=2000.0, cap=3500.0, + late_at=(), soc=60.0): + """Alarm times (s from the start of the first quarter) and a digest of + every cycle's target and written command. A sample is also late at each + `t % 900` in `late_at`.""" + opts = rig._options(1, { + "meter_source": "ha_signed", "p1_net_entity": "sensor.net", + "meter_phases": 1, "peak_cap_w": cap, "peak_margin_w": margin, + "battery_modes_enabled": True, "max_w": rating}) + store = rig._Store() + store.data[unit_key("inverter-a", packmode.USE_KEY)] = False + store.data[packmode.USE_KEY] = False + db = os.path.join(tempfile.mkdtemp(prefix="s81-"), "tariff.db") + + async def go(): + plant = _Plant(load, rating, soc) + c = Controller(opts, plant, store, rig._Pub(), stop=asyncio.Event(), + peak_db_path=db) + for i in c.inverters: + i.dev_min, i.dev_max = -5000.0, 5000.0 + c.auto = True + real_dt, clock = m.datetime, [0.0] + + class _DT(real_dt): + @classmethod + def now(cls, tz=None): + return rig.BASE + timedelta(seconds=clock[0]) + m.datetime = _DT + rows, late = [], random.Random(8100) + try: + t = 0.0 + while t < dur: + plant.t = clock[0] = t + ts = t - SAMPLE_LEAD_S + if late.random() >= LATE_P and t % 900 not in late_at: + plant.meter = plant.grid(ts) + imp, exp = split_signed(plant.meter) + c.p1.submit(make_sample( + "ha_signed", imp, exp, phases=1, + ingest_ts=rig.BASE + timedelta(seconds=ts), + ingest_mono=time.monotonic())) + await c.read_inputs(now_mono=t) + await c.cycle() + rows.append((t, c.target, round(plant.hist[-1][1], 6))) + t += TICK + finally: + m.datetime = real_dt + return plant, c, rows + plant, c, rows = asyncio.run(go()) + alarms = [t for t, nid in plant.notes if nid == ALARM] + return alarms, hashlib.sha256(repr(rows).encode()).hexdigest(), c, rows + + +# Three quarters each (2700 s); a new quarter starts at 900 s and 1800 s. +SCENARIOS = { + # F1: constant and sine loads the battery carries, across quarter edges. + "const4500": dict(load=constant(4500.0)), + "const4500_m0": dict(load=constant(4500.0), margin=0), + "sine4500": dict(load=sine(4500.0, 400.0)), + # F1 at the start of a quarter: the sample after the battery's return + # is late, so the held reading is the 1 s spike (the battery at 0 W). + "edge4600": dict(load=constant(4600.0), late_at=(2.0,)), + "edge4600_m0": dict(load=constant(4600.0), margin=0, late_at=(2.0,)), + # 6000 W in a quarter's last 20 s: over cap + battery, but the quarter + # still lands between the aim and the cap. + "burst_end": dict(load=lambda t: 6000.0 if t % 900 >= 880 else 4500.0), + # F2: a noisy load the battery carries, at margin 50 and 0. + "noise5000_m50": dict(load=noisy(5000.0, 150.0)), + "noise5000_m0": dict(load=noisy(5000.0, 150.0), margin=0), + # Real: from 1200 s the house needs 1000 W more than cap + battery. + "step6500": dict(load=step(4500.0, 6500.0, 1200.0)), + # Real, small: from 1200 s, 60 W (+/- 20 W noise) more than cap + battery. + "miss5560": dict(load=lambda t: step(4500.0, 5560.0, 1200.0)(t) + + noisy(0.0, 20.0)(t)), + # Real, slow: 4500 -> 6500 W over 200 s from 1200 s, through the band + # between the aim (cap - 50) and the real cap. + "ramp6500": dict(load=ramp(4500.0, 6500.0, 1200.0, 200.0)), + # The pack under its peak reserve (20 %), and a load far over cap + + # battery: that is "Battery stopped limiting the peak", not this alarm. + "step7500_reserve": dict(load=step(4500.0, 7500.0, 1200.0), soc=15.0), +} + + +if __name__ == "__main__": + for k, v in SCENARIOS.items(): + a, d, _, _ = run(**v) + print(f"{k:16s} alarms at {a} digest {d}")