SAFETY-81: no false 'Load too high' alarms
The alarm now also needs peakguard.load_too_high(): with the battery at full power, the quarter still ends more than 10 W over the real limit. The battery reading is the lower of this cycle's and the last, so a meter sample from before the battery's last increase is not counted twice. At most one alarm per quarter. Control outputs unchanged. Co-Authored-By: Claude Opus 5.5 <noreply@anthropic.com>
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# SAFETY-81 — no false "Load too high for battery" alarms
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**Status: 2026-09-29, owner go for the card. The 10 W tolerance is this PR's choice, for review.**
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## Defect
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The SAFETY-79 test (SAFETY-79-test-report.md, F1/F2) saw 6 false alarms in 7.
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The alarm fired whenever `decide()` clamped its floor to the rating
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(`saturated`). Three things set that while the quarter landed on target:
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- **Double count.** `decide()` sizes from the held meter reading plus the
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battery reading. When the meter sample predates the battery's last increase,
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the increase is counted twice. It happens under noise, and at each quarter
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start, where the battery is back while the held sample is still the spike.
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- **The aim, not the cap.** `saturated` is graded against cap − margin, so at
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margin 50 noise needs 50 W less to trip it (F2).
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- **Last seconds.** The gain 900 / remaining turns a few W over the aim into
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thousands of W wanted, with the battery far from its rating.
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## Decision
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The alarm needs `saturated` and `peakguard.load_too_high()`: with the battery
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at full power from now on, the quarter still ends more than `ALARM_MISS_W`
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(10 W) over the real limit (`ceiling_w`). That is the miss itself, without the
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gain. The battery reading it uses is the lower of this cycle's and the last
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one's. At most one alarm per quarter, because near the threshold the test
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flickers with the meter.
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**Why 10 W:** at margin 0 the guard itself lands up to +5.7 W over (SAFETY-79
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test, check 5), and those misses are real but tiny; the alarm would fire in
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the last second of most guarded quarters. The margin (default 50) is the fix
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for them. Cost: a real miss of 10 W or less is not alarmed.
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**Cost:** a load that climbs slowly through the band between the aim and the
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cap alarms when the quarter will end over the cap, not at the aim (10 s later
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in `ramp6500`). A step overload alarms in the same cycle as before; a real
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overload shows on the meter before the battery moves, so the lower reading
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costs it nothing. A quarter already over that the battery cannot win back
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still alarms (test_peakguard.py's saturated fixture).
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## Not changed: the 1 s spike itself
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The cycle after a quarter boundary and before the new quarter's first meter
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sample still sees 0 s left, files no claim, and an Off battery drops to 0 W for
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one cycle. That is the same edge tick as OPT-15 F1, so it is left to OPT-15.
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Control is unchanged here: every command in `tools/safety81_sim.py` is
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byte-identical to 5a4cdc2 (test_safety81.py part 1).
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