SAFETY-02: a loop can be fresh, tracking and inside its rating and still push the wrong way

The stale-input watchdog asks whether the meter is still talking. The saturation
freeze asks whether the inverter can follow. The output clamp asks whether the
number is too big. A loop can pass all three while charging the battery out of
the grid, because the only thing wrong is the sign.

On 2026-08-20 a commercial controller did exactly that four times in one day,
for up to 77 minutes at a stretch, reaching a commanded -14 768 W against a
±5000 W inverter. app/watchdog.py compares the emitted setpoint against the
authoritative P1 figure and, when they oppose each other with both over 300 W
for 180 s continuously, files a failsafe SET claim at P_SAFETY, commands 0 W and
latches there until an operator starts control again.

Validated against that day rather than against an argument: sim/replay_sign.py
in the infra repo drives this module over the committed captures of both
2026-08-20 and the healthy 2026-08-23 and reaches 18 trips on the fault day -
every one inside a window NOTES.md §4.7 accounts for - and 0 on the healthy day.
The four episodes do share one signature: 0.3 / 0.9 / 10.5 / 0.0 % sign
agreement inside them against 92.9 % healthy.

Three decisions the ticket could not make:

- It is DISARMED whenever the grid-following loop is not what is driving. Sign
  agreement is a property of a loop that follows the meter, and a maintenance
  grid charge opposes the meter by design - 2500 W of charge into a house
  drawing 500 W is +3000 W on the meter against a -2500 W command, for hours.
  The gate tests the emitted number, not the winning claim's name, because a
  limit claim can let the loop "win" and still replace its value.
- The trip LATCHES. Commanding 0 W removes the command side of the comparison,
  so the disagreement always clears the moment the trip works.
- sign_disagree_w at or above max_w is refused at startup. The arbiter never
  lets a command exceed max_w, so such a threshold leaves the watchdog incapable
  of firing while the status page still reports it armed.

What it does not catch, said out loud: an inverter that ACTS opposite to its
command moves the meter further the same way, leaving command and meter in
agreement. That is the saturation freeze's job.

Co-Authored-By: Claude Opus 5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01Du77usMj8XNKNFZGmUiWDa
This commit is contained in:
glenn schrooyen
2026-08-28 21:51:35 +02:00
co-authored by Claude Opus 5
parent 35856a73ae
commit 9aed43990b
9 changed files with 755 additions and 8 deletions
+11 -3
View File
@@ -53,14 +53,22 @@ Run the checks before deploying. No framework needed:
```bash
cd goodwe_controller
python3 test_control.py && python3 test_maintenance.py && python3 test_arbiter.py \
&& python3 test_validate.py && python3 test_p1.py && python3 test_loop.py
&& python3 test_validate.py && python3 test_p1.py && python3 test_watchdog.py \
&& python3 test_loop.py
```
`test_watchdog.py` covers SAFETY-02's logic and its trip path. Its headline
validation is not here at all: `sim/replay_sign.py` in the infra repo drives the
same module over the two captured RS485 days and must fire on all four of the
2026-08-20 episodes and stay silent on 2026-08-23. That needs both checkouts —
`GOODWE_ADDON_REPO=/path/to/goodwe-addon python3 sim/replay_sign.py`.
⚠️ `test_loop.py` takes about **95 seconds** (measured 93 s) and that is not a bug. It
drives the real control loop, which sleeps 1 s a tick, eight times over, to prove a
wall-clock property about it (SAFETY-12); mocking the clock there would leave the
assertion testing the mock. The other five suites together are ~395 checks and finish in
seconds. If you shorten `test_loop.py`'s windows, re-measure and correct this figure —
assertion testing the mock. The other six suites together are ~440 checks and finish in
seconds — `test_watchdog.py` spends ~3 s of that driving a real `Controller` through a
trip. If you shorten `test_loop.py`'s windows, re-measure and correct this figure —
an understated runtime is what makes a slow test look like a hung one, and a slow test
that looks hung gets deleted.