SAFETY-40: the integrator bound is not a BUG SIGNAL; numbers from the clamp tick
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The clamp alarm gave `i_clamped` (normal anti-windup) the over-rating BUG
SIGNAL text, printed `Decision.i_w` as "the loop asked for", and printed
`self.target` (after slew/freeze) as "was clamped to".

- clamp.loop_clamp_note(): i_clamped says "the loop's integrator reached its
  N W anti-windup bound" with this tick's command; clamped keeps BUG SIGNAL
  with the requested command and the clamp's own result.
- Decision carries i_bound_w / requested_w / clamped_w, set at the clamp.
- i_clamped still counts and notifies (same id, cadence, SAFETY-41
  escalation) but as a WARNING, amber row, plain title. A bug has its own
  notification budget and its text is not overwritten within an episode.
- test_clamp.py part 9: red on the old code per defect; 5 mutations killed.
- DOCS.md alarm section (and its stale 30 s cadence), DECISIONS/SAFETY-40.

Co-Authored-By: Claude Opus 5.5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01LyR88rXETvwhTgx6yHE39p
This commit is contained in:
glenn schrooyen
2026-09-26 22:37:01 +02:00
co-authored by Claude Opus 5.5
parent 59415ea83f
commit fd14569a71
6 changed files with 340 additions and 54 deletions
+17 -4
View File
@@ -1630,7 +1630,9 @@ share no reason code, no notification id, no status row and no counter.
running - this is not the sign-disagreement failsafe, which commands 0 W. You
get a persistent notification (`goodwe_output_clamp`, replaced rather than
stacked), an `ERROR` in the log with the reason code `OUTPUT_CLAMP`, a row in
the event list, and a red status banner while it is engaged. Once it clears, a
the event list, and a red status banner while it is engaged. The message quotes
the command the loop computed and the value it was clamped to, both from the
cycle that clamped. Once it clears, a
warning row keeps the engagement count so the evidence does not vanish with the
condition. Consecutive engagements share one event row carrying the exact count,
because the event list keeps only 40 rows and a row per cycle would flush every
@@ -1639,9 +1641,11 @@ other guard's entries out of it.
**There is nothing to configure**, deliberately. The bound is `max_w`, which you
already set; giving the guard a limit of its own would be a second number that
can disagree with the first, which is exactly the failure the startup validation
exists to prevent. The alarm's cadence - first engagement, then re-asserted every
30 s while it persists, cleared after 3 clean cycles - is fixed for the same
reason `RAIL_FRAC` is: it describes the notification bus, not the plant.
exists to prevent. The alarm's cadence - at most one notification per 150 s
(an episode that has not yet notified does so once it has engaged 3 cycles in
a row), cleared after 3 clean
cycles - is fixed for the same reason `RAIL_FRAC` is: it describes the
notification bus, not the plant.
WARNING: **on a default install the engagement you will see is the integrator's,
not the output's.** The control law bounds the integrator to `max_w` and *then*
@@ -1650,6 +1654,15 @@ rating unless `integrator_max_w` has been deliberately raised above `max_w`.
Both are watched. A guard that watched only the emitted value would be silent on
every standard configuration.
**The integrator bound is not a bug, and it is reported as what it is.** It
reads *"the loop's integrator reached its +5000 W anti-windup bound; the loop's
command this cycle was +2000 W"*, titled *"the control loop is at its integrator
bound"*, logged as a `WARNING`, with an amber (not red) status row. Brief
engagements after a large load or solar step are normal. If it stays engaged,
check that the battery is following its commands. Only a command over the rating
carries the BUG SIGNAL text, and it never waits behind integrator-bound notices.
Why: [`DECISIONS/SAFETY-40-the-integrator-bound-is-not-a-bug.md`](DECISIONS/SAFETY-40-the-integrator-bound-is-not-a-bug.md).
### The frozen-meter alarm
A meter that has died is easy — it stops answering, the sample age climbs past