CalejoControl/IMPLEMENTATION_SUMMARY.md

# Pump Control Preprocessing Implementation Summary

## Overview
Successfully implemented configurable pump control preprocessing logic for converting MPC outputs to pump actuation signals in the Calejo Control system.

## What Was Implemented

### 1. Core Pump Control Preprocessor (`src/core/pump_control_preprocessor.py`)
- **Three configurable control logics**:
  - **MPC-Driven Adaptive Hysteresis**: Primary logic for normal operation with MPC + live level data
  - **State-Preserving MPC**: Enhanced logic to minimize pump state changes
  - **Backup Fixed-Band Control**: Fallback logic for when level sensors fail
- **State tracking**: Maintains pump state and switch timing to prevent excessive cycling
- **Safety integration**: Built-in safety overrides for emergency conditions

### 2. Integration with Existing System
- **Extended preprocessing system**: Added `pump_control_logic` rule type to existing preprocessing framework
- **Setpoint manager integration**: New `PumpControlPreprocessorCalculator` class for setpoint calculation
- **Protocol mapping support**: Configurable through dashboard protocol mappings

### 3. Configuration Methods
- **Protocol mapping preprocessing**: Configure via dashboard with JSON rules
- **Pump metadata configuration**: Set control logic in pump configuration
- **Control type selection**: Use `PUMP_CONTROL_PREPROCESSOR` control type

## Key Features

### Safety & Reliability
- **Safety overrides**: Automatic shutdown on level limit violations
- **Minimum switch intervals**: Prevents excessive pump cycling
- **State preservation**: Minimizes equipment wear
- **Fallback modes**: Graceful degradation when sensors fail

### Flexibility
- **Per-pump configuration**: Different logics for different pumps
- **Parameter tuning**: Fine-tune each logic for specific station requirements
- **Multiple integration points**: Protocol mappings, pump config, or control type

### Monitoring & Logging
- **Comprehensive logging**: Each control decision logged with reasoning
- **Performance tracking**: Monitor pump state changes and efficiency
- **Safety event tracking**: Record all safety overrides

## Files Created/Modified

### New Files
- `src/core/pump_control_preprocessor.py` - Core control logic implementation
- `docs/PUMP_CONTROL_LOGIC_CONFIGURATION.md` - Comprehensive documentation
- `examples/pump_control_configuration.json` - Configuration examples
- `test_pump_control_logic.py` - Test suite

### Modified Files
- `src/dashboard/configuration_manager.py` - Extended preprocessing system
- `src/core/setpoint_manager.py` - Added new calculator class

## Testing
- **Unit tests**: All three control logics tested with various scenarios
- **Integration tests**: Verified integration with configuration manager
- **Safety tests**: Confirmed safety overrides work correctly
- **Import tests**: Verified system integration

## Usage Examples

### Configuration via Protocol Mapping
```json
{
  "preprocessing_enabled": true,
  "preprocessing_rules": [
    {
      "type": "pump_control_logic",
      "parameters": {
        "logic_type": "mpc_adaptive_hysteresis",
        "control_params": {
          "safety_min_level": 0.5,
          "adaptive_buffer": 0.5
        }
      }
    }
  ]
}
```

### Configuration via Pump Metadata
```sql
UPDATE pumps 
SET control_type = 'PUMP_CONTROL_PREPROCESSOR',
    control_parameters = '{
      "control_logic": "mpc_adaptive_hysteresis",
      "control_params": {
        "safety_min_level": 0.5,
        "adaptive_buffer": 0.5
      }
    }'
WHERE station_id = 'station1' AND pump_id = 'pump1';
```

## Benefits
1. **Improved pump longevity** through state preservation
2. **Better energy efficiency** by minimizing unnecessary switching
3. **Enhanced safety** with multiple protection layers
4. **Flexible configuration** for different operational requirements
5. **Graceful degradation** when sensors or MPC fail
6. **Comprehensive monitoring** for operational insights

## Next Steps
- Deploy to test environment
- Monitor performance and adjust parameters
- Extend to other actuator types (valves, blowers)
- Add more sophisticated control algorithms