109 lines
4.1 KiB
Markdown
109 lines
4.1 KiB
Markdown
# Pump Control Preprocessing Implementation Summary
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## Overview
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Successfully implemented configurable pump control preprocessing logic for converting MPC outputs to pump actuation signals in the Calejo Control system.
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## What Was Implemented
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### 1. Core Pump Control Preprocessor (`src/core/pump_control_preprocessor.py`)
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- **Three configurable control logics**:
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- **MPC-Driven Adaptive Hysteresis**: Primary logic for normal operation with MPC + live level data
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- **State-Preserving MPC**: Enhanced logic to minimize pump state changes
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- **Backup Fixed-Band Control**: Fallback logic for when level sensors fail
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- **State tracking**: Maintains pump state and switch timing to prevent excessive cycling
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- **Safety integration**: Built-in safety overrides for emergency conditions
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### 2. Integration with Existing System
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- **Extended preprocessing system**: Added `pump_control_logic` rule type to existing preprocessing framework
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- **Setpoint manager integration**: New `PumpControlPreprocessorCalculator` class for setpoint calculation
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- **Protocol mapping support**: Configurable through dashboard protocol mappings
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### 3. Configuration Methods
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- **Protocol mapping preprocessing**: Configure via dashboard with JSON rules
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- **Pump metadata configuration**: Set control logic in pump configuration
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- **Control type selection**: Use `PUMP_CONTROL_PREPROCESSOR` control type
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## Key Features
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### Safety & Reliability
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- **Safety overrides**: Automatic shutdown on level limit violations
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- **Minimum switch intervals**: Prevents excessive pump cycling
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- **State preservation**: Minimizes equipment wear
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- **Fallback modes**: Graceful degradation when sensors fail
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### Flexibility
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- **Per-pump configuration**: Different logics for different pumps
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- **Parameter tuning**: Fine-tune each logic for specific station requirements
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- **Multiple integration points**: Protocol mappings, pump config, or control type
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### Monitoring & Logging
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- **Comprehensive logging**: Each control decision logged with reasoning
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- **Performance tracking**: Monitor pump state changes and efficiency
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- **Safety event tracking**: Record all safety overrides
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## Files Created/Modified
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### New Files
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- `src/core/pump_control_preprocessor.py` - Core control logic implementation
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- `docs/PUMP_CONTROL_LOGIC_CONFIGURATION.md` - Comprehensive documentation
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- `examples/pump_control_configuration.json` - Configuration examples
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- `test_pump_control_logic.py` - Test suite
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### Modified Files
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- `src/dashboard/configuration_manager.py` - Extended preprocessing system
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- `src/core/setpoint_manager.py` - Added new calculator class
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## Testing
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- **Unit tests**: All three control logics tested with various scenarios
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- **Integration tests**: Verified integration with configuration manager
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- **Safety tests**: Confirmed safety overrides work correctly
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- **Import tests**: Verified system integration
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## Usage Examples
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### Configuration via Protocol Mapping
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```json
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{
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"preprocessing_enabled": true,
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"preprocessing_rules": [
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{
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"type": "pump_control_logic",
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"parameters": {
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"logic_type": "mpc_adaptive_hysteresis",
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"control_params": {
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"safety_min_level": 0.5,
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"adaptive_buffer": 0.5
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}
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}
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}
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]
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}
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```
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### Configuration via Pump Metadata
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```sql
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UPDATE pumps
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SET control_type = 'PUMP_CONTROL_PREPROCESSOR',
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control_parameters = '{
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"control_logic": "mpc_adaptive_hysteresis",
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"control_params": {
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"safety_min_level": 0.5,
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"adaptive_buffer": 0.5
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}
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}'
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WHERE station_id = 'station1' AND pump_id = 'pump1';
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```
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## Benefits
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1. **Improved pump longevity** through state preservation
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2. **Better energy efficiency** by minimizing unnecessary switching
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3. **Enhanced safety** with multiple protection layers
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4. **Flexible configuration** for different operational requirements
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5. **Graceful degradation** when sensors or MPC fail
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6. **Comprehensive monitoring** for operational insights
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## Next Steps
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- Deploy to test environment
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- Monitor performance and adjust parameters
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- Extend to other actuator types (valves, blowers)
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- Add more sophisticated control algorithms |