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

{
  "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

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