完善流量控制前馈、稳态判定与阀门标定流程

- 前馈冻结改用可配置的 3 秒流量绝对误差滑窗，修复采样抖动造成的重复解冻，并保留下游扰动后的自动更新
- 支持非单调阀特性反解、最小可测面积以下直接全关，以及闭阀端精细扫点与辨识开关
- 调整双压力判稳、最长等待时间、在线入口全开收尾和闭环四联图
- 更新配置、README、阀模型及离线测试，归档本轮实验数据与诊断产物

open_loop.py

@@ -2,7 +2,8 @@
 
 本模块可独立运行，用于阀门开度—流量特性的开环标定/扫点。程序会：
 
-1. 生成 0%~100%（默认 5% 间隔）共 21 个开度值并随机打乱；
+1. 生成 0%~100%（默认 5% 间隔）的开度值并随机打乱、转换为行程，
+   然后在序列末尾追加配置指定的闭阀端精细行程点；
 2. 逐个开度：写入电机行程 → 以固定周期采集控流阀前后 4 个传感器
    （前压力、前流量、后压力、后流量）→ 等待“控流阀后流量”进入稳态后
    切换到下一个开度；
@@ -56,7 +57,7 @@ RANDOM_SEED = 42            # 设为整数可复现同一打乱顺序
 SAMPLE_PERIOD_S = 0.1                                  # 采样周期（秒）
 STEADY_STATE_WINDOW_S = config.STEADY_STATE_WINDOW_S   # 滑窗长度，复用 config
 STEADY_STATE_STD_PCT = config.STEADY_STATE_STD_PCT     # 相对标准差阈值（%）
-MAX_WAIT_S = 60.0                                      # 单个开度的最长等待时间
+MAX_WAIT_S = config.STEADY_STATE_MAX_WAIT_S             # 单个扫点的最长等待时间
 MIN_ABS_STD_SLM = 0.05                                 # 近零流量时的绝对标准差下限
 MAX_CONSECUTIVE_READ_FAILURES = 5                      # 后流量连续读取失败判定设备断开
 
@@ -453,6 +454,71 @@ def generate_openings(min_pct, max_pct, step_pct, seed):
     return openings
 
 
+def motor_position_to_opening(position, motor_open_position, motor_closed_position):
+    """把反向作用的电机行程换算为 0~100% 阀门开度。"""
+    position = float(position)
+    open_position = float(motor_open_position)
+    closed_position = float(motor_closed_position)
+    if open_position >= closed_position:
+        raise ValueError("打开端行程必须小于关闭端行程")
+    if not open_position <= position <= closed_position:
+        raise ValueError("电机行程超出打开端/关闭端范围")
+    return 100.0 * (closed_position - position) / (
+        closed_position - open_position
+    )
+
+
+def generate_fine_strokes(start, end, step):
+    """生成包含起点和终点的闭阀端精细行程序列。"""
+    start = float(start)
+    end = float(end)
+    step = float(step)
+    if step <= 0.0:
+        raise ValueError("精细行程间隔必须大于 0")
+    if start >= end:
+        raise ValueError("精细行程起点必须小于终点")
+
+    count = int(math.floor((end - start) / step))
+    strokes = [round(start + i * step, 6) for i in range(count + 1)]
+    if not strokes or abs(strokes[-1] - end) > 1e-6:
+        strokes.append(end)
+    return strokes
+
+
+def generate_scan_points(min_pct, max_pct, step_pct, seed):
+    """先生成并打乱开度点、转换为行程，再追加闭阀端精细行程点。"""
+    openings = generate_openings(min_pct, max_pct, step_pct, seed)
+    points = [
+        (
+            opening,
+            opening_to_motor_position(
+                opening,
+                config.MOTOR_OPEN_POSITION,
+                config.MOTOR_CLOSED_POSITION,
+            ),
+        )
+        for opening in openings
+    ]
+
+    fine_strokes = generate_fine_strokes(
+        config.OPEN_LOOP_FINE_STROKE_START,
+        config.MOTOR_CLOSED_POSITION,
+        config.OPEN_LOOP_FINE_STROKE_STEP,
+    )
+    points.extend(
+        (
+            motor_position_to_opening(
+                stroke,
+                config.MOTOR_OPEN_POSITION,
+                config.MOTOR_CLOSED_POSITION,
+            ),
+            stroke,
+        )
+        for stroke in fine_strokes
+    )
+    return points
+
+
 # ---------------------------------------------------------------------------
 # 日志
 # ---------------------------------------------------------------------------
@@ -530,12 +596,15 @@ def run(args):
         motor_output_addr=config.MOTOR_OUTPUT_ADDR,
     )
 
-    openings = generate_openings(
+    scan_points = generate_scan_points(
         args.min, args.max, args.step, args.seed
     )
     logger.info(
-        "开度扫描顺序（已打乱）: %s",
-        ", ".join(f"{o:.1f}%" for o in openings),
+        "最终扫描顺序（随机开度转行程后追加精细行程）: %s",
+        ", ".join(
+            f"{opening:.2f}%/x={position:.1f}"
+            for opening, position in scan_points
+        ),
     )
 
     connected = False
@@ -550,12 +619,16 @@ def run(args):
             exit_code = 2
             return exit_code
 
-        # 启动前先关阀。
-        ok, _ = set_opening(hardware, 0.0)
+        # 连接后的全开动作发生在记录器及实验计时开始之前。
+        ok, position = set_opening(hardware, 100.0)
         if not ok:
-            logger.critical("启动前关阀失败，实验中止")
+            logger.critical("连接后设置阀门 100%% 开度失败，实验中止")
             exit_code = 2
             return exit_code
+        logger.info(
+            "PLC 已连接；阀门已设置为 100%% 开度（行程 %.1f），不计入实验计时",
+            position,
+        )
 
         recorder = OpenLoopRecorder(
             Path(__file__).resolve().parent / OUTPUT_DIRECTORY,
@@ -573,8 +646,10 @@ def run(args):
         run_start = time.perf_counter()
         read_failures = 0
 
-        for step_index, opening in enumerate(openings):
-            ok, position = set_opening(hardware, opening)
+        for step_index, (opening, position) in enumerate(scan_points):
+            ok = bool(
+                hardware.set_motor_position(position, channel=MOTOR_CHANNEL)
+            )
             if not ok:
                 logger.critical(
                     "写入开度 %.1f%% 对应行程 %.1f 失败，实验中止", opening, position
@@ -584,7 +659,7 @@ def run(args):
 
             logger.info(
                 "步 %d/%d：设置开度 %.1f%%（行程 %.1f），等待后流量稳定…",
-                step_index + 1, len(openings), opening, position,
+                step_index + 1, len(scan_points), opening, position,
             )
 
             detector.reset()
@@ -614,7 +689,10 @@ def run(args):
                     pressure_before, flow_before, pressure_after, flow_after
                 )
                 if fault is not None:
-                    logger.critical("安全阈值触发：%s，实验中止并关阀", fault)
+                    logger.critical(
+                        "安全阈值触发：%s，实验中止并在断开前恢复全开",
+                        fault,
+                    )
                     exit_code = 2
                     break
 
@@ -665,13 +743,18 @@ def run(args):
     finally:
         if connected:
             try:
-                close_ok, _ = set_opening(hardware, 0.0)
-                if not close_ok:
+                open_ok, position = set_opening(hardware, 100.0)
+                if open_ok:
+                    logger.info(
+                        "断开 PLC 前已设置阀门为 100%% 开度（行程 %.1f），不计入实验计时",
+                        position,
+                    )
+                else:
                     exit_code = max(exit_code, 4)
-                    logger.critical("收尾安全关阀失败，请立即人工检查")
+                    logger.critical("断开 PLC 前设置阀门 100%% 开度失败，请立即人工检查")
             except Exception:
                 exit_code = max(exit_code, 4)
-                logger.exception("收尾安全关阀时发生异常")
+                logger.exception("断开 PLC 前设置阀门 100%% 开度时发生异常")
             try:
                 hardware.disconnect()
             except Exception: