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

test_valve.py

@@ -1,4 +1,4 @@
-"""手动设置阀门开度，并每秒显示流量、压力和电机行程。"""
+"""手动设置阀门开度，并每秒显示阀前、阀后传感器数据和电机行程。"""
 
 import contextlib
 import csv
@@ -30,9 +30,10 @@ class ManualValveRecorder:
     CSV_FIELDS = (
         "time_s",
         "timestamp",
-        "flow_slm",
+        "flow_after_slm",
         "opening_pct",
-        "pressure_kpa",
+        "pressure_before_kpa",
+        "pressure_after_kpa",
         "motor_position",
     )
 
@@ -49,16 +50,25 @@ class ManualValveRecorder:
         self.sample_count = 0
         self._closed = False
 
-    def record(self, sample_time, flow, opening, pressure, position):
+    def record(
+        self,
+        sample_time,
+        flow_after,
+        opening,
+        pressure_before,
+        pressure_after,
+        position,
+    ):
         if self._start_time is None:
             self._start_time = sample_time
         self._writer.writerow(
             {
                 "time_s": f"{sample_time - self._start_time:.6f}",
                 "timestamp": datetime.now().isoformat(timespec="milliseconds"),
-                "flow_slm": self._format_number(flow),
+                "flow_after_slm": self._format_number(flow_after),
                 "opening_pct": self._format_number(opening),
-                "pressure_kpa": self._format_number(pressure),
+                "pressure_before_kpa": self._format_number(pressure_before),
+                "pressure_after_kpa": self._format_number(pressure_after),
                 "motor_position": self._format_number(position),
             }
         )
@@ -85,15 +95,21 @@ class ManualValveRecorder:
         import matplotlib.pyplot as plt
 
         time_s = []
-        flow = []
+        flow_after = []
         opening = []
-        pressure = []
+        pressure_before = []
+        pressure_after = []
         with self.csv_path.open("r", newline="", encoding="utf-8-sig") as file:
             for row in csv.DictReader(file):
                 time_s.append(float(row["time_s"]))
-                flow.append(self._float_or_nan(row["flow_slm"]))
+                flow_after.append(self._float_or_nan(row["flow_after_slm"]))
                 opening.append(self._float_or_nan(row["opening_pct"]))
-                pressure.append(self._float_or_nan(row["pressure_kpa"]))
+                pressure_before.append(
+                    self._float_or_nan(row["pressure_before_kpa"])
+                )
+                pressure_after.append(
+                    self._float_or_nan(row["pressure_after_kpa"])
+                )
 
         figure, axes = plt.subplots(
             3,
@@ -104,19 +120,33 @@ class ManualValveRecorder:
         )
         figure.suptitle("Manual Valve Test", fontsize=15)
 
-        axes[0].plot(time_s, flow, color="#1565C0", linewidth=1.4)
-        axes[0].set_ylabel("Flow (SLM)")
-        axes[0].set_title("Flow")
+        axes[0].plot(time_s, flow_after, color="#1565C0", linewidth=1.4)
+        axes[0].set_ylabel("Flow after valve (SLM)")
+        axes[0].set_title("Flow after valve")
 
         axes[1].plot(time_s, opening, color="#2E7D32", linewidth=1.4)
         axes[1].set_ylabel("Opening (%)")
         axes[1].set_title("Valve opening")
         axes[1].set_ylim(-2, 102)
 
-        axes[2].plot(time_s, pressure, color="#6A1B9A", linewidth=1.4)
+        axes[2].plot(
+            time_s,
+            pressure_before,
+            color="#6A1B9A",
+            linewidth=1.4,
+            label="Pressure before valve",
+        )
+        axes[2].plot(
+            time_s,
+            pressure_after,
+            color="#D84315",
+            linewidth=1.4,
+            label="Pressure after valve",
+        )
         axes[2].set_ylabel("Pressure (kPa)")
         axes[2].set_xlabel("Time (s)")
-        axes[2].set_title("Pressure")
+        axes[2].set_title("Pressure before and after valve")
+        axes[2].legend()
 
         for axis in axes:
             axis.grid(True, alpha=0.3, linestyle="--")
@@ -156,6 +186,25 @@ def format_value(value, unit):
     return f"{number:.2f} {unit}"
 
 
+def format_analog_raw(value, physical_range, analog_raw_max):
+    """把物理量反算为 PLC 的 0~analog_raw_max 模拟量原始值。"""
+    try:
+        number = float(value)
+        full_scale = float(physical_range)
+        raw_maximum = float(analog_raw_max)
+    except (TypeError, ValueError):
+        return "--"
+    if (
+        not math.isfinite(number)
+        or not math.isfinite(full_scale)
+        or not math.isfinite(raw_maximum)
+        or full_scale <= 0.0
+        or raw_maximum <= 0.0
+    ):
+        return "--"
+    return str(round(number / full_scale * raw_maximum))
+
+
 def motor_position_for(opening_pct):
     return opening_to_motor_position(
         opening_pct,
@@ -180,17 +229,22 @@ def set_opening(hardware, opening_pct):
 
 
 def read_sensors(hardware, quiet=False):
-    """读取一次传感器；输入模式中丢弃底层硬件代码的终端输出。"""
+    """读取阀后流量及阀前、阀后压力；输入模式中隐藏硬件输出。"""
     output = io.StringIO()
     stream = output if quiet else sys.stdout
     with contextlib.redirect_stdout(stream):
-        flow = hardware.get_flow(config.FLOW_AFTER_ADDR)
-        pressure = (
+        flow_after = hardware.get_flow(config.FLOW_AFTER_ADDR)
+        pressure_before = (
+            None
+            if config.PRESSURE_BEFORE_ADDR is None
+            else hardware.get_pressure(config.PRESSURE_BEFORE_ADDR)
+        )
+        pressure_after = (
             None
             if config.PRESSURE_AFTER_ADDR is None
             else hardware.get_pressure(config.PRESSURE_AFTER_ADDR)
         )
-    return flow, pressure
+    return flow_after, pressure_before, pressure_after
 
 
 def main():
@@ -199,7 +253,7 @@ def main():
         return 1
 
     try:
-        from PcControl import Easy521ModbusClient
+        from PcControl import Easy521ModbusClient, raw_max as analog_raw_max
     except ModuleNotFoundError as exc:
         print(f"无法导入硬件客户端: {exc}")
         return 2
@@ -234,6 +288,13 @@ def main():
             print("连接失败。")
             return 3
 
+        # 先全开，再创建记录器和启动采样计时。
+        opening, position = set_opening(hardware, 100.0)
+        print(
+            f"连接后已设置为 100% 开度（行程 {position:.1f}），"
+            "不计入采样计时。"
+        )
+
         recorder = ManualValveRecorder(OUTPUT_DIRECTORY)
         print("手动阀门控制已启动：按 S 输入新开度，按 Ctrl+C 退出。")
         print(
@@ -295,14 +356,27 @@ def main():
 
             now = time.perf_counter()
             if now >= next_sample_time:
-                flow, pressure = read_sensors(hardware, quiet=input_mode)
-                recorder.record(now, flow, opening, pressure, position)
+                flow_after, pressure_before, pressure_after = read_sensors(
+                    hardware, quiet=input_mode
+                )
+                recorder.record(
+                    now,
+                    flow_after,
+                    opening,
+                    pressure_before,
+                    pressure_after,
+                    position,
+                )
                 if not input_mode:
                     timestamp = time.strftime("%H:%M:%S")
                     print(
                         f"[{timestamp}] "
-                        f"流量={format_value(flow, 'SLM')}  "
-                        f"压力={format_value(pressure, 'kPa')}  "
+                        f"阀后流量={format_value(flow_after, 'SLM')}"
+                        f"（模拟量={format_analog_raw(flow_after, config.FLOW_AFTER_RANGE_SLM, analog_raw_max)}）  "
+                        f"阀前压力={format_value(pressure_before, 'kPa')}"
+                        f"（模拟量={format_analog_raw(pressure_before, config.PRESSURE_BEFORE_RANGE_KPA, analog_raw_max)}）  "
+                        f"阀后压力={format_value(pressure_after, 'kPa')}"
+                        f"（模拟量={format_analog_raw(pressure_after, config.PRESSURE_AFTER_RANGE_KPA, analog_raw_max)}）  "
                         f"开度={opening:.2f}%  行程={position:.1f}"
                     )
                 # 不追补错过的终端输出；输入期间的样本只写入 CSV。
@@ -321,6 +395,15 @@ def main():
         exit_code = 4
     finally:
         if connected:
+            try:
+                opening, position = set_opening(hardware, 100.0)
+                print(
+                    f"断开前已设置为 100% 开度（行程 {position:.1f}），"
+                    "不计入采样计时。"
+                )
+            except Exception as exc:
+                print(f"警告：断开前设置阀门 100% 开度失败：{exc}")
+                exit_code = max(exit_code, 4)
             try:
                 hardware.disconnect()
             except Exception as exc: