Show leak rates immediately and add independent long term measurements

CHANGELOG.md

@@ -2,6 +2,14 @@
 
 All notable changes are documented here. The project follows semantic versioning.
 
+## [Unreleased]
+
+- Add independent manual long term leak measurements for cell and cylinder, with two-hour moving averages and separate Reset buttons.
+
+- Show pressure-loss rates and leak warnings from the first two valid readings, without the three-minute delay.
+- Use a time-weighted five-minute moving average, including available startup history, for both loss indicators and CONTROL autonomy.
+- Keep green confirmation tied to uninterrupted monitoring time, independently of the averaging window.
+
 ## [1.1.0] - 2026-09-07
 
 - Stabilized sample-side and cylinder-side pressure-loss estimates by requiring at least three minutes of regression history before displaying a rate.

README.md

@@ -53,7 +53,8 @@ No NI-VISA, Druck USB driver, Python, LabVIEW, or Internet connection is require
 - Nine telemetry cards visible together on two rows, with three-decimal display.
 - Manual targets, selectable slew, CONTROL/MEASURE behaviour, and protected advanced parameters.
 - Indenting cycle and editable multi-step JSON routines.
-- Stable sample-side and cylinder-side loss indicators based on at least three minutes of data, with rates in bar/h and estimated CONTROL autonomy.
+- Immediate sample-side and cylinder-side loss indicators using a five-minute moving average, with rates in bar/h and estimated CONTROL autonomy.
+- Independent manual long term leak measurements for sample and cylinder, using two-hour moving averages and separate Reset buttons.
 - Source-margin interlock: CONTROL stops below 2.0 bar margin and rearms at 2.2 bar.
 - Confirmation for target increases of at least 10 bar and slew above 0.5 bar/s.
 - Automatic MEASURE attempt on required-telemetry loss during CONTROL.

cross_platform/README.md

@@ -48,7 +48,8 @@ Ethernet and RS-232 use the same SCPI control engine and the same safety checks.
 - **Indenting**: target, 120-second hold, return to zero, final MEASURE.
 - Editable JSON pressure routines with target, slew, dwell, and notes.
 - Protected pressurization parameters behind a padlock and danger confirmation.
-- Stable sample-side and cylinder-side loss indicators based on at least three minutes of data, with rates in bar/h and estimated CONTROL autonomy.
+- Immediate sample-side and cylinder-side loss indicators using a five-minute moving average, with rates in bar/h and estimated CONTROL autonomy.
+- Independent manual long term leak measurements for sample and cylinder, using two-hour moving averages and separate Reset buttons.
 - CSV telemetry and diagnostic logs at full received precision.
 - Offline simulator for hardware-free validation.
 - Bilingual Help menu with author/affiliation acknowledgements and a direct

cross_platform/docs/PACE_Controller_Manual.md

@@ -303,23 +303,29 @@ Only decreases are considered pressure losses. Increases are clipped to zero los
 
 ### 13.2 Operating condition
 
-Sample-side history is collected in MEASURE with no active automation. Cylinder/positive-source history is collected both in MEASURE and during steady, in-limits CONTROL, but is reset while the target is moving. No rate is shown until at least three minutes of data have been averaged by regression, avoiding unstable instantaneous estimates.
+Sample-side history is collected in MEASURE with no active automation. Cylinder/positive-source history is collected both in MEASURE and during steady, in-limits CONTROL, but is reset while the target is moving. The loss rate is shown as soon as two valid readings at different times are available; there is no three-minute waiting period.
 
 ### 13.3 Calculation and default classes
 
-A linear least-squares slope is calculated over the rolling history. The fitted loss rate is displayed in bar/h. During steady CONTROL, cylinder autonomy is estimated as $(P_{source,+} - P_{sample}) / r$, where $r$ is the cylinder pressure-loss rate in bar/h. This is an operational estimate, not a safety guarantee; it does not reserve the 2 bar software-interlock margin. With default settings:
+The signed pressure-loss rates are averaged over a rolling five-minute window, weighted by the duration between readings. This equals the net pressure drop divided by the window duration, with negative average losses clipped to zero. A boundary value is interpolated when needed. During startup, the available history is used without waiting for five minutes. The average loss rate is displayed in bar/h. During steady CONTROL, cylinder autonomy is estimated as $(P_{source,+} - P_{sample}) / r$, where $r$ is the cylinder pressure-loss rate in bar/h. This is an operational estimate, not a safety guarantee; it does not reserve the 2 bar software-interlock margin. With default settings:
 
-| Display | Colour | Equivalent fitted loss rate |
+| Display | Colour | Equivalent average loss rate |
 |---|---|---|
-| NO LEAK | Green | `<=0.0005 bar/min` after 10 min |
-| WARNING: slight leak | Yellow | `>0.0005` and `<=0.001 bar/min` after 5 min |
-| WARNING: pressure leak | Orange | `>0.001` and `<=0.005 bar/min` after at least 3 min |
-| WARNING: SIGNIFICANT PRESSURE LEAK | Red | `>0.005 bar/min` after at least 3 min |
+| NO LEAK | Green | `<=0.0005 bar/min` after 10 min of uninterrupted monitoring |
+| WARNING: slight leak | Yellow | `>0.0005` and `<=0.001 bar/min`, immediately |
+| WARNING: pressure leak | Orange | `>0.001` and `<=0.005 bar/min` immediately |
+| WARNING: SIGNIFICANT PRESSURE LEAK | Red | `>0.005 bar/min` immediately |
 
 The SETTINGS page permits editing the reference drop and green, yellow, and orange times. Required ordering is `green > yellow > orange > 0`.
 
 A pressure trend does not uniquely identify a physical leak. Thermal equilibration, regulator hysteresis, pressure-medium behaviour, and sensor noise can produce similar signals. Confirm warnings using an appropriate laboratory leak-test procedure.
 
+### 13.4 Manual long term leak measurement
+
+Each side has its own **Measure long term leak** button and adjacent **Reset** button. Start this measurement when the system is stable. The additional result uses a two-hour moving average, independently of the always-visible five-minute result and of the other side. During startup, it uses the available readings and displays the collected window duration out of 120 minutes.
+
+**Reset** clears only that side's long term history and restarts collection from new readings. The short term result and the other side are unaffected. Sample-side collection requires MEASURE without automation; cylinder-side collection permits MEASURE or steady, in-limits CONTROL. Leaving those conditions clears the corresponding history, and changing the cylinder operating mode also restarts its history. Disconnecting ends both manual measurements; reconnect and start them again as needed.
+
 ## 14. Data and logs
 
 The application writes:

cross_platform/src/pace_controller/i18n.py

@@ -53,6 +53,12 @@
         "slight_leak": "WARNING: slight leak",
         "pressure_leak": "WARNING: pressure leak",
         "significant_leak": "WARNING: SIGNIFICANT PRESSURE LEAK",
+        "long_term_start": "Measure long term leak",
+        "long_term_reset": "Reset",
+        "long_term_hint": "Start at a stable system. Independent two-hour moving average; startup uses available data.",
+        "long_term_reset_hint": "Restart only this side's long term measurement from new readings.",
+        "long_term_status": "Long term leak (2 h): {status}",
+        "long_term_window": "Available window: {minutes:.1f} / 120 min",
         "loss_rate_hour": "Loss: {rate:.3f} bar/h",
         "control_autonomy": "CONTROL autonomy: ~{hours:.1f} h",
         "control_autonomy_infinite": "CONTROL autonomy: ∞ at current rate",
@@ -186,6 +192,12 @@
         "slight_leak": "ATTENZIONE, lieve perdita",
         "pressure_leak": "ATTENZIONE, perdita pressione",
         "significant_leak": "ATTENZIONE, PERDITA SIGNIFICATIVA PRESSIONE",
+        "long_term_start": "Misura long term leak",
+        "long_term_reset": "Reset",
+        "long_term_hint": "Avvia a sistema stabile. Media mobile indipendente di due ore; all'avvio usa i dati disponibili.",
+        "long_term_reset_hint": "Ricomincia solo la misura long term di questo lato con nuove letture.",
+        "long_term_status": "Long term leak (2 h): {status}",
+        "long_term_window": "Finestra disponibile: {minutes:.1f} / 120 min",
         "loss_rate_hour": "Perdita: {rate:.3f} bar/h",
         "control_autonomy": "Autonomia CONTROL: ~{hours:.1f} h",
         "control_autonomy_infinite": "Autonomia CONTROL: ∞ al tasso attuale",

cross_platform/src/pace_controller/leak.py

@@ -32,17 +32,19 @@ class LeakAssessment:
 
 
 class LeakMonitor:
-    def __init__(
-        self, thresholds: LeakThresholds, minimum_observation_minutes: float = 3.0
-    ) -> None:
+    """Display loss immediately, averaging signed rates over a configurable rolling window."""
+
+    def __init__(self, thresholds: LeakThresholds, window_minutes: float = 5.0) -> None:
+        if not isfinite(window_minutes) or window_minutes <= 0:
+            raise ValueError("Averaging window must be finite and positive")
+        self.window_seconds = window_minutes * 60.0
         self.thresholds = thresholds
-        if minimum_observation_minutes <= 0:
-            raise ValueError("Minimum observation time must be positive")
-        self.minimum_observation_minutes = minimum_observation_minutes
         self.samples: deque[tuple[float, float]] = deque()
+        self.started_at: float | None = None
 
     def reset(self) -> None:
         self.samples.clear()
+        self.started_at = None
 
     def update_thresholds(self, thresholds: LeakThresholds) -> None:
         thresholds.validate()
@@ -53,21 +55,32 @@ def add(self, timestamp: float, value: float, enabled: bool) -> LeakAssessment:
         if not enabled:
             self.reset()
             return LeakAssessment("paused_control")
-        if not isfinite(value):
+        if not (isfinite(timestamp) and isfinite(value)):
+            return LeakAssessment("assessing")
+        if self.samples and timestamp <= self.samples[-1][0]:
             return LeakAssessment("assessing")
+        if self.started_at is None:
+            self.started_at = timestamp
         self.samples.append((timestamp, value))
-        window_seconds = self.thresholds.green_minutes * 60.0
-        while self.samples and timestamp - self.samples[0][0] > window_seconds:
+        cutoff = timestamp - self.window_seconds
+        # Keep one point at/before the boundary for interpolation when polling
+        # times do not land exactly on the rolling-window cutoff.
+        while len(self.samples) > 1 and self.samples[1][0] <= cutoff:
             self.samples.popleft()
         if len(self.samples) < 2:
             return LeakAssessment("assessing")
 
-        elapsed_minutes = (self.samples[-1][0] - self.samples[0][0]) / 60.0
-        if elapsed_minutes <= 0:
-            return LeakAssessment("assessing")
-        rate = max(0.0, -self._linear_slope_bar_min())
-        if elapsed_minutes < self.minimum_observation_minutes:
-            return LeakAssessment("assessing")
+        start, start_value = self.samples[0]
+        if start < cutoff:
+            next_time, next_value = self.samples[1]
+            fraction = (cutoff - start) / (next_time - start)
+            start_value += fraction * (next_value - start_value)
+            start = cutoff
+        elapsed_minutes = (timestamp - start) / 60.0
+        # Time-weighted mean of successive signed pressure-loss rates:
+        # sum(rate_i * dt_i) / sum(dt_i) = net pressure drop / duration.
+        # Clip only the final mean, so noise/increases do not create false loss.
+        rate = max(0.0, (start_value - value) / elapsed_minutes)
 
         t = self.thresholds
         green_rate = t.reference_drop_bar / t.green_minutes
@@ -76,22 +89,12 @@ def add(self, timestamp: float, value: float, enabled: bool) -> LeakAssessment:
 
         if rate > orange_rate:
             return LeakAssessment("significant_leak", rate, elapsed_minutes)
-        if elapsed_minutes >= t.orange_minutes and rate > yellow_rate:
+        if rate > yellow_rate:
             return LeakAssessment("pressure_leak", rate, elapsed_minutes)
-        if elapsed_minutes >= t.yellow_minutes and rate > green_rate:
+        if rate > green_rate:
             return LeakAssessment("slight_leak", rate, elapsed_minutes)
-        if elapsed_minutes >= t.green_minutes and rate <= green_rate:
+        # Green confirmation uses total uninterrupted monitoring time, not
+        # window length: its configurable default is longer than the averaging window.
+        if (timestamp - self.started_at) / 60.0 >= t.green_minutes:
             return LeakAssessment("no_leak", rate, elapsed_minutes)
         return LeakAssessment("assessing", rate, elapsed_minutes)
-
-    def _linear_slope_bar_min(self) -> float:
-        origin = self.samples[0][0]
-        xs = [(stamp - origin) / 60.0 for stamp, _ in self.samples]
-        ys = [value for _, value in self.samples]
-        count = len(xs)
-        mean_x = sum(xs) / count
-        mean_y = sum(ys) / count
-        denominator = sum((x - mean_x) ** 2 for x in xs)
-        if denominator == 0:
-            return 0.0
-        return sum((x - mean_x) * (y - mean_y) for x, y in zip(xs, ys)) / denominator