+fix: hourly stats become invalid if battery is not reachable, sanity check added

Author: mlauke

nginx/app.js

@@ -167,8 +167,9 @@ function renderConsStats(dayIdx) {
   }
   const bars = document.getElementById("statsBars");
   bars.innerHTML = "";
-  const currentDay = new Date().getDay();
-  const currentHour = new Date().getHours()
+  const now = new Date();
+  const currentDay = now.getDay();
+  const currentHour = now.getHours()
   const currentAvg = document.getElementById("cons_avg_w").getAttribute("data-value");
   data.forEach((v, h) => {
     const col = document.createElement("div");
@@ -197,7 +198,7 @@ function renderConsStats(dayIdx) {
     for (let h = 0; h < 24; h++) {
       const lbl = document.createElement("div");
       lbl.className = "bar-lbl";
-      lbl.textContent = (h % 6 === 0) ? h : "";
+      lbl.textContent = (h % 6 === 0) ? (h.toString().padStart(2, '0') + ":00") : "";
       xAxis.appendChild(lbl);
     }
   }

smartswitch.espxx/include/Logic.h

@@ -70,8 +70,11 @@ void updateSystemState(SystemConfig *systemConfig, SystemState *systemState)
       uint8_t slot_day = (uint8_t)(systemState->stat_hour_key / 24); // day of the hour being closed out (differs from current day at midnight)
       uint8_t slot_hour = (uint8_t)(systemState->stat_hour_key % 24);
       uint16_t *slot = &systemConfig->cons_stats_Wh[slot_day][slot_hour];
-      *slot = (*slot == 0) ? systemState->cons_avg_W
-                           : (uint16_t)(((uint32_t)*slot * 9 + systemState->cons_avg_W) / 10);
+      // sanity check, do we have enough samples collected in one hour, at least 80% uptime?
+      if (systemState->cons_count >= (0.8 * 3600 / (SYSTEM_UPDATE_INTERVAL_MS / 1000)))
+      {
+        *slot = (*slot == 0) ? systemState->cons_avg_W : (uint16_t)(((uint32_t)*slot * 9 + systemState->cons_avg_W) / 10);
+      }
       systemState->cons_sum_W = 0;
       systemState->cons_count = 0;
     }
@@ -190,7 +193,7 @@ const char *const EVENTS[] = {
     "SoC %0% - consumption %2W too high, to much grid purchase %3W",
     "SoC %0% - consumption %2W, battery min SoC %4% reached%7",
     "SoC %0% - boiler temperature %1°C >= %5°C (max) reached",
-    "SoC %0% - battery will full charge, but SoC too low",
+    "SoC %0% - battery will be full charged%7, but SoC too low",
 };
 
 static bool isSurplusAvailable(SystemConfig *systemConfig, SystemState *systemState)
@@ -267,8 +270,8 @@ static bool determineDesiredState(char *msg, int len, SystemConfig *systemConfig
 
   if (event != 0)
   {
-    char label[16];
-    snprintf(label, sizeof(label), state.hours > 0 ? " in ~%dh" : "", state.hours);
+    char hour_label[16];
+    snprintf(hour_label, sizeof(hour_label), state.hours > 0 ? " in ~%dh" : "", state.hours);
 
     Arg args[] = {
         ARG_UINT8, &systemState->usoc,
@@ -278,7 +281,7 @@ static bool determineDesiredState(char *msg, int len, SystemConfig *systemConfig
         ARG_UINT8, &systemConfig->bat_soc_min,
         ARG_FLT, &temp_off,
         ARG_FLT, &temp_on,
-        ARG_STR, &label,
+        ARG_STR, &hour_label,
         ARG_STR, (void *)SystemStatusLabel[status]};
 
     format_indexed(msg, len, EVENTS[event], args);

smartswitch.espxx/include/SmartSwitch.h

@@ -49,6 +49,9 @@
 #define LPB_ADDR_DEST 0
 #define LPB_RETRIES 5
 
+#define SYSTEM_UPDATE_INTERVAL_MS 2000 // update intervall millis
+#define SYSTEM_ON_COUNT MAX(1, (10000 + (SYSTEM_UPDATE_INTERVAL_MS >> 1)) / SYSTEM_UPDATE_INTERVAL_MS)
+
 #define SONNEN_API_URI "api/v2"
 #define SONNEN_API_CONFIGURATIONS "configurations"
 #define SONNEN_API_LATEST_DATA "latestdata"
@@ -57,8 +60,6 @@
 #define SONNEN_INVERTER_LATENCY_MS 5000 // battery inverter latency until load is compensated - sonnen battery 10 specific
 #define SONNEN_INVERTER_LATENCY_COUNT (1 + (SONNEN_INVERTER_LATENCY_MS + (SYSTEM_UPDATE_INTERVAL_MS >> 1)) / SYSTEM_UPDATE_INTERVAL_MS)
 
-#define SYSTEM_ON_COUNT MAX(1, (10000 + (SYSTEM_UPDATE_INTERVAL_MS >> 1)) / SYSTEM_UPDATE_INTERVAL_MS)
-
 #define URL_LOCATION "http://ip-api.com/json/"
 
 #define SOLAR_FORECAST_INTERVAL_MS (12 * 60 * 1000) // update intervall every 12min
@@ -67,7 +68,6 @@
 #define URL_SOLAR_FORECAST "http://api.forecast.solar/estimate/watthours/period/%.4f/%.4f/%d/%d/%.2f?time=seconds&no_sun=0&full=1"
 #define URL_SOLAR_FORECAST_DEV "http://192.168.188.20:8080/estimate/watthours/period/%.4f/%.4f/%d/%d/%.2f?time=seconds&no_sun=0&full=1"
 
-#define SYSTEM_UPDATE_INTERVAL_MS 2000 // update intervall millis
 #define GRID_PURCHASE_THRESHOLD_W 100
 #define BATTERY_MAX_USOC 10
 #define BATTERY_MIN_USOC 3
@@ -156,8 +156,7 @@ typedef struct
 typedef struct
 {
   uint32_t start_ts;  // system start timestamp
-  uint32_t ts;        // current system time (UTC) - taken from battery status
-  uint16_t tm_yday;   // day of year
+  uint32_t ts;        // current system timestamp in seconds (UTC) - taken from battery status
   int16_t utc_offset; // UTC to local time offset in seconds
   bool switchEnabled; // state of the load switch
 

smartswitch.espxx/include/app_js.h

@@ -467,8 +467,10 @@ void handleData()
   json[F("start_ts")] = toLocalDate(&systemState, systemState.start_ts);
 
   JsonArray forecast = json[F("pv_forecast")].to<JsonArray>();
-  for (int i = 0; i < SOLAR_FORECAST_HOURS; i++) {
-    if (systemState.pv_forecast_ts_wh[i][0] == 0) break;
+  for (int i = 0; i < SOLAR_FORECAST_HOURS; i++)
+  {
+    if (systemState.pv_forecast_ts_wh[i][0] == 0)
+      break;
     JsonArray entry = forecast.add<JsonArray>();
     entry.add(systemState.pv_forecast_ts_wh[i][0]); // Unix ts (s)
     entry.add(systemState.pv_forecast_ts_wh[i][1]); // Wh
@@ -1029,7 +1031,6 @@ static bool updateSystemData()
     {
       systemState.start_ts = systemState.ts;
     }
-    systemState.tm_yday = time.tm_yday;
 
     int16_t prev_stat_key = systemState.stat_hour_key;
     updateSystemState(&config, &systemState);

smartswitch.espxx/src/main.ino

@@ -334,7 +334,7 @@ void test_determineDesiredStateBelowMinCapacityButSurplusWillFullCharge()
   systemState.switchEnabled = true;
 
   bool state = determineState(msg, sizeof(msg));
-  TEST_ASSERT_EQUAL_STRING("SoC 1% - battery will full charge, but SoC too low", msg);
+  TEST_ASSERT_EQUAL_STRING("SoC 1% - battery will be full charged in ~7h, but SoC too low", msg);
   TEST_ASSERT_FALSE(state);
 
   systemState.ts = TEST_TS + 35 * 3600;
@@ -428,6 +428,50 @@ void test_determineDesiredState_BatteryCapacityFinallyAboveMinCapacityButUsocToo
   TEST_ASSERT_FALSE(state);
 }
 
+void test_updateConsumptionStats_Mean()
+{
+  time_t local_ts0 = (time_t)(TEST_TS + systemState.utc_offset);
+  struct tm lt0;
+  gmtime_r(&local_ts0, &lt0);
+  int wday = lt0.tm_wday;
+  int hour0 = lt0.tm_hour;
+  int hour1 = (hour0 + 1) % 24;
+  int wday1 = wday;
+
+  systemState.ts = TEST_TS;
+  systemState.cons_W = 300;
+  updateSystemState(&systemConfig, &systemState);
+  TEST_ASSERT_EQUAL(0, systemConfig.cons_stats_Wh[wday][hour0]); // slot not written yet
+  TEST_ASSERT_EQUAL(300, systemState.cons_sum_W);
+  TEST_ASSERT_EQUAL(1, systemState.cons_count);
+  int i = 0;
+  for (; i < (55 * 60 * 1000 / SYSTEM_UPDATE_INTERVAL_MS); i++)
+  {
+    updateSystemState(&systemConfig, &systemState);
+    systemState.ts += SYSTEM_UPDATE_INTERVAL_MS / 1000;
+  }
+  TEST_ASSERT_EQUAL(300 + 300 * i, systemState.cons_sum_W);
+  TEST_ASSERT_EQUAL(1 + i, systemState.cons_count);
+
+  systemState.cons_W = 4200;
+  int j = 0;
+  for (; j < (5 * 60 * 1000 / SYSTEM_UPDATE_INTERVAL_MS); j++) // 5min before next hour
+  {
+    updateSystemState(&systemConfig, &systemState);
+    systemState.ts += SYSTEM_UPDATE_INTERVAL_MS / 1000;
+  }
+  TEST_ASSERT_EQUAL(300 + 300 * i + 4200 * j, systemState.cons_sum_W);
+  TEST_ASSERT_EQUAL(1 + i + j, systemState.cons_count);
+
+  // rollover
+  systemState.cons_W = 1200;
+  updateSystemState(&systemConfig, &systemState);
+  systemState.ts += SYSTEM_UPDATE_INTERVAL_MS / 1000;
+  TEST_ASSERT_EQUAL(1200, systemState.cons_sum_W);
+  TEST_ASSERT_EQUAL(1, systemState.cons_count);
+  TEST_ASSERT_EQUAL(624, systemConfig.cons_stats_Wh[wday][hour0]); // slot has been written yet
+}
+
 void test_updateConsumptionStats()
 {
   // Use TEST_TS local time to find wday/hour of hour being tested (hour 0) and next hour (hour 1)
@@ -437,7 +481,7 @@ void test_updateConsumptionStats()
   int wday = lt0.tm_wday;
   int hour0 = lt0.tm_hour;
   int hour1 = (hour0 + 1) % 24;
-  int wday1 = (hour0 == 23) ? (wday + 1) % 7 : wday;
+  int wday1 = wday;
 
   // Accumulate 3 ticks in hour0: 300W, 400W, 500W → mean = 400W
   systemState.ts = TEST_TS;
@@ -454,23 +498,35 @@ void test_updateConsumptionStats()
   TEST_ASSERT_EQUAL(0, systemConfig.cons_stats_Wh[wday][hour0]); // still within same hour
 
   // Advance to hour1 — triggers rollover: slot gets mean of hour0 samples (300+400+500)/3 = 400
-  systemState.ts = TEST_TS + 3600;
+  for (int i = 0; i < 750; i++)
+  {
+    updateSystemState(&systemConfig, &systemState);
+  }
   systemState.cons_W = 200;
+  for (int i = 0; i < 750; i++)
+  {
+    updateSystemState(&systemConfig, &systemState);
+  }
+  systemState.ts = TEST_TS + 3600;
   updateSystemState(&systemConfig, &systemState);
-  TEST_ASSERT_EQUAL(400, systemConfig.cons_stats_Wh[wday][hour0]);  // true mean written
-  TEST_ASSERT_EQUAL(0,   systemConfig.cons_stats_Wh[wday1][hour1]); // hour1 slot not yet written
+  TEST_ASSERT_EQUAL(350, systemConfig.cons_stats_Wh[wday][hour0]); // true mean written
+  TEST_ASSERT_EQUAL(0, systemConfig.cons_stats_Wh[wday1][hour1]);  // hour1 slot not yet written
 
   // Simulate a second occurrence of hour0 (next week): accumulate 200W
   systemState.ts = TEST_TS + 7 * 24 * 3600; // same weekday, same hour, one week later
   systemState.cons_W = 200;
-  updateSystemState(&systemConfig, &systemState); // triggers hour1→hour0 rollover (writes hour1, resets)
-  TEST_ASSERT_EQUAL(400, systemConfig.cons_stats_Wh[wday][hour0]); // unchanged until its own rollover
+  updateSystemState(&systemConfig, &systemState);                  // triggers hour1→hour0 rollover (writes hour1, resets)
+  TEST_ASSERT_EQUAL(350, systemConfig.cons_stats_Wh[wday][hour0]); // unchanged until its own rollover
 
-  // Advance past hour0 again: EMA blends 200W mean into existing 400W: (400*9 + 200) / 10 = 380
+  // Advance past hour0 again: EMA blends 200W mean into existing 350W: (350*9 + 200) / 10 = 335
+  for (int i = 0; i < 1440; i++)
+  {
+    updateSystemState(&systemConfig, &systemState);
+  }
   systemState.ts = TEST_TS + 7 * 24 * 3600 + 3600;
   systemState.cons_W = 200;
   updateSystemState(&systemConfig, &systemState);
-  TEST_ASSERT_EQUAL(380, systemConfig.cons_stats_Wh[wday][hour0]); // cross-week EMA applied
+  TEST_ASSERT_EQUAL(335, systemConfig.cons_stats_Wh[wday][hour0]); // cross-week EMA applied
 }
 
 void test_predictBatteryCapacityStateUsesStats()
@@ -516,7 +572,9 @@ int main(int argc, char **argv)
   UNITY_BEGIN();
 
   RUN_TEST(test_upateConsumption);
+  RUN_TEST(test_updateConsumptionStats_Mean);
   RUN_TEST(test_updateConsumptionStats);
+
   RUN_TEST(test_predictBatteryCapacityStateNoData);
   RUN_TEST(test_predictBatteryCapacityStateSwitchOff);
   RUN_TEST(test_predictBatteryCapacityStateSwitchOn);