From 809cc6bd41618b4591d8eaa264a4ae6d9ec98970 Mon Sep 17 00:00:00 2001
From: Christian <80114847+TheBest6337@users.noreply.github.com>
Date: Mon, 23 Feb 2026 12:45:00 +0100
Subject: [PATCH] feat: implement automatic PID tuning for extruder pressure
 regulation

---
 .../extruder/extruder2/Extruder2Settings.tsx  | 182 ++++++++++++++----
 .../extruder/extruder2/extruder2Namespace.ts  |  21 ++
 .../extruder/extruder2/useExtruder.ts         |  34 ++++
 .../extruder/extruder3/Extruder3Settings.tsx  | 182 ++++++++++++++----
 .../extruder/extruder3/extruder3Namespace.ts  |  21 ++
 .../extruder/extruder3/useExtruder.ts         |  34 ++++
 6 files changed, 398 insertions(+), 76 deletions(-)

diff --git a/electron/src/machines/extruder/extruder2/Extruder2Settings.tsx b/electron/src/machines/extruder/extruder2/Extruder2Settings.tsx
index 71f13ff9..0d9cfbc7 100644
--- a/electron/src/machines/extruder/extruder2/Extruder2Settings.tsx
+++ b/electron/src/machines/extruder/extruder2/Extruder2Settings.tsx
@@ -16,14 +16,19 @@ export function Extruder2SettingsPage() {
     resetInverter,
     setExtruderPressureLimit,
     setExtruderPressureLimitEnabled,
+    setInverterTargetPressure,
     setPressurePidKp,
     setPressurePidKi,
     setPressurePidKd,
     setTemperaturePidValue,
     setTemperatureTargetEnabled,
+    startPressurePidAutoTune,
+    stopPressurePidAutoTune,
   } = useExtruder2();
 
   const [showAdvanced, setShowAdvanced] = useState(false);
+  const [tuneDelta, setTuneDelta] = useState(1.0);
+  const [frequencyStepHz, setFrequencyStepHz] = useState(5.0);
 
   return (
     <Page>
@@ -91,44 +96,144 @@ export function Extruder2SettingsPage() {
 
       {showAdvanced && (
         <>
-          <ControlCard title="Pressure PID Settings ">
-            <Label label="Kp">
-              <EditValue
-                value={state?.pid_settings.pressure.kp}
-                defaultValue={defaultState?.pid_settings.pressure.kp}
-                min={0}
-                max={100}
-                step={0.01}
-                renderValue={(v) => roundToDecimals(v, 2)}
-                onChange={setPressurePidKp}
-                title="Pressure PID KP"
-              />
-            </Label>
-            <Label label="Ki">
-              <EditValue
-                value={state?.pid_settings.pressure.ki}
-                defaultValue={defaultState?.pid_settings.pressure.ki}
-                min={0}
-                max={100}
-                step={0.01}
-                renderValue={(v) => roundToDecimals(v, 2)}
-                onChange={setPressurePidKi}
-                title="Pressure PID KI"
-              />
-            </Label>
-            <Label label="Kd">
-              <EditValue
-                value={state?.pid_settings.pressure.kd}
-                defaultValue={defaultState?.pid_settings.pressure.kd}
-                min={0}
-                max={100}
-                step={0.01}
-                renderValue={(v) => roundToDecimals(v, 2)}
-                onChange={setPressurePidKd}
-                title="Pressure PID KD"
-              />
-            </Label>
-          </ControlCard>
+          <ControlGrid columns={2}>
+            <ControlCard title="Pressure PID Settings">
+              <Label label="Kp">
+                <EditValue
+                  value={state?.pid_settings.pressure.kp}
+                  defaultValue={defaultState?.pid_settings.pressure.kp}
+                  min={0}
+                  max={100}
+                  step={0.01}
+                  renderValue={(v) => roundToDecimals(v, 2)}
+                  onChange={setPressurePidKp}
+                  title="Pressure PID KP"
+                />
+              </Label>
+              <Label label="Ki">
+                <EditValue
+                  value={state?.pid_settings.pressure.ki}
+                  defaultValue={defaultState?.pid_settings.pressure.ki}
+                  min={0}
+                  max={100}
+                  step={0.01}
+                  renderValue={(v) => roundToDecimals(v, 2)}
+                  onChange={setPressurePidKi}
+                  title="Pressure PID KI"
+                />
+              </Label>
+              <Label label="Kd">
+                <EditValue
+                  value={state?.pid_settings.pressure.kd}
+                  defaultValue={defaultState?.pid_settings.pressure.kd}
+                  min={0}
+                  max={100}
+                  step={0.01}
+                  renderValue={(v) => roundToDecimals(v, 2)}
+                  onChange={setPressurePidKd}
+                  title="Pressure PID KD"
+                />
+              </Label>
+            </ControlCard>
+            <ControlCard title="Pressure PID Auto-Tune">
+              <Label label="Target Pressure">
+                <EditValue
+                  value={state?.pressure_state.target_bar}
+                  defaultValue={defaultState?.pressure_state.target_bar}
+                  unit="bar"
+                  title="Target Pressure for Tuning"
+                  description="The pressure setpoint around which the tuner will oscillate"
+                  min={0}
+                  max={350}
+                  renderValue={(v) => roundToDecimals(v, 1)}
+                  onChange={setInverterTargetPressure}
+                />
+              </Label>
+              <Label label="Tune Delta">
+                <EditValue
+                  value={tuneDelta}
+                  defaultValue={1.0}
+                  unit="bar"
+                  title="Tune Delta"
+                  description="Allowed pressure oscillation band around target"
+                  min={0.1}
+                  max={10}
+                  step={0.1}
+                  renderValue={(v) => roundToDecimals(v, 1)}
+                  onChange={setTuneDelta}
+                />
+              </Label>
+              <Label label="Frequency Step">
+                <EditValue
+                  value={frequencyStepHz}
+                  defaultValue={5.0}
+                  title="Frequency Step (Hz)"
+                  description="Inverter frequency deviation around operating point"
+                  min={1}
+                  max={20}
+                  step={0.5}
+                  renderValue={(v) => roundToDecimals(v, 1)}
+                  onChange={setFrequencyStepHz}
+                />
+              </Label>
+              <Label label="Actions">
+                <div className="flex gap-4">
+                  <button
+                    onClick={() => startPressurePidAutoTune(tuneDelta, frequencyStepHz)}
+                    disabled={state?.pid_autotune_state.state === "running"}
+                    className="inline-block w-fit rounded bg-blue-600 px-4 py-4 text-base text-white hover:bg-blue-700 disabled:opacity-50"
+                  >
+                    Start Auto-Tune
+                  </button>
+                  <button
+                    onClick={stopPressurePidAutoTune}
+                    disabled={state?.pid_autotune_state.state !== "running"}
+                    className="inline-block w-fit rounded bg-red-600 px-4 py-4 text-base text-white hover:bg-red-700 disabled:opacity-50"
+                  >
+                    Stop
+                  </button>
+                </div>
+              </Label>
+              <Label label="Status">
+                <div className="flex flex-col gap-2">
+                  <span className="text-base capitalize">
+                    {(state?.pid_autotune_state.state ?? "not_started").replace(/_/g, " ")}
+                  </span>
+                  <div className="h-3 w-full rounded bg-slate-200">
+                    <div
+                      className="h-3 rounded bg-blue-500 transition-all"
+                      style={{ width: `${state?.pid_autotune_state.progress ?? 0}%` }}
+                    />
+                  </div>
+                  <span className="text-sm text-muted-foreground">
+                    {roundToDecimals(state?.pid_autotune_state.progress ?? 0, 1)}%
+                  </span>
+                </div>
+              </Label>
+              {state?.pid_autotune_state.result && (
+                <Label label="Result">
+                  <div className="flex flex-col gap-2">
+                    <span className="text-sm">
+                      Kp: {roundToDecimals(state.pid_autotune_state.result.kp, 4)}&nbsp;&nbsp;
+                      Ki: {roundToDecimals(state.pid_autotune_state.result.ki, 4)}&nbsp;&nbsp;
+                      Kd: {roundToDecimals(state.pid_autotune_state.result.kd, 4)}
+                    </span>
+                    <button
+                      onClick={() => {
+                        const r = state.pid_autotune_state.result!;
+                        setPressurePidKp(r.kp);
+                        setPressurePidKi(r.ki);
+                        setPressurePidKd(r.kd);
+                      }}
+                      className="inline-block w-fit rounded bg-green-600 px-4 py-4 text-base text-white hover:bg-green-700"
+                    >
+                      Apply to PID Settings
+                    </button>
+                  </div>
+                </Label>
+              )}
+            </ControlCard>
+          </ControlGrid>
           <ControlGrid>
             <ControlCard title="Temperature PID Settings (Front) ">
               <Label label="Kp">
@@ -297,6 +402,7 @@ export function Extruder2SettingsPage() {
           </ControlGrid>
         </>
       )}
+
     </Page>
   );
 }
diff --git a/electron/src/machines/extruder/extruder2/extruder2Namespace.ts b/electron/src/machines/extruder/extruder2/extruder2Namespace.ts
index 9a46e54e..a50ec518 100644
--- a/electron/src/machines/extruder/extruder2/extruder2Namespace.ts
+++ b/electron/src/machines/extruder/extruder2/extruder2Namespace.ts
@@ -164,6 +164,26 @@ export const pidSettingsSchema = z.object({
   }),
 });
 
+/**
+ * PID auto-tune result schema
+ */
+export const pidAutoTuneResultSchema = z.object({
+  kp: z.number(),
+  ki: z.number(),
+  kd: z.number(),
+});
+
+/**
+ * PID auto-tune state schema
+ */
+export const pidAutoTuneStateSchema = z.object({
+  state: z.string(),
+  progress: z.number(),
+  result: pidAutoTuneResultSchema.nullable(),
+});
+
+export type PidAutoTuneState = z.infer<typeof pidAutoTuneStateSchema>;
+
 /**
  * Consolidated state event schema (state changes only)
  */
@@ -178,6 +198,7 @@ export const stateEventDataSchema = z.object({
   extruder_settings_state: extruderSettingsStateSchema,
   inverter_status_state: inverterStatusStateSchema,
   pid_settings: pidSettingsSchema,
+  pid_autotune_state: pidAutoTuneStateSchema,
 });
 
 // ========== Event Schemas with Wrappers ==========
diff --git a/electron/src/machines/extruder/extruder2/useExtruder.ts b/electron/src/machines/extruder/extruder2/useExtruder.ts
index beaaf5de..55802f9e 100644
--- a/electron/src/machines/extruder/extruder2/useExtruder.ts
+++ b/electron/src/machines/extruder/extruder2/useExtruder.ts
@@ -350,6 +350,25 @@ export function useExtruder2() {
     });
   };
 
+  const startPressurePidAutoTune = (tuneDelta: number, frequencyStepHz: number) => {
+    requestStartPressurePidAutoTune({
+      machine_identification_unique: machineIdentification,
+      data: {
+        StartPressurePidAutoTune: {
+          tune_delta: tuneDelta,
+          frequency_step_hz: frequencyStepHz,
+        },
+      },
+    });
+  };
+
+  const stopPressurePidAutoTune = () => {
+    requestStopPressurePidAutoTune({
+      machine_identification_unique: machineIdentification,
+      data: { StopPressurePidAutoTune: true },
+    });
+  };
+
   // Mutation hooks
   const { request: requestInverterRotationDirection } = useMachineMutation(
     z.object({ SetInverterRotationDirection: z.boolean() }),
@@ -424,6 +443,19 @@ export function useExtruder2() {
     z.object({ ResetInverter: z.boolean() }),
   );
 
+  const { request: requestStartPressurePidAutoTune } = useMachineMutation(
+    z.object({
+      StartPressurePidAutoTune: z.object({
+        tune_delta: z.number(),
+        frequency_step_hz: z.number(),
+      }),
+    }),
+  );
+
+  const { request: requestStopPressurePidAutoTune } = useMachineMutation(
+    z.object({ StopPressurePidAutoTune: z.boolean() }),
+  );
+
   return {
     // Consolidated state
     state: stateOptimistic.value?.data,
@@ -479,5 +511,7 @@ export function useExtruder2() {
     setTemperaturePidValue,
     setTemperatureTargetEnabled,
     resetInverter,
+    startPressurePidAutoTune,
+    stopPressurePidAutoTune,
   };
 }
diff --git a/electron/src/machines/extruder/extruder3/Extruder3Settings.tsx b/electron/src/machines/extruder/extruder3/Extruder3Settings.tsx
index 045bcbc3..1d2fdf60 100644
--- a/electron/src/machines/extruder/extruder3/Extruder3Settings.tsx
+++ b/electron/src/machines/extruder/extruder3/Extruder3Settings.tsx
@@ -16,14 +16,19 @@ export function Extruder3SettingsPage() {
     resetInverter,
     setExtruderPressureLimit,
     setExtruderPressureLimitEnabled,
+    setInverterTargetPressure,
     setPressurePidKp,
     setPressurePidKi,
     setPressurePidKd,
     setTemperaturePidValue,
     setTemperatureTargetEnabled,
+    startPressurePidAutoTune,
+    stopPressurePidAutoTune,
   } = useExtruder3();
 
   const [showAdvanced, setShowAdvanced] = useState(false);
+  const [tuneDelta, setTuneDelta] = useState(1.0);
+  const [frequencyStepHz, setFrequencyStepHz] = useState(5.0);
 
   return (
     <Page>
@@ -91,44 +96,144 @@ export function Extruder3SettingsPage() {
 
       {showAdvanced && (
         <>
-          <ControlCard title="Pressure PID Settings ">
-            <Label label="Kp">
-              <EditValue
-                value={state?.pid_settings.pressure.kp}
-                defaultValue={defaultState?.pid_settings.pressure.kp}
-                min={0}
-                max={100}
-                step={0.01}
-                renderValue={(v) => roundToDecimals(v, 2)}
-                onChange={setPressurePidKp}
-                title="Pressure PID KP"
-              />
-            </Label>
-            <Label label="Ki">
-              <EditValue
-                value={state?.pid_settings.pressure.ki}
-                defaultValue={defaultState?.pid_settings.pressure.ki}
-                min={0}
-                max={100}
-                step={0.01}
-                renderValue={(v) => roundToDecimals(v, 2)}
-                onChange={setPressurePidKi}
-                title="Pressure PID KI"
-              />
-            </Label>
-            <Label label="Kd">
-              <EditValue
-                value={state?.pid_settings.pressure.kd}
-                defaultValue={defaultState?.pid_settings.pressure.kd}
-                min={0}
-                max={100}
-                step={0.01}
-                renderValue={(v) => roundToDecimals(v, 2)}
-                onChange={setPressurePidKd}
-                title="Pressure PID KD"
-              />
-            </Label>
-          </ControlCard>
+          <ControlGrid columns={2}>
+            <ControlCard title="Pressure PID Settings">
+              <Label label="Kp">
+                <EditValue
+                  value={state?.pid_settings.pressure.kp}
+                  defaultValue={defaultState?.pid_settings.pressure.kp}
+                  min={0}
+                  max={100}
+                  step={0.01}
+                  renderValue={(v) => roundToDecimals(v, 2)}
+                  onChange={setPressurePidKp}
+                  title="Pressure PID KP"
+                />
+              </Label>
+              <Label label="Ki">
+                <EditValue
+                  value={state?.pid_settings.pressure.ki}
+                  defaultValue={defaultState?.pid_settings.pressure.ki}
+                  min={0}
+                  max={100}
+                  step={0.01}
+                  renderValue={(v) => roundToDecimals(v, 2)}
+                  onChange={setPressurePidKi}
+                  title="Pressure PID KI"
+                />
+              </Label>
+              <Label label="Kd">
+                <EditValue
+                  value={state?.pid_settings.pressure.kd}
+                  defaultValue={defaultState?.pid_settings.pressure.kd}
+                  min={0}
+                  max={100}
+                  step={0.01}
+                  renderValue={(v) => roundToDecimals(v, 2)}
+                  onChange={setPressurePidKd}
+                  title="Pressure PID KD"
+                />
+              </Label>
+            </ControlCard>
+            <ControlCard title="Pressure PID Auto-Tune">
+              <Label label="Target Pressure">
+                <EditValue
+                  value={state?.pressure_state.target_bar}
+                  defaultValue={defaultState?.pressure_state.target_bar}
+                  unit="bar"
+                  title="Target Pressure for Tuning"
+                  description="The pressure setpoint around which the tuner will oscillate"
+                  min={0}
+                  max={350}
+                  renderValue={(v) => roundToDecimals(v, 1)}
+                  onChange={setInverterTargetPressure}
+                />
+              </Label>
+              <Label label="Tune Delta">
+                <EditValue
+                  value={tuneDelta}
+                  defaultValue={1.0}
+                  unit="bar"
+                  title="Tune Delta"
+                  description="Allowed pressure oscillation band around target"
+                  min={0.1}
+                  max={10}
+                  step={0.1}
+                  renderValue={(v) => roundToDecimals(v, 1)}
+                  onChange={setTuneDelta}
+                />
+              </Label>
+              <Label label="Frequency Step">
+                <EditValue
+                  value={frequencyStepHz}
+                  defaultValue={5.0}
+                  title="Frequency Step (Hz)"
+                  description="Inverter frequency deviation around operating point"
+                  min={1}
+                  max={20}
+                  step={0.5}
+                  renderValue={(v) => roundToDecimals(v, 1)}
+                  onChange={setFrequencyStepHz}
+                />
+              </Label>
+              <Label label="Actions">
+                <div className="flex gap-4">
+                  <button
+                    onClick={() => startPressurePidAutoTune(tuneDelta, frequencyStepHz)}
+                    disabled={state?.pid_autotune_state.state === "running"}
+                    className="inline-block w-fit rounded bg-blue-600 px-4 py-4 text-base text-white hover:bg-blue-700 disabled:opacity-50"
+                  >
+                    Start Auto-Tune
+                  </button>
+                  <button
+                    onClick={stopPressurePidAutoTune}
+                    disabled={state?.pid_autotune_state.state !== "running"}
+                    className="inline-block w-fit rounded bg-red-600 px-4 py-4 text-base text-white hover:bg-red-700 disabled:opacity-50"
+                  >
+                    Stop
+                  </button>
+                </div>
+              </Label>
+              <Label label="Status">
+                <div className="flex flex-col gap-2">
+                  <span className="text-base capitalize">
+                    {(state?.pid_autotune_state.state ?? "not_started").replace(/_/g, " ")}
+                  </span>
+                  <div className="h-3 w-full rounded bg-slate-200">
+                    <div
+                      className="h-3 rounded bg-blue-500 transition-all"
+                      style={{ width: `${state?.pid_autotune_state.progress ?? 0}%` }}
+                    />
+                  </div>
+                  <span className="text-sm text-muted-foreground">
+                    {roundToDecimals(state?.pid_autotune_state.progress ?? 0, 1)}%
+                  </span>
+                </div>
+              </Label>
+              {state?.pid_autotune_state.result && (
+                <Label label="Result">
+                  <div className="flex flex-col gap-2">
+                    <span className="text-sm">
+                      Kp: {roundToDecimals(state.pid_autotune_state.result.kp, 4)}&nbsp;&nbsp;
+                      Ki: {roundToDecimals(state.pid_autotune_state.result.ki, 4)}&nbsp;&nbsp;
+                      Kd: {roundToDecimals(state.pid_autotune_state.result.kd, 4)}
+                    </span>
+                    <button
+                      onClick={() => {
+                        const r = state.pid_autotune_state.result!;
+                        setPressurePidKp(r.kp);
+                        setPressurePidKi(r.ki);
+                        setPressurePidKd(r.kd);
+                      }}
+                      className="inline-block w-fit rounded bg-green-600 px-4 py-4 text-base text-white hover:bg-green-700"
+                    >
+                      Apply to PID Settings
+                    </button>
+                  </div>
+                </Label>
+              )}
+            </ControlCard>
+          </ControlGrid>
           <ControlGrid>
             <ControlCard title="Temperature PID Settings (Front) ">
               <Label label="Kp">
@@ -297,6 +402,7 @@ export function Extruder3SettingsPage() {
           </ControlGrid>
         </>
       )}
+
     </Page>
   );
 }
diff --git a/electron/src/machines/extruder/extruder3/extruder3Namespace.ts b/electron/src/machines/extruder/extruder3/extruder3Namespace.ts
index b8fa2ea3..002be32a 100644
--- a/electron/src/machines/extruder/extruder3/extruder3Namespace.ts
+++ b/electron/src/machines/extruder/extruder3/extruder3Namespace.ts
@@ -164,6 +164,26 @@ export const pidSettingsSchema = z.object({
   }),
 });
 
+/**
+ * PID auto-tune result schema
+ */
+export const pidAutoTuneResultSchema = z.object({
+  kp: z.number(),
+  ki: z.number(),
+  kd: z.number(),
+});
+
+/**
+ * PID auto-tune state schema
+ */
+export const pidAutoTuneStateSchema = z.object({
+  state: z.string(),
+  progress: z.number(),
+  result: pidAutoTuneResultSchema.nullable(),
+});
+
+export type PidAutoTuneState = z.infer<typeof pidAutoTuneStateSchema>;
+
 /**
  * Consolidated state event schema (state changes only)
  */
@@ -178,6 +198,7 @@ export const stateEventDataSchema = z.object({
   extruder_settings_state: extruderSettingsStateSchema,
   inverter_status_state: inverterStatusStateSchema,
   pid_settings: pidSettingsSchema,
+  pid_autotune_state: pidAutoTuneStateSchema,
 });
 
 // ========== Event Schemas with Wrappers ==========
diff --git a/electron/src/machines/extruder/extruder3/useExtruder.ts b/electron/src/machines/extruder/extruder3/useExtruder.ts
index 7587b44e..209613d2 100644
--- a/electron/src/machines/extruder/extruder3/useExtruder.ts
+++ b/electron/src/machines/extruder/extruder3/useExtruder.ts
@@ -358,6 +358,25 @@ export function useExtruder3() {
     });
   };
 
+  const startPressurePidAutoTune = (tuneDelta: number, frequencyStepHz: number) => {
+    requestStartPressurePidAutoTune({
+      machine_identification_unique: machineIdentification,
+      data: {
+        StartPressurePidAutoTune: {
+          tune_delta: tuneDelta,
+          frequency_step_hz: frequencyStepHz,
+        },
+      },
+    });
+  };
+
+  const stopPressurePidAutoTune = () => {
+    requestStopPressurePidAutoTune({
+      machine_identification_unique: machineIdentification,
+      data: { StopPressurePidAutoTune: true },
+    });
+  };
+
   // Mutation hooks
   const { request: requestInverterRotationDirection } = useMachineMutation(
     z.object({ SetInverterRotationDirection: z.boolean() }),
@@ -432,6 +451,19 @@ export function useExtruder3() {
     z.object({ ResetInverter: z.boolean() }),
   );
 
+  const { request: requestStartPressurePidAutoTune } = useMachineMutation(
+    z.object({
+      StartPressurePidAutoTune: z.object({
+        tune_delta: z.number(),
+        frequency_step_hz: z.number(),
+      }),
+    }),
+  );
+
+  const { request: requestStopPressurePidAutoTune } = useMachineMutation(
+    z.object({ StopPressurePidAutoTune: z.boolean() }),
+  );
+
   return {
     // Consolidated state
     state: stateOptimistic.value?.data,
@@ -487,5 +519,7 @@ export function useExtruder3() {
     setPressurePidKd,
     setTemperaturePidValue,
     resetInverter,
+    startPressurePidAutoTune,
+    stopPressurePidAutoTune,
   };
 }