sprint-9: integration tests + hardening + operator manual
Integration tests (64 new tests, 462 total): - test_integration_cascade: full cascade closed-loop simulation -- outer PID → inner PID → rudder dynamics → vessel heading; verifies convergence across small/90°/180° turns, wrap-around, and low speed - test_integration_ekf_pid: EKF-smoothed heading feeding outer PID; confirms EKF reduces rudder total-variation vs raw noisy heading - test_integration_alarm_audit: alarm engine → audit log hash-chain; verify, tamper detection, cross-session reload, multi-alarm logging - test_modbus_utils: 38 tests for scale/raw conversion, bounds checking, heading/rudder helpers, signed int16 two's-complement round-trip Hardening: - heading_ekf: guard NaN/inf in update_heading() and update_rot() -- skip bad measurements silently rather than corrupting filter state - adaptive_tuner: guard NaN/inf in step() -- ignore corrupt error samples - modbus_utils.py: new shared module with scale_to_raw, scale_to_raw_signed, raw_signed_to_scaled, clamp_uint16, validate_holding_write, heading_deg_to_raw, rudder_deg_to_raw_signed Documentation: - docs/operator_manual.md: 15-section operator manual covering safety, installation, all operating modes, alarm reference, commissioning, fault-finding, Modbus register summary, and activation/audit log procedure Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>
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"""Integration: alarm engine → audit log hash-chain -- Sprint 9.
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Tests the complete flow: alarm fires → AlarmEngine produces Alarm records →
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AuditEvent is written to the log → hash-chain verifies OK.
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"""
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from __future__ import annotations
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from pathlib import Path
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import pytest
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from arautopilot.core.alarm_engine import AlarmEngine, TelemetrySnapshot
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from arautopilot.core.alarms import AlarmType, AlarmSeverity
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from arautopilot.core.audit import AuditEvent, AuditLog, AuditOutcome
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def _alarm_to_event(alarm) -> AuditEvent:
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return AuditEvent(
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action=f"alarm.{alarm.type}",
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outcome=AuditOutcome.FAILED,
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reason=alarm.message,
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extra={"severity": str(alarm.severity), "auto_disengage": alarm.auto_disengage_triggered},
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)
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def _ack_event(alarm_type: AlarmType, user_id: str = "operator") -> AuditEvent:
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return AuditEvent(
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user_id=user_id,
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action=f"alarm.acknowledge.{alarm_type}",
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outcome=AuditOutcome.SUCCESS,
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)
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class TestAlarmFiredAndLogged:
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def test_single_alarm_logged_and_chain_valid(self, tmp_path: Path):
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log = AuditLog(tmp_path / "audit.jsonl")
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engine = AlarmEngine()
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# Fire an off-course alarm
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alarms = engine.evaluate(TelemetrySnapshot(fw_alarm_off_course=True))
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assert len(alarms) == 1
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log.append(_alarm_to_event(alarms[0]))
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ok, reason = log.verify_chain()
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assert ok, reason
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assert len(log) == 1
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def test_alarm_acknowledge_logged_and_chain_valid(self, tmp_path: Path):
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log = AuditLog(tmp_path / "audit.jsonl")
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engine = AlarmEngine()
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alarms = engine.evaluate(TelemetrySnapshot(fw_alarm_off_course=True))
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log.append(_alarm_to_event(alarms[0]))
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engine.acknowledge(AlarmType.OFF_COURSE)
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log.append(_ack_event(AlarmType.OFF_COURSE))
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ok, reason = log.verify_chain()
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assert ok, reason
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assert len(log) == 2
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def test_multiple_alarms_all_logged(self, tmp_path: Path):
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log = AuditLog(tmp_path / "audit.jsonl")
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engine = AlarmEngine()
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snap = TelemetrySnapshot(
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fw_alarm_off_course=True,
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fw_alarm_voltage_low=True,
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)
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alarms = engine.evaluate(snap)
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assert len(alarms) == 2
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for a in alarms:
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log.append(_alarm_to_event(a))
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ok, reason = log.verify_chain()
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assert ok, reason
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assert len(log) == 2
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def test_disengage_event_logged_in_chain(self, tmp_path: Path):
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log = AuditLog(tmp_path / "audit.jsonl")
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disengages = []
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engine = AlarmEngine(on_disengage=lambda: disengages.append(True))
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# EMERGENCY alarm triggers auto-disengage
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alarms = engine.evaluate(TelemetrySnapshot(fw_alarm_heading_lost=True))
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assert len(disengages) >= 1
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assert alarms[0].auto_disengage_triggered
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log.append(_alarm_to_event(alarms[0]))
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log.append(AuditEvent(
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action="pilot.disengage",
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outcome=AuditOutcome.SUCCESS,
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reason="auto-disengage from alarm",
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extra={"trigger": str(alarms[0].type)},
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))
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ok, reason = log.verify_chain()
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assert ok, reason
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def test_alarm_clear_and_refire_both_logged(self, tmp_path: Path):
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log = AuditLog(tmp_path / "audit.jsonl")
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engine = AlarmEngine()
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alarms = engine.evaluate(TelemetrySnapshot(fw_alarm_off_course=True))
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log.append(_alarm_to_event(alarms[0]))
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# Clear
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engine.evaluate(TelemetrySnapshot(fw_alarm_off_course=False))
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log.append(AuditEvent(action="alarm.cleared.off_course", outcome=AuditOutcome.SUCCESS))
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# Refire
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alarms2 = engine.evaluate(TelemetrySnapshot(fw_alarm_off_course=True))
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assert len(alarms2) == 1
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log.append(_alarm_to_event(alarms2[0]))
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ok, reason = log.verify_chain()
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assert ok, reason
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assert len(log) == 3
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class TestAuditPersistenceAcrossReload:
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def test_reloaded_log_continues_chain(self, tmp_path: Path):
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p = tmp_path / "audit.jsonl"
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log1 = AuditLog(p)
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engine = AlarmEngine()
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alarms = engine.evaluate(TelemetrySnapshot(fw_alarm_off_course=True))
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log1.append(_alarm_to_event(alarms[0]))
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# Simulate restarting the Studio
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log2 = AuditLog(p)
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log2.append(AuditEvent(action="studio.startup", outcome=AuditOutcome.SUCCESS))
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ok, reason = log2.verify_chain()
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assert ok, reason
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assert len(log2) == 2
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def test_tampered_alarm_entry_detected(self, tmp_path: Path):
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import json
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p = tmp_path / "audit.jsonl"
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log = AuditLog(p)
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engine = AlarmEngine()
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alarms = engine.evaluate(TelemetrySnapshot(fw_alarm_off_course=True))
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log.append(_alarm_to_event(alarms[0]))
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# Tamper: change the action field
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lines = p.read_text(encoding="utf-8").splitlines()
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data = json.loads(lines[0])
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data["action"] = "alarm.no_problem_here"
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lines[0] = json.dumps(data)
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p.write_text("\n".join(lines) + "\n", encoding="utf-8")
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log2 = AuditLog(p)
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ok, reason = log2.verify_chain()
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assert not ok
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assert "mismatch" in reason.lower() or "tamper" in reason.lower()
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class TestAlarmSeverityInAudit:
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def test_emergency_severity_recorded(self, tmp_path: Path):
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log = AuditLog(tmp_path / "audit.jsonl")
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engine = AlarmEngine()
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alarms = engine.evaluate(TelemetrySnapshot(fw_alarm_heading_lost=True))
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assert alarms[0].severity == AlarmSeverity.EMERGENCY
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event = _alarm_to_event(alarms[0])
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assert event.extra["severity"] == "emergency"
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log.append(event)
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events = log.read_all()
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assert events[0].extra["severity"] == "emergency"
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