fix(car): clamp num_cars to supported maximum, exclude suspended Octopus devices

apps/predbat/const.py

@@ -40,6 +40,7 @@
 INVERTER_MAX_RETRY_REST = 5  # Maximum number of retries for inverter REST commands
 INVERTER_REST_TIMEOUT = 10  # Seconds to wait for a REST response before giving up (local network call, should be fast)
 INVERTER_QUICK_UPDATE_SECONDS = 120  # Minimum seconds between quick inverter data updates
+PREDBAT_MAX_CARS = 4  # Matches PK_MAX_CARS in prediction_kernel.cpp and the car_charging_rate_0..3 config items - the hard ceiling on num_cars
 
 # 240v x 100 amps x 3 phases / 1000 to kW / 60 minutes in an hour is the maximum kWh in a 1 minute period
 MAX_INCREMENT = 240 * 100 * 3 / 1000 / 60

apps/predbat/fetch.py

@@ -20,7 +20,7 @@
 
 from datetime import datetime, timedelta
 from utils import minutes_to_time, str2time, dp1, dp2, dp3, dp4, time_string_to_stamp, minute_data, get_now_from_cumulative, MinuteArray
-from const import MINUTE_WATT, PREDICT_STEP, TIME_FORMAT, PREDBAT_MODE_OPTIONS, PREDBAT_MODE_CONTROL_SOC, PREDBAT_MODE_CONTROL_CHARGEDISCHARGE, PREDBAT_MODE_CONTROL_CHARGE, PREDBAT_MODE_MONITOR, LOAD_FORECAST_HISTORY_MAX_DAYS
+from const import MINUTE_WATT, PREDICT_STEP, TIME_FORMAT, PREDBAT_MODE_OPTIONS, PREDBAT_MODE_CONTROL_SOC, PREDBAT_MODE_CONTROL_CHARGEDISCHARGE, PREDBAT_MODE_CONTROL_CHARGE, PREDBAT_MODE_MONITOR, LOAD_FORECAST_HISTORY_MAX_DAYS, PREDBAT_MAX_CARS
 from predbat_metrics import metrics
 from futurerate import FutureRate
 from axle import fetch_axle_sessions, load_axle_slot, fetch_axle_active
@@ -2345,6 +2345,10 @@ def fetch_config_options(self):
         forecast_hours = max(self.get_arg("forecast_hours", 48), 24)
 
         self.num_cars = self.get_arg("num_cars", 1)
+        if self.num_cars > PREDBAT_MAX_CARS:
+            self.log("Warn: num_cars {} exceeds the {} cars Predbat supports - clamping to {}".format(self.num_cars, PREDBAT_MAX_CARS, PREDBAT_MAX_CARS))
+            self.record_status("Warn: num_cars {} clamped to the maximum of {} supported cars".format(self.num_cars, PREDBAT_MAX_CARS), had_errors=True)
+            self.num_cars = PREDBAT_MAX_CARS
         self.calculate_plan_every = max(self.get_arg("calculate_plan_every"), 5)
         self.calculate_savings_max_charge_slots = self.get_arg("calculate_savings_max_charge_slots", 1)
 

apps/predbat/octopus.py

@@ -1094,21 +1094,26 @@ def automatic_config(self, tariffs):
                 self.set_arg("metric_standing_charge", self.get_entity_name("sensor", tariff + "_standing"))
         devices = self.get_intelligent_devices()
         if devices:
+            # Suspended devices (e.g. an old/decommissioned charger still linked to the Octopus
+            # account) aren't actively charging, so exclude them from the entity lists and from
+            # the num_cars count below - otherwise a stale suspended device can silently push
+            # num_cars past what Predbat actually supports (see fetch_config_options' clamp).
+            active_devices = {device_id: device for device_id, device in devices.items() if not device.get("suspended")}
             slot_list = []
             ready_list = []
             limit_list = []
-            for device_id in devices:
+            for device_id in active_devices:
                 index_suffix = self.device_id_to_index_suffix(device_id)
                 slot_list.append(self.get_entity_name("binary_sensor", "intelligent_dispatch", index=index_suffix))
                 ready_list.append(self.get_entity_name("select", "intelligent_target_time", index=index_suffix))
                 limit_list.append(self.get_entity_name("number", "intelligent_target_soc", index=index_suffix))
             self.set_arg("octopus_intelligent_slot", slot_list)
             self.set_arg("octopus_ready_time", ready_list)
             self.set_arg("octopus_charge_limit", limit_list)
-            # Increase number of cars if we have more devices than the current limit to ensure all devices can be configured
+            # Increase number of cars if we have more active devices than the current limit to ensure all devices can be configured
             num_cars = self.get_arg("num_cars", 0)
-            if num_cars < len(devices):
-                self.set_arg("num_cars", len(devices))
+            if num_cars < len(active_devices):
+                self.set_arg("num_cars", len(active_devices))
 
     async def async_get_saving_sessions(self, account_id):
         """

apps/predbat/prediction_kernel.py

@@ -27,15 +27,15 @@
 import sys
 import weakref
 
-from const import PREDICT_STEP
+from const import PREDICT_STEP, PREDBAT_MAX_CARS
 from utils import get_curve_value, find_battery_temperature_cap, in_car_slot, in_iboost_slot
 
 # Expected ABI/parity revisions of the shared library (see prediction_kernel.cpp)
 KERNEL_ABI_VERSION = 3
 KERNEL_PARITY_REVISION = 5
 
 # Maximum number of cars supported by the kernel (PK_MAX_CARS in prediction_kernel.cpp)
-KERNEL_MAX_CARS = 4
+KERNEL_MAX_CARS = PREDBAT_MAX_CARS
 
 # Module-level loader state, inherited by forked worker processes
 KERNEL_LIB = None

apps/predbat/tests/test_fetch_config_options.py

@@ -356,6 +356,24 @@ def mock_expose_config(key, value):
 
     print("✓ Case-insensitivity test passed")
 
+    # Test 14: num_cars is clamped to the maximum Predbat/kernel supports
+    print("\n*** Test 14: num_cars is clamped to the supported maximum ***")
+
+    # An Octopus account with more registered devices than Predbat supports (or any other
+    # misconfiguration) must not be allowed through - car indices beyond the supported maximum
+    # have no HA config entity, which previously crashed get_car_charging_planned() with
+    # TypeError: float() argument must be a string or a real number, not 'NoneType'.
+    mock_config.config["num_cars"] = 6
+
+    my_predbat.fetch_config_options()
+
+    assert my_predbat.num_cars == 4, "num_cars should be clamped to 4 (the supported maximum), got {}".format(my_predbat.num_cars)
+
+    print("✓ num_cars clamp test passed")
+
+    # Restore num_cars for any tests appended after this one
+    mock_config.config["num_cars"] = 2
+
     # Restore original methods
     my_predbat.get_arg = original_get_arg
     my_predbat.manual_times = original_manual_times

apps/predbat/tests/test_infra.py

@@ -404,8 +404,10 @@ def get_default_config(self):
             "inverter_clock_skew_discharge_end": 0,
             "set_window_minutes": 0,
             # Car charging config for each car (postfix _0, _1, etc.)
-            "car_charging_rate_0": 7400,
-            "car_charging_rate_1": 7400,
+            "car_charging_rate_0": 7.4,
+            "car_charging_rate_1": 7.4,
+            "car_charging_rate_2": 7.4,
+            "car_charging_rate_3": 7.4,
             "car_charging_battery_size_0": 100.0,
             "car_charging_battery_size_1": 100.0,
             "car_charging_limit_0": 100.0,

apps/predbat/tests/test_octopus_misc.py

@@ -26,6 +26,7 @@ async def test_octopus_misc(my_predbat):
     failed += test_octopus_get_intelligent_target_time(my_predbat)
     failed += test_octopus_get_intelligent_battery_size(my_predbat)
     failed += test_octopus_get_intelligent_vehicle(my_predbat)
+    failed += test_octopus_automatic_config_num_cars(my_predbat)
     failed += await test_octopus_run(my_predbat)
 
     if failed == 0:
@@ -1852,6 +1853,79 @@ def test_octopus_get_intelligent_vehicle(my_predbat):
         return 0
 
 
+def test_octopus_automatic_config_num_cars(my_predbat):
+    """
+    Test OctopusAPI automatic_config method's num_cars auto-discovery from Octopus Intelligent devices.
+
+    Tests:
+    - Test 1: Suspended devices (e.g. an old/decommissioned charger still linked to the account) are
+      excluded from the entity lists and don't count towards num_cars
+    - Test 2: num_cars auto-discovery only ever raises num_cars, never lowers an existing higher value
+    """
+    print("\n**** Running Octopus automatic_config num_cars tests ****")
+    failed = False
+
+    # automatic_config() writes several keys (num_cars, octopus_saving_session_join,
+    # octopus_intelligent_slot, metric_octopus_*, ...) directly into my_predbat.args, and
+    # my_predbat is a single shared instance reused across every test in the run - so without
+    # saving/restoring, those writes would leak into unrelated tests that run afterwards.
+    original_args = dict(my_predbat.args)
+
+    # Test 1: 5 registered devices, 2 suspended - only the 3 active devices should count towards
+    # num_cars and appear in the entity lists. Without this filter num_cars would be bumped to 5,
+    # which exceeds the 4 cars Predbat/the kernel support and previously crashed
+    # get_car_charging_planned() with TypeError: float() argument must be a string or a real number,
+    # not 'NoneType' (car_charging_rate_4 has no config entity).
+    print("\n*** Test 1: Suspended devices are excluded from num_cars and entity lists ***")
+    api = OctopusAPI(my_predbat, key="test-api-key", account_id="test-account", automatic=False)
+    api.intelligent_devices = {
+        "device-aaa1": {"suspended": False},
+        "device-bbb2": {"suspended": True},
+        "device-ccc3": {"suspended": False},
+        "device-ddd4": {"suspended": True},
+        "device-eee5": {"suspended": False},
+    }
+    my_predbat.args["num_cars"] = 0
+
+    api.automatic_config(["import", "export"])
+
+    if my_predbat.args.get("num_cars") != 3:
+        print(f"ERROR: Expected num_cars to be raised to 3 active devices, got {my_predbat.args.get('num_cars')}")
+        failed = True
+    else:
+        print("PASS: num_cars raised to the count of active (non-suspended) devices only")
+
+    slot_list = my_predbat.args.get("octopus_intelligent_slot", [])
+    if len(slot_list) != 3:
+        print(f"ERROR: Expected 3 entities in octopus_intelligent_slot, got {len(slot_list)}")
+        failed = True
+    else:
+        print("PASS: octopus_intelligent_slot only contains active devices")
+
+    # Test 2: num_cars auto-discovery never lowers an already-higher value
+    print("\n*** Test 2: num_cars is not lowered below an existing higher value ***")
+    my_predbat.args["num_cars"] = 4
+
+    api.automatic_config(["import", "export"])
+
+    if my_predbat.args.get("num_cars") != 4:
+        print(f"ERROR: Expected num_cars to remain at 4, got {my_predbat.args.get('num_cars')}")
+        failed = True
+    else:
+        print("PASS: num_cars left unchanged when already >= the active device count")
+
+    # Restore my_predbat.args so this test's auto-discovery writes don't leak into later tests
+    my_predbat.args.clear()
+    my_predbat.args.update(original_args)
+
+    if failed:
+        print("\n**** ❌ Octopus automatic_config num_cars tests FAILED ****")
+        return 1
+    else:
+        print("\n**** ✅ Octopus automatic_config num_cars tests PASSED ****")
+        return 0
+
+
 def _mock_run_api(my_predbat, key, account_id, automatic=False):
     """Create an OctopusAPI instance with all run() methods mocked."""
     api = OctopusAPI(my_predbat, key=key, account_id=account_id, automatic=automatic)