Add profile + Smart + calibration redesign spec to roadmap with research citations

Author: Producer Guy

ROADMAP.md

@@ -59,6 +59,92 @@ Research-grade data export: `thermalforge log`
 
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+## Profile + Smart + Calibration Redesign (In Progress)
+
+The entire profile system, Smart curve, and calibration need to be redesigned as one cohesive system. Current profiles are binary switches that immediately set fans to a fixed percentage. They should be proportional curves that respect Apple's fan hardware behavior.
+
+### Research basis
+
+Apple's fan hardware behavior (sources: macos-smc-fan reverse engineering, Tunabelly blog, NMB/Nidec fan motor engineering docs, Analog Devices fan controller datasheets):
+
+- **0 to minimum RPM is binary** — fans jump from off to minimum (2317 RPM on M5 Max, 1200 on M1 Max, 1000 on Mac Studio). No slow start possible — brushless DC motors require a startup burst to overcome static friction. Hardware limitation, not software.
+- **Above minimum, smooth ramping** — Apple ramps at ~350-550 RPM/sec up, ~150-300 RPM/sec down. Evaluated every 100ms with small increments.
+- **Start/stop cycles are the #1 fan bearing wear factor** — fluid dynamic bearings suffer contact wear during startup (boundary lubrication before hydrodynamic film builds). Minimize on/off cycling.
+- **Once spinning, keep spinning** — Apple holds fans at minimum RPM with hysteresis rather than cycling between 0 and spinning. At least 5°C hysteresis between start and stop thresholds.
+- **Smoother transitions extend lifespan up to 50%** — per fan engineering literature. Abrupt speed jumps while running cause acoustic and mechanical transients.
+
+### Profile curve design
+
+Each profile has three zones:
+
+**Zone 1: Off** — below the stop threshold, fans stay at 0 RPM (Apple auto).
+**Zone 2: Minimum hold** — between stop threshold and start threshold (hysteresis band), fans stay at minimum RPM if already running, stay off if already off.
+**Zone 3: Proportional curve** — above the start threshold, fan speed scales proportionally from minimum RPM to the profile's max RPM cap, increasing with temperature.
+
+Ramp governors (matching Apple's behavior):
+- Ramp up: max ~400 RPM/sec (~5% of max per 2-second tick)
+- Ramp down: max ~200 RPM/sec (~2.5% of max per 2-second tick, already implemented)
+
+### Profile specifications
+
+| Profile | Fans off below | Start ramp at | Max fan speed | Target ceiling | Stop threshold |
+|---|---|---|---|---|---|
+| **Silent** | 73°C | 78°C | Apple default (reset to auto) | 78°C | 73°C |
+| **Balanced** | 50°C | 60°C | 60% of max RPM | 70°C | 50°C |
+| **Performance** | 45°C | 50°C | 85% of max RPM | 65°C | 45°C |
+| **Max** | Never | Always on | 100% | N/A | N/A |
+| **Smart** | 60°C | 60°C | 100% (adapts) | 85°C | 60°C |
+
+**Balanced example curve (60-70°C, 0-60% of max RPM):**
+- 60°C: fans jump to minimum RPM (2317)
+- 63°C: fans at ~30% of max RPM (~2348 RPM, just above min)
+- 65°C: fans at ~40% of max RPM (~3130 RPM)
+- 67°C: fans at ~50% of max RPM (~3913 RPM)
+- 70°C: fans at 60% of max RPM (~4696 RPM) — cap reached
+- Below 50°C and stable: fans off
+
+The curve between start and ceiling is proportional, not stepped. Fan speed = minRPM + (maxRPMCap - minRPM) × ((temp - startTemp) / (ceilingTemp - startTemp)).
+
+**Silent** is special: it doesn't control fans directly. It stays in Apple auto mode and only intervenes if temp hits 78°C, at which point it resets to auto (letting Apple's own thermal management handle it). Below 73°C it returns to hands-off. This is for users who want ThermalForge monitoring without fan control.
+
+### Smart curve redesign
+
+Smart uses the same three-zone model but with:
+- Rate-of-change awareness: if temp is rising, boost fan speed proportionally to the rate
+- Calibration data: the adaptive intensity finder discovers the machine's thermal response, and calibration maps how each fan speed handles proportional load
+- Without calibration: conservative S-curve (already built, stays as fallback)
+
+### Calibration redesign
+
+Calibration needs to work with the new curve system:
+- Pre-calibration: adaptive intensity finder discovers ~1°C/sec stress level (already built)
+- At each fan level: ramp load using discovered baseline, measure where temp stabilizes within the curve
+- Records: at what fan percentage does this machine hold each temperature target?
+- Smart uses this to choose the right point on its curve for current conditions
+
+### Logging changes
+
+- Log every fan speed change: from RPM, to RPM, what triggered it (profile curve, rate boost, safety)
+- Log when fans turn on from idle (with temperature that triggered it)
+- Log when fans return to idle (with temperature and stability confirmation)
+- Temperature anomaly logging with process capture (already built: >10°C in 30s)
+
+### Build order
+
+1. Redesign FanProfile model — add curve parameters (startTemp, ceilingTemp, stopTemp, maxRPMPercent)
+2. Add ramp-up governor to ThermalMonitor (~400 RPM/sec)
+3. Implement proportional curve in ThermalMonitor.tick() for Balanced/Performance
+4. Implement Silent as hands-off with 78°C intervention
+5. Redesign Smart to use same curve model with rate-of-change and calibration
+6. Update calibration to work with new curve parameters
+7. Add fan speed change logging
+8. Update all documentation (README, ROADMAP, in-app text)
+9. Audit and debug
+10. Test on M5 Max
+11. Test on Mac Studio and M1 Max
+
+---
+
 ## Planned Features
 
 ### Enhanced Logging