A constant-value plant rung passed every binary gate with record scores - and shipped 60% thinner posture margins that hardware exposed

Symptom

s2_lag1 (trained at constant 1-frame latency) posted the strongest sim gate sheet in history (20/20 everywhere) yet was unstable on hardware, while s1e (trained across the full 0-3 frame band) was the every-run-stable SOTA at the same power.

Context

The sim autopsy (new --delay-jitter harness modeling the BusWorker's time-varying phase drift): 18 runs across constant and time-varying delays ALL survived - time variation alone does not kill - but the tilt-margin ordering reproduced hardware exactly: s1e 7.7-9.1 deg (thickest) < s2_lag1 10.7-15.0 < s1c 16.2-18.2. Attribution: constant-value training permits precise specialization to that one value; s1e's band diversity forced cross-value robustness - "恒定 1 帧训练 vs s1e 的 0~3 帧全带——分布多样性逼出跨值鲁棒,恒定值允许精确 特化" - so the constant-rung policy's margins were ~60% thinner, fine in sim's clean world, pushed over the line by real-world disturbances. Tool lesson booked: "存活门二值饱和后掩盖裕度差" - binary survival gates saturate and hide margin differences; graded margin columns (tilt-max) belong in the report. The synthesis with the opposite failure (wide tails cause drag-glide): the proposed resolution was a NARROW uniform band (0.02, 0.04) covering exactly the real 1-2 ticks - diversity inside the measured support, no tail, no single point. s1e's root selection later leaned on the same property: its full-band latency training "预装" the delay rungs and delivered "全工况稳定裕度" that survived power derating.

Change

DR-on-an-axis design refined to a three-way distinction: no wide fictitious tails (drag), no single constant values (thin margins), but a narrow band spanning the measured real support; acceptance reports gained graded margin columns alongside binary gates.

Outcome

The tilt-margin column entered the standard report; the s1e root (band-trained) carried the C ladder while the constant-value branch was archived with its three contributions credited.

Mechanism

Robustness margins are shaped by the diversity of the training distribution, not just its support: a point-mass distribution lets the optimizer trade margin for on-point performance, while a band forces solutions that keep margin across the band - and binary survival metrics cannot see the difference until the margin is spent on hardware.

Conflicts

The narrow-band (0.02,0.04) resolution was a pending recommendation ("裁决建议(待用户)") at the time of writing; the lineage instead moved root to s1e whose full-band training predated the staged ladder - the deterministic-staging card and this card record the two failure modes the final design must avoid simultaneously.

Applies when

• a rung trained at a fixed plant value aces sim but wobbles on hardware
• binary acceptance gates are all saturated across candidates
• choosing between constant, banded, and wide DR on one axis