基于H∞回路成形的鲁棒PID参数整定

积分过程在工业过程控制中经常遇到,采用常规的PID参数整定方法很难得到理想的控制效果。本文采用基于H∞回路成形的鲁棒PID参数整定方法,实现对积分过程的有效控制。通过Simulink软件的仿真结果表明该方法的有效性。     

基于PLC的PID参数自整定

PID控制在过程工业控制中应用广泛,但在实际工业现场运行的PID回路的控制性能差异较大,有许多系统长期置于手动控制。一部分由于系统过程特性使PID调节不能满足控制要求,还有一部分却是由于PID回路参数整定的不合理。针对控制系统现场实施中PID参数整定繁琐、整定质量差异大、经验不易移植的问题,采用了基于PLC的PID参数自整定方法。该方法概念清晰,实施方便,在某锅炉的恒压供水控制中应用效果良好。该方法基于继电器反馈自整定,具有一定的普适性,对工程实施人员要求低,易于推广。     

RUL prediction for automatic machines: a mixed edge-cloud solution based on model-of-signals and particle filtering techniques

This work aims to provide useful insights into the course of action and the challenges faced by machine manufacturers when dealing with the actual application of Prognostics and Health Management procedures in industrial environments. Taking into account the computing capabilities and connectivity of the hardware available for smart manufacturing, we propose a particular solution that allows meeting one of the essential requirements of intelligent production processes, i.e., autonomous health management. Indeed, efficient and fast algorithms, that does not require a high computational cost and can be appropriately performed on machine controllers, i.e., on edge, are combined with others, which can handle large amounts of data and calculations, executed on remote powerful supervisory platforms, i.e., on the cloud. In detail, new condition monitoring algorithms based on Model-of-Signals techniques are developed and implemented on local controllers to process the raw sensor readings and extract meaningful and compact features, according to System Identification rules and guidelines. These results are then transmitted to remote supervisors, where Particle Filters are exploited to model components degradation and predict their Remaining Useful Life. Practitioners can use this information to optimise production planning and maintenance policies. The proposed architecture allows keeping the communication traffic between edge and cloud in the nowadays affordable “Big data” range, preventing the unmanageable “Huge data” scenario that would follow from the transmission of raw sensor data. Furthermore, the robustness and effectiveness of the proposed method are tested considering a meaningful benchmark, the PRONOSTIA dataset, allowing reproducibility and comparison with other approaches.

     

A DESIGN OF MULTILOOP PID CONTROLLERS WITH A NEURAL‐NET BASED DECOUPLER

In process industries, PID control schemes have been widely used due to their simple structures and easiness of comprehending the physical meanings of control parameters. However, the good control performance cannot be obtained by simply using PID controlschemes, since most processes are considered as nonlinear multivariable systems with mutual interactions. In this paper, a design method of multiloop PID controllers neural‐net based decoupler is proposed for nonlinear multivariable systems with mutual interactions. The proposed method consists of a decoupler given by the sum of a static decoupler and a neural‐net based decoupler, and multi‐loop PID controllers. Finally, the effectiveness of the proposed control scheme is evaluated on the simulation examples.     

数据与未建模动态驱动的非线性PID切换控制

本文充分利用系统的数据信息和知识,把数据驱动控制、PID控制与一步超前最优控制策略相结合,提出了数据与未建模动态驱动的非线性PID切换控制方法.该方法首先利用被控对象往往运行在工作点附近的特点及系统丰富可测的数据信息,把被控对象表示成低阶控制器设计模型与高阶非线性项(未建模动态)和的形式.与以往方法的本质区别在于,所提的方法直接将未建模动态分解为前一拍数据与未知增量的和,并充分利用未建模动态可测数据信息补偿系统未知的非线性动态特性,设计非线性PID控制器,对未建模动态的未知增量采用自适应神经模糊推理系统(ANFIS)进行估计,从而设计带有未建模动态增量估计的非线性PID控制器.将控制器的跟踪误差引入切换指标,两个控制器通过切换机制协调控制系统,既保证系统的稳定,同时提高系统的性能.为解决PID控制器参数难以选择的问题,采用一步超前最优控制策略进行参数设计,从理论上给出了PID控制器参数选择的一般原则和方法,推导了保证闭环系统输入输出稳定性的条件;最后,通过数值仿真实验以及在水箱液位控制系统的物理对比实验,实验结果验证了所提算法的有效性和实用性.     

PID control of MIMO process based on rank niching genetic algorithm

Non-linear multiple-input multiple-output (MIMO) processes which are common in industrial plants are characterized by significant interactions and non- linearities among their variables. Thus, tuning several controllers in complex industrial plants is a challenge for process engineers and operators. An approach for adjusting the parameters of n proportional–integral–derivative (PID) controllers based on multiobjective optimization and genetic algorithms (GA) is presented in this paper. A modified genetic algorithm with elitist model and niching method is developed to guarantee a set of solutions (set of PID parameters) with different tradeoffs regarding the multiple requirements of the control performance. Experiments considering a fluid catalytic cracking (FCC) unit, under PI and dynamic matrix control (DMC) are carried out in order to evaluate the proposed method. The results show that the proposed approach is an alternative to classical techniques as Ziegler–Nichols rules and others.     

Nonlinear process monitoring based on kernel dissimilarity analysis

To overcome the disadvantage of linear dissimilarity analysis (DISSIM) when monitoring nonlinear processes, a kernel dissimilarity analysis algorithm, termed KDISSIM here, is presented, which is the nonlinear version of DISSIM algorithm. A kernel dissimilarity index is introduced to quantitatively evaluate the differences between nonlinear data distribution structures, which can reflect the changes of nonlinear process correlations and operating conditions. In KDISSIM algorithm, the input space is first nonlinearly mapped into a high-dimensional feature space, where the initial nonlinear correlations are changed into linear ones. Then the process operating condition can be effectively tracked by investigating the linear data distributions in the feature space. The idea and effectiveness of the proposed algorithm are illustrated with respect to the simulated data collected from one typical nonlinear numerical process and the well-known Tennessee Eastman benchmark chemical process. Both the results show that the proposed method works well to capture the underlying nonlinear process correlations thus providing a feasible and promising solution for nonlinear process monitoring.     

基于PID参数整定的线性自抗扰控制参数整定

线性自抗扰控制(linear active disturbance rejection control,LADRC)是不依赖于被控对象的数学模型,在工业过程中具有极大的应用前景,LADRC参数整定是其在工业过程中能否应用的重要环节.鉴于实际工业控制中大都采用PID控制器,通过对二阶LADRC结构与其状态观测器的传递函数...     

Monitoring and prediction of big process data with deep latent variable models and parallel computing

Process monitoring and quality prediction are crucial for maintaining favorable operating conditions and have received considerable attention in previous decades. For majority complicated cases in chemical and biological industrial processes with particular nonlinear characteristics, traditional latent variable models, such as principal component analysis (PCA), principal component regression (PCR), partial least squares (PLS), may not work well. In this paper, various nonlinear latent variable models based on autoencoder (AE) are developed. In order to extract deeper nonlinear features from process data, the basic shallow AE models are extended to the deep latent variable models, which provides a deep generative structure for nonlinear process monitoring and quality prediction. Meanwhile, with the ever increasing scale of industrial data, the computational burden for process modeling and analytics has becoming more and more tremendous, particularly for large-scale processes. To handle the big data problem, the parallel computing strategy is further applied to the above model, which partitions the whole computational task into a few sub-tasks and assigns them to parallel computing nodes. Then the parallel models are utilized for process monitoring and quality prediction applications. The effectiveness of the developed methods are evaluated through the Tennessee Eastman (TE) benchmark process and a real-life industrial process in an ammonia synthesis plant (ASP).     

Design and Implementation of a Hierarchical‐Clustering CMAC PID Controller

In industrial control processes, proportional‐integral‐derivative (PID) control algorithm is widely employed. Therefore, it is meaningful to design advanced PID controllers, especially for nonlinear control objects. One of the advanced PID controllers is a cerebellar model articulation controller (CMAC) PID controller. In this controller, the PID control parameters are calculated and tuned. The CMAC achieves a higher accuracy by increasing the number of labels of each weight table; this requires a larger memory, and the generalization ability of the controller decreases. On the other hand, if the CMAC requires less memory, the generalization ability increases and accuracy decreases. Hence, in this paper, a novel CMAC in which the accuracy is compatible with the generalization ability is proposed in this paper. In the proposed CMAC, the number of labels of each weight table can be decided by using a hierarchical clustering technology. Moreover, the efficiency of the memory allocation is improved. The effectiveness of the proposed method is verified by experiments.     

Batch process monitoring with tensor factorization

A batch process monitoring method using tensor factorization, tensor locality preserving projections (TLPP), is proposed. In many existing vector-based methods on batch process monitoring such as MPCA and MLPP, a batch data is represented as a vector in high-dimensional space. But vectorizing batch data will lead to information loss. Essentially, a batch data is presented as a second order tensor, or a matrix. In this case, tensor factorization may be used to deal with the two-way batch data matrix directly instead of performing vectorizing procedure. Furthermore, tensor representation has some advantages such as low memory and storage requirements and less estimated parameters for normal operating condition (NOC) model. On the other hand, different from principal component analysis (PCA) which aims at preserving the global Euclidean structure of the data, the TLPP aims to preserve the local neighborhood information and to detect the intrinsic manifold structure of the data. Consequently, TLPP may be used to find more meaningful intrinsic information hidden in the observations. The effectiveness and advantages of the TLPP monitoring approach are tested with the data from a benchmark fed-batch penicillin fermentation and two industrial fermentation processes, penicillin and cephalosporin, respectively.     

Multivariable PID control by decoupling

This paper presents a new methodology to design multivariable proportional-integral-derivative (PID) controllers based on decoupling control. The method is presented for general n × n processes. In the design procedure, an ideal decoupling control with integral action is designed to minimise interactions. It depends on the desired open-loop processes that are specified according to realisability conditions and desired closed-loop performance specifications. These realisability conditions are stated and three common cases to define the open-loop processes are studied and proposed. Then, controller elements are approximated to PID structure. From a practical point of view, the wind-up problem is also considered and a new anti-wind-up scheme for multivariable PID controller is proposed. Comparisons with other works demonstrate the effectiveness of the methodology through the use of several simulation examples and an experimental lab process.     

Deadtime compensation via setpoint variation

It is known that the PID controller is ill-suited to handle time-delay processes, especially in applications with stringent control objectives to be met. For such purposes, deadtime compensators may be used. But such controllers still face resistance towards actual industrial applications due to their difficulties in implementation and realisation. In this paper, a PID solution involving setpoint weighting is proposed to achieve good setpoint tracking and load regulatory performance. Simulation and experimental results are provided to demonstrate the effectiveness of the proposed approach.     

Integrating independent component analysis and local outlier factor for plant-wide process monitoring

We propose a novel process monitoring method integrating independent component analysis (ICA) and local outlier factor (LOF). LOF is a recently developed outlier detection technique which is a density-based outlierness calculation method. In the proposed monitoring scheme, ICA transformation is performed and the control limit of LOF value is obtained based on the normal operating condition (NOC) dataset. Then, at the monitoring phase, the LOF value of current observation is computed at each monitoring time, which determines whether the current process is a fault or not. The comparison experiments are conducted with existing ICA-based monitoring schemes on widely used benchmark processes, a simple multivariate process and the Tennessee Eastman process. The proposed scheme shows the improved accuracy over existing schemes. By adopting LOF, the monitoring statistic is computed regardless of data distribution. Therefore, the proposed scheme integrating ICA and LOF is more suitable for real industry where the monitoring variables are the mixture of Gaussian and non-Gaussian variables, whereas existing ICA-based schemes assume only non-Gaussian distribution.     

基于Backstepping方法的MIMO过程分散PID控制器设计

A novel decentralized PID controller design procedure based on backstepping principles is presented to operate multiple-input multiple-output (MIMO) dynamic processes. The first key feature of the design procedure is that a whole MIMO control system is decomposed into multiple control loops, therefore the sub-controllers can be efficiently flexibly designed in parallel prototype. The second key feature is that the decentralized controller has equivalency to those designed by backstepping approach. As a complementary support to the design procedure, the sufficient condition of the whole closed-loop system stability is analyzed via the small gain theorem and it can be proven that the process tracking performance is improved. The simulation results of the Shell benchmark control problem are provided to verify the effectiveness and practicality of the proposed decentralized PID control.     

Backstepping-based Decentralized PID Controller Design for MIMO Processes

A novel decentralized PID controller design procedure based on backstepping principles is presented to operate multiple-input multiple-output(MIMO)dynamic processes.The first key feature of the design procedure is that a whole MIMO control system is decomposed into multiple control loops,therefore the sub-controllers can be efficiently flexibly designed in parallel prototype. The second key feature is that the decentralized controller has equivalency to those designed by backstepping approach.As a complementary support to the design procedure,the sufficient condition of the whole closed-loop system stability is analyzed via the small gain theorem and it can be proven that the process tracking performance is improved.The simulation results of the Shell benchmark control problem are provided to verify the effectiveness and practicality of the proposed decentralized PID control.     

Actuator fault monitoring and fault tolerant control in distillation columns

This paper presents, from a practical viewpoint, an investigation of real-time actuator fault detection, propagation and accommodation in distillation columns. Addressing faults in industrial processes, coupled with the growing demand for higher performance, improved safety and reliability necessitates implementation of less complex alternative control strategies in the events of malfunctions in actuators, sensors and or other system components. This work demonstrates frugality in the design and implementation of fault tolerant control system by integrating fault detection and diagnosis techniques with simple active restructurable feedback controllers and with backup feedback signals and switchable reference points to accommodate actuator fault in distillation columns based on a priori assessed control structures. A multivariate statistical process monitoring based fault detection and diagnosis technique through dynamic principal components analysis is integrated with one-point control or alternative control structure for prompt and effective fault detection, isolation and accommodation. The work also investigates effects of disturbances on fault propagation and detection. Specifically, the reflux and vapor boil-up control strategy used for a binary distillation column during normal operation is switched to one point control of the more valued product by utilizing the remaining healthy actuator. The proposed approach was implemented on two distillation processes: a simulated methanol-water separation column and the benchmark Shell standard heavy oil fractionation process to assess its effectiveness.     

Gaussian Discriminative Analysis aided GAN for imbalanced big data augmentation and fault classification

With data in industrial processes being larger in scale and easier to access, data-driven technologies have become more prevalent in process monitoring. Fault classification is an indispensable part of process monitoring, while machine learning is an effective tool for fault classification. In most practical cases, however, the number of fault data is far smaller than normal data, and this imbalance of dataset would lead to the significant decline in performance of common classifier learning algorithms. To this issue, we propose a data augmentation method, which is based on Generative Adversarial Networks(GAN) and aided by Gaussian Discriminant Analysis(GDA), for enhancement of fault classification accuracy. To validate the effectiveness of this method for imbalanced fault classification, on toy data and the Tennessee Eastman (TE) benchmark process, common oversampling method and the basic GAN are compared to our method, with different classification algorithms. Besides, proposed method is deployed and parallelly trained on Tensorflow platform, which is suitable for applications like data augmentation and imbalanced fault classification in industrial big data environments.     

Integral minimum variance control and benchmarking

A minimum-variance control problem is defined that involves the minimisation of the integral of estimation error. This introduces integral action into the controller. It is believed that the resulting solution is more valuable for closed-loop performance assessment and benchmarking, than the usual minimum-variance results. This is because most industrial controllers need to have integral action and hence the proposed benchmark, which is based on a controller that includes an integrator, will often be more appropriate. The advantage over many other benchmarking methods lies in the simplicity of the results. The situation where the controller structure has a limited, or restricted structure, is also considered. That is, a method is presented where the controller structure may be prespecified, and the coefficients obtained by direct parameter optimisation. This provides a more direct basis for comparison with controllers implemented in existing plants, that may only include, say PID, restricted structures.     

Real-time control of a water-gas shift reactor by a model-based fuzzy gain scheduling technique

A model-based fuzzy gain scheduling technique is proposed. Fuzzy gain scheduling is a form of variable gain scheduling which involves implementing several linear controllers over a partitioned process space. A higher-level rule-based controller determines which local controller is executed. Unlike conventional gain scheduling, a controller with fuzzy gain scheduling uses fuzzy logic to dynamically interpolate controller parameters near region boundaries based on known local controller parameters. Model-based fuzzy gain scheduling (MFGS) was applied to PID controllers to control a laboratory-scale water-gas shift reactor. The experimental results were compared with those obtained by PID with standard fuzzy gain scheduling, PID with conventional gain scheduling, simple PID and a nonlinear model predictive control (NMPC) strategy. The MFGS technique performed comparably to the NMPC method. It exhibited excellent control behaviour over the desired operating space, which spanned a wide temperature range. The other three PID-based techniques were adequate only within a limited range of the same operating space. Due to the simple algorithm involved, the MFGS technique provides a low cost alternative to other computationally intensive control algorithms such as NMPC.