Nonlinear controllers for solar thermal plants: A comparative study

Solar plants have nonlinear dynamics which must be taken into account when a control system is applied to them. The main purpose of the control systems is to maintain the outlet temperature in a desired reference value and, at the same time, attenuate the undesirable transients caused by the disturbances. Linear controllers, like PID ones, are not able to obtain good performance over the whole operation range of these kind of plants. To overcome these limitations two nonlinear controllers, a nonlinear model-based predictive controller and a distributed sliding mode controller, are applied to a solar plant in this work. The performance of these controllers is tested through experimental and simulation results, which show the tracking and disturbance rejection capabilities of the proposed controllers.     

Optimal feedback scheduling of model predictive controllers

Model predictive control （MPC） could not be reliably applied to real-time control systems because its computation time is not well defined. Implemented as anytime algorithm, MPC task allows computation time to be traded for control performance, thus obtaining the predictability in time. Optimal feedback scheduling （FS-CBS） of a set of MPC tasks is presented to maximize the global control performance subject to limited processor time. Each MPC task is assigned with a constant bandwidth server （CBS）, whose reserved processor time is adjusted dynamically. The constraints in the FS- CBS guarantee scheduler of the total task set and stability of each component. The FS-CBS is shown robust against the variation of execution time of MPC tasks at runtime. Simulation results illustrate its effectiveness.     

Design of output constraints for model-based non-square controllers using interval operability

A steady-state interval operability methodology is introduced here for multivariable non-square systems with fewer inputs than output variables to be used in the design of model-based constrained controllers (MPC, DMC). For such systems, set-point control is not possible for all the outputs and interval control is needed. The proposed iterative approach enables the selection of the needed interval constraints systematically, so that the tightest possible control is achieved without rendering the control problem infeasible. The application of this methodology to high-dimensional industrial problems characterizing processes of Air Products and Chemicals and DuPont shows that very significant reduction of the constrained region can be achieved from the steady-state point of view. Ratios of the initial to the calculated volume of the constrained regions examined range between 10⁴ and 10⁸.     

On-line tuning strategy for model predictive controllers

This paper presents an intuitive on-line tuning strategy for linear model predictive control (MPC) algorithms. The tuning strategy is based on the linear approximation between the closed-loop predicted output and the MPC tuning parameters. By direct utilization of the sensitivity expressions for the closed-loop response with respect to the MPC tuning parameters, new values of the tuning parameters can be found to steer the MPC feedback response inside predefined time-domain performance specifications. Hence, the algorithm is cast as a simple constrained least squares optimization problem which has a straightforward solution. The simplicity of this strategy makes it more practical for on-line implementation. Effectiveness of the proposed strategy is tested on two simulated examples. One is a linear model for a three-product distillation column and the second is a non-linear model for a CSTR. The effectiveness of the proposed tuning method is compared to an exiting offline tuning method and showed superior performance.     

Predictive and interactive controllers for solar absorption cooling systems in buildings

A predictive control approach is proposed for a solar powered hot water storage (SHWS) system which interacts with a simple thermal building control. The primary objective of this first controller is to optimize the use of the solar energy in order to ensure the cooling requirement of the building. The main difficulties are related to the presence of safety constraints and the nonlinearity as well as the hybrid nature of the system. The resulting optimization problem is simplified using various relaxations. The second controller is dedicated to the control of the building temperature. Using a model of the building thermal behavior, it sends its predicted operating profile to the SHWS controller. The performances of these two interacting controllers are illustrated by various simulations on a TRNSYS model of the building and its subsystems.     

A receding horizon control approach to sampled-data implementation of continuous-time controllers

We propose a novel way for sampled-data implementation (with the zero order hold assumption) of continuous-time controllers for general nonlinear systems. We assume that a continuous-time controller has been designed so that the continuous-time closed-loop satisfies all performance requirements. Then, we use this control law indirectly to compute numerically a sampled-data controller. Our approach exploits a model predictive control (MPC) strategy that minimizes the mismatch between the solutions of the sampled-data model and the continuous-time closed-loop model. We propose a control law and present conditions under which stability and sub-optimality of the closed loop can be proved. We only consider the case of unconstrained MPC. We show that the recent results in [G. Grimm, M.J. Messina, A.R. Teel, S. Tuna, Model predictive control: for want of a local control Lyapunov function, all is not lost, IEEE Trans. Automat. Control 2004, to appear] can be directly used for analysis of stability of our closed-loop system.     

Heuristic on-line tuning for nonlinear model predictive controllers using fuzzy logic

In this paper a systematic mechanism for on-line tuning of the non-linear model predictive controllers is presented. The proposed method automatically adjusts the prediction horizon P, the diagonal elements of the input weight matrix Λ, and the diagonal elements of the output weight matrix Γ for the sake of good performance. The desired good performance is cast as a time-domain specification. The control horizon (M) is left constant because of the importance of its relative value with respect to P. The concepts from fuzzy logic are used in designing the tuning algorithm. In the mechanism considered here, predefined fuzzy rules represent available tuning guidelines and the performance violation measure in the form of fuzzy sets determine the new tuning parameter values Therefore, the tuning algorithm is formulated as a simple and straightforward mechanism, which makes it more appealing for on-line implementation. The effectiveness of the proposed tuning method is tested through simulated implementation on three non-linear process examples. Two of these examples possess open-loop unstable dynamics. The result of the simulations shows that this method is successful and promising.     

A tool to analyze robust stability for model predictive controllers

A strategy based on Nonlinear Programming (NLP) sensitivity is developed to establish stability bounds on the plant/model mismatch for a class of optimization-based Model Predictive Control (MPC) algorithms. By extending well-known nominal stability properties for these controllers, we derive a sufficient condition for robust stability of these controllers. This condition can also be used to assess the extent of model mismatch that can be tolerated to guarantee robust stability. In this derivation we deal with MPC controllers with final time constraints or infinite time horizons. Also for this initial study we concentrate only on discrete time systems and unconstrained state feedback control laws with all of the states measured. To illustrate this approach we give two examples: a linear first-order dynamic system and a nonlinear SISO system involving a first order reaction. ©     

Input to state stability of min-max MPC controllers for nonlinear systems with bounded uncertainties

Min-max model predictive control (MPC) is one of the control techniques capable of robustly stabilize uncertain nonlinear systems subject to constraints. In this paper we extend existing results on robust stability of min-max MPC to the case of systems with uncertainties which depend on the state and the input and not necessarily decaying, i.e. state and input dependent bounded uncertainties. This allows us to consider both plant uncertainties and external disturbances in a less conservative way.It is shown that the input-to-state practical stability (ISpS) notion is suitable to analyze the stability of worst-case based controllers. Thus, we provide Lyapunov-like sufficient conditions for ISpS. Based on this, it is proved that if the terminal cost is an ISpS-Lyapunov function then the optimal cost is also an ISpS-Lyapunov function for the system controlled by the min-max MPC and hence, the controlled system is ISpS. Moreover, we show that if the system controlled by the terminal control law locally admits certain stability margin, then the system controlled by the min-max MPC retains the stability margin in the feasibility region.     

Enlarging the domain of attraction of stable MPC controllers, maintaining the output performance

This work presents an alternative way to formulate the stable Model Predictive Control (MPC) optimization problem that allows the enlargement of the domain of attraction, while preserving the controller performance. Based on the dual MPC that uses the null local controller, it proposed the inclusion of an appropriate set of slacked terminal constraints into the control problem. As a result, the domain of attraction is unlimited for the stable modes of the system, and the largest possible for the non-stable modes. Although this controller does not achieve local optimality, simulations show that the input and output performances may be comparable to the ones obtained with the dual MPC that uses the LQR as a local controller.     

Comparison of three control strategies for optimization of spray dryer operation

Spray drying is the preferred process to reduce the water content of many chemicals, pharmaceuticals, and foodstuffs. A significant amount of energy is used in spray drying to remove water and produce a free flowing powder product. In this paper, we present and compare the performance of three controllers for operation of a four-stage spray dryer. The three controllers are a proportional-integral (PI) controller that is used in industrial practice for spray dryer operation, a linear model predictive controller with real-time optimization (MPC with RTO, MPC-RTO), and an economically optimizing nonlinear model predictive controller (E-NMPC). The MPC with RTO is based on the same linear state space model in the MPC and the RTO layer. The E-NMPC consists of a single optimization layer that uses a nonlinear system of ordinary differential equations for its predictions. The PI control strategy has a fixed target that is independent of the disturbances, while the MPC-RTO and the E-NMPC adapt the operating point to the disturbances. The goal of spray dryer operation is to optimize the profit of operation in the presence of feed composition and ambient air humidity variations; i.e. to maximize the production rate, while minimizing the energy consumption, keeping the residual moisture content of the powder below a maximum limit, and avoiding that the powder sticks to the chamber walls. We use an industrially recorded disturbance scenario in order to produce realistic simulations and conclusions. The key performance indicators such as the profit of operation, the product flow rate, the specific energy consumption, the energy efficiency, and the residual moisture content of the produced powder are computed and compared for the three controllers. In this simulation study, we find that the economic performance of the MPC with RTO as well as the E-NMPC is considerably improved compared to the PI control strategy used in industrial practice. The MPC with RTO improves the profit of operation by 8.61%, and the E-NMPC improves the profit of operation by 9.66%. The energy efficiency is improved by 6.21% and 5.51%, respectively.     

A sufficient condition for the stability of optimizing controllers with saturating actuators

The quadratic programme that must be solved with certain output–feedback model predictive controllers can be expressed as a continuous sector‐bounded nonlinearity together with two linear transformations. Thus, the multivariable circle criterion gives a simple test for stability, with or without model mismatch. In particular, it may be applied if the open‐loop plant is stable and the actuators are subject to simple saturation constraints. In the case of single horizon model predictive control, it suffices to check for positive realness a transfer function matrix whose dimension corresponds to the number of inputs. For an arbitrary length receding horizon it suffices to check the poles of a low dimension transfer function matrix and the eigenvalues (over an appropriate range of operator values) of a matrix whose dimension is independent of the horizon length. Copyright © 2005 John Wiley & Sons, Ltd.     

Enlarging the domain of attraction of MPC controllers

This paper presents a method for enlarging the domain of attraction of nonlinear model predictive control (MPC). The usual way of guaranteeing stability of nonlinear MPC is to add a terminal constraint and a terminal cost to the optimization problem such that the terminal region is a positively invariant set for the system and the terminal cost is an associated Lyapunov function. The domain of attraction of the controller depends on the size of the terminal region and the control horizon. By increasing the control horizon, the domain of attraction is enlarged but at the expense of a greater computational burden, while increasing the terminal region produces an enlargement without an extra cost.In this paper, the MPC formulation with terminal cost and constraint is modified, replacing the terminal constraint by a contractive terminal constraint. This constraint is given by a sequence of sets computed off-line that is based on the positively invariant set. Each set of this sequence does not need to be an invariant set and can be computed by a procedure which provides an inner approximation to the one-step set. This property allows us to use one-step approximations with a trade off between accuracy and computational burden for the computation of the sequence. This strategy guarantees closed loop-stability ensuring the enlargement of the domain of attraction and the local optimality of the controller. Moreover, this idea can be directly translated to robust MPC.     

An alternative structure for next generation regulatory controllers: Part I: Basic theory for design, development and implementation

Even though employed widely in industrial practice, the popular PID controller has weaknesses that limit its achievable performance, and an intrinsic structure that makes tuning not only more complex than necessary, but also less transparent with respect to the key attributes of the overall controller performance, namely: robustness, set-point tracking, and disturbance rejection. In this paper, we propose an alternative control scheme that combines the simplicity of the PID controller with the versatility of model predictive control (MPC) while avoiding the tuning problems associated with both. The tuning parameters of the proposed control scheme are related directly to the controller performance attributes; they are normalized to lie between 0 and 1; and they arise naturally from the formulation in a manner that makes it possible to tune the controller directly for each performance attribute independently. The result is a controller that can be designed and implemented much more directly and transparently, and one that outperforms the classical PID controller both in set-point tracking and disturbance rejection while using precisely the same process reaction curve information required to tune PID controllers. The design, implementation and performance of the controller are demonstrated via simulation on a nonlinear polymerization process.     

Coal-fired utility boiler modelling for advanced economical low-NOx combustion controller design

This paper focuses on developing a control-oriented coal-fired utility boiler model for advanced economical Low-NO_x combustion (ELNC) controller design. Two boiler combustion models are proposed in this paper: one is a mathematical model describing the key dynamics of the real-time boiler thermal efficiency and the furnace one-dimensional NO_x concentration distribution under conventional fuel and overfire air operations; the other recast from the first model is a control-oriented grey-box model with a data-driven furnace combustion submodel. Simulation studies on static and dynamic properties of the first mathematical model indicate that the model can function as a real-time simulator for both advanced boiler combustion control laws testing and generating training and validation data for the control-oriented grey-box model. At the end of this paper, the control-oriented grey-box modelling procedure as well as an optional discrete time linear state-space model are summarised to facilitate model-based advanced combustion controllers design.     

A hybrid model predictive control strategy for nonlinear plant-wide control

A plant-wide control strategy based on integrating linear model predictive control (LMPC) and nonlinear model predictive control (NMPC) is proposed. The hybrid method is applicable to plants that can be decomposed into approximately linear subsystems and highly nonlinear subsystems that interact via mass and energy flows. LMPC is applied to the linear subsystems and NMPC is applied to the nonlinear subsystems. A simple controller coordination strategy that counteracts interaction effects is proposed for the case of one linear subsystem and one nonlinear subsystem. A reactor/separator process with recycle is used to compare the hybrid method to conventional LMPC and NMPC techniques.     

Handling uncertainty in economic nonlinear model predictive control: A comparative case study

In the last years, the use of an economic cost function for model predictive control (MPC) has been widely discussed in the literature. The main motivation for this choice is that often the real goal of control is to maximize the profit or the efficiency of a certain system, rather than tracking a predefined set-point as done in the typical MPC approaches, which can be even counter-productive. Since the economic optimal operation of a system resulting from the application of an economic model predictive control approach drives the system to the constraints, the explicit consideration of the uncertainties becomes crucial in order to avoid constraint violations. Although robust MPC has been studied during the past years, little attention has yet been devoted to this topic in the context of economic nonlinear model predictive control, especially when analyzing the performance of the different MPC approaches. In this work, we present the use of multi-stage scenario-based nonlinear model predictive control as a promising strategy to deal with uncertainties in the context of economic NMPC. We make a comparison based on simulations of the advantages of the proposed approach with an open-loop NMPC controller in which no feedback is introduced in the prediction and with an NMPC controller which optimizes over affine control policies. The approach is efficiently implemented using CasADi, which makes it possible to achieve real-time computations for an industrial batch polymerization reactor model provided by BASF SE. Finally, a novel algorithm inspired by tube-based MPC is proposed in order to achieve a trade-off between the variability of the controlled system and the economic performance under uncertainty. Simulations results show that a closed-loop approach for robust NMPC increases the performance and that enforcing low variability under uncertainty of the controlled system might result in a big performance loss.     

A stabilizing model predictive control for networked control system with data packet dropout

A constrained model predictive control （MPC） algorithm for networked control system with data packet dropout is proposed in this paper. A buffer is designed to store the predicted control sequence between controller and actuator. It is shown that if the control horizon of MPC is not less than the number of data packets lost continuously, feasibility of MPC at initial time implies asymptotical stability of the closed-loop system. A simulation example illustrates the effectiveness of the proposed approach.     

A robust gradient-based MPC for integrating real time optimizer (RTO) with control

A gradient-based model predictive control (MPC) strategy was recently proposed to reduce the computational burden derived from the explicit inclusion of an economic real time optimization (RTO). The main idea is to compute a suboptimal solution, which is the convex combination of a feasible solution and a solution of an approximated (linearized) problem. The main benefits of this strategy are that convergence is still guaranteed and good economic performances are obtained, according to several simulation scenarios. The formulation, however, is developed only for the nominal case, which significantly reduces its applicability. In this work, an extension of the gradient-based MPC to explicitly account for disturbances is made. The resulting robust formulation considers a nominal prediction model, but restricted constraints (in order to account for the effect of additive disturbances). The nominal economic performance is preserved and robust stability is ensured. An illustrative example shows the benefits of the proposal.     

Switched linear model predictive controllers for periodic exogenous signals

This article develops switched linear controllers for periodic exogenous signals using the framework of a continuous-time model predictive control. In this framework, the control signal is generated by an algorithm that uses receding horizon control principle with an on-line optimisation scheme that permits inclusion of operational constraints. Unlike traditional repetitive controllers, applying this method in the form of switched linear controllers ensures bumpless transfer from one controller to another. Simulation studies are included to demonstrate the efficacy of the design with or without hard constraints.