Multi‐rate observer design for process monitoring using asynchronous inter‐sample output predictions

In this article, the problem of observer design in linear multi‐output systems with asynchronous sampling is addressed. The proposed multi‐rate observer is based on a continuous‐time Luenberger observer design coupled with an inter‐sample predictor for each sampled measurement, which generates an estimate of the output in between consecutive measurements. The sampling times are not necessarily uniformly spaced, but there exists a maximum sampling period among all the sensors. Sufficient and explicit conditions are derived to guarantee exponential stability of the multi‐rate observer. The proposed framework of multi‐rate observer design is examined through a mathematical example and a gas‐phase polyethylene reactor. In the latter case, the amount of active catalyst sites is estimated, with a convergence rate that is comparable to the case of continuous measurements. © 2017 American Institute of Chemical Engineers AIChE J, 63: 3384–3394, 2017     

FIR model identification of multirate processes with random delays using EM algorithm

The motivation for this article comes from our development of soft sensors for chemical processes where several challenges are encountered. For example, quality variables in chemical processes are often measured off‐line through laboratory analysis. Collection of samples and subsequent analyses inevitably introduce uncertain time delays associated with the irregularly sampled quality variables, which add significant difficulty in identification of process with multirate (MR) data. Considering the MR system with random sampling delays described by a finite impulse response (FIR) model, an Expectation–Maximization (EM)‐based algorithm to estimate its parameters along with the time delays is developed. Based on the identified FIR model, two algorithms are proposed to recover the approximate output error (OE) or transfer function model. Two simulation examples as well as a pilot‐scale experiment are provided to illustrate the effectiveness of the proposed methods. © 2013 American Institute of Chemical Engineers AIChE J, 59: 4124–4132, 2013     

Parameter estimation for nonlinear systems with multirate measurements and random delays

We present an approach for parameter estimation with multirate measurements, with the slow measurements having variable time delays due to laboratory analysis, and also being functions of all the states during the sample collection. We formulate a particle filter-based approach under the framework of the expectation maximization algorithm to develop the estimates. The effectiveness and applicability of the proposed method are demonstrated though a simulation example, a hybrid tank experiment and an industrial case study; in each case, the slow and fast measurements are for the same variable. We show that this approach results in improved parameter estimation when the information from the delayed measurements is fused with the fast measurement information.     

利用非线性规划技术的固定床反应器在线过程辨识

提出了基于非线性规划的在线过程辨识的一般性方法．辨识器对动态测量数据采用了移动水平法,并把具有不同采样速率的测量值统一考虑在辨识公式中,同时还可以处理具有时滞和约束的情况．概率解释说明,在一定的情况下最小二乘估计与最大似然估计具有一致性．本文以壁冷式固定床反应器为例,从仿真和实验两方面考察了所提出的在线过程辨识器的性能,并研究了各辨识器参数的影响．结果表明,该辨识器具有很好的收敛性能和鲁棒性,同时在计算速度上也能满足在线要求．     

含时滞测量值下间歇过程的双维状态估计

基于粒子滤波研究了间歇过程的状态估计问题。根据间歇过程双维动态特性,针对关键参数在线检测精度低、离线分析时滞大等问题,分别建立一种双维状态转移模型和时滞测量模型,并利用贝叶斯方法及前/后向平滑,提出一种含时滞测量值下的双维状态估计算法。该算法通过融合先前批次和时滞测量值的信息提高估计精度,并且克服了离线采样周期和时滞时间不确定的问题。在数字仿真和啤酒发酵过程中的仿真应用验证了该算法的有效性。     

Composite fast‐slow MPC design for nonlinear singularly perturbed systems

The design of a composite control system for nonlinear singularly perturbed systems using model predictive control (MPC) is described. Specifically, a composite control system comprised of a “fast” MPC acting to regulate the fast dynamics and a “slow” MPC acting to regulate the slow dynamics is designed. The composite MPC system uses multirate sampling of the plant state measurements, i.e., fast sampling of the fast state variables is used in the fast MPC and slow‐sampling of the slow state variables is used in the slow MPC. Using singular perturbation theory, the stability and optimality of the closed‐loop nonlinear singularly perturbed system are analyzed. A chemical process example which exhibits two‐time‐scale behavior is used to demonstrate the structure and implementation of the proposed fast–slow MPC architecture in a practical setting. © 2012 American Institute of Chemical Engineers AIChE J, 58: 1802–1811, 2012     

Economic model predictive control of nonlinear process systems using Lyapunov techniques

In this work, we develop model predictive control (MPC) designs, which are capable of optimizing closed‐loop performance with respect to general economic considerations for a broad class of nonlinear process systems. Specifically, in the proposed designs, the economic MPC optimizes a cost function, which is related directly to desired economic considerations and is not necessarily dependent on a steady‐state—unlike conventional MPC designs. First, we consider nonlinear systems with synchronous measurement sampling and uncertain variables. The proposed economic MPC is designed via Lyapunov‐based techniques and has two different operation modes. The first operation mode corresponds to the period in which the cost function should be optimized (e.g., normal production period); and in this operation mode, the MPC maintains the closed‐loop system state within a predefined stability region and optimizes the cost function to its maximum extent. The second operation mode corresponds to operation in which the system is driven by the economic MPC to an appropriate steady‐state. In this operation mode, suitable Lyapunov‐based constraints are incorporated in the economic MPC design to guarantee that the closed‐loop system state is always bounded in the predefined stability region and is ultimately bounded in a small region containing the origin. Subsequently, we extend the results to nonlinear systems subject to asynchronous and delayed measurements and uncertain variables. Under the assumptions that there exist an upper bound on the interval between two consecutive asynchronous measurements and an upper bound on the maximum measurement delay, an economic MPC design which takes explicitly into account asynchronous and delayed measurements and enforces closed‐loop stability is proposed. All the proposed economic MPC designs are illustrated through a chemical process example and their performance and robustness are evaluated through simulations. © 2011 American Institute of Chemical Engineers AIChE J, 2012     

A two-tier architecture for networked process control

Traditionally, process control systems utilize dedicated, point-to-point wired communication links using a small number of sensors and actuators to regulate appropriate process variables at desired values. While this paradigm to process control has been successful, chemical plant operation could substantially benefit from an efficient integration of the existing, point-to-point control networks (wired connections from each actuator/sensor to the control system using dedicated local area networks) with additional networked (wired or wireless) actuator/sensor devices. However, augmenting existing control networks with real-time wired/wireless sensor and actuator networks challenges many of the assumptions made in the development of traditional process control methods dealing with dynamical systems linked through ideal channels with flawless, continuous communication. In the context of control systems which utilize networked sensors and actuators, key issues that need to be carefully handled at the control system design level include data losses due to field interference and time delays due to network traffic. Motivated by the above technological advances and the lack of methods to design control systems that utilize hybrid communication networks, in the present work, we present a novel two-tier control architecture for networked process control problems that involve nonlinear processes and heterogeneous measurements consisting of continuous measurements and asynchronous, delayed measurements. This class of control problems arises naturally when nonlinear processes are controlled via control systems based on hybrid communication networks (i.e., point-to-point wired links integrated with networked wired/wireless communication) or utilizing multiple heterogeneous measurements (e.g., temperature measurements which can be taken to be continuous and species concentration measurements which are fed to the control system at asynchronous time instants and frequently involve delays). While point-to-point wired links are very reliable, the presence of a shared communication network in the closed-loop system introduces additional delays and data losses and these issues should be handled at the controller design level. In the two-tier control architecture presented in this work, a lower-tier control system, which relies on point-to-point communication and continuous measurements, is first designed to stabilize the closed-loop system, and an upper-tier networked control system is subsequently designed, using Lyapunov-based model predictive control theory, to profit from both the continuous and the asynchronous, delayed measurements as well as from additional networked control actuators to improve the closed-loop system performance. The proposed two-tier control architecture preserves the stability properties of the lower-tier controller while improving the closed-loop performance. The applicability and effectiveness of the proposed control method is demonstrated using two chemical process examples.     

Communication delays and data losses in distributed adaptive high‐gain EKF

In this work, we consider distributed adaptive high‐gain extended Kalman filtering for nonlinear systems subject to data losses and delays in communications. Specifically, we consider a class of nonlinear systems that consist of several subsystems interacting with each other via their states. A local adaptive high‐gain extended Kalman filter is designed for each subsystem and the distributed estimators communicate to exchange the information. Each subsystem estimator takes the advantage of a predictor accounting for the delays and data losses simultaneously. The predictor of each subsystem is used to generate state predictions of interacting subsystems for interaction compensation. To get a reliable prediction, the predictors are designed based on a prediction‐update algorithm. The convergence of the proposed distributed state estimation is ensured under sufficient conditions handling communication delays and data losses. Finally, a chemical process example is used to evaluate the applicability and effectiveness of the proposed design. © 2016 American Institute of Chemical Engineers AIChE J, 62: 4321–4333, 2016     

Heat exchanger system boundary regulation

The boundary feedback regulator design for heat exchangers with delayed feedback is developed. Counter-flow/parallel-flow heat exchanger systems described by a pair of coupled transport hyperbolic partial differential equations (PDEs) with delayed boundary feedback loop modeled by the boundary time lag are considered. The coupled transport hyperbolic PDEs and boundary delay by application of boundary transformation are transformed in the corresponding linear infinite-dimensional system utilized in the regulator design. The regulator design initially addresses a full state feedback controller realization augmented by the observer design to achieve simultaneously output exponential stabilization as well as tracking and disturbance rejection of polynomial and/or harmonic type of reference signals. The simulations studies demonstrate the proposed design for counter-flow and parallel-flow heat exchangers, two common configurations present in industrial practice.     

Guaranteed cost distributed fuzzy observer‐based control for a class of nonlinear spatially distributed processes

The guaranteed cost distributed fuzzy (GCDF) observer‐based control design is proposed for a class of nonlinear spatially distributed processes described by first‐order hyperbolic partial differential equations (PDEs). Initially, a T–S fuzzy hyperbolic PDE model is proposed to accurately represent the nonlinear PDE system. Then, based on the fuzzy PDE model, the GCDF observer‐based control design is developed in terms of a set of space‐dependent linear matrix inequalities. In the proposed control scheme, a distributed fuzzy observer is used to estimate the state of the PDE system. The designed fuzzy controller can not only ensure the exponential stability of the closed‐loop PDE system but also provide an upper bound of quadratic cost function. Moreover, a suboptimal fuzzy control design is addressed in the sense of minimizing an upper bound of the cost function. The finite difference method in space and the existing linear matrix inequality optimization techniques are used to approximately solve the suboptimal control design problem. Finally, the proposed design method is applied to the control of a nonisothermal plug‐flow reactor. © 2013 American Institute of Chemical Engineers AIChE J, 59: 2366–2378, 2013     

Multi-rate observer design and optimal control to maximize productivity of an industry-scale fermentation process

Chemical industries focus primarily on profitable operations, resulting in growing attention and advances in the field of digital twins and optimal control algorithms. However, most industries still struggle due to a lack of physical sensors, infrequent measurements, and asynchronous sampling. Thus, in this work, we have designed a multi-rate state observer for state estimation from plant measurements and developed a model predictive controller (MPC) that maximized the profitability of an industry-scale fermentation process (fermenter volume < 378,500 L). Additionally, as the fermentation process is complex due to the use of microorganisms, which cannot be accurately captured using a first-principles model, we utilize a previously developed hybrid model in the proposed MPC formulation. The MPC uses a GAMS-MATLAB framework to determine the optimal input profiles while considering practical process constraints. It is shown using multiple datasets, that the MPC can increase productivity while also decreasing the plant operating cost.     

Adaptive multirate estimation and control of nutrient levels in a fed-batch fermentation using off-line and on-line measurements

A multirate adaptive estimation algorithm developed earlier (Gudi et al., 1995) is extended to perform estimation of nutrient levels using frequent on-line measurements of the carbon dioxide evolution rate (CER) and off-line, infrequent and delayed measurements of the biomass and substrate concentrations. It has been shown that the algorithm can be designed to track changing substrate yield coefficients as well. The estimation algorithm has been verified using simulations and industrial data from a fed-batch fermentation involving a Streptomyces specie. It has been coupled with a nonlinear control law designed to track prespecified optimal nutrient trajectories. The resulting closed loop control scheme is evaluated using simulation runs.     

Fault detection and isolation in hybrid process systems using a combined data‐driven and observer‐design methodology

A combined data‐driven and observer‐design methodology for fault detection and isolation (FDI) in hybrid process systems with switching operating modes is proposed. The main contribution is to construct a unified framework for FDI by integrating Gaussian mixture models (GMM), subspace model identification (SMI), and results from unknown input observer (UIO) theory. Initially, a GMM is built to identify and describe the multimodality of hybrid systems using the recorded input/output process data. A state‐space model is then obtained for each specific operating mode based on SMI if the system matrices are unknown. An UIO is designed to estimate the system states robustly, based on which the fault detection is laid out through a multivariate analysis of the residuals. Finally, by designing a set of unknown input matrices for specific fault scenarios, fault isolation is performed through the disturbance‐decoupling principle from the UIO theory. A significant benefit of the developed framework is to overcome some of the limitations associated with individual model‐based and data‐based approaches in dealing with the problem of FDI in hybrid systems. Finally, the validity and effectiveness of the proposed monitoring framework are demonstrated using a numerical example, a simulated continuous stirred tank heater process, and the Tennessee Eastman benchmark process. © 2014 American Institute of Chemical Engineers AIChE J, 60: 2805–2814, 2014     

Nonlinear observer design for two-time-scale systems

A two-time-scale system involves both fast and slow dynamics. This article studies observer design for general nonlinear two-time-scale systems and presents two alternative nonlinear observer design approaches, one full-order and one reduced-order. The full-order observer is designed by following a scheme to systematically select design parameters, so that the fast and slow observer dynamics are assigned to estimate the corresponding system modes. The reduced-order observer is derived based on a lower dimensional model to reconstruct the slow states, along with the algebraic slow-motion invariant manifold function to reconstruct the fast states. Through an error analysis, it is shown that the reduced-order observer is capable of providing accurate estimation of the states for the detailed system with an exponentially decaying estimation error. In the last part of the article, the two proposed observers are designed for an anaerobic digestion process, as an illustrative example to evaluate their performance and convergence properties.     

Decoupling internal model control for multivariable systems with multiple time delays

In this paper, the decoupling internal model control (IMC) with stability is investigated for multivariable stable processes with multiple time delays. All the stabilizing IMC controllers which solve this decoupling problem and the resulting closed-loop systems are characterized in terms of the open-loop system's time delays and non-minimum phase zeros. It shows that the inclusion of some time delays and non-minimum phase zeros might be necessary to make a decoupling solution realizable and stabilizing. Based on this characterization, a control design method for best achievable performance is presented. However, owing to the high complexity of the theoretical controller, a practical controller design procedure is developed with the help of the proposed model reduction algorithm. Examples are given to illustrate our analysis and design. Significant performance improvement over the existing multivariable Smith predictor control has been achieved with the proposed approach.     

A new predictive PID controller for the processes with time delay

A new proportional-integral-derivative (PID) controller is proposed based upon a simplified generalized predictive control (GPC) control law. The tuning parameters of the proposed predictive PID controller are obtained from the simplified GPC control law for the 1 ^st -order and 2 ^nd -order processes with time delays of integer and non-integer multiples of the sampling time. The internal model technique is employed to compensate the effect of time delay of the target process. The predictive PID controller is equivalent to the PI controller when the target process is 1 ^st -order and to the PID controller when the target process is an integrating process. The performance of the proposed predictive PID controller is almost the same as that of the simplified GPC. The main advantage of the proposed control scheme over other control methods is the ease of tuning and operation.     

Temperature distribution reconstruction in Czochralski crystal growth process

A mechanical geometric crystal growth model is developed to describe the crystal length and radius evolution. The crystal radius regulation is achieved by feedback linearization and accounts for parametric uncertainty in the crystal growth rate. The associated parabolic partial differential equation (PDE) model of heat conduction is considered over the time‐varying crystal domain and coupled with crystal growth dynamics. An appropriately defined infinite‐dimensional representation of the thermal evolution is derived considering slow time‐varying process effects. The computational framework of the Galerkin's method is used for parabolic PDE order reduction and observer synthesis for temperature distribution reconstruction over the entire crystal domain. It is shown that the proposed observer can be utilized to reconstruct temperature distribution from boundary temperature measurements. The developed observer is implemented on the finite‐element model of the process and demonstrates that despite parametric and geometric uncertainties present in the model, the temperature distribution is reconstructed with the high accuracy. © 2014 American Institute of Chemical Engineers AIChE J, 60: 2839–2852, 2014     

Distributed economic model predictive control for operational safety of nonlinear processes

Achieving operational safety of chemical processes while operating them in an economically‐optimal manner is a matter of great importance. Our recent work integrated process safety with process control by incorporating safety‐based constraints within model predictive control (MPC) design; however, the safety‐based MPC was developed with a centralized architecture, with the result that computation time limitations within a sampling period may reduce the effectiveness of such a controller design for promoting process safety. To address this potential practical limitation of the safety‐based control design, in this work, we propose the integration of a distributed model predictive control architecture with Lyapunov‐based economic model predictive control (LEMPC) formulated with safety‐based constraints. We consider both iterative and sequential distributed control architectures, and the partitioning of inputs between the various optimization problems in the distributed structure based on their impact on process operational safety. Moreover, sufficient conditions that ensure feasibility and closed‐loop stability of the iterative and sequential safety distributed LEMPC designs are given. A comparison between the proposed safety distributed EMPC controllers and the safety centralized EMPC is demonstrated via a chemical process example. © 2017 American Institute of Chemical Engineers AIChE J, 63: 3404–3418, 2017     

Two-degree-of-freedom output feedback controllers for discrete-time nonlinear systems

A discrete-time, model-based output feedback control structure for nonlinear processes is developed in the present work. The structure makes use of a closed-loop observer, while at the same time it guarantees that the overall feedback controller possesses integral action. An algebraic transformation is applied on the observer states to insure that the input/output gain of the observer matches the model upon which the static state feedback control law is based. The resulting control algorithm is a two-degree-of-freedom control law, in the sense that the output and the set point are processed in different ways. The control structure is shown not only to have the same properties as the standard model-state feedback structure, but also that it emerges from a model algorithmic control framework. Finally, a simulation example using an exothermic CSTR operating at an open-loop unstable steady state is used to evaluate the closed-loop performance of the proposed method.