This research work proposes two robust empirical model-based predictive control algorithms for nonlinear processes. Chemical process are generally highly nonlinear thus predictive control algorithms that explicitly account for the nonlinearity of the process are expected to provide better closed-loop performance as compared to algorithms based on linear models. Two types of models can be considered for control: first-principles and empirical. Empirical models were chosen for the proposed algorithms for the following reasons: (i) they are less complex for on-line optimization, (ii) they are easy to identify from input-output data and (iii) their structure is suitable for the formulation of robustness tests. One of the key problems of every model that is used for prediction within a control strategy is that some model parameters cannot be known accurately due to measurement noise and/or error in the structure of the assumed model. In the robust control approach it is assumed that processes can be represented by models with parameters' values that are assumed to lie between a lower and upper bound or equivalently, that these parameters can be represented by a nominal value plus uncertainty. When this uncertainty in control parameters is not considered by the controller the control actions might be insufficient to effectively control the process and in some extreme cases the closed-loop may become unstable. Accordingly, the two robust control algorithms proposed in the current work explicitly account for the effect of uncertainty on stability and closed-loop performance. The first proposed controller is a robust gain-scheduling model predictive controller (MPC). In this case the process is represented within each operating region by a state-affine model obtained from input-output data. The state-affine model matrices are used to obtain a state-space based MPC for every operating region. By combining the state-affine, disturbance and controller equations a closed-loop representation was obtained. Then, the resulting mathematical representation was tested for robustness with linear matrix inequalities (LMI's) based on a test where the vertices of the parameter box were obtained by an iterative procedure. The result of the LMI's test gives a measure of performance referred to as γ that relates the effect of the disturbances on the process outputs. Finally, for the gain-scheduling part of the algorithm a set of rules was proposed to switch between the available controllers according to the current process conditions. Since every combination of the controller tuning parameters results in a different value of γ, an optimization problem was proposed to minimize γ with respect to the tuning parameters. Accordingly, for the proposed controller it was ensured that the effect of the disturbances on the output variables was kept to its minimum. A bioreactor case study was presented to show the benefits of the proposed algorithm. For comparison purposes a non-robust linear MPC was also designed. The results show that the proposed algorithm has a clear advantage in terms of performance as compared to non-robust linear MPC techniques. The second controller proposed in this work is a robust nonlinear model predictive controller (NMPC) based on an empirical Volterra series model. The benefit of using a Volterra series model for this case is that its structure can be split in two sections that account for the nominal and uncertain parameter values. Similar to the previously proposed gain-scheduled controller the model parameters were obtained from input-output data. After identifying the Volterra model, an interconnection matrix and its corresponding uncertainty description were found. The interconnection matrix relates the process inputs and outputs and is built according to the type of cost function that the controller uses. Based on the interconnection representing the system a robustness test was proposed based on a structured singular value norm calculation (SSV). The test is based on a min-max formulation where the worst possible closed-loop error is minimized with respect to the manipulated variables. Additional factors that were considered in the cost function were: manipulated variables weighting, manipulated variables restrictions and a terminal condition. To show the benefits of this controller two case studies were considered, a single-input-single-output (SISO) and a multiple-input-multiple-output (MIMO) process. Both case studies show that the proposed controller is able to control the process. The results showed that the controller could efficiently track set-points in the presence of disturbances while complying with the saturation limits imposed on the manipulated variables. This controller was also compared against a non-robust linear MPC, non-robust NMPC and non-robust first-principles NMPC. These comparisons were performed for different levels of uncertainty and for different values of the suppression or control actions weights. It was shown through these comparisons that a tradeoff exists between nominal performance and robustness to model error. Thus, for larger weights the controller is less aggressive resulting in more sluggish performance but less sensitivity to model error thus resulting in smaller differences between the robust and non-robust schemes. On the other hand when these weights are smaller the controller is more aggressive resulting in better performance at the nominal operating conditions but also leading to larger sensitivity to model error when the system is operated away from nominal conditions. In this case, as a result of this increased sensitivity to model error, the robust controller is found to be significantly better than the non-robust one.

This work focuses on the robustness issues related to distributed model predictive control (DMPC) strategies in the presence of model uncertainty. The robustness of DMPC with respect to model uncertainty has been identified by researchers as a key factor in the successful application of DMPC. A first task towards the formulation of robust DMPC strategy was to propose a new systematic methodology for the selection of a control structure in the context of DMPC. The methodology is based on the trade-off between performance and simplicity of structure (e.g., a centralized versus decentralized structure) and is formulated as a multi-objective mixed-integer nonlinear program (MINLP). The multi-objective function is composed of the contribution of two indices: 1) closed-loop performance index computed as an upper bound on the variability of the closed-loop system due to the effect on the output error of either set-point or disturbance input, and 2) a connectivity index used as a measure of the simplicity of the control structure. The parametric uncertainty in the models of the process is also considered in the methodology and it is described by a polytopic representation whereby the actual process’s states are assumed to evolve within a polytope whose vertices are defined by linear models that can be obtained from either linearizing a nonlinear model or from their identification in the neighborhood of different operating conditions. The system’s closed-loop performance and stability are formulated as Linear Matrix Inequalities (LMI) problems so that efficient interior-point methods can be exploited. To solve the MINLP a multi-start approach is adopted in which many starting points are generated in an attempt to obtain global optima. The efficiency of the proposed methodology is shown through its application to benchmark simulation examples. The simulation results are consistent with the conclusions obtained from the analysis. The proposed methodology can be applied at the design stage to select the best control configuration in the presence of model errors. A second goal accomplished in this research was the development of a novel online algorithm for robust DMPC that explicitly accounts for parametric uncertainty in the model. This algorithm requires the decomposition of the entire system’s model into N subsystems and the solution of N convex corresponding optimization problems in parallel. The objective of this parallel optimizations is to minimize an upper bound on a robust performance objective by using a time-varying state-feedback controller for each subsystem. Model uncertainty is explicitly considered through the use of polytopic description of the model. The algorithm employs an LMI approach, in which the solutions are convex and obtained in polynomial time. An observer is designed and embedded within each controller to perform state estimations and the stability of the observer integrated with the controller is tested online via LMI conditions. An iterative design method is also proposed for computing the observer gain. This algorithm has many practical advantages, the first of which is the fact that it can be implemented in real-time control applications and thus has the benefit of enabling the use of a decentralized structure while maintaining overall stability and improving the performance of the system. It has been shown that the proposed algorithm can achieve the theoretical performance of centralized control. Furthermore, the proposed algorithm can be formulated using a variety of objectives, such as Nash equilibrium, involving interacting processing units with local objective functions or fully decentralized control in the case of communication failure. Such cases are commonly encountered in the process industry. Simulations examples are considered to illustrate the application of the proposed method. Finally, a third goal was the formulation of a new algorithm to improve the online computational efficiency of DMPC algorithms. The closed-loop dual-mode paradigm was employed in order to perform most of the heavy computations offline using convex optimization to enlarge invariant sets thus rendering the iterative online solution more efficient. The solution requires the satisfaction of only relatively simple constraints and the solution of problems each involving a small number of decision variables. The algorithm requires solving N convex LMI problems in parallel when cooperative scheme is implemented. The option of using Nash scheme formulation is also available for this algorithm. A relaxation method was incorporated with the algorithm to satisfy initial feasibility by introducing slack variables that converge to zero quickly after a small number of early iterations. Simulation case studies have illustrated the applicability of this approach and have demonstrated that significant improvement can be achieved with respect to computation times. Extensions of the current work in the future should address issues of communication loss, delays and actuator failure and their impact on the robustness of DMPC algorithms. In addition, integration of the proposed DMPC algorithms with other layers in automation hierarchy can be an interesting topic for future work.

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This thesis presents a data-driven approach to constrained control in the form of a subspace-based state-space system identification algorithm integrated into a model predictive controller. Generally this approach has been termed model-free predictive control in the literature. Previous research into this area focused on the system identification aspects resulting in an omission of many of the features that would make such a control strategy attractive to industry. These features include constraint handling, zero-offset setpoint tracking and non-stationary disturbance rejection. The link between non-stationary disturbance rejection in subspace-based state-space system identification and integral action in state-space based model predictive control was shown. Parameterization with Laguerre orthonormal functions was proposed for the reduction in computational load of the controller. Simulation studies were performed using three real-world systems demonstrating: identification capabilities in the presence of white noise and non-stationary disturbances; unconstrained and constrained control; and the benefits and costs of parameterization with Laguerre polynomials.

Minimum invasive surgery is based on bilateral teleoperation in which surgeon interacts with the master side to the slave side that is located at a distance. The synchronization in between the two ends is through a communication channel. The primary objective in the telesurgery is the position and force tracking providing the surgeon with high fidelity. The presence of time delays in the communication channels makes the realization more difficult, and sometimes it may even destabilize the system. The work focuses on a design of the force control system by using Model Predictive Control to compensate for the effects of the time delay related to the use of surgical arms. Another vital issue of minimum impact velocity during contact with the environment has been tried to achieve by using the prediction from the Model Predictive Control to prevent accidental tissue damage. This work also addresses a problem of the developing a simple delayed free predictive kinematic imaging to understand the type of behavior of the system during contact with the environment when no perception is available.

Flight control design for modern fighter aircraft is a challenging task. Aircraft are dynamical systems, which naturally contain a variety of constraints and nonlinearities such as, e.g., maximum permissible load factor, angle of attack and control surface deflections. Taking these limitations into account in the design of control systems is becoming increasingly important as the performance and complexity of the aircraft is constantly increasing. The aeronautical industry has traditionally applied feedforward, anti-windup or similar techniques and different ad hoc engineering solutions to handle constraints on the aircraft. However these approaches often rely on engineering experience and insight rather than a theoretical foundation, and can often require a tremendous amount of time to tune. In this thesis we investigate model predictive control as an alternative design tool to handle the constraints that arises in the flight control design. We derive a simple reference tracking MPC algorithm for linear systems that build on the dual mode formulation with guaranteed stability and low complexity suitable for implementation in real time safety critical systems. To reduce the computational burden of nonlinear model predictive control we propose a method to handle the nonlinear constraints, using a set of dynamically generated local inner polytopic approximations. The main benefit of the proposed method is that while computationally cheap it still can guarantee recursive feasibility and convergence. An alternative to deriving MPC algorithms with guaranteed stability properties is to analyze the closed loop stability, post design. Here we focus on deriving a tool based on Mixed Integer Linear Programming for analysis of the closed loop stability and robust stability of linear systems controlled with MPC controllers. To test the performance of model predictive control for a real world example we design and implement a standard MPC controller in the development simulator for the JAS 39 Gripen aircraft at Saab Aeronautics. This part of the thesis focuses on practical and tuning aspects of designing MPC controllers for fighter aircraft. Finally we have compared the MPC design with an alternative approach to maneuver limiting using a command governor.

In line with Anglo American’s asset optimization and environmental policies, the coal burning flash dryer operations at its smelters have been identified for potential optimization by means of advanced process control. For this project, the process and related literature were studied in detail and a revised control philosophy, which includes modifications to the existing basic control structure as well as a hybrid rule and model-predictive advanced control layer, was developed, installed and tested on one of these flash drying operations. Since commissioning of the APC, the flash dryer’s average throughput has increased by more than 6 %, despite higher feed moistures. Furthermore, even though coal consumption has increased slightly, the operation efficiency has improved by almost 5 %. This was made possible by improving the stability of the drying column outlet temperature by approximately 40 %, which in turn enabled the selection of a more optimal setpoint. Recent data has shown that APC utilization now exceeds 95 %. This is indicative of a successful controller installation with good site acceptance. / Dissertation (MEng)--University of Pretoria, 2011. / Chemical Engineering / unrestricted

This dissertation forms part of the ongoing process at UP to model and control the electric arc furniture process. Previous work focused on modelling the furnace process from empirical thermodynamic principles as well as fitting the model to actual plant data. Automation of the process mainly focused on subsystems of the process, for example the electric subsystem and the off-gas subsystem. The modelling effort, especially the model fitting resulted in parameter values that are described with confidence intervals, which gives rise to uncertainty in the model, because the parameters can potentially lie anywhere in the confidence interval space. Robust model predictive control is used in this dissertation, because it can explicityly take the model uncertainty into account as part of the synthesis process. Nominal model predictive control – not taking model uncertainty into account – is also applied in order to determine if robust model predictive control provides any advantages over the nominal model predictive control. This dissertation uses the process model from previous wok together with robust model predictive control to determine the feasibility of automating the process with regards to the primary process variables. Possible hurdles that prevent practical implementation are identified and studied. / Dissertation (MEng (Electronic Engineering))--University of Pretoria, 2007. / Electrical, Electronic and Computer Engineering / MEng / unrestricted

This dissertation forms part of the ongoing process at UP to model and control the electric arc furniture process. Previous work focused on modelling the furnace process from empirical thermodynamic principles as well as fitting the model to actual plant data. Automation of the process mainly focused on subsystems of the process, for example the electric subsystem and the off-gas subsystem. The modelling effort, especially the model fitting resulted in parameter values that are described with confidence intervals, which gives rise to uncertainty in the model, because the parameters can potentially lie anywhere in the confidence interval space. Robust model predictive control is used in this dissertation, because it can explicityly take the model uncertainty into account as part of the synthesis process. Nominal model predictive control – not taking model uncertainty into account – is also applied in order to determine if robust model predictive control provides any advantages over the nominal model predictive control. This dissertation uses the process model from previous wok together with robust model predictive control to determine the feasibility of automating the process with regards to the primary process variables. Possible hurdles that prevent practical implementation are identified and studied. / Dissertation (MEng (Electronic Engineering))--University of Pretoria, 2007. / Electrical, Electronic and Computer Engineering / MEng / unrestricted

Please read the abstract in the section, 00front of this document / Dissertation (MEng (Electronic Engineering))--University of Pretoria, 2007. / Electrical, Electronic and Computer Engineering / MEng / unrestricted