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Cycle-to-cycle control is a method for using feedback to improve product quality for processes that are inaccessible within a single processing cycle. This limitation stems from the impossibility or the prohibitively high cost of placing sensors and actuators that could facilitate control during, or within, the process cycle. Our previous work introduced cycle to cycle control for single input-single output systems, and here it is extended to multiple input-multiple output systems. Gain selection, stability, and process noise amplification results are developed and compared with those obtained by previous researchers, showing good agreement. The limitation of imperfect knowledge of the plant model is then imposed. This is consistent with manufacturing environments where the cost and number of tests to determine a valid process model is desired to be minimal. The implications of this limitation are modes of response that are hidden from the controller. Their effects on system performance and stability are discussed. / Singapore-MIT Alliance (SMA)

<p>Inom processindustrin finns en etablerad reglerhierarki där basreglering sker med PID-regulatorer och där avancerad, multivariabel styrning sköts av MPC-programvara. Steget mellan dessa två nivåer kan upplevas som stort. För mindre och snabba multivariabla processer undvikes helst en multivariabel ansats, med försämrad reglering som följd. På Preem AB har detta upplevts som ett problem. Syftet med examensarbetet har varit att utveckla en alternativ, multivariabel styrstrategi för en process med ett mindre antal reglerstorheter som interagerar. Detta har gjorts genom en utveckling av en LQG-regulator i styrsystemet DeltaV.</p><p>För att implementera en regulator i ett styrsystem måste hänsyn tas till en rad faktorer, såsom hantering av olika körlägen, bortfall av signaler, integratoruppvridning, kommunikation med slavregulatorer och inte minst operatörernas gränssnitt för hantering av regulatorn. Att sedan utveckla en regulator för en process kräver bland annat stegförsök, analys och anpassning av stegtestdata, modellidentifiering, framtagning av trimningskonstanter, testning av styrstrategi i simulerad miljö och idrifttagning. Den typen av frågeställningar addresseras i rapporten.</p><p>Examensarbetet visar att det finns en plats för LQG-regulatorn i processindustrin för en viss typ av problem. Den utvecklade regulatorn har implementerats på en avsvavlingsprocess på Preems oljeraffenaderi i Lysekil med lyckat resultat. Oscillationer i processen, som tidvis påverkat produktionen av propen, har kunnat reduceras.</p> / <p>Process control in process industry is done in a hierarchy in which PID controllers are used for basic control and MPC software is used for advanced, multivariable process control. The implementation of multivariable control using MPC software is a major undertaking and development of such controllers for small and fast multivariable processes is therefore avoided. To achieve better control for such processes, a simpler approach to multivariable control is often sought. The purpose of this masters thesis is to develop an alternative, multivariable control strategy for processes with a smaller number of interacting control variables. This is achieved by developing an LQG-controller in the DCS DeltaV at Preem AB.</p><p>Implementation of such a controller in a DCS requires that consideration is given to a number of factors, including handling of different modes, loss of signals, reset windup, communication with slave controllers and construction of operator interface. To develop a controller for a specific process also requires step testing, model identification, tuning of the controller parameters, simulation of the control strategy and commissioning. Solutions to such issues are addressed in this report.</p><p>The thesis shows that  LQG-controllers can be useful in process industry for some niche applications. The LQG-controller has successfully been applied to a desulphurisation process at Preem's oil refinery in Lysekil, where oscillations affecting the production of propylene have been reduced.</p>

Inom processindustrin finns en etablerad reglerhierarki där basreglering sker med PID-regulatorer och där avancerad, multivariabel styrning sköts av MPC-programvara. Steget mellan dessa två nivåer kan upplevas som stort. För mindre och snabba multivariabla processer undvikes helst en multivariabel ansats, med försämrad reglering som följd. På Preem AB har detta upplevts som ett problem. Syftet med examensarbetet har varit att utveckla en alternativ, multivariabel styrstrategi för en process med ett mindre antal reglerstorheter som interagerar. Detta har gjorts genom en utveckling av en LQG-regulator i styrsystemet DeltaV. För att implementera en regulator i ett styrsystem måste hänsyn tas till en rad faktorer, såsom hantering av olika körlägen, bortfall av signaler, integratoruppvridning, kommunikation med slavregulatorer och inte minst operatörernas gränssnitt för hantering av regulatorn. Att sedan utveckla en regulator för en process kräver bland annat stegförsök, analys och anpassning av stegtestdata, modellidentifiering, framtagning av trimningskonstanter, testning av styrstrategi i simulerad miljö och idrifttagning. Den typen av frågeställningar addresseras i rapporten. Examensarbetet visar att det finns en plats för LQG-regulatorn i processindustrin för en viss typ av problem. Den utvecklade regulatorn har implementerats på en avsvavlingsprocess på Preems oljeraffenaderi i Lysekil med lyckat resultat. Oscillationer i processen, som tidvis påverkat produktionen av propen, har kunnat reduceras. / Process control in process industry is done in a hierarchy in which PID controllers are used for basic control and MPC software is used for advanced, multivariable process control. The implementation of multivariable control using MPC software is a major undertaking and development of such controllers for small and fast multivariable processes is therefore avoided. To achieve better control for such processes, a simpler approach to multivariable control is often sought. The purpose of this masters thesis is to develop an alternative, multivariable control strategy for processes with a smaller number of interacting control variables. This is achieved by developing an LQG-controller in the DCS DeltaV at Preem AB. Implementation of such a controller in a DCS requires that consideration is given to a number of factors, including handling of different modes, loss of signals, reset windup, communication with slave controllers and construction of operator interface. To develop a controller for a specific process also requires step testing, model identification, tuning of the controller parameters, simulation of the control strategy and commissioning. Solutions to such issues are addressed in this report. The thesis shows that  LQG-controllers can be useful in process industry for some niche applications. The LQG-controller has successfully been applied to a desulphurisation process at Preem's oil refinery in Lysekil, where oscillations affecting the production of propylene have been reduced.

Diss. Luleå : Luleå tekniska univ., 2002.

L'industrie sidérurgique rencontre depuis des années un développement important. Les caractéristiques des produits destinés aux différents secteurs industriels deviennent de plus en plus exigeantes. Actuellement des régulateurs avancés de type PID sont utilisés avec une structure multi-boucles locales. Afin de traiter les cahiers des charges de plus en plus contraints, il devient intéressant de revoir cette stratégie de contrôle. Ce sujet de thèse CIFRE entre ArcelorMittal et le CRAN a pour objectif de proposer de nouvelles stratégies de contrôle avancé pour le laminage à froid des bandes d'acier de type tôle fine, notamment des stratégies centralisées de contrôle remplaçant des boucles de régulation locales et indépendantes, afin d'élargir le champ des matériaux traitables, d'augmenter et d'optimiser la productivité et les capabilités du procédé ainsi que de minimiser les coûts de production. Dans une première partie, une étude bibliographique sera effectuée afin de mieux cerner les différents modèles métallurgiques et dynamiques du système à piloter. Dans une seconde partie, le cahier des charges sera traduit en termes d'un problème d'optimisation dont la solution est un contrôleur de type retour d'état. Enfin dans une troisième et dernière partie, une synthèse de retour de sortie dynamique sera proposée pour résoudre le problème des mesures manquantes / The steel industry has been developing for years. The characteristics of the products intended for the various industrial sectors are becoming more and more demanded. Currently advanced PID controllers are used with a local multi-loop structure. In order to deal with the increasingly constrained specifications, it is interesting to review this control strategy. This CIFRE PhD thesis between ArcelorMittal and CRAN aims to propose new advanced control strategies for the cold rolling of thin sheet steel strips, including centralized control strategies replacing local and independent control loops, to broaden the scope of treatable materials, increase and optimize process productivity and capabilities, and minimize production costs. In a first part, a bibliographic study will be carried out in order to better define the various metallurgical and dynamic models of the system to be controlled. In a second part, the specifications will be translated in terms of an optimization problem whose solution is the state feedback controller. Finally, in a third and final part, a dynamic output feedback synthesis will be proposed to solve the problem of missing measurements

Este trabalho faz uma introdução à evolução dos processos de laminação a frio, acionamento e controle dos mesmos, com foco na laminação de encruamento. O principal objetivo é estabelecer um modelo linear dos sistemas de acionamento, que permita o projeto de um controle multivariável. Pretende-se que a robustez do controle multivariável contribua para a eliminação de defeitos associados aos processos de bobinamento e desbobinamento. A eliminação destes defeitos traz um grande retorno econômico em função do grande volume de produção destas instalações. Para isto é desenvolvido um modelo matemático do sistema completo. No modelo são evidenciadas não linearidades associadas à variação dos diâmetros e inércias das bobinas na desenroladeira e enroladeira. Para solucionar esse problema as parcelas contendo as não linearidades são removidas do modelo. Posteriormente essas parcelas são repostas através de malhas feedforward no controle. Para validar o modelo são projetados controladores PID semelhantes aos utilizados no laminador real. Com os resultados obtidos através de simulação, discute-se a validade do modelo comparando-os com os dados do processo real. A partir desse modelo é desenvolvido o modelo linear em espaço de estados, a ser utilizado no projeto do controlador robusto multivariável. Em seguida é desenvolvido o projeto deste controlador multivariável utilizando a técnica LQG/LTR. Finalmente, são discutidos os resultados das simulações, comparando-os com os dados reais da planta. De um modo geral, os resultados apontam para uma boa aproximação entre a planta real e o modelo proposto. / This work is an introduction to the evolution of the processes of cold rolling, drive and control, focusing on skinpass rolling. The main objective is to establish a model of linear drive systems, allowing the design of a multivariable control. It is intended that the robustness of multivariable control contributes to the elimination of defects associated with processes of coiling and uncoiling. The elimination of these defects poses a great economic return due to the large volume of production of these facilities. To achieve this deal it was developed a mathematical model of the complete system. Nonlinearities associated with variation in diameters and inertia reels in desenroladeira and reel are evidenced in the model. To solve this problem the terms containing nonlinearities were removed from the model and, subsequently reintroduced by feedforward control loops. To validate the model, PID controllers were designed in a similar way to those used in real mill. With the results obtained by simulation, we discuss the validity of the model by comparing them with the actual process data. From this model it was developed a linear state space model to be used in the design of robust multivariable controller. After that it was developed the design of this multivariable controller using the technique LQG / LTR. Finally, it was discussed the simulation results, comparing them with actual data of the plant. Overall, the results point to a good approximation of the real plant and the proposed model.

<p>The goal of this Master thesis has on the one hand been to create a simulation environment for robots, where not only the simulations in this work can be performed, but also similar robot simulations, and on the other hand to study regulators that can increase the possibilities of rejecting disturbances on an industrial robot. The robot model used has three degrees of freedom, corresponding to the three main links on ABB:s IRB7600. </p><p>The simulation environment is created using Matlab, Simulink, and Robotics Toolbox. It is constructed in a general way and can be used for simulations of other robot objects created in Robotics Toolbox. </p><p>A gain scheduling is added to the LQ-regulator, where the feedback matrix is varied depending on the arm position in the workspace. The gain scheduling is implemented along a reference path in the workspace, around which the simulations and frequency analyses are performed. </p><p>The regulators that have been tested are a PID-regulator, a gain scheduled LQ-regulator, a gain scheduled LQ-regulator with reconstructed states, and finally a fix LQ-regulator with reconstructed states. Results from the tests show that the gain scheduling LQ-regulator is the one that yields the best rejection of disturbances, but the corresponding regulator with reconstructed states, which is more realistic, performs nearly as well. The model based regulators are, however, significantly better when it comes to rejecting disturbances than the PID-regulator.</p>

The goal of this Master thesis has on the one hand been to create a simulation environment for robots, where not only the simulations in this work can be performed, but also similar robot simulations, and on the other hand to study regulators that can increase the possibilities of rejecting disturbances on an industrial robot. The robot model used has three degrees of freedom, corresponding to the three main links on ABB:s IRB7600. The simulation environment is created using Matlab, Simulink, and Robotics Toolbox. It is constructed in a general way and can be used for simulations of other robot objects created in Robotics Toolbox. A gain scheduling is added to the LQ-regulator, where the feedback matrix is varied depending on the arm position in the workspace. The gain scheduling is implemented along a reference path in the workspace, around which the simulations and frequency analyses are performed. The regulators that have been tested are a PID-regulator, a gain scheduled LQ-regulator, a gain scheduled LQ-regulator with reconstructed states, and finally a fix LQ-regulator with reconstructed states. Results from the tests show that the gain scheduling LQ-regulator is the one that yields the best rejection of disturbances, but the corresponding regulator with reconstructed states, which is more realistic, performs nearly as well. The model based regulators are, however, significantly better when it comes to rejecting disturbances than the PID-regulator.