Trucks are responsible for the major part of inland freight and so, they are a backbone of the modern economy but they are also a large consumer of energy. In this context, a dominating vehicle is a truck with heavy load on a long trip. The aim with look-ahead control is to reduce the energy consumption of heavy vehicles by utilizing information about future conditions focusing on the road topography ahead of the vehicle. The possible gains with look-ahead control are evaluated by performing experiments with a truck on highway. A real-time control system based on receding horizon control (RHC) is set up where the optimization problem is solved repeatedly on-line for a certain horizon ahead of the vehicle. The experimental results show that significant reductions of the fuel consumption are achieved, and that the controller structure, where the algorithm calculates set points fed to lower level controllers, has satisfactory robustness to perform well on-board in a real environment. Moreover, the controller behavior has the preferred property of being intuitive, and the behavior is perceived as comfortable and natural by participating drivers and passengers. A well-behaved and efficient algorithm is developed, based on dynamic programing, for the mixed-integer nonlinear minimum-fuel problem. A modeling framework is formulated where special attention is given to properly include gear shifting with physical models. Fuel equivalents are used to reformulate the problem into a tractable form and to construct a residual cost enabling the use of a shorter horizon ahead of the vehicle. Analysis of errors due to discretization of the continuous dynamics and due to interpolation shows that an energy formulation is beneficial for reducing both error sources. The result is an algorithm giving accurate solutions with low computational effort for use in an on-board controller for a fuel-optimal velocity profile and gear selection. The prevailing approach for the look-ahead problem is RHC where main topics are the approximation of the residual cost and the choice of the horizon length. These two topics are given a thorough investigation independent of the method of solving the optimal control problem in each time step. The basis for the fuel equivalents and the residual cost is formed from physical intuition as well as mathematical interpretations in terms of the Lagrange multipliers used in optimization theory. Measures for suboptimality are introduced that enables choosing horizon length with the appropriate compromise between fuel consumption and trip time. Control of a hybrid electric powertrain is put in the framework together with control of velocity and gear. For an efficient solution of the minimum-fuel problem in this case, more fuel equivalence factors and an energy formulation are employed. An application is demonstrated in a design study where it is shown how the optimal trade-off between size and capacity of the electrical system depends on road characteristics, and also that a modestly sized electrical system achieves most of the gain. The contributions develop algorithms, create associated design tools, and carry out experiments. Altogether, a feasible framework is achieved that pave the way for on-board fuel-optimal look-ahead control.

Predictive control relies on predictions of the future behaviour of the system to be controlled. These predictions are calculated from a model of this system, thus making the model the cornerstone of the predictive controller. Furthermore predictive control is the only advanced control methodology that has managed to become widely used in the industry. The necessity of good models in the predictive control context can thus be motivated both from the very nature of predictive control and from its widespread use in industry. This thesis is concerned with examining the use of multiple models in the predictive controller. In order to do this the standard predictive control formulation has been extended to incorporate the use of multiple models. The most general case of this new formulation allows the use of an individual model for each prediction horizon. The models are estimated using measurements of the input and output sequences from the true system. When using this data to find a good model of the system it is important to remember the intended purpose of the model. In this case the model is going to be used in a predictive controller and the most important feature of the models is to deliver good k-step ahead predictions. The identification algorithms used to estimate the models thus strives for estimating models good at calculating these predictions. Finally this thesis presents some complete simulations of these ideas showing the potential of using multiple models in the predictive control framework.

Battery energy management plays a crucial role in fuel economy improvement of charge-sustaining parallel hybrid electric vehicles. Currently available control strategies consider battery state of charge (SOC) and driver’s request through the pedal input in decision-making. This method does not achieve an optimal performance for saving fuel or maintaining appropriate SOC level, especially during the operation in extreme driving conditions or hilly terrain. The objective of this thesis is to develop a control algorithm using forthcoming traffic condition and road elevation, which could be fed from navigation systems. This would enable the controller to predict potential of regenerative charging to capture cost-free energy and intentionally depleting battery energy to assist an engine at high power demand. The starting point for this research is the modelling of a small sport-utility vehicle by the analysis of the vehicles currently available in the market. The result of the analysis is used in order to establish a generic mild hybrid powertrain model, which is subsequently examined to compare the performance of controllers. A baseline is established with a conventional powertrain equipped with a spark ignition direct injection engine and a continuously variable transmission. Hybridisation of this vehicle with an integrated starter alternator and a traditional rule-based control strategy is presented. Parameter optimisation in four standard driving cycles is explained, followed by a detailed energy flow analysis. An additional potential improvement is presented by dynamic programming (DP), which shows a benefit of a predictive control. Based on these results, a predictive control algorithm using fuzzy logic is introduced. The main tools of the controller design are the DP, adaptive-network-based fuzzy inference system with subtractive clustering and design of experiment. Using a quasi-static backward simulation model, the performance of the controller is compared with the result from the instantaneous control and the DP. The focus is fuel saving and SOC control at the end of journeys, especially in aggressive driving conditions and a hilly road. The controller shows a good potential to improve fuel economy and tight SOC control in long journey and hilly terrain. Fuel economy improvement and SOC correction are close to the optimal solution by the DP, especially in long trips on steep road where there is a large gap between the baseline controller and the DP. However, there is little benefit in short trips and flat road. It is caused by the low improvement margin of the mild hybrid powertrain and the limited future journey information. To provide a further step to implementation, a software-in-the-loop simulation model is developed. A fully dynamic model of the powertrain and the control algorithm are implemented in AMESim-Simulink co-simulation environment. This shows small deterioration of the control performance by driver’s pedal action, powertrain dynamics and limited computational precision on the controller performance.

The automotive industry is required to deal with increasingly stringent legislationfor greenhouse gases. Hybrid Electric Vehicles, HEV, are gaining acceptance as thefuture path of lower emissions and fuel consumption. The increased complexityof multiple prime movers demand more advanced control systems, where futuredriving conditions also becomes interesting. For a plug-in Hybrid Electric Vehicle,PIHEV, it is important to utilize the comparatively inexpensive electric energybefore the driving cycle is complete, this for minimize the cost of the driving cycle,since the battery in a PIHEV can be charged from the grid. A strategy with lengthinformation of the driving cycle from a global positioning system, GPS, couldreduce the cost of driving. This by starting to blend the electric energy with fuelearlier, a strategy called blended driving accomplish this by distribute the electricenergy, that is charged externally, with fuel over the driving cycle, and also ensurethat the battery’s minimum level reaches before the driving cycle is finished. Astrategy called Charge Depleting Charge Sustaining, CDCS, does not need lengthinformation. This strategy first depletes the battery to a minimum State of Charge,SOC, and after this engages the engine to maintain the SOC at this level. In thisthesis, a variable SOC reference is developed, which is dependent on knowledgeabout the cycle’s length and the current length the vehicle has driven in the cycle.With assistance of a variable SOC reference, is a blended strategy realized. Thisis used to minimize the cost of a driving cycle. A comparison between the blendedstrategy and the CDCS strategy was done, where the CDCS strategy uses a fixedSOC reference. During simulation is the usage of fuel minimized; and the blendedstrategy decreases the cost of the driving missions compared to the CDCS strategy.To solve the energy management problem is a model predictive control used. Thedesigned control system follows the driving cycles, is charge sustaining and solvesthe energy management problem during simulation. The system also handlesmoderate model errors. / Fordonsindustrin måste hantera allt strängare lagkrav mot utsläpp av emissioneroch växthusgaser. Hybridfordon har börjat betraktas som den framtida vägenför att ytterligare minska utsläpp och användning av fossila bränslen. Den ökadekomplexiteten från flera olika motorer kräver mera avancerade styrsystem. Begränsningarfrån motorernas energikällor gör att framtida förhållanden är viktigaatt estimera. För plug-in hybridfordon, PIHEV, är det viktigt att använda denvvijämförelsevis billiga elektriska energin innan fordonet har nått fram till slutdestinationen.Batteriets nuvarande energimängd mäts i dess State of Charge, SOC.Genom att utnyttja information om hur långt det är till slutdestinationen från ettGlobal Positioning System, GPS, blandar styrsystemet den elektriska energin medbränsle från början, detta kallas för blandad körning. En strategi som inte hartillgång till hur långt fordonet ska köras kallas Charge Depleting Charge Sustaining,CDCS. Denna strategi använder först energin från batteriet, för att sedanbörja använda förbränningsmotorn när SOC:s miniminivå har nåtts. Strategin attanvända GPS informationen är jämförd med en strategi som inte har tillgång tillinformation om körcykelns längd. Blandad körning använder en variabel SOC referens,till skillnad från CDCS strategin som använder sig av en konstant referenspå SOC:s miniminivå. Den variabla SOC referensen beror på hur långt fordonethar kört av den totala körsträckan, med hjälp av denna realiseras en blandad körning.Från simuleringarna visade det sig att blandad körning gav minskad kostnadför de simulerade körcyklerna jämfört med en CDCS strategi. En modellbaseradprediktionsreglering används för att lösa energifördelningsproblemet. Styrsystemetföljer körcykler och löser energifördelningsproblemet för de olika drivkällorna undersimuleringarna. Styrsystemet hanterar även måttliga modellfel.

Friction stir welding has become a popular forging technique used in many applications. The Swedish Nuclear Fuel and Waste Management Company (SKB) evaluates this method to seal the 5 cm thick copper canisters that will contain the spent nuclear fuel. To produce repetitive, high quality welds, the process must be controlled, and today a cascade controller is used to keep the desired stir zone temperature. In this thesis, the control system is extended to also include a plunge depth controller. Two different approaches are evaluated; the first attempt is a decentralized solution where the cascaded temperature controller is kept, and the second approach uses a non-linear model predictive controller for both depth and temperature. Suitable models have been derived and used to design the controllers; a simpler model for the decentralized control and a more extensive, full model used in the non-linear model predictive controller that relates all the important process variables. The two controller designs are compared according to important performance measures, and the achieved increase in performance with the more complex non-linear model predictive controller is evaluated. The non-linear model predictive controller has not been implemented on the real process. Hence, simulations of the closed loop systems using the full model have been used to compare and evaluate the control strategies. The decentralized controller has been implemented on the real system. Two welds have been made using plunge depth control with excellent experimental results, confirming that the decentralized controller design proposed in this thesis can be successfully used. Even though the controller manages to regulate the plunge depth with satisfying performance, simulations indicate that the non-linear model predictive controller achieves even better closed loop performance. This controller manages to compensate for the cross-connections between the process variables, and the resulting closed loop system is almost decoupled. Further research will reveal which control design that will finally be used. / ''Friction stir welding'' har blivit en populär svetsmetod inom många olika tillämpningar. På Svensk Kärnbränslehantering AB (SKB) undersöks möjligheten att använda metoden för att försegla de 5 cm tjocka kopparkapslarna som kommer innehålla det använda kärnbränslet. För att kunna producera repeterbara svetsar utav hög kvalité krävs det att processen regleras. Idag löses detta med en temperaturregulator som reglerar svetszonens temperatur. I detta examensarbete utökas styrsystemet med en regulator för svetsdjupet. Två olika lösningar har utvärderats; först en decentraliserad lösning där temperatur-regulatorn behålls och sedan en lösning med en olinjär modellprediktiv reglering (MPC) som reglerar både djup och temperatur. Passande modeller har tagits fram och har använts för att designa regulatorerna; en enklare modell för den decentraliserade regulatorn och en utökad, komplett modell som används i den olinjära MPC:n och som beskriver alla viktiga variabler i processen. Viktiga prestandamått har jämförts för de båda regulatorstrukturerna och även prestandaökningen med den olinjära MPC:n har utvärderats. Då denna regulator inte har implementerats på den verkliga processen har simuleringar av den kompletta modellen använts för att jämföra och utvärdera regulatorstrukturerna. Den decentraliserade regulatorn har implementerats och testats på processen. Två svetsar har gjorts och de har givit utmärkta resultat, vilket visar att regulatorstrukturen som presenteras i rapporten fungerar bra för reglering av svetsdjupet. Trots att den implementerade regulatorn klarar av att reglera svetsdjupet med godkänt resultat, så visar simuleringar att den olinjära MPC:n ger ännu bättre reglerprestanda. Denna regulator kompenserar för korskopplingar i systemet och resulterar i ett slutet system som är nästan helt frikopplat. Ytterligare forskning kommer avgöra vilken av strategierna som kommer att användas i slutprodukten.

In the pulp industry, digesters are used to disolve lignin in wood chips. The concentration of lignin is measured and is called the Kappa number. In this thesis, the question of whether an online Kappa sensor, taking samples from the mid-phase of the digester, is useful or not is analyzed. For the samples to be useful, there has to be a relationship between the measured Kappa at the mid- phase and the measured Kappa in the blowpipe at the bottom of the digester. An ARX model of the lower part of the digester has been estimated. Despite a lot of noise, it seems that it might be possible to use the mid-phase samples and for this model predict the blowpipe flow Kappa signal. It is concluded that the mid-phase samples should be further improved to be more useful. The mid-phase samples have also been used in another ARX model, this time to LP-filter these values without time loss. Another important issue has been to examine if the existing controller is good or not. In order to be able to compare it with other controllers, a simulator has been created in MATLAB - Simulink. Test results from this simulator show that the existing controller's use of the mid-phase Kappa samples improves its performance. For a simplified digester model, the existing controller has also been compared with an MPC controller. This test shows that the MPC controller is significantly better. Hence, the conclusion in this thesis is that it might be interesting to study MPC further using a more advanced model.

<p>Predictive control relies on predictions of the future behaviour of the system to be controlled. These predictions are calculated from a model of this system, thus making the model the cornerstone of the predictive controller. Furthermore predictive control is the only advanced control methodology that has managed to become widely used in the industry. The necessity of good models in the predictive control context can thus be motivated both from the very nature of predictive control and from its widespread use in industry. </p><p>This thesis is concerned with examining the use of multiple models in the predictive controller. In order to do this the standard predictive control formulation has been extended to incorporate the use of multiple models. The most general case of this new formulation allows the use of an individual model for each prediction horizon. </p><p>The models are estimated using measurements of the input and output sequences from the true system. When using this data to find a good model of the system it is important to remember the intended purpose of the model. In this case the model is going to be used in a predictive controller and the most important feature of the models is to deliver good k-step ahead predictions. The identification algorithms used to estimate the models thus strives for estimating models good at calculating these predictions. </p><p>Finally this thesis presents some complete simulations of these ideas showing the potential of using multiple models in the predictive control framework.</p>

Solid oxide fuel cells are a promising option for distributed stationary power generation that offers efficiencies ranging from 50% in stand-alone applications to greater than 80% in cogeneration. To advance SOFC technology for widespread market penetration, the SOFC should demonstrate improved cell lifetime and load-following capability. This work seeks to improve lifetime through dynamic analysis of critical lifetime variables and advanced control algorithms that permit load-following while remaining in a safe operating zone based on stress analysis. Control algorithms typically have addressed SOFC lifetime operability objectives using unconstrained, single-input-single-output control algorithms that minimize thermal transients. Existing SOFC controls research has not considered maximum radial thermal gradients or limits on absolute temperatures in the SOFC. In particular, as stress analysis demonstrates, the minimum cell temperature is the primary thermal stress driver in tubular SOFCs. This dissertation presents a dynamic, quasi-two-dimensional model for a high-temperature tubular SOFC combined with ejector and prereformer models. The model captures dynamics of critical thermal stress drivers and is used as the physical plant for closed-loop control simulations. A constrained, MIMO model predictive control algorithm is developed and applied to control the SOFC. Closed-loop control simulation results demonstrate effective load-following, constraint satisfaction for critical lifetime variables, and disturbance rejection. Nonlinear programming is applied to find the optimal SOFC size and steady-state operating conditions to minimize total system costs. / text

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Submerged Arc Welding (SAW) for fillet joints is one of the major applications in the shipbuilding industry. Due to the requirement for the weld size, a sufficient amount of metal must be deposited. In conventional SAW process, the heat input is proportional to the amount of metal melted and is thus determined by the required weld size. To meet this requirement, an excessive amount of heat is applied causing large distortions on the welded structures whose follow-up straightening is highly costly. In order to reduce the needed heat input, Double-Electrode (DE) technology has been practiced creating the Double-Electrode SAW (DE-SAW) method for fillet joints. The reduction in the heat input, however, also reduces the penetration capability of the process, and the ability to produce required weld beads has to be compromised. To eliminate the unwanted side effect after using DE-SAW, a root opening between the panel and the tee has been proposed in this dissertation to form a modified fillet joint design. Experimental results verified that the use of root opening improves the ability of DE-SAW to produce the required weld beads at reduced heat input and penetration capability. Unfortunately, the use of root opening decreases the stability of the process significantly. To control the heat input at a minimally necessary level that guarantees the weld size and meanwhile the process stability, a feedback is needed to control the currents at their desired levels. To this end, the fillet DE-SAW process is modeled and a multivariable predictive control algorithm is developed based on the process model. Major parameters including the root opening size, travel speed and heat input level have been selected/optimized/minimized to produce required fillet weld beads with a minimized heat input based on qualitative and quantitative analyses. At the end of this dissertation, a series of experiments validated the feasibility and repeatability of the predictive control based DE-SAW process for fillet joints with root opening.