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Adaptive model-predictive control and its applications in paper-making processes Lu, Qiugang


Model-based controllers such as model-predictive control (MPC) have become dominated control strategies for various industrial applications including sheet and film processes such as the machine-directional (MD) and cross-directional (CD) processes of paper machines. However, many industrial processes may have varying dynamics over time and consequently model-based controllers may experience significant performance loss under such circumstances, due to the presence of model-plant mismatch (MPM). We propose an adaptive control scheme for sheet and film processes, consisting of performance assessment, MPM detection, optimal input design, closed-loop identification and controller adaptive tuning. In this work, four problems are addressed for the above adaptive control strategy. First, we extend conventional performance assessment techniques based on minimum-variance control (MVC) to the CD process, accounting for both spatial and temporal performance limitations. A computationally efficient algorithm is provided for large-scale CD processes. Second, we propose a novel closed-loop identification algorithm for the MD process and then extend it to the CD process. This identification algorithm can give consistent parameter estimates asymptotically even when true noise model structure is not known. Third, we propose a novel MPM detection method for MD processes and then further extend it to the CD process. This approach is based on routine closed-loop identifications with moving windows and process model classifications. A one-class support vector machine (SVM) is used to characterize normal process models from training data and detect the MPM by predicting the classification of models from test data. Fourth, an optimal closed-loop input design is proposed for the CD process based on noncausal modeling to address the complexity from high-dimensional inputs and outputs. Causal-equivalent models can be obtained for the CD noncausal models and thus closed-loop optimal input design can be performed based on the causal-equivalent models. The effectiveness of the proposed algorithms are verified by industrial examples from paper machines. It is shown that the developed adaptive controllers can automatically tune controller parameters to account for process dynamic changes, without the interventions from users or recommissioning the process. Therefore, the proposed methodology can greatly reduce the costs on the controller maintenance in the process industry.

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Attribution-NonCommercial-NoDerivatives 4.0 International