PID controller design and tuning in networked control systems

Networked control systems (NCS) are distributed real-time computing and control systems with sensors, actuators and controllers that communicate over a shared medium. The distributed nature of NCS and issues related to the shared communication medium pose significant challenges for control design, as the control system no longer follows the rules of classical control theory. The main problems that are not well covered by the traditional control theory are varying time-delays due to communication and computation, and packet losses. During recent years, the control design of NCS and varying time-delay systems has been extensively researched. This investment has provided us with new results on stability. Often the proposed methods and solutions are far too complex for industrial use, especially if wireless automation applications are considered. The algorithms are computationally heavy, possibly requiring complete information from say, a network of hundreds or thousands of nodes. In the wireless case this is not feasible. The above justifies the use and research of simple controller structures and algorithms for NCS. Despite the growing interest towards more advanced control algorithms, the Proportional-Integral-Derivative (PID) controller still has a dominant status in the industry. Nevertheless, using PID for NCS has not been thoroughly investigated, especially with regard to controller tuning. This thesis proposes several PID tuning methods, which provide robustness against the challenges of NCS, namely varying time-delays (jitter) and packet loss. The doctoral thesis consists of a summary and eight publications that focus on the PID controller design, tuning and experimentation in NCS. The thesis includes a literature review of recent stability and control design results in NCS, a summary of publications and the original publications. The control design methods applied in the publications are also reviewed. In the thesis, several new methods for PID tuning in NCS are proposed. To make the methods usable, a PID tuning tool that implements one of the tuning methods is also developed. In order to verify the results of control design with real processes, the thesis suggests using the MoCoNet platform developed at the Helsinki University of Technology, Finland. The platform provides the tools for remote laboratory experiments in NCS settings. The results of the thesis indicate that the PID controller is well suited for NCS provided that the properties of the integrated communication and control system are taken into account in the tuning phase

SYSTEM IDENTIFICATION AND MODEL PREDICTIVE CONTROL FOR INTERACTING SERIES PROCESS WITH NONLINEAR DYNAMICS

This thesis discusses the empirical modeling using system identification technique and the implementation of a linear model predictive control with focus on interacting series processes. In general, a structure involving a series of systems occurs often in process plants that include processing sequences such as feed heat exchanger, chemical reactor, product cooling, and product separation. The study is carried out by experimental works using the gaseous pilot plant as the process. The gaseous pilot plant exhibits the typical dynamic of an interacting series process, where the strong interaction between upstream and downstream properties occurs in both ways. The subspace system identification method is used to estimate the linear model parameters. The developed model is designed to be robust against plant nonlinearities. The plant dynamics is first derived from mass and momentum balances of an ideal gas. To provide good estimations, two kinds of input signals are considered, and three methods are taken into account to determine the model order. Two model structures are examined. The model validation is conducted in open-loop and in closed-loop control system. Real-time implementation of a linear model predictive control is also studied. Rapid prototyping of such controller is developed using the available equipments and software tools. The study includes the tuning of the controller in a heuristic way and the strategy to combine two kinds of control algorithm in the control system. A simple set of guidelines for tuning the model predictive controller is proposed. Several important issues in the identification process and real-time implementation of model predictive control algorithm are also discussed. The proposed method has been successfully demonstrated on a pilot plant and a number of key results obtained in the development process are presented