Probing Control : Analysis and Design with Application to Fed-Batch Bioreactors

In most control problems the objective is to control the output at a desired value in spite of disturbances. In some cases, the best setpoint is not known a priori and it should be found online to optimize the process performance. This thesis examines a probing strategy that can be applied for this class of problems. The focus is on the application of the technique to the control of feed supply in fed-batch fermentations of the bacterium Escherichia coli. The thesis is divided into three parts. In the first part, the convergence properties of the probing algorithm are examined. The analysis is limited to processes modeled by a linear time-invariant dynamic in series with a static nonlinearity. Stability and performance analysis taking into account the process dynamic is performed. Tuning guidelines that help the user for the design are also derived. The second part presents a novel cultivation technique based on the probing approach. The fermentation technique combines the advantages of probing control and temperature-limited fed-batch technique. The feeding strategy is well adapted for prolonged operation at the maximum oxygen transfer capacity of the reactor. The efficiency of the method is demonstrated by simulations and experimental results. The strategy leads to a high biomass and it limits the degradation of the recombinant protein activity in the late production phase. In the third part, the probing feeding strategy is evaluated in industrial-scale bioreactors. Based on experimental results the influence of scale and complex medium is discussed. It is shown that the flexibility and robustness of the technique makes it a useful tool for process development

Modélisation dynamique et commande optimale d'un système de réfrigération à base d'éjecteur

Recently, the ejector-based refrigeration system (ERS) has been widely used in the cooling industry as an appropriate alternative to the compressor-based cooling systems. However, the advantages of ERS such as the reliable operation and low operation and maintenance costs are overshadowed by its low efficiency and design complexity. In this context, this thesis presents the efforts to develop a control model enabling the ERS to operate in its optimal operational conditions. The extensive experimental studies of ERS revealed that at a fixed condenser inlet condition, there exists an optimal primary stream mass flow rate (generating pressure) that simultaneously maximizes the compression ratio (Cr) and exergy efficiency and minimizes the evaporating pressure. Then, the steady state models of the heat exchangers were developed and used to investigate the influence of the increase in generating pressure on the coefficient of performance (COP) of the system and it showed that increasing the generating pressure reduces the COP, linearly. In order to predict the choking regime of the ejector and explain the reasons of observed physical phenomenon, the 1D model of a fixed geometry ejector installed within an R245fa ERS was developed. The developed model demonstrated that the ejector operates in the subcritical mode when the generating pressure is below the Cr optimum point, while it operates in critical mode at or above the optimum generating pressure. Next, a dynamic model of the ERS was built to evaluate the ERS transient response to an increase in the primary stream mass flow rate. Since the ERS dynamics is mainly dominated by the thermal dynamics of the heat exchangers, the dynamic models of the heat exchangers were developed using the moving boundary approach and connected to the developed models of the ejector and steady state models of the pump and expansion valve to build a single dynamic model of the system. The built dynamic model of an ERS was used to estimate the time response of the system in the absence of accurate experimental data of the system’s dynamics. Finally, a control model was designed to drive an ERS towards its optimal operation condition. A self-optimizing, model-free control strategy known as Extremum seeking control (ESC) was adopted to minimize evaporating pressure in a fixed condenser thermal fluid inlet condition. The innovative ESC model named batch phasor ESC (BPESC) was proposed based on estimating the gradient by evaluating the phasor of the output, in batch time. The simulation results indicated that the designed BPESC model can seek and find the optimum evaporating pressure with good performance in terms of predicting the steady state optimal values and the convergence rates.Récemment, le système de réfrigération à éjecteur (SRE) a été largement utilisé dans l'industrie du refroidissement en tant que solution de remplacement appropriée aux systèmes de refroidissement à compresseur. Cependant, les avantages du SRE, tels que le fonctionnement fiable et les faibles couts d'exploitation et de maintenance, sont éclipsés par son faible rendement et sa complexité de conception. Dans ce contexte, ce projet de recherche de doctorat a détaillé les efforts déployés pour développer une stratégie de commande permettant au système de fonctionner dans ses conditions opérationnelles optimales. Les études expérimentales approfondies du SRE ont révélé que, dans une condition d'entrée de condensateur constante, il existe un débit massique optimal du flux primaire (générant une pression) qui maximise simultanément le taux de compression (Cr) et l'efficacité exergétique, et minimise la pression d’évaporation. Ensuite, les modèles à l’état d’équilibre des échangeurs de chaleur ont été développés et utilisés pour étudier l’influence de l’augmentation de la pression générée sur le coefficient de performance (COP) du système et il en ressort que l'augmentation de la pression génératrice réduit le COP de manière linéaire. Afin de prédire le régime d'étouffement de l'éjecteur et d'expliquer les raisons du phénomène physique observé, le modèle 1D d'un éjecteur à géométrie fixe installé dans un système SRE R245fa a été développé. Le modèle développé a démontré que l'éjecteur fonctionne en mode sous-critique lorsque la pression génératrice est inférieure au point optimal de Cr, alors qu'il fonctionne en mode critique à une pression égale ou supérieure à la pression génératrice optimale. Ensuite, un modèle dynamique du SRE a été développé pour étudier la réponse transitoire du SRE lors d’une augmentation du débit massique du flux primaire. Puisque la dynamique du SRE est principalement dominée par la dynamique thermique des échangeurs de chaleur, les modèles dynamiques des échangeurs de chaleur ont été développés à l'aide de l'approche des limites mobiles et connectés aux modèles développés de l'éjecteur et des modèles à l'état stationnaire de la pompe et de la vanne un seul modèle dynamique du système. En l’absence de données expérimentales précises sur la dynamique d’un système SRE, le modèle dynamique développé du SRE a été simulé numériquement pour étudier sa réponse temporelle. Enfin, une stratégie de commande extrêmale (ESC) a été élaboré pour régler automatiquement le SRE à ses conditions de fonctionnement optimales, c’est-à-dire pour trouver la vitesse de la pompe qui minimise la pression dans des conditions d'entrée de condenseur fixes. Afin de proposer une ESC implémentable en temps discret sur une installation réelle sujette à un bruit de mesure important et un traitement hors-ligne par trame, une nouvelle commande extrémale basée sur une approche par phaseur avec une procédure de traitement de signal par trame (BPESC) a été développée et simulée avec le modèle numérique. Les résultats de la simulation ont indiqué que le modèle BPESC peut trouver la vitesse optimale de la pompe avec de bonnes performances en termes de précision et de vitesse de convergence

Process Control of Crushing Circuits

Kivenmurskaus on keskeinen osaprosessi kiviaineksen, metallien ja sementin tuotannossa. Murskaamalla tuotetut raaka-aineet muodostavat nykyaikaisen infrastruktuurimme perustan. Huolimatta merkittävästä roolistaan, kivenmurskaus on yksi harvoista teollisista prosesseista, jonka prosessinohjaus toteutetaan edelleen kokemusperäisesti, ilman luotettavaa mittaustietoa suoritettujen ohjaustoimien vaikutuksista. Nykykäytäntö altistaa murskausprosessit prosessivaihteluille ja –häiriöille, ja johtaa viime kädessä tehottomaan tuotantoon ja kapasiteetin vajaakäyttöön. Pääsyinä nykytilaan voidaan pitää murskausprosessien puutteellista anturointia ja tutkimustiedon puutetta korkeamman automaatioasteen tuomista hyödyistä. Tässä väitöskirjassa pyrittiin ratkaisemaan edellä mainittu ongelma automaattisen prosessinohjauksen avulla. Päätavoitteena oli kehittää säätömenetelmät murskauspiirin suorituskyvyn saattamiseksi lähelle parasta saavutettavissa olevaa tasoa. Tämä tutkimus perustuu mallipohjaiseen säädönsuunnittelumenetelmään. Systemaattinen suunnitteluprosessi alkoi säätötavoitteiden määrittelystä ja dynaamisten prosessimallien kehittämisestä. Kehitettyjen prosessimallien avulla luotiin säätötavoitteet täyttävä säätöstrategia ja viritettiin strategian vaatimat prosessisäätimet. Lopuksi simulointimallien avulla kehitetty ja testattu säätöstrategia implementoitiin osaksi laitoksen automaatiojärjestelmää ja sen suorituskyky arvioitiin täyden mittakaavan prosessikokeiden avulla. Tämä väitöskirja on osoittanut, että murskauspiirin tehokas ja tarkoituksenmukainen toiminta vaatii eri kahden säätötavan toteuttamista: massataseen säätö ja hienonnusmäärän säätö. Massatasesäädön tavoitteena on varmistaa 100 % käyttöaste murskauspiirin pullonkaulassa. Hienonnusmäärän säätö varmistaa halutun murskaimen tuotemateriaalin partikkelikokojakauman. Kehitetyt hienonnusmäärän säätömenetelmät perustuvat itseoptimoituvaan säätötapaan, joka mahdollistaa likimain optimaalisen suorituskyvyn käyttämällä säätimessä vakio-asetusarvoa. Kun tämä asetusarvo valitaan optimaalisesti, mahdollistaa esitelty ohjausstrategia parhaan saavutettavissa olevan murskauspiirin suorituskyvyn. Työn merkittävä tunnuspiirre on erityisen kattava empiria. Kehitetyt menetelmät testattiin kattavasti useissa erilaisissa tuotantoskenaarioissa ja prosessikonfiguraatioissa. Täyden mittakaavan prosessikokeiden tulokset vastasivat hyvin lähelle simulaatioilla saatuja tuloksia. Tämä väitöskirja on merkittävä edistysaskel murskausprosessien säädössä. Työn tuloksena kehitetyt mittaus- ja säätötavat mahdollistavat tehokkaamman ja tarkoituksenmukaisemman raaka-ainetuotannon. Työn tuloksilla voidaan olettaa olevan merkittävä vaikutus siihen, miten ja millä tavoin murskausprosesseja ohjataan tulevaisuudessa. Työssä kehitetyn murskauspiirin automaattisen säätöstrategian voidaan olettaa toimivan perustana tulevaisuuden murskausprosessien prosessiautomaatio-toteutuksille.Crushing is an essential high-volume processing stage in the production of aggregates, metals and cement. Crushed products form the basis of our modern infrastructure and therefore play a major role in the economic growth and welfare. Despite its significant role in society, crushing is one of the few remaining industrial processes that is currently being operated using belief-based manual control without the possibility to quantify the consequences of performed control actions. This practice makes crushing processes vulnerable to process variation and exposes them to inefficient production and capacity underutilization. The aim of this thesis is to address this deficiency by bridging the gap between theoretically possible and realized crushing circuit performance, by means of automatic process control. This thesis covers the entire model-based control system design procedure – from the formulation of control objectives and development of dynamic process model(s), through the development of control strategy, to the control system implementation and performance evaluation – for crushing circuits. Research has led to significant advances within crushing process measurement and control. Developed methods have been rigorously tested in various production scenarios and circuit flowsheets, using both dynamic simulations and full-scale experiments. Experiments revealed expected behavior with a significant increase in performance. The results have shown that the efficient operation of a crushing circuit requires addressing two control tasks: mass balance control and size reduction control. The objective of mass balance control is to guarantee 100 percent circuit utilization, whereas size reduction control ensures the desired degree of size reduction. The ideal degree of size reduction is determined empirically to maximize the value of the used KPI. The developed control strategy delivers near-maximum circuit performance. This thesis represents a major leap forward in the area of process control of crushing circuits. It has opened entirely new possibilities by making it possible to quantify the instantaneous performance of crushing circuits and by introducing the ability to ensure consistent and efficient long-term production. These major breakthroughs can have a significant impact on how crushing plants will be operated in the future. Developed standard control practice can be expected to serve as a basis for future control system implementations of industrial crushing circuits

Robust Hybrid Systems for Control, Learning, and Optimization in Networked Dynamical Systems

The deployment of advanced real-time control and optimization strategies in socially-integratedengineering systems could significantly improve our quality of life whilecreating jobs and economic opportunity. However, in cyber-physical systems such assmart grids, transportation networks, healthcare, and robotic systems, there still existseveral challenges that prevent the implementation of intelligent control strategies.These challenges include the existence of limited communication networks, dynamicand stochastic environments, multiple decision makers interacting with the system,and complex hybrid dynamics emerging from the feedback interconnection of physicalprocesses and computational devices.In this dissertation, we study the problem of designing robust control and optimizationalgorithms for cyber-physical systems using the framework of hybrid dynamicalsystems. We propose different theoretical frameworks for the design and analysis offeedback mechanisms that optimize the performance of dynamical systems without requiringan explicit characterization of their mathematical model, i.e., in a model-freeway. The closed-loop system that emerges of the interconnection of the plant with thefeedback mechanism describes, in general, a set-valued hybrid dynamical system. Thesetypes of systems combine continuous-time and discrete-time dynamics, and they usuallylack the uniqueness of solutions property. The framework of set-valued hybriddynamical systems allows us to study many complex dynamical systems that emerge indifferent engineering applications, such as networked multi-agent systems with switching graphs, non-smooth mechanical systems, dynamic pricing mechanisms in transportationsystems, autonomous robots with logic-based controllers, etc. We proposea step-by-step approach to the design of different types of discrete-time, continuous-time,hybrid, and stochastic controllers for different types of applications, extendingand generalizing different results in the literature in the area of extremum seeking control,sampled-data extremization, robust synchronization, and stochastic learning innetworked systems. Our theoretical results are illustrated via different simulations andnumerical examples

Deep Learning-Based Machinery Fault Diagnostics

This book offers a compilation for experts, scholars, and researchers to present the most recent advancements, from theoretical methods to the applications of sophisticated fault diagnosis techniques. The deep learning methods for analyzing and testing complex mechanical systems are of particular interest. Special attention is given to the representation and analysis of system information, operating condition monitoring, the establishment of technical standards, and scientific support of machinery fault diagnosis

Nonlinear hydrodynamic modelling of wave energy converters under controlled conditions

One of the major challenges facing modern industrialized countries is the provision of energy: traditional sources, mainly based on fossil fuels, are not only growing scarcer and more expensive, but are also irremediably damaging the environment. Renewable and sustainable energy sources are attractive alternatives that can substantially diversify the energy mix, cut down pollution, and reduce the human footprint on the environment. Ocean energy, including energy generated from the motion of wave, is a tremendous untapped energy resource that could make a decisive contribution to the future supply of clean energy. However, numerous obstacles must be overcome for ocean energy to reach economic viability and compete with other energy sources. Energy can be generated from ocean waves by wave energy converters (WECs). The amount of energy extracted from ocean waves, and therefore the profitability of the extraction, can be increased by optimizing the geometry and the control strategy of the wave energy converter, both of which require mathematical hydrodynamic models that are able to correctly describe the WEC- uid interaction. On the one hand, the accuracy and representativeness of such models have a major in uence on the effectiveness of the WEC design. On the other hand, the computational time required by a model limits its applicability, since many iterations or real-time calculations may be required. Critically, computational time and accuracy are often mutually contrasting features of a mathematical model, so an appropriate compromise should be defined in accordance with the purpose of the model, the device type, and the operational conditions. Linear models, often chosen due to their computational convenience, are likely to be imprecise when a control strategy is implemented in a WEC: under controlled conditions, the motion of the device is exaggerated in order to maximize power absorption, which invalidates the assumption of linearity. The inclusion of nonlinearities in a model is likely to improve the model's accuracy, but increases the computational burden. Therefore, the objective is to define a parsimonious model, in which only relevant nonlinearities are modelled in order to obtain an appropriate compromise between accuracy and computational time. In addition to presenting a wider discussion of nonlinear hydrodynamic modelling for WECs, this thesis contributes the development of a computationally efficient nonlinear hydrodynamic model for axisymmetric WEC devices, from one to six degrees of freedom, based on a novel approach to the nonlinear computation of static and dynamic Froude-Krylov forces