DESIGN OF OPTIMAL PROCEDURAL CONTROLLERS FOR CHEMICAL PROCESSES MODELLED AS STOCHASTIC DISCRETE EVENT SYSTEMS

This thesis presents a formal method for the the design of optimal and provably correct procedural controllers for chemical processes modelled as Stochastic Discrete Event Systems (SDESs). The thesis extends previous work on Procedural Control Theory (PCT) [1], which used formal techniques for the design of automation Discrete Event Systems (DESs). Many dynamic processes for example, batch operations and the start-up and shut down of continuous plants, can be modelled as DESs. Controllers for these systems are typically of the sequential type. Most prior work on characterizing the behaviour of DESs has been restricted to deterministic systems. However, DESs consisting of concurrent interacting processes present a broad spectrum of uncertainty such as uncertainty in the occurrence of events. The formalism of weighted probabilistic Finite State Machine (wp-FSM) is introduced for modelling SDESs and pre-de ned failure models are embedded in wp-FSM to describe and control the abnormal behaviour of systems. The thesis presents e cient algorithms and procedures for synthesising optimal procedural controllers for such SDESs. The synthesised optimal controllers for such stochastic systems will take into consideration probabilities of events occurrence, operation costs and failure costs of events in making optimal choices in the design of control sequences. The controllers will force the system from an initial state to one or more goal states with an optimal expected cost and when feasible drive the system from any state reached after a failure to goal states. On the practical side, recognising the importance of the needs of the target end user, the design of a suitable software implementation is completed. The potential of both the approach and the supporting software are demonstrated by two industry case studies. Furthermore, the simulation environment gPROMS was used to test whether the operating speci cations thus designed were met in a combined discrete/continuous environment

CONFIG: Integrated engineering of systems and their operation

This article discusses CONFIG 3, a prototype software tool that supports integrated conceptual design evaluation from early in the product life cycle, by supporting isolated or integrated modeling, simulation, and analysis of the function, structure, behavior, failures and operations of system designs. Integration and reuse of models is supported in an object-oriented environment providing capabilities for graph analysis and discrete event simulation. CONFIG supports integration among diverse modeling approaches (component view, configuration or flow path view, and procedure view) and diverse simulation and analysis approaches. CONFIG is designed to support integrated engineering in diverse design domains, including mechanical and electro-mechanical systems, distributed computer systems, and chemical processing and transport systems

State Estimation of Timed Discrete Event Systems and Its Applications

Many industrial control systems can be described as discrete event systems (DES), whose state space is a discrete set where event occurrences cause transitions from one state to another. Timing introduces an additional dimension to DES modeling and control. This dissertation provides two models of timed DES endowed with a single clock, namely timed finite automata (TFA) and generalized timed finite automata (GTFA). In addition, a timing function is defined to associate each transition with a time interval specifying at which clock values it may occur. While the clock of a TFA is reset to zero after each event occurs and the time semantics constrain the dwell time at each discrete state, there is an additional clock resetting function associated with a GTFA to denote whether the clock is reset to a value in a given closed time interval. We assume that the logical and time structure of a partially observable TFA/GTFA is known. The main results are summarized as follows. 1. The notion of a zone automaton is introduced as a finite automaton providing a purely discrete event description of the behaviour of a TFA/GTFA of interest. Each state of a zone automaton contains a discrete state of the timed DES and a zone that is a time interval denoting a range of possible clock values. We investigate the dynamics of a zone automaton and show that one can reduce the problem of investigating the reachability of a given timed DES to the reachability analysis of a zone automaton. 2. We present a formal approach that allows one to construct offline an observer for TFA/GTFA, i.e., a finite structure that describes the state estimation for all possible evolutions. During the online phase to estimate the current discrete state according to each measurement of an observable event, one can determine which is the state of the observer reached by the current observation and check to which interval (among a finite number of time intervals) the time elapsed since the last observed event occurrence belongs. We prove that the discrete states consistent with a timed observation and the range of clock values associated with each estimated discrete state can be inferred following a certain number of runs in the zone automaton. In particular, the state estimation of timed DES under multiple clocks can be investigated in the framework of GTFA. We model such a system as a GTFA with multiple clocks, which generalizes the timing function and the clock resetting function to multiple clocks. 3. As an application of the state estimation approach for TFA, we assume that a given TFA may be affected by a set of faults described using timed transitions and aim at diagnosing a fault behaviour based on a timed observation. The problem of fault diagnosis is solved by constructing a zone automaton of the TFA with faults and a fault recognizer as the parallel composition of the zone automaton and a fault monitor that recognizes the occurrence of faults. We conclude that the occurrence of faults can be analyzed by exploring runs in the fault recognizer that are consistent with a given timed observation. 4. We also study the problem of attack detection in the context of DESs, assuming that a system may be subject to multiple types of attacks, each described by its own attack dictionary. Furthermore, we distinguish between constant attacks, which corrupt observations using only one of the attack dictionaries, and switching attacks, which may use different attack dictionaries at different steps. The problem we address is detecting whether a system has been attacked and, if so, which attack dictionaries have been used. To solve it in the framework of untimed DES, we construct a new structure that describes the observations generated by a system under attack. We show that the attack detection problem can be transformed into a classical state estimation/diagnosis problem for these new structures

Experimental Validation of Model-Based Prognostics for Pneumatic Valves

Because valves control many critical operations, they are prime candidates for deployment of prognostic algorithms. But, similar to the situation with most other components, examples of failures experienced in the field are hard to come by. This lack of data impacts the ability to test and validate prognostic algorithms. A solution sometimes employed to overcome this shortcoming is to perform run-to-failure experiments in a lab. However, the mean time to failure of valves is typically very high (possibly lasting decades), preventing evaluation within a reasonable time frame. Therefore, a mechanism to observe development of fault signatures considerably faster is sought. Described here is a testbed that addresses these issues by allowing the physical injection of leakage faults (which are the most common fault mode) into pneumatic valves. What makes this testbed stand out is the ability to modulate the magnitude of the fault almost arbitrarily fast. With that, the performance of end-of-life estimation algorithms can be tested. Further, the testbed is mobile and can be connected to valves in the field. This mobility helps to bring the overall process of prognostic algorithm development for this valve a step closer to validation. The paper illustrates the development of a model-based prognostic approach that uses data from the testbed for partial validation

Experimental Validation of Model-Based Prognostics for Pneumatic Valves

Because valves control many critical operations, they are prime candidates for deployment of prognostic algorithms. But, similar to the situation with most other components, examples of failures experienced in the field are hard to come by. This lack of data impacts the ability to test and validate prognostic algorithms. A solution sometimes employed to overcome this shortcoming is to perform run-to-failure experiments in a lab. However, the mean time to failure of valves is typically very high (possibly lasting decades), preventing evaluation within a reasonable time frame. Therefore, a mechanism to observe development of fault signatures considerably faster is sought. Described here is a testbed that addresses these issues by allowing the physical injection of leakage faults (which are the most common fault mode) into pneumatic valves. What makes this testbed stand out is the ability to modulate the magnitude of the fault almost arbitrarily fast. With that, the performance of end-of-life estimation algorithms can be tested. Further, the testbed is mobile and can be connected to valves in the field. This mobility helps to bring the overall process of prognostic algorithm development for this valve a step closer to validation. The paper illustrates the development of a model-based prognostic approach that uses data from the testbed for partial validation

Hybrid modeling and control of mechatronic systems using a piecewise affine dynamics approach

This thesis investigates the topic of modeling and control of PWA systems based on two experimental cases of an electrical and hydraulic nature with varying complexity that were also built, instrumented and evaluated. A full-order model has been created for both systems, including all dominant system dynamics and non-linearities. The unknown parameters and characteristics have been identi ed via an extensive parameter identi cation. In the following, the non-linear characteristics are linearized at several points, resulting in PWA models for each respective setup. Regarding the closed loop control of the generated models and corresponding experimental setups, a linear control structure comprised of integral error, feed-forward and state-feedback control has been used. Additionally, the hydraulic setup has been controlled in an autonomous hybrid position/force control mode, resulting in a switched system with each mode's dynamics being de ned by the previously derived PWA-based model in combination with the control structure and respective mode-dependent controller gains. The autonomous switch between control modes has been de ned by a switching event capable of consistently switching between modes in a deterministic manner despite the noise-a icted measurements. Several methods were used to obtain suitable controller gains, including optimization routines and pole placement. Validation of the system's fast and accurate response was obtained through simulations and experimental evaluation. The controlled system's local stability was proven for regions in state-space associated with operational points by using pole-zero analysis. The stability of the hybrid control approach was proven by using multiple Lyapunov functions for the investigated test scenarios.publishedVersio