Resilience and risk analysis of fault-tolerant control design in continuous pharmaceutical manufacturing

PresentationThe effects of the paradigm shift from batch to continuous manufacturing on pharmaceutical industry, in terms of process safety and product quality, e.g., danger of dust explosions and risk of off-spec products, are of major concerns in the recent research progress in control system design. Specifically, a fault-tolerant control of critical process parameters (CPPs) and critical quality attributes (CQAs) is of paramount importance for the continuous operation with built-in safety and quality. In this study, a systematic framework for fault-tolerant control design, analysis, and evaluation for continuous pharmaceutical solid-dosage manufacturing is proposed, consisting of system identification, control design and analysis (controllability, stability, resilience, etc.), hierarchical three-layer control structures (model predictive control, state estimation, data reconciliation, etc.), risk mapping, assessment and planning (Risk MAP) strategies, and control performance evaluation. The key idea of the proposed framework is to identify the potential risks in the control design, material variance, and process uncertainties, under which the control strategies are evaluated. The framework is applied to a continuous direct compaction process, specifically the feeding-blending system wherein the major source of variance in the process operation and product quality arises. It can be demonstrated that the process operation failures and product quality variances in the feeding-blending system can be mitigated and managed through the proposed systematic fault-tolerant control system design and risk analysis framework

Fault tolerant model predictive control of open channels

Automated control of water systems (irrigation canals, navigation canals, rivers etc.) relies on the measured data. The control action is calculated, in case of feedback controller, directly from the on-line measured data. If the measured data is corrupted, the calculated control action will have a different effect than it is desired. Therefore, it is crucial that the feedback controller receives good quality measurement data. On-line fault detection techniques can be applied in order to detect the faulty data and correct it. After the detection and correction of the sensor data, the controller should be able to still maintain the set point of the system. In this paper this principle using the sensor fault masking is applied to model predictive control of open channels. A case study of a reach of the northwest of the inland navigation network of France is presented. Model predictive control and water level sensor masking is applied.Peer ReviewedPostprint (published version

Fault-tolerant formation driving mechanism designed for heterogeneous MAVs-UGVs groups

A fault-tolerant method for stabilization and navigation of 3D heterogeneous formations is proposed in this paper. The presented Model Predictive Control (MPC) based approach enables to deploy compact formations of closely cooperating autonomous aerial and ground robots in surveillance scenarios without the necessity of a precise external localization. Instead, the proposed method relies on a top-view visual relative localization provided by the micro aerial vehicles flying above the ground robots and on a simple yet stable visual based navigation using images from an onboard monocular camera. The MPC based schema together with a fault detection and recovery mechanism provide a robust solution applicable in complex environments with static and dynamic obstacles. The core of the proposed leader-follower based formation driving method consists in a representation of the entire 3D formation as a convex hull projected along a desired path that has to be followed by the group. Such an approach provides non-collision solution and respects requirements of the direct visibility between the team members. The uninterrupted visibility is crucial for the employed top-view localization and therefore for the stabilization of the group. The proposed formation driving method and the fault recovery mechanisms are verified by simulations and hardware experiments presented in the paper

A survey on fractional order control techniques for unmanned aerial and ground vehicles

In recent years, numerous applications of science and engineering for modeling and control of unmanned aerial vehicles (UAVs) and unmanned ground vehicles (UGVs) systems based on fractional calculus have been realized. The extra fractional order derivative terms allow to optimizing the performance of the systems. The review presented in this paper focuses on the control problems of the UAVs and UGVs that have been addressed by the fractional order techniques over the last decade

AFTI/F-16 digital flight control system experience

The Advanced Flighter Technology Integration (AFTI) F-16 program is investigating the integration of emerging technologies into an advanced fighter aircraft. The three major technologies involved are the triplex digital flight control system; decoupled aircraft flight control; and integration of avionics, pilot displays, and flight control. In addition to investigating improvements in fighter performance, the AFTI/F-16 program provides a look at generic problems facing highly integrated, flight-crucial digital controls. An overview of the AFTI/F-16 systems is followed by a summary of flight test experience and recommendations

A fault-tolerant intelligent robotic control system

This paper describes the concept, design, and features of a fault-tolerant intelligent robotic control system being developed for space and commercial applications that require high dependability. The comprehensive strategy integrates system level hardware/software fault tolerance with task level handling of uncertainties and unexpected events for robotic control. The underlying architecture for system level fault tolerance is the distributed recovery block which protects against application software, system software, hardware, and network failures. Task level fault tolerance provisions are implemented in a knowledge-based system which utilizes advanced automation techniques such as rule-based and model-based reasoning to monitor, diagnose, and recover from unexpected events. The two level design provides tolerance of two or more faults occurring serially at any level of command, control, sensing, or actuation. The potential benefits of such a fault tolerant robotic control system include: (1) a minimized potential for damage to humans, the work site, and the robot itself; (2) continuous operation with a minimum of uncommanded motion in the presence of failures; and (3) more reliable autonomous operation providing increased efficiency in the execution of robotic tasks and decreased demand on human operators for controlling and monitoring the robotic servicing routines

Advanced information processing system: The Army fault tolerant architecture conceptual study. Volume 1: Army fault tolerant architecture overview

Digital computing systems needed for Army programs such as the Computer-Aided Low Altitude Helicopter Flight Program and the Armored Systems Modernization (ASM) vehicles may be characterized by high computational throughput and input/output bandwidth, hard real-time response, high reliability and availability, and maintainability, testability, and producibility requirements. In addition, such a system should be affordable to produce, procure, maintain, and upgrade. To address these needs, the Army Fault Tolerant Architecture (AFTA) is being designed and constructed under a three-year program comprised of a conceptual study, detailed design and fabrication, and demonstration and validation phases. Described here are the results of the conceptual study phase of the AFTA development. Given here is an introduction to the AFTA program, its objectives, and key elements of its technical approach. A format is designed for representing mission requirements in a manner suitable for first order AFTA sizing and analysis, followed by a discussion of the current state of mission requirements acquisition for the targeted Army missions. An overview is given of AFTA's architectural theory of operation

A Fault-Tolerant Emergency-Aware Access Control Scheme for Cyber-Physical Systems

Access control is an issue of paramount importance in cyber-physical systems (CPS). In this paper, an access control scheme, namely FEAC, is presented for CPS. FEAC can not only provide the ability to control access to data in normal situations, but also adaptively assign emergency-role and permissions to specific subjects and inform subjects without explicit access requests to handle emergency situations in a proactive manner. In FEAC, emergency-group and emergency-dependency are introduced. Emergencies are processed in sequence within the group and in parallel among groups. A priority and dependency model called PD-AGM is used to select optimal response-action execution path aiming to eliminate all emergencies that occurred within the system. Fault-tolerant access control polices are used to address failure in emergency management. A case study of the hospital medical care application shows the effectiveness of FEAC