Model-Driven Development of Control Applications: On Modeling Tools, Simulations and Safety

Control systems are required in various industrial applications varying from individual machines to manufacturing plants and enterprises. Software applications have an important role as an implementation technology in such systems, which can be based on Distributed Control System (DCS) or Programmable Control System (PLC) platforms, for example. Control applications are computer programs that, with control system hardware, perform control tasks. Control applications are efficient and flexible by nature; however, their development is a complex task that requires the collaboration of experts and information from various domains of expertise.This thesis studies the use of Model-Driven Development (MDD) techniques in control application development. MDD is a software development methodology in which models are used as primary engineering artefacts and processed with both manual work and automated model transformations. The objective of the thesis is to explore whether or not control application development can benefit from MDD and selected technologies enabled by it. The research methodology followed in the thesis is the constructive approach of design science.To answer the research questions, tools are developed for modeling and developing control applications using UML Automation Profile (UML AP) in a model-driven development process. The modeling approach is developed based on open source tools on Eclipse platform. In the approach, modeling concepts are kept extendable. Models can be processed with model transformation techniques that plug in to the tool. The approach takes into account domain requirements related to, for example, re-use of design. According to assessment of industrial applicability of the approach and tools as part of it, they could be used for developing industrial DCS based control applications.Simulation approaches that can be used in conjunction to model-driven development of control applications are presented and compared. Development of a model-in-the-loop simulation support is rationalized to enable the use of simulations early while taking into account the special characteristics of the domain. A simulator integration is developed that transforms UML AP control application models to Modelica Modeling Language (ModelicaML) models, thus enabling closed-loop simulations with ModelicaML models of plants to be controlled. The simulation approach is applied successfully in simulations of machinery applications and process industry processes.Model-driven development of safety applications, which are parts of safety systems, would require taking into account safety standard requirements related to modeling techniques and documentation, for example. Related to this aspect, the thesis focuses on extending the information content of models with aspects that are required for safety applications. The modeling of hazards and their associated risks is supported with fault tree notation. The risk and hazard information is integrated into the development process in order to improve traceability. Automated functions enable generating documentation and performing consistency checks related to the use of standard solutions, for example. When applicable, techniques and notations, such as logic diagrams, have been chosen so that they are intuitive to developers but also comply with recommendations of safety standards

Empirical validation of a usability inspection method for model-driven Web development

Web applications should be usable in order to be accepted by users and to improve their success probability. Despite the fact that this requirement has promoted the emergence of several usability evaluation methods, there is a need for empirically validated methods that provide evidence about their effectiveness and that can be properly integrated into early stages of Web development processes. Model-driven Web development processes have grown in popularity over the last few years, and offer a suitable context in which to perform early usability evaluations due to their intrinsic traceability mechanisms. These issues have motivated us to propose a Web Usability Evaluation Process (WUEP) which can be integrated into model-driven Web development processes. This paper presents a family of experiments that we have carried out to empirically validate WUEP. The family of experiments was carried out by 64 participants, including PhD and Master¿s computer science students. The objective of the experiments was to evaluate the participants¿ effectiveness, efficiency, perceived ease of use and perceived satisfaction when using WUEP in comparison to an industrial widely used inspection method: Heuristic Evaluation (HE). The statistical analysis and meta-analysis of the data obtained separately from each experiment indicated that WUEP is more effective and efficient than HE in the detection of usability problems. The evaluators were also more satisfied when applying WUEP, and found it easier to use than HE. Although further experiments must be carried out to strengthen these results, WUEP has proved to be a promising usability inspection method for Web applications which have been developed by using model-driven development processes.The authors would like to thank all the participants in the experiments, along with the usability experts that supported certain tasks of the evaluation design stage, and of which the control group was composed. This research work is funded by the MULTIPLE project (TIN2009-13838) and the FPU program (AP2007-03731) from the Spanish Ministry of Science and Education.Fernández Martínez, A.; Abrahao Gonzales, SM.; Insfrán Pelozo, CE. (2013). Empirical validation of a usability inspection method for model-driven Web development. Journal of Systems and Software. 86(1):161-186. https://doi.org/10.1016/j.jss.2012.07.043S16118686

Nonlinear predictive restricted structure control

This thesis defines new developments in predictive restricted structure control for industrial applications. It begins by describing the augmented system for both state-space and polynomial model descriptions. These descriptions can contain the plant model, the disturbance model, and any additional essential model subsystems. It then describes the predictive restricted structure control solution for both linear and nonlinear systems in state-space form. The solution utilizes the recent development in nonlinear predictive generalized minimum variance by adding a general operator subsystem that defines nonlinear system along with the linear or the linear parameter varying output subsystem. The next contribution is the polynomial predictive restricted structure control algorithm for polynomial linear parameter varying model that may result from nonlinear equations or experimental data-driven model identification. This algorithm utilizes the generalised predictive control method to approximate and control nonlinear systems in the linear parameter varying system inputoutput transfer operator matrices. The solution is simple in unconstrained and constrained optimization solutions and required a small computing capacity. Four examples have been chosen to test the algorithms for different nonlinear characteristics. In the first three examples, state-space versions of the algorithm for the linear, the quasi-linear parameter varying and the state-dependent were employed to control the quadruple tank process, electronic throttle body, and the continuous stirred tank reactors. In the last example, the polynomial linear parameter varying restricted structure controller is used to control automotive variable camshaft timing system.This thesis defines new developments in predictive restricted structure control for industrial applications. It begins by describing the augmented system for both state-space and polynomial model descriptions. These descriptions can contain the plant model, the disturbance model, and any additional essential model subsystems. It then describes the predictive restricted structure control solution for both linear and nonlinear systems in state-space form. The solution utilizes the recent development in nonlinear predictive generalized minimum variance by adding a general operator subsystem that defines nonlinear system along with the linear or the linear parameter varying output subsystem. The next contribution is the polynomial predictive restricted structure control algorithm for polynomial linear parameter varying model that may result from nonlinear equations or experimental data-driven model identification. This algorithm utilizes the generalised predictive control method to approximate and control nonlinear systems in the linear parameter varying system inputoutput transfer operator matrices. The solution is simple in unconstrained and constrained optimization solutions and required a small computing capacity. Four examples have been chosen to test the algorithms for different nonlinear characteristics. In the first three examples, state-space versions of the algorithm for the linear, the quasi-linear parameter varying and the state-dependent were employed to control the quadruple tank process, electronic throttle body, and the continuous stirred tank reactors. In the last example, the polynomial linear parameter varying restricted structure controller is used to control automotive variable camshaft timing system

Data-driven Soft Sensors in the Process Industry

In the last two decades Soft Sensors established themselves as a valuable alternative to the traditional means for the acquisition of critical process variables, process monitoring and other tasks which are related to process control. This paper discusses characteristics of the process industry data which are critical for the development of data-driven Soft Sensors. These characteristics are common to a large number of process industry fields, like the chemical industry, bioprocess industry, steel industry, etc. The focus of this work is put on the data-driven Soft Sensors because of their growing popularity, already demonstrated usefulness and huge, though yet not completely realised, potential. A comprehensive selection of case studies covering the three most important Soft Sensor application fields, a general introduction to the most popular Soft Sensor modelling techniques as well as a discussion of some open issues in the Soft Sensor development and maintenance and their possible solutions are the main contributions of this work

Data-driven modelling and monitoring of industrial processes with applications in nuclear waste vitrification

PhD ThesisProcess models are critical for process monitoring, control, and optimisation. With the increasing amount of process data and advancements in computational hardware, data-driven models are a good alternative to mechanistic models, which often have inaccuracies or are too costly to develop. One problem with data-driven models is the difficulty in ensuring that the models perform well on new data and produce accurate predictions in complex situations, which are frequently encountered in the process industry. Within this context, part of this thesis explores developing better data-driven models through using a latent variable technique, known as slow feature analysis, as a pre-processing step to regression. Slow feature analysis extracts slow varying features that contain underlying trends in the data, which can improve model performance through providing more meaningful information to regression, reducing noise, and reducing dimensionality. Firstly, the effectiveness of combining linear slow feature analysis with a neural network is demonstrated on two industrial case studies of soft sensor development and is compared with conventional techniques, such as neural networks and integration of principal component analysis with a neural network. It is shown that integration of slow feature analysis with neural networks can significantly improve model performance. However, linear slow feature analysis can fail to extract the driving forces behind data in nonlinear situations such as batch processes. Therefore, using kernel slow feature analysis with a neural network is proposed to further enhance process model performance. A numerical example was used to demonstrate the effective extraction of driving forces in a nonlinear case where linear slow feature analysis cannot. Model generalisation performance was improved using the proposed method on both this numerical example, and an industrial penicillin process case study. Dealing with radioactive nuclear waste is an important obstacle in nuclear energy. Sellafield Ltd have a nuclear waste vitrification plant which converts high-level nuclear waste into a more stable, lower volume glass form, which is more appropriate for long term storage in sealed containers. This thesis presents three applications of data-driven modelling to this nuclear waste vitrification process. A predictive model of the pour rate of processed nuclear waste into containers, an early detection system for blockages in the dust scrubber, and a model of the long-term chemical durability of the stored glass waste. These applications use the previously developed slow feature analysis methods, as well as other data-driven techniques such as extreme learning machine and bootstrap aggregation, for enhancing the model performance.Engineering and Physical Sciences Research Council (EPSRC) and Sellafield Lt

A Model-Driven Engineering Approach for ROS using Ontological Semantics

This paper presents a novel ontology-driven software engineering approach for the development of industrial robotics control software. It introduces the ReApp architecture that synthesizes model-driven engineering with semantic technologies to facilitate the development and reuse of ROS-based components and applications. In ReApp, we show how different ontological classification systems for hardware, software, and capabilities help developers in discovering suitable software components for their tasks and in applying them correctly. The proposed model-driven tooling enables developers to work at higher abstraction levels and fosters automatic code generation. It is underpinned by ontologies to minimize discontinuities in the development workflow, with an integrated development environment presenting a seamless interface to the user. First results show the viability and synergy of the selected approach when searching for or developing software with reuse in mind.Comment: Presented at DSLRob 2015 (arXiv:1601.00877), Stefan Zander, Georg Heppner, Georg Neugschwandtner, Ramez Awad, Marc Essinger and Nadia Ahmed: A Model-Driven Engineering Approach for ROS using Ontological Semantic