EASILY VERIFIABLE CONTROLLER DESIGN WITH APPLICATION TO AUTOMOTIVE POWERTRAINS

Bridging the gap between designed and implemented model-based controllers is a major challenge in the design cycle of industrial controllers. This gap is mainly created due to (i) digital implementation of controller software that introduces sampling and quantization imprecisions via analog-to-digital conversion (ADC), and (ii) uncertainties in the modeled plant’s dynamics, which directly propagate through the controller structure. The failure to identify and handle these implementation and model uncertainties results in undesirable controller performance and costly iterative loops for completing the controller verification and validation (V&V) process. This PhD dissertation develops a novel theoretical framework to design controllers that are robust to implementation imprecision and uncertainties within the models. The proposed control framework is generic and applicable to a wide range of nonlinear control systems. The final outcome from this study is an uncertainty/imprecisions adaptive, easily verifiable, and robust control theory framework that minimizes V&V iterations in the design of complex nonlinear control systems. The concept of sliding mode controls (SMC) is used in this study as the baseline to construct an easily verifiable model-based controller design framework. SMC is a robust and computationally efficient controller design technique for highly nonlinear systems, in the presence of model and external uncertainties. The SMC structure allows for further modification to improve the controller robustness against implementation imprecisions, and compensate for the uncertainties within the plant model. First, the conventional continuous-time SMC design is improved by: (i) developing a reduced-order controller based on a novel model order reduction technique. The reduced order SMC shows better performance, since it uses a balanced realization form of the plant model and reduces the destructive internal interaction among different states of the system. (ii) developing an uncertainty-adaptive SMC with improved robustness against implementation imprecisions. Second, the continuous-time SMC design is converted to a discrete-time SMC (DSMC). The baseline first order DSMC structure is improved by: (i) inclusion of the ADC imprecisions knowledge via a generic sampling and quantization uncertainty prediction mechanism which enables higher robustness against implementation imprecisions, (ii) deriving the adaptation laws via a Lyapunov stability analysis to overcome uncertainties within the plant model, and (iii) developing a second order adaptive DSMC with predicted ADC imprecisions, which provides faster and more robust performance under modeling and implementation imprecisions, in comparison with the first order DSMC. The developed control theories from this PhD dissertation have been evaluated in real-time for two automotive powertrain case studies, including highly nonlinear combustion engine, and linear DC motor control problems. Moreover, the DSMC with predicted ADC imprecisions is experimentally tested and verified on an electronic air throttle body testbed for model-based position tracking purpose

Multi-Input Multi-Output Repetitive Control Theory And Taylor Series Based Repetitive Control Design

Repetitive control (RC) systems aim to achieve zero tracking error when tracking a periodic command, or when tracking a constant command in the presence of a periodic disturbance, or both a periodic command and periodic disturbance. This dissertation presents a new approach using Taylor Series Expansion of the inverse system z-transfer function model to design Finite Impulse Response (FIR) repetitive controllers for single-input single-output (SISO) systems, and compares the designs obtained to those generated by optimization in the frequency domain. This approach is very simple, straightforward, and easy to use. It also supplies considerable insight, and gives understanding of the cause of the patterns for zero locations in the optimization based design. The approach forms a different and effective time domain design method, and it can also be used to guide the choice of parameters in performing in the frequency domain optimization design. Next, this dissertation presents the theoretical foundation for frequency based optimization design of repetitive control design for multi-input multi-output (MIMO) systems. A comprehensive stability theory for MIMO repetitive control is developed. A necessary and sufficient condition for asymptotic stability in MIMO RC is derived, and four sufficient conditions are created. One of these is the MIMO version of the approximate monotonic decay condition in SISO RC, and one is a necessary and sufficient condition for stability for all possible disturbance periods. An appropriate optimization criterion for direct MIMO is presented based on minimizing a Frobenius norm summed over frequencies from zero to Nyquist. This design process is very tractable, requiring only solution of a linear algebraic equation. An alternative approach reduces the problem to a set of SISO design problems, one for each input-output pair. The performances of the resulting designs are studied by extensive examples. Both approaches are seen to be able to create RC designs with fast monotonic decay of the tracking error. Finally, this dissertation presents an analysis of using an experiment design sequence for parameter identification based on the theory of iterative learning control (ILC), a sister field to repetitive control. This is suggested as an alternative to the results in optimal experiment design. Modified ILC laws that are intentionally non-robust to model errors are developed, as a way to fine tune the use of ILC for identification purposes. The non-robustness with respect to its ability to improve identification of system parameters when the model error is correct is studied. It is demonstrated that in many cases the approach makes the learning particularly sensitive to relatively small parameter errors in the model, but sensitivity is sometimes limited to parameter errors of a specific sign

A Model-Free Control System Based on the Sliding Mode Control with Automatic Tuning Using as On-Line Parameter Estimation Approach

The sliding mode control algorithm and Lyapunov-based methods, have received much attention recently due to their ability to directly handle nonlinear systems while guaranteeing closed-loop tracking stability. In this work, a unique model-free sliding mode control technique has developed solely based on previous control inputs. The new method requires only knowledge of the system order and state measurements and does not require a theoretical model of the dynamic system. Lyapunov’s stability theorem is used in the controller formulation process to ensure closed-loop asymptotic stability. High frequency chattering of the control effort is reduced by using a smoothing boundary layer into the control law. Parameters variation during control operating and noise effect cannot be handled by the model-free controller if the controller tuning parameters are chosen arbitrarily since tracking performance becomes unacceptable. In addition, in previous work, the bounds of the input influence gain parameters were assumed to be known to derive the model-free controller. Therefore, in this work, a new approach is proposed for estimating the increment to the switching gain in real-time to ensure the sliding condition (which guarantees closed-loop tracking stability) is satisfied using a control law form that assumes a strictly unitary input influence gain. In formulation of estimation law, an exponential forgetting factor is combined with the least-squares estimator to ensure the updated data are used and past data are excluded. An automatic bounded forgetting tuning technique is developed to maintain the benefits of data forgetting while avoiding the possibility of gain unboundedness in absence of persistent excitation. The tuning estimator is assured that the resulting gain matrix is upper bounded regardless of the persistent excitation by suspending the data forgetting if the gain matrix reaches the specified upper bound. Simulations are performed on a series of linear and nonlinear SISO and MIMO systems with and without including actuator time-delay effects. Finally, a model is developed to simulate a quadcopter as a real-world application case. In all cases, the controller achieved perfect or near-perfect tracking performance using updated controller and on-line estimator tuning process

EXPERIMENTAL SETUP AND CONTROLLER DESIGN FOR AN HCCI ENGINE

Homogeneous charged compression ignition (HCCI) is a promising combustion mode for internal combustion (IC) engines. HCCI engines have very low NOx and soot emission and low fuel consumption compared to traditional engines. The aim of this thesis is divided into two main parts: (1) engine instrumentation with a step towards converting a gasoline turbocharged direct injection (GTDI) engine to an HCCI engine; and (2) developing controller for adjusting the crank angle at 50% mass fuel burn (CA50), exhaust gas temperature Texh, and indicated mean effective pressure (IMEP) of a single cylinder Ricardo HCCI engine. The base GTDI engine is modified by adding an air heater, inter-cooler, and exhaust gas recirculation (EGR) in the intake and exhaust loops. dSPACE control units are programmed for adding monitoring sensors and implementing actuators in the engine. Control logics for actuating electronic throttle control (ETC) valve, EGR valve, and port fuel injector (PFI) are developed using the rapid control prototyping (RCP) feature of dSPACE. A control logic for crank/cam synchronization to determine engine crank angle with respect to firing top dead center (TDC) is implemented and validated using in-cylinder pressure sensor data. A control oriented model (COM) is developed for estimating engine parameters including CA50, Texh, and IMEP for a single cylinder Ricardo engine. The COM is validated using experimental data for steady state and transient engine operating conditions. A novel three-input three-output controller is developed and tested on a detailed physical HCCI engine plant model. Two type of controller design approaches are used for designing HCCI controllers: (1) empirical, and (2) model-based. A discrete sub-optimal sliding mode controller (DSSMC) is designed as a model-based controller to control CA50 and Texh, and a PI controller is designed to control IMEP. The results show that the designed controllers can successfully track the reference trajectories and can reject the external disturbances within the given operating region

MIMO PID Controller Tuning Method for Quadrotor Based on LQR/LQG Theory

In this work, a new pre-tuning multivariable PID (Proportional Integral Derivative) controllers method for quadrotors is put forward. A procedure based on LQR/LQG (Linear Quadratic Regulator/Gaussian) theory is proposed for attitude and altitude control, which suposes a considerable simplification of the design problem due to only one pretuning parameter being used. With the aim to analyze the performance and robustness of the proposed method, a non-linear mathematical model of the DJI-F450 quadrotor is employed, where rotors dynamics, together with sensors drift/bias properties and noise characteristics of low-cost commercial sensors typically used in this type of applications are considered. In order to estimate the state vector and compensate bias/drift effects in the measures, a combination of filtering and data fusion algorithms (Kalman filter and Madgwick algorithm for attitude estimation) are proposed and implemented. Performance and robustness analysis of the control system is carried out by employing numerical simulations, which take into account the presence of uncertainty in the plant model and external disturbances. The obtained results show the proposed controller design method for multivariable PID controller is robust with respect to: (a) parametric uncertainty in the plant model, (b) disturbances acting at the plant input, (c) sensors measurement and estimation errors

Intelligent methods for complex systems control engineering

This thesis proposes an intelligent multiple-controller framework for complex systems that incorporates a fuzzy logic based switching and tuning supervisor along with a neural network based generalized learning model (GLM). The framework is designed for adaptive control of both Single-Input Single-Output (SISO) and Multi-Input Multi-Output (MIMO) complex systems. The proposed methodology provides the designer with an automated choice of using either: a conventional Proportional-Integral-Derivative (PID) controller, or a PID structure based (simultaneous) Pole and Zero Placement controller. The switching decisions between the two nonlinear fixed structure controllers is made on the basis of the required performance measure using the fuzzy logic based supervisor operating at the highest level of the system. The fuzzy supervisor is also employed to tune the parameters of the multiple-controller online in order to achieve the desired system performance. The GLM for modelling complex systems assumes that the plant is represented by an equivalent model consisting of a linear time-varying sub-model plus a learning nonlinear sub-model based on Radial Basis Function (RBF) neural network. The proposed control design brings together the dominant advantages of PID controllers (such as simplicity in structure and implementation) and the desirable attributes of Pole and Zero Placement controllers (such as stable set-point tracking and ease of parameters’ tuning). Simulation experiments using real-world nonlinear SISO and MIMO plant models, including realistic nonlinear vehicle models, demonstrate the effectiveness of the intelligent multiple-controller with respect to tracking set-point changes, achieve desired speed of response, prevent system output overshooting and maintain minimum variance input and output signals, whilst penalising excessive control actions