AI based state observer for optimal process control: application to digital twins of manufacturing plants

Les plantes de fabricació estan subjectes a restriccions dinàmiques que requereixen una optimització robusta per millorar el rendiment i l' eficiència del sistema. En aquest projecte es presenta un nou sistema de control òptim basat en IA per a un bessó digital d' una planta de fabricació. El sistema proposat implementa un observador d' estat basat en IA per predir l' estat intern d' un model de procés altament incert i no lineal, tal com seria un sistema de producció real. Una funció d' optimització multi-objectiu es utilitzada per controlar els paràmetres de producció i mantenir el procés funcionant en condicions òptimes. El mètode d'Optimització del Control basat en AI es va implementar en un cas d'estudi d'una planta de fabricació d'acer. El rendiment del sistema es va avaluar utilitzant els KPIs de fabricació rellevants, com ara les taxes d'utilització i productivitat de l'equip del procés. L'ús de sistema de control optimitzat via AI millora amb èxit els KPIs de procés i potencialment podria reduir els costos de producció.Las plantas de fabricación están sujetas a restricciones dinámicas que requieren una optimización robusta para mejorar el rendimiento y la eficiencia. En este informe se presenta un nuevo sistema de control óptimo basado en IA para un gemelo digital de una planta de fabricación. El sistema propuesto implementa un observador de estado basado en IA para predecir el estado interno de un modelo de proceso altamente incierto y no lineal, tal y como sería un sistema de producción real. Una función de optimización multiobjetivo es utilizada para controlar los parámetros de producción y mantener el proceso funcionando en condiciones óptimas. El método de Optimización del Control basado en AI se implementó en un caso de estudio de una planta de fabricación de acero. El rendimiento del sistema se evaluó utilizando los KPIs de fabricación relevantes, como la utilización del equipo y las tasas de productividad del proceso. El uso del sistema de control óptimo de IA mejora los KPIs del proceso y podría reducir potencialmente los costos de producción.Manufacturing plants are subject to dynamic constrains requiring robust optimization methods for improved performance and efficiency. A novel AI based optimal control system for a Digital Twin of a manufacturing plant is presented in this report. The proposed system implements an AI based state observer to predict the internal state of a highly uncertain and non-linear process model, such as a real production system. A multi-objective optimization function is used to control production parameters and keeps the process running at an optimal condition. The AI Optimization Control method was implemented on a study case on a steel manufacturing plant. The performance of the system was evaluated using the relevant manufacturing KPIs such as the equipment utilization and productivity rates of the process. The use of the AI optimal control system successfully improves the process KPIs and could potentially reduce production costs

STABILITY AND PERFORMANCE OF NETWORKED CONTROL SYSTEMS

Network control systems (NCSs), as one of the most active research areas, are arousing comprehensive concerns along with the rapid development of network. This dissertation mainly discusses the stability and performance of NCSs into the following two parts. In the first part, a new approach is proposed to reduce the data transmitted in networked control systems (NCSs) via model reduction method. Up to our best knowledge, we are the first to propose this new approach in the scientific and engineering society. The "unimportant" information of system states vector is truncated by balanced truncation method (BTM) before sending to the networked controller via network based on the balance property of the remote controlled plant controllability and observability. Then, the exponential stability condition of the truncated NCSs is derived via linear matrix inequality (LMI) forms. This method of data truncation can usually reduce the time delay and further improve the performance of the NCSs. In addition, all the above results are extended to the switched NCSs. The second part presents a new robust sliding mode control (SMC) method for general uncertain time-varying delay stochastic systems with structural uncertainties and the Brownian noise (Wiener process). The key features of the proposed method are to apply singular value decomposition (SVD) to all structural uncertainties, to introduce adjustable parameters for control design along with the SMC method, and new Lyapunov-type functional. Then, a less-conservative condition for robust stability and a new robust controller for the general uncertain stochastic systems are derived via linear matrix inequality (LMI) forms. The system states are able to reach the SMC switching surface as guaranteed in probability 1 by the proposed control rule. Furthermore, the novel Lyapunov-type functional for the uncertain stochastic systems is used to design a new robust control for the general case where the derivative of time-varying delay can be any bounded value (e.g., greater than one). It is theoretically proved that the conservatism of the proposed method is less than the previous methods. All theoretical proofs are presented in the dissertation. The simulations validate the correctness of the theoretical results and have better performance than the existing results

Adaptive neural network cascade control system with entropy-based design

A neural network (NN) based cascade control system is developed, in which the primary PID controller is constructed by NN. A new entropy-based measure, named the centred error entropy (CEE) index, which is a weighted combination of the error cross correntropy (ECC) criterion and the error entropy criterion (EEC), is proposed to tune the NN-PID controller. The purpose of introducing CEE in controller design is to ensure that the uncertainty in the tracking error is minimised and also the peak value of the error probability density function (PDF) being controlled towards zero. The NN-controller design based on this new performance function is developed and the convergent conditions are. During the control process, the CEE index is estimated by a Gaussian kernel function. Adaptive rules are developed to update the kernel size in order to achieve more accurate estimation of the CEE index. This NN cascade control approach is applied to superheated steam temperature control of a simulated power plant system, from which the effectiveness and strength of the proposed strategy are discussed by comparison with NN-PID controllers tuned with EEC and ECC criterions

Microgrids

Microgrids are a growing segment of the energy industry, representing a paradigm shift from centralized structures toward more localized, autonomous, dynamic, and bi-directional energy networks, especially in cities and communities. The ability to isolate from the larger grid makes microgrids resilient, while their capability of forming scalable energy clusters permits the delivery of services that make the grid more sustainable and competitive. Through an optimal design and management process, microgrids could also provide efficient, low-cost, clean energy and help to improve the operation and stability of regional energy systems. This book covers these promising and dynamic areas of research and development and gathers contributions on different aspects of microgrids in an aim to impart higher degrees of sustainability and resilience to energy systems

Issues on Stability of ADP Feedback Controllers for Dynamical Systems

This paper traces the development of neural-network (NN)-based feedback controllers that are derived from the principle of adaptive/approximate dynamic programming (ADP) and discusses their closed-loop stability. Different versions of NN structures in the literature, which embed mathematical mappings related to solutions of the ADP-formulated problems called “adaptive critics” or “action-critic” networks, are discussed. Distinction between the two classes of ADP applications is pointed out. Furthermore, papers in “model-free” development and model-based neurocontrollers are reviewed in terms of their contributions to stability issues. Recent literature suggests that work in ADP-based feedback controllers with assured stability is growing in diverse forms

Dissipative Imitation Learning for Discrete Dynamic Output Feedback Control with Sparse Data Sets

Imitation learning enables the synthesis of controllers for complex objectives and highly uncertain plant models. However, methods to provide stability guarantees to imitation learned controllers often rely on large amounts of data and/or known plant models. In this paper, we explore an input-output (IO) stability approach to dissipative imitation learning, which achieves stability with sparse data sets and with little known about the plant model. A closed-loop stable dynamic output feedback controller is learned using expert data, a coarse IO plant model, and a new constraint to enforce dissipativity on the learned controller. While the learning objective is nonconvex, iterative convex overbounding (ICO) and projected gradient descent (PGD) are explored as methods to successfully learn the controller. This new imitation learning method is applied to two unknown plants and compared to traditionally learned dynamic output feedback controller and neural network controller. With little knowledge of the plant model and a small data set, the dissipativity constrained learned controller achieves closed loop stability and successfully mimics the behavior of the expert controller, while other methods often fail to maintain stability and achieve good performance

Networked Control System Design and Parameter Estimation

Networked control systems (NCSs) are a kind of distributed control systems in which the data between control components are exchanged via communication networks. Because of the attractive advantages of NCSs such as reduced system wiring, low weight, and ease of system diagnosis and maintenance, the research on NCSs has received much attention in recent years. The first part (Chapter 2 - Chapter 4) of the thesis is devoted to designing new controllers for NCSs by incorporating the network-induced delays. The thesis also conducts research on filtering of multirate systems and identification of Hammerstein systems in the second part (Chapter 5 - Chapter 6). Network-induced delays exist in both sensor-to-controller (S-C) and controller-to-actuator (C-A) links. A novel two-mode-dependent control scheme is proposed, in which the to-be-designed controller depends on both S-C and C-A delays. The resulting closed-loop system is a special jump linear system. Then, the conditions for stochastic stability are obtained in terms of a set of linear matrix inequalities (LMIs) with nonconvex constraints, which can be efficiently solved by a sequential LMI optimization algorithm. Further, the control synthesis problem for the NCSs is considered. The definitions of H₂ and H∞ norms for the special system are first proposed. Also, the plant uncertainties are considered in the design. Finally, the robust mixed H₂/H∞ control problem is solved under the framework of LMIs. To compensate for both S-C and C-A delays modeled by Markov chains, the generalized predictive control method is modified to choose certain predicted future control signal as the current control effort on the actuator node, whenever the control signal is delayed. Further, stability criteria in terms of LMIs are provided to check the system stability. The proposed method is also tested on an experimental hydraulic position control system. Multirate systems exist in many practical applications where different sampling rates co-exist in the same system. The l₂-l∞ filtering problem for multirate systems is considered in the thesis. By using the lifting technique, the system is first transformed to a linear time-invariant one, and then the filter design is formulated as an optimization problem which can be solved by using LMI techniques. Hammerstein model consists of a static nonlinear block followed in series by a linear dynamic system, which can find many applications in different areas. New switching sequences to handle the two-segment nonlinearities are proposed in this thesis. This leads to less parameters to be estimated and thus reduces the computational cost. Further, a stochastic gradient algorithm based on the idea of replacing the unmeasurable terms with their estimates is developed to identify the Hammerstein model with two-segment nonlinearities. Finally, several open problems are listed as the future research directions

A Robust Tracking Method for MIMO Uncertain Discrete-Time Systems: Mechatronic Applications

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