On the Finite-Time Behavior of Suboptimal Linear Model Predictive Control

Inexact methods for model predictive control (MPC), such as real-time iterative schemes or time-distributed optimization, alleviate the computational burden of exact MPC by providing suboptimal solutions. While the asymptotic stability of such algorithms is well studied, their finite-time performance has not received much attention. In this work, we quantify the performance of suboptimal linear model predictive control in terms of the additional closed-loop cost incurred due to performing only a finite number of optimization iterations. Leveraging this novel analysis framework, we propose a novel suboptimal MPC algorithm with a diminishing horizon length and finite-time closed-loop performance guarantees. This analysis allows the designer to plan a limited computational power budget distribution to achieve a desired performance level. We provide numerical examples to illustrate the algorithm's transient behavior and computational complexity.Comment: Accepted for Publication at the 62nd IEEE Conference on Decision and Control (CDC), Singapore, 202

Stochastic Wasserstein Gradient Flows using Streaming Data with an Application in Predictive Maintenance

We study estimation problems in safety-critical applications with streaming data. Since estimation problems can be posed as optimization problems in the probability space, we devise a stochastic projected Wasserstein gradient flow that keeps track of the belief of the estimated quantity and can consume samples from online data. We show the convergence properties of our algorithm. Our analysis combines recent advances in the Wasserstein space and its differential structure with more classical stochastic gradient descent. We apply our methodology for predictive maintenance of safety-critical processes: Our approach is shown to lead to superior performance when compared to classical least squares, enabling, among others, improved robustness for decision-making.Comment: Accepted for presentation at, and publication in the proceedings of, the 2023 IFAC World Congres

A Model Predictive Control Framework for Improving Risk-Tolerance of Manufacturing Systems

The need for control strategies that can address dynamic system uncertainty is becoming increasingly important. In this work, we propose a Model Predictive Control by quantifying the risk of failure in our system model. The proposed control scheme uses a Priced Timed Automata representation of the manufacturing system to promote the fail-safe operation of systems under uncertainties. The proposed method ensures that in case of unforeseen failure(s), the optimization-based control strategy can still achieve the manufacturing system objective. In addition, the proposed strategy establishes a trade-off between minimizing the cost and reducing failure risk to allow the manufacturing system to function effectively in the presence of uncertainties. An example from manufacturing systems is presented to show the application of the proposed control strategy.Comment: 7 page

Efficient sample selection for safe learning

Ensuring safety in industrial control systems usually involves imposing constraints at the design stage of the control algorithm. Enforcing constraints is challenging if the underlying functional form is unknown. The challenge can be addressed by using surrogate models, such as Gaussian processes, which provide confidence intervals used to find solutions that can be considered safe. This in turn involves an exhaustive search on the entire search space. That approach can quickly become computationally expensive. We reformulate the exhaustive search as a series of optimization problems to find the next recommended points. We show that the proposed reformulation allows using a wide range of available optimization solvers, such as derivative-free methods. We show that by exploiting the properties of the solver, we enable the introduction of new stopping criteria into safe learning methods and increase flexibility in trading off solver accuracy and computational time. The results from a non-convex optimization problem and an application for controller tuning confirm the flexibility and the performance of the proposed reformulation

Risk-Averse Model Predictive Control for Priced Timed Automata

In this paper, we propose a Risk-Averse Priced Timed Automata (PTA) Model Predictive Control (MPC) framework to increase flexibility of cyber-physical systems. To improve flexibility in these systems, our risk-averse framework solves a multi-objective optimization problem to minimize the cost and risk, simultaneously. While minimizing cost ensures the least effort to achieve a task, minimizing risk provides guarantees on the feasibility of the task even during uncertainty. Our framework explores the trade-off between these two qualities to obtain risk-averse control actions. The solution of risk-averse PTA MPC dynamic decision-making algorithm reacts relatively better to PTA changes compared to PTA MPC without risk-averse feature. An example from manufacturing systems is presented to show the application of the proposed control strategy.Comment: 7 page

Sequential Quadratic Programming-based Iterative Learning Control for Nonlinear Systems

Learning-based control methods for industrial processes leverage the repetitive nature of the underlying process to learn optimal inputs for the system. While many works focus on linear systems, real-world problems involve nonlinear dynamics. In this work, we propose an algorithm for the nonlinear iterative learning control problem based on sequential quadratic programming, a well-studied method for nonconvex optimization. We repeatedly solve quadratic subproblems built using approximate nonlinear models and process measurements, to find an optimal input for the original system. We demonstrate our method in a trajectory optimization problem for a precision motion system. We present simulations to illustrate the performance of the proposed method for linear and nonlinear dynamics models

Data-Driven Process Optimization of Fused Filament Fabrication based on In Situ Measurements

The tuning of fused filament fabrication parameters is notoriously challenging. We propose an autonomous data-driven method to select parameters based on in situ measurements. We use a laser sensor to evaluate the surface roughness of a printed part. We then correlate the roughness to the mechanical properties of the part, and show how print quality affects mechanical performance. Finally, we use Bayesian optimization to search for optimal print parameters. We demonstrate our method by printing liquid crystal polymer samples, and successfully find parameters that produce high-performance prints and maximize the manufacturing process efficiency.Comment: 7 pages, 6 figures. Submitted to IFAC WC 202

Safe Risk-averse Bayesian Optimization for Controller Tuning

Controller tuning and parameter optimization are crucial in system design to improve both the controller and underlying system performance. Bayesian optimization has been established as an efficient model-free method for controller tuning and adaptation. Standard methods, however, are not enough for high-precision systems to be robust with respect to unknown input-dependent noise and stable under safety constraints. In this work, we present a novel data-driven approach, RaGoOSE, for safe controller tuning in the presence of heteroscedastic noise, combining safe learning with risk-averse Bayesian optimization. We demonstrate the method for synthetic benchmark and compare its performance to established BO-based tuning methods. We further evaluate RaGoOSE performance on a real precision-motion system utilized in semiconductor industry applications and compare it to the built-in auto-tuning routine

Efficient safe learning for controller tuning with experimental validation

Optimization-based controller tuning is challenging because it requires formulating optimization problems explicitly as functions of controller parameters. Safe learning algorithms overcome the challenge by creating surrogate models from measured data. To ensure safety, such data-driven algorithms often rely on exhaustive grid search, which is computationally inefficient. In this paper, we propose a novel approach to safe learning by formulating a series of optimization problems instead of a grid search. We also develop a method for initializing the optimization problems to guarantee feasibility while using numerical solvers. The performance of the new method is first validated in a simulated precision motion system, demonstrating improved computational efficiency, and illustrating the role of exploiting numerical solvers to reach the desired precision. Experimental validation on an industrial-grade precision motion system confirms that the proposed algorithm achieves 30% better tracking at sub-micrometer precision as a state-of-the-art safe learning algorithm, improves the default auto-tuning solution, and reduces the computational cost seven times compared to learning algorithms based on exhaustive search

Layer-to-Layer Melt Pool Control in Laser Power Bed Fusion

Additive manufacturing processes are flexible and efficient technologies for producing complex geometries. However, ensuring reliability and repeatability is challenging due to the complex physics and various sources of uncertainty in the process. In this work, we investigate closed-loop control of the melt pool dimensions in a laser powder bed fusion (LPBF) process. We propose a trajectory optimization-based layer-to-layer controller that adjusts the laser power input to the next layer to track a desired melt pool depth and validate our controller by placing it in closed-loop high-fidelity multi-layer smoothed particle hydrodynamics simulator of a 2D LPBF process. Detailed numerical case studies demonstrate successful regulation of the melt pool depth on brick and overhang geometries and provide first of its kind results on the effectiveness of layer-to-layer input optimization for the LPBF process as well as detailed insight into the physics of the controlled process. Computational complexity and process performance results illustrate the method's effectiveness and provide an outlook for its implementation onto real systems