Health-aware predictive control schemes based on industrial processes

Aplicat embargament des de la data de defensa fins el dia 30 de desembre de 2021The research is motivated by real applications, such as pasteurization plant, water networks and autonomous system, which each of them require a specific control system to provide proper management able to take into account their particular features and operating limits in presence of uncertainties related to their operation and failures from component breakdowns. According to that most of the real systems have nonlinear behaviors, it can be approximated them by polytopic linear uncertain models such as Linear Parameter Varying (LPV) and Takagi-Sugeno (TS) models. Therefore, a new economic Model Predictive Control (MPC) approach based on LPV/TS models is proposed and the stability of the proposed approach is certified by using a region constraint on the terminal state. Besides, the MPC-LPV strategy is extended based on the system with varying delays affecting states and inputs. The control approach allows the controller to accommodate the scheduling parameters and delay change. By computing the prediction of the state variables and delay along a prediction time horizon, the system model can be modified according to the evaluation of the estimated state and delay at each time instant. To increase the system reliability, anticipate the appearance of faults and reduce the operational costs, actuator health monitoring should be considered. Regarding several types of system failures, different strategies are studied for obtaining system failures. First, the damage is assessed with the rainflow-counting algorithm that allows estimating the component’s fatigue and control objective is modified by adding an extra criterion that takes into account the accumulated damage. Besides, two different health-aware economic predictive control strategies that aim to minimize the damage of components are presented. Then, economic health-aware MPC controller is developed to compute the components and system reliability in the MPC model using an LPV modeling approach and maximizes the availability of the system by estimating system reliability. Additionally, another improvement considers chance-constraint programming to compute an optimal list replenishment policy based on a desired risk acceptability level, managing to dynamically designate safety stocks in flowbased networks to satisfy non-stationary flow demands. Finally, an innovative health-aware control approach for autonomous racing vehicles to simultaneously control it to the driving limits and to follow the desired path based on maximization of the battery RUL. The proposed approach is formulated as an optimal on-line robust LMI based MPC driven from Lyapunov stability and controller gain synthesis solved by LPV-LQR problem in LMI formulation with integral action for tracking the trajectory.Esta tesis pretende proporcionar contribuciones teóricas y prácticas sobre seguridad y control de sistemas industriales, especialmente en la forma maten ática de sistemas inciertos. La investigación está motivada por aplicaciones reales, como la planta de pasteurización, las redes de agua y el sistema autónomo, cada uno de los cuales requiere un sistema de control específico para proporcionar una gestión adecuada capaz de tener en cuenta sus características particulares y limites o de operación en presencia de incertidumbres relacionadas con su operación y fallas de averías de componentes. De acuerdo con que la mayoría de los sistemas reales tienen comportamientos no lineales, puede aproximarse a ellos mediante modelos inciertos lineales politopicos como los modelos de Lineal Variación de Parámetros (LPV) y Takagi-Sugeno (TS). Por lo tanto, se propone un nuevo enfoque de Control Predictivo del Modelo (MPC) económico basado en modelos LPV/TS y la estabilidad del enfoque propuesto se certifica mediante el uso de una restricción de región en el estado terminal. Además, la estrategia MPC-LPV se extiende en función del sistema con diferentes demoras que afectan los estados y las entradas. El enfoque de control permite al controlador acomodar los parámetros de programación y retrasar el cambio. Al calcular la predicción de las variables de estado y el retraso a lo largo de un horizonte de tiempo de predicción, el modelo del sistema se puede modificar de acuerdo con la evaluación del estado estimado y el retraso en cada instante de tiempo. Para aumentar la confiabilidad del sistema, anticipar la aparición de fallas y reducir los costos operativos, se debe considerar el monitoreo del estado del actuador. Con respecto a varios tipos de fallas del sistema, se estudian diferentes estrategias para obtener fallas del sistema. Primero, el daño se evalúa con el algoritmo de conteo de flujo de lluvia que permite estimar la fatiga del componente y el objetivo de control se modifica agregando un criterio adicional que tiene en cuenta el daño acumulado. Además, se presentan dos estrategias diferentes de control predictivo económico que tienen en cuenta la salud y tienen como objetivo minimizar el daño de los componentes. Luego, se desarrolla un controlador MPC económico con conciencia de salud para calcular los componentes y la confiabilidad del sistema en el modelo MPC utilizando un enfoque de modelado LPV y maximiza la disponibilidad del sistema mediante la estimación de la confiabilidad del sistema. Además, otra mejora considera la programación de restricción de posibilidades para calcular una política ´optima de reposición de listas basada en un nivel de aceptabilidad de riesgo deseado, logrando designar dinámicamente existencias de seguridad en redes basadas en flujo para satisfacer demandas de flujo no estacionarias. Finalmente, un enfoque innovador de control consciente de la salud para vehículos de carreras autónomos para controlarlo simultáneamente hasta los límites de conducción y seguir el camino deseado basado en la maximización de la bacteria RUL. El diseño del control se divide en dos capas con diferentes escalas de tiempo, planificador de ruta y controlador. El enfoque propuesto está formulado como un MPC robusto en línea optimo basado en LMI impulsado por la estabilidad de Lyapunov y la síntesis de ganancia del controlador resuelta por el problema LPV-LQR en la formulación de LMI con acción integral para el seguimiento de la trayectoria.Postprint (published version

Output-feedback model predictive control of a pasteurization pilot plant based on an LPV model

In order to optimize the trade-off between components life and energy consumption, the integration of a system health management and control modules is required. This paper proposes the integration of model predictive control (MPC) with a fatigue estimation approach that minimizes the damage of the components of a pasteurization plant. The fatigue estimation is assessed with the rainflow counting algorithm. Using data from this algorithm, a simplified model that characterizes the health of the system is developed and integrated with MPC. The MPC controller objective is modified by adding an extra criterion that takes into account the accumulated damage. But, a steady-state offset is created by adding this extra criterion. Finally, by including an integral action in the MPC controller, the steady-state error for regulation purpose is eliminated. The proposed control scheme is validated in simulation using a simulator of a utility-scale pasteurization plant.Peer ReviewedPostprint (author's final draft

Model predictive control based on LPV models with parameter-varying delays

© 2019 IEEE. Personal use of this material is permitted. Permission from IEEE must be obtained for all other uses, in any current or future media, including reprinting/republishing this material for advertising or promotional purposes, creating new collective works, for resale or redistribution to servers or lists, or reuse of any copyrighted component of this work in other works.This paper presents a Model Predictive Control (MPC) strategy based on Linear Parameter Varying (LPV) models with varying delays affecting states and inputs. The proposed control approach allows the controller to accommodate the scheduling parameters and delay change. By computing the prediction of the state variables and delay along a prediction time horizon, the system model can be modified according to the evaluation of the estimated state and delay at each time instant. Moreover, the solution of the optimization problem associated with the MPC design is achieved by solving a series of Quadratic Programming (QP) problem at each time instant. This iterative approach reduces the computational burden compared to the solution of a non-linear optimization problem. A pasteurization plant system is used as a case study to demonstrate the effectiveness of the proposed approach.Peer ReviewedPostprint (author's final draft

Economic health-aware LPV-MPC based on system reliability assessment for water transport network

This paper proposes a health-aware control approach for drinking water transport networks. This approach is based on an economic model predictive control (MPC) that considers an additional goal with the aim of extending the components and system reliability. The components and system reliability are incorporated into the MPC model using a Linear Parameter Varying (LPV) modeling approach. The MPC controller uses additionally an economic objective function that determines the optimal filling/emptying sequence of the tanks considering that electricity price varies between day and night and that the demand also follows a 24-h repetitive pattern. The proposed LPV-MPC control approach allows considering the model nonlinearities by embedding them in the parameters. The values of these varying parameters are updated at each iteration taking into account the new values of the scheduling variables. In this way, the optimization problem associated with the MPC problem is solved by means of Quadratic Programming (QP) to avoid the use of nonlinear programming. This iterative approach reduces the computational load compared to the solution of a nonlinear optimization problem. A case study based on the Barcelona water transport network is used for assessing the proposed approach performance.Peer ReviewedPostprint (published version

Health-aware model predictive control including fault-tolerant capabilities for drinking water transport networks

© 2021 IEEE. Personal use of this material is permitted. Permission from IEEE must be obtained for all other uses, in any current or future media, including reprinting /republishing this material for advertising or promotional purposes, creating new collective works, for resale or redistribution to servers or lists, or reuse of any copyrighted component of this work in other worksThis paper presents a health-aware Model Predictive Control (MPC) including fault-tolerant capabilities for drinking water transport networks. When a fault has occurred, the predictive controller must be redesigned to deal with the fault. This is done by considering the system reliability that is incorporated into the MPC model. The inclusion of components and system reliability in the MPC model is done through the Linear Parameter Varying (LPV) modelling approach with the aim of maximizing the availability of the system by considering system reliability. As a result, the MPC design is modified by considering the reliability model such that additionally to achieve the best achievable performance after the fault, the controller try to preserve the remaining useful life. The solution to the optimization problem related to the MPC problem is achieved by solving a series of Quadratic Programming (QP) problems thanks to the proposed LPV formulation. The proposed approach is applied to a part of a real drinking water transport network of Barcelona for demonstrating the performance of the method.Peer ReviewedPostprint (author's final draft

Health-aware LPV-MPC based on a reliability-based remaining useful life assessment

© . This manuscript version is made available under the CC-BY-NC-ND 4.0 license http://creativecommons.org/licenses/by-nc-nd/4.0/One of the relevant information provided by the prognostics and health management algorithms is the estimation of the Remaining Useful Life (RUL). The prediction of the expected RUL is very useful to decrease maintenance cost, operational downtime and safety hazards. This paper proposes a new strategy of health-aware Model Predictive Control (MPC) for a Linear Parameter Varying (LPV) system that includes as an additional goal extending the system RUL via their estimation using reliability tools. In this approach, the RUL maximization is included in the objective function of the LPV-MPC controller. The RUL is included in the MPC model as an extra parameter varying equation that considers the control action as scheduling variable. The proposed control approach allows the controller to accommodate to the parameter changes. Through computing an estimation of the state variables during prediction, the MPC model can be modified to the estimated state evolution at each time instant. Moreover, for solving the optimization problem by using a series of Quadratic Programs (QP) in each time instant, a new iterative approach is exhibited, which improves the computational efficiency. A pasteurization plant control system is used as a case study to illustrate the performance of the proposed approach.Peer ReviewedPostprint (author's final draft

Multi–layer health–aware economic predictive control of a pasteurization pilot plant

This paper proposes two different health-aware economic predictive control strategies that aim at minimizing the damage of components in a pasteurization plant. The damage is assessed with a rainflow-counting algorithm that allows estimating the components’ fatigue. By using the results obtained from this algorithm, a simplified model that characterizes the health of the system is developed and integrated into the predictive controller. The overall control objective is modified by adding an extra criterion that takes into account the accumulated damage. The first strategy is a single-layer predictive controller with an integral action to eliminate the steady-state error that appears when adding the extra criterion. In order to achieve the best minimal accumulated damage and operational costs, the single-layer approach is improved with a multi-layer control scheme, where the solution of the dynamic optimization problem is obtained from the model in two different time scales. Finally, to achieve the advisable trade-off between minimal accumulated damage and operational costs, both control strategies are compared in simulation over a utility-scale pasteurization plant.Peer ReviewedPostprint (author's final draft

Health-aware LPV-MPC based on system reliability assessment for drinking water networks

© 2018 IEEE. Personal use of this material is permitted. Permission from IEEE must be obtained for all other uses, in any current or future media, including reprinting/republishing this material for advertising or promotional purposes, creating new collective works, for resale or redistribution to servers or lists, or reuse of any copyrighted component of this work in other works.This paper proposes a health-aware model predictive control (MPC) for drinking water networks that includes an additional goal to extend the components and system reliability. The components and system reliability are incorporated in the MPC model as an extra parameter varying equation that considers the control action as a scheduling variable. The main goal of this work is to exhibit the advantage of taking into account system and component reliability, computed on-line by means of an LPV-MPC algorithm through an instance dedicated to DWNs. The proposed control approach allows the controller to accommodate to the parameter changes. By computing an estimation of the state variables during prediction, the MPC model can be modified considering the estimated state evolution at each time instant. Moreover, the solution of the optimization problem associate to the MPC problem is achieved by solving a series of Quadratic Programs (QP) at each sampling time. A small part of a real water network is used as a case study for illustrating the performance of the proposed approach.Peer ReviewedPostprint (author's final draft

Economic MPC-LPV control for the operational management of water distribution networks

This paper presents an Economic Model Predictive Control (EMPC) for the operational management of water distribution networks (WDNs) with periodic operation based on embedding the nonlinearity of the model to the Linear Parameter Varying (LPV) model of WDNs. The performance of the WDN is identified by a set of difference-algebraic equations while the relation of hydraulic head/pressure and flow in connected pipes is nonlinear. In particular, the WDN model consists of two sections of nonlinear algebraic equations for bidirectional and unidirectional flows in pipes, respectively. The proposed algorithm is embedded the nonlinear algebraic equations into the LPV model. The proposed control approach allows the controller to accommodate the scheduling parameters. By computing the prediction of the state variables along a prediction time horizon, the system model can be modified according to the evaluation of the estimated state at each time instant. This iterative approach improves the implementation efficiency and reduces the computational burden compared to the solution of a non-linear optimization problem. Finally, the proposed strategy is applied to a well-known benchmark of the Richmond WDN.Peer ReviewedPostprint (author's final draft

A two-layer control architecture for operational management and hydroelectricity production maximization in inland waterways using model predictive control

This work presents the design of a combined control and state estimation approach to simultaneously maintain optimal water levels and maximize hydroelectricity generation in inland waterways using gates and ON/OFF pumps. The latter objective can be achieved by installing turbines within canal locks, which harness the energy generated during lock filling and draining operations. Hence, the two objectives are antagonistic in nature, as energy generation maximization results from optimizing the number of lock operations, which in turn causes unbalanced upstream and downstream water levels. To overcome this problem, a two-layer control architecture is proposed. The upper layer receives external information regarding the current tidal period, and determines control actions that maintain optimal navigation conditions and maximize energy production using model predictive control (MPC) and moving horizon estimation (MHE). This information is provided to the lower layer, in which a scheduling problem is solved to determine the activation instants of the pumps that minimize the error with respect to the optimal pumping references. The strategy is applied to a realistic case study, using a section of the inland waterways in northern France, which allows to showcase its efficacy.Peer ReviewedPostprint (author's final draft