Advanced strategies for Computer aided process control

The ideal control methodology or strategy should satisfy the requirements:

To guarantee the stability and particularly, robustness To be as efficient as possible as required by the desired performance criteria To be easy to implement and operate in real time through the use of digital computers.

 As processes increase in complexity, they become less amenable to direct mathematical modeling based on physical laws, since they may be:
Distributed, stochastic, nonlinear, and time varying Subject to large unpredictable environment disturbances Have variables that are difficult to measure, have unknown causal relationships, or too difficult or expensive to evaluate in real-time.

Benefits of advanced controls

Increased throughput Increased product recovery Energy conservation Reduced disturbance or other processing units Minimum rework or recycle of off-spec products Reduced operating manpower Increased plant flexibility

Advanced controls
In this chapter the following advanced controls will be discussed
Predictive control Adaptive control Inferential control Statistical process control Intelligent control (AI)

Model based controllers

Model based controllers may be classified into two categories
Optimal control Adaptive control

Adaptive control
Generalized approach

Two approaches
Model reference adaptive control

 Gradient search method and liapunov method can be used to determine the parameters of controllers.

 Model identification adaptive control

 The following methods can be used for parameter estimation

Least square method Method of instrumental variables Maximum likelihood method Stochastic approximation method

The controller approach is also known as self-tuning control.

Optimal control

 The following methods are used for optimization

Linear programming Non-linear programming Gradient method Dynamic programming Calculus of variation Kalman filter

Predictive control

Predictive controller

Inferential control

Example of inferential control

Artificial intelligence
Artificial intelligence is subdivided into the following major categories:
Expert systems Robotics Vision Natural language processing Artificial neural networks(ANN) Fuzzy logic

Expert system

Expert control system

Structure of real time expert system

Neural network analogy with human brain

Advantages of neural networks

Good fit for nonlinear models. Ability to adapt, generalize and extrapolate results. Speed of execution in recall mode. Ease of maintenance.

Three layer fully connected neural network

Plant modeling using neural network

Cascade neural network controller

Feed forward architecture

Linearization architecture

Functional operation of a fuzzy controller

Statistical process control

SPC is also called as statistical quality control(SQC), involves the application of statistical concepts to determine whether a process is operating satisfactorily.

Statistical process control

Problem solving techniques associated with SPC include:
Analysis of processes for stability and the effects of process modifications (control charts and capability indices) Defining problems and setting priorities (Pareto charts) Identifying causes for good and bad performances (cause and effect diagram fishbone) Qualifying relationships between process or product variables (scatter plots or other correlation tools)

Example of SPC

Algorithms for processes with dead time

Smith predictor algorithm Analytical predictor algorithm General purpose algorithm

Smith predictor algorithm

Preliminary smith predictor scheme

Final smith predictor scheme

Block diagram of smith predictor