g(k) is an alternating sequence of +b and -b
6. p <-1
g(k) is a divergent sequence with alternating
signs, because p is both negative and greater than 1 in absolute value
CHAP 25 DYNAMIC ANALYSIS OF DISCRETE-TIME SYSTEMS
913
z-plane
Imaginary
1111111
I~ Real
Figure 25.5.
Impulse responses of the first-order process with a ZOH as a function of the location of the single pole (adapted from Ref. [4]).
One should realize that for the discrete, first-order process resulting from sampling a real, continuous first-order process, it is physically impossible to obtain the ·response types 4, 5, and 6; this is because the single pole at z = p arises from the real continuous pole at, say, s = s 1 and since these poles are related according to p = e5 • 111, it becomes clear that p cannot be negative. Responses 4-6 are typically associated, not with physical first-order processes, but with certain discrete controllers to be discussed in the next chapter.
Second-Order Process with a ZOH The Pulse Transfer Function As indicated in Example 25.2, the pulse transfer function for a second-order process including a ZOH is given in the backward shift, unfactored form as:
g(z)
=
blz-1 + b2z-2 1 + alz I + a2z
2
and if the two roots of the denominator quadratic are p 1 and p2, then g(z) has the factored form:
(25.125)
g(z)
In the forward shift form, the transfer function is:
g(z) =
z2 +
a
I
z+
a
(25.126) 2
L COMPUTER PROCESS CONTRO 914
or
(25.127) g(z)
The Transfer Function Characteris
tics
ver form) is characterized by: The transfer function (in whiche real and ch cou ld be real and distinct, • Two poles, at z = p 1, p 2 , whi coincident, or complex conjugates. • One zero at z =- b21br tha t the transfer s, we are also able to deduce From the backward shift form ess. proc ld -ho and y due to the samplefunction has the usual uni t dela The Transient Response Charact
eristics: Real Poles
ans ion of distinct, a par tial fraction exp and l rea are es pol the en Wh Eq. (25.125) yields: (25.128)
where the constants A 1 and A 2 are: (25.129)
and
(25.130)
sfer functions (25.128) is a sum of two pulse tran Thus the transfer function in Eq. tribution of con the and , the first-order system for h wit lt dea just e typ the of ure 25.5. To t response is as illustrated in Fig each term to the overall transien to pro duc e the tha t taking the inverse ofg (z) see this more explicitly, not e ' impulse response, g(k), gives: (25.131) : whe n the poles are distinct and k-l; k;:: l g(k) = blk pk- l+b 2(k -l)p
(25.132)
whe n the poles are identical. we mig ht transient response shows up, as A significant difference in the will be case this s; of complex conjugate pole expect, wh en we have a pai r treated below.
OF DISCRETE-TIME SYSTEMS CHAP 25 DYNAMIC ANALYSIS
915
and A 2i they only through the constanb!:i> A 1 The effect of the zeros are felt olutely no abs :ise tributing response, but exe rc:: tely: this fini affect the magnitude of each con inde ws e dies out with time or gro influence on whether the respons s. rmined by the pole aspect of the response is solely dete ~les eristics: Complex Conjugate Pc:J The Transient Response Charact as: jugates, they may be exp res sed When the poles are complex con (25.133)
or, in the polar form as:
(25.134)
where, as usual:
(25.135)
and OJ*
= tan- 1 (
:: )
(25.136)
the pul se par tial fraction exp ans ion of Un der these circumstances, a transfer function gives: A2z-t A1z-l (25.137) r*e-it»•z-1 1 + 1 o*zg(z) = 1 - r*eic ulti ng com ple x sforms, con soli dat ing the res and upo n tak ing inverse tran se response in pul U:n tity, and tidying up, the exponentials usin g the Euler iden this case is obtained as: g(k)
= C(r*)k- 1 cos [w *(k -l)+ l{l ]; fork~l
(25.138)
dix C). related to A1 and A2 (cf. Ap pen where the constants C and l{l are oscillatory; icated in Eq. (25.138) wil l be It is clear tha t the response ind real and the by en tak al numerical values r* and e however, dep end ing on the actu tud gni ma the y, entl es (or equival lita tive ima gin ary por tion s of these pol qua es of identify the four different typ arg um ent w•) it is possible to ry response sho wn in Figure 25.6:
oscillato
1. r* > 1, w• :F. 7t
2. r*
=1, OJ* ::f. 1t
3. r* < 1, w* ::t-1t 4. r* < 1, w" = 1t
(Poles outside the uni t circle) ing am plit ude g(k) is oscillatory with increas (Poles on the uni t circle) t am plit ude g(k) is oscillatory wit h constan (Poles inside the uni t circle) g(k) is dam ped oscillatory t circle) (Coincident poles inside the uni the h wit i ory illat g(k) is dam ped osc with ng cidi coin ion illat osc frequency of OJ cy, uen 5 freq g samplin
916
COMPUTER PROCESS CONTR OL
Fig ure 25.6.
Imp ulse responses of the seco nd-order process wit h a ZO H as a function of the location of the complex con jugate poles (adapted from Ref. [4]).
The Type 4 response requires some sp~ial mention. Since (J),. = n:, the two pol are located at z = r*e+ Jtt, and es z = r•e- Jn:. Using the relation z = e51ll, we easily deduce tha t the correspondin g poles in the s-plane have ima ginary par ts n:/ M and ..:.n;f h.t; i.e., these pol es are located exactly on the upp er and low er bou nda ries of the primary stri p in the s-plane. Because the se imaginary par ts are sep ara ted by a factor of precisely 2n:/ At= (1)5 , we see tha t the y wil l ma p into the single pole in the uni t circle indicated by the number 4 in Figure 25.6.
Dy na mi c Response of Gener al Discrete-Time Processes wi th ZO
H
The pulse transfer function of a general process incorpora ting a ZO H has the form: (25.139)
wh ere the additional z-1 term has occurred as a result of the sampling and hol d process. Let us now observe that upo n decomposing Eq. (25.139) into fractions, we wil l obtain onl simpler partial y two typ es of terms: the typ e corresponding to those poles in Eq. (25.128) of A(z -1) tha t are real, and the type in Eq. (25.137) cor res pon din g to those pol es tha t are complex conjug ate pairs. Thus the tran sie nt res pon se of any gen eral sam ple d-d ata process will simply be an app rop riat e combination of the transient responses catalo ged in Figures 25.5 and 25.6, as det erm ine d by the nat ure of the poles of the den om ina tor polynomial. These transien t responses therefore constit ute the basic building blocks from which the respon se of any other linear process can be deduced. Again, as noted in the discus sion of the second-order pro affect only the magnitude of cess, the zeros each contributing response; they do not affect the ultimate behavior as k ~ oo. So lon g as the zeros all lie wit hin the uni t circle, not much else can be said in term s of their influence on transien t responses. Discrete processes wit h zer os out sid e the uni t circle beh ave like the ir con tin uou s cou nte rpa rts wit h zeros in the right-half pla ne: the y exhibit inverse-response behavior.
2
cc
0\
;~,
.?l
CHAP 25 DYNAMIC ANALYSIS OF DISC RETE-TIME SYSTEMS
917
We may now sum mar ize the effec t of pole s and zeros on the dyn ami c behavior of discrete systems as follo ws: 1. Real pole s with in the unit circl e cont ribu te tran sien t responses that ulti mat ely die out with time ; if the pole s are posi tive , the cont ribu tion s decrease monotonicall y; if the pole s are negative, the contributions alternate in sign while decreasing in mag nitu de, an effect sometimes referred to as "ringing." 2. Real pole s on the unit circle cont ribute transiP.nt responses that neit her grow nor decrease with time; alternati ng sign changes accompany the response whe n the pole is located at z = -1. 3. Com plex conj ugat e pole s alwa ys occu r in pair s, and they alw ays contribute oscillatory transient response s. 4. Com plex conjugate pole s loca ted with in the unit circle con tribu te dam ped oscillatory behavior; the freq uency of oscillation is equa l to the ima gina ry part . 5. Complex conjugate poles whose real part s lie with in the unit circle but who se ima gina ry part s are mul tiple s of ±1t. app ear as a dou ble pole loca ted on the real axis; they contribu te dam ped oscillatory responses with the frequency of oscillation iden tical to the sam plin g frequency, ro5• These types of poles arise from sam plin g a continuous process who se pole s hap pen to be located at s =-a ± C05 /2. (Note the relationship of the continuous system pole to the sam pling frequency.) 6. A conj ugat e pair of pole s on the unit circle con tribu te sust aine d oscillatory responses. 7. Any pole outs ide the unit circl e cont ribu tes a resp onse that grow s indefinitely with time; the response will be oscillatory with increasing amp litud e if the poles are complex conj ugate pairs. 8. There is no simple, general way to characterize the effect of zeros that lie with in the unit circle: they affec t the mag nitu de of the contributed resp onse s but not the ultimate beha vior; zeros that lie outs ide the unit circle contribute inverse-response tran sient behavior. 9. Time delays cause a shift in time response; they also contribute poles at the origin of the complex z-plane.
25.3
BLOCK DIA GR AM ANALYSIS FOR SAMPLED-DATA SYSTEMS
Wha t dist ingu ishe s a sam pled -dat a control syst em from its pure ly cont inuo us coun terp art is that it consists of a discr ete controller - which accepts and give s out only disc rete signals - in conj unction with a continuous syst em who se '•
OL COMPUTER PROCESS CONTR 918
~
e*(t)~
--
~
DISCRETE R
,-.- CONTROLLE
y"'( t)
~
_j - ,
IDLD
SAMPLER .....
oo mu oo s
PROCESS
II
y(t )
I ..
------------------~
~---------------'~-Figure 25.7.
ta control system. Basic elements of a sampled-da
the discrete inp uts be sampled, and for wh ich now st mu s put out ous tinu con ear continuous wit h a troller mu st be ma de to app pro duc ed by the discrete con t is illustrated in Figure 25.7.
refore consist hold element. This concep ation of such systems will the ent res rep tic ma gra dia ck The blo nnecting continuous ll as sampled signals interco we as ous tinu con of e tur mix of a functions. as well as discrete transfer sampled-data systems t block dia gra m analysis for tha ar cle It is therefore block diagrams are tem sampled-data control sys feedback control can not be han dle d cavalierly; ous tinu con ns of the familiar sio ver d tize cre dis re me t not jus valuable concepts and Ho we ver , the re are som e . ms gra dia ck blo tem sys d-d ata sys tem blo ck rify and sim pli fy sam ple pri nci ple s tha t hel p to cla sen t these next. dia gra m analysis; we wil l pre
ts an d Principles 25.3.1 Some Useful Concep ansfer Functions No tat ion for Signals and Tr m continuous tinguish sam ple d signals fro dis to d use is (•) bol sym r A sta um ent indicates the chment. As usual, an (s) arg atta h suc no ry car t tha s nal sig um ent indicates the icated signal, while a (z) arg Laplace transform of the ind st be discrete. mu signal which, by definition, z-transform of the indicated
sform Concept The us ta" ed # Laplace Tran nal is ind ica ted by a discrete (or sampled) sig The Laplace transform of rod uce d in Ch apt er int s transform; it wa e lac Lap ed" arr "st led cal j"(s), the so24, in Eq. (24.3): (24.3) 41
..
f*(s) == L{f *(t) }
= "~f
orm u*(s) and the "st arr ed" Laplace transf The transfer function relating d as: n define y*(s) is the s•-transfer functio y*(s)
= g*(s) u*(s)
(25.140) ·J·•
s. sform of two sampled signal It relates the Laplace tran
Two Basic Problems block dia gra m wit h two pro ble ms in the ned cer con lly ica bas are We tems: analysis of sampled-data sys
919 RETE-TIME SYSTEMS CHAP 25 DYNAMIC·ANALYSIS OF DISC ts with continuous systems, e.g., u•(s) 1. The com bina tion of sampled inpu with g(s), and function relat ions to puls e transfer 2. The conversion of s-do main transfer function relations.
The first prob lem is easily resolved:
regardless of tohat input it By the nature of a continuous process, receives, its output is always continuous. Thu s, we have that:
y(s)
= g(s) u*(s)
(25.141)
(*)i n y(s) indi cate s it is the Lapl ace whe re the abse nce of a star sym bol transform of a continuous signaL the puls e tran sfer function relation The seco nd prob lem is that of obtaining of the type : (25.142) y(z)
= g(z) u(z)
41}, and it cons ists of three parts: (1) from expr essio ns of the type in Eq. (25.1 hold need s to be adde d to g(s); norm ally deci ding whe ther or not a zero -ord er rete version of the cont inuo us signal (i.e., this is requ ired ; (2) obta inin g the disc finally (3) obta inin g the z-tra nsfo rm of obta inin g y•(s) from Eq. (25.141)); and e er hold is adde d, the resu lting puls the disc retiz ed sign al. If a zero -ord The lts. resu (z) KNn then , used is hold tran sfer func tion is g(z), whe reas if no following "sta rred " Laplace tran sfor m the g usin by eved achi is on mati sfor tran resu lts.
,,
'(
Res ults The Basic "Starred" Laplace Transfonn
·' }t,..
Obta inin g "Sta rred " Transforms from a
Product of Transforms
Give n the cont inuo us signal, y(s), resulting y(s)
from a sam pled inpu t u•(s):
= g(s) u*(s)
(25.143)
n by: then, the sam pled outp ut, y•(s), is give y*(s)
= [g(s) u*(s)J* = g*(s) u*(s)
(25.144)
k diag ram anal ysis for sam pled -dat a This very usef ul resu lt is cent ral to bloc . [2, p. 184-5], and [4, p. 86] systems; its proo f may be foun d in Refs Rela ting the "Starred" Tran sfor m to the
z-Transform
to us: The key resu lt here is alrea dy familiar
transform is actUillly nothing but By definition, the "starred" Laplace z. Thus the z variable may be 541 by e replaced :·.::·
the z-transform with notation for the (implicit) considered a more convenient, "shorthand" may therefore be used "starred" transform variable, and the two interchangeably.
COMPUTER PROCESS CONTROL has alre ady ined earlier in Cha pter 24 and Recall that this result was obta for block tion lica imp n mai The chapter. bee n use d liberally in this curr ent diag ram analysis is that:
920
y*(s ) = g*(s) u*(s)
is completely equivalent to: y(z)
(25.145)
= KNH (z)u(z)
in our will become clearer as we now beg The application of these results . discussion of block diagram analysis
ms 25.3.2 Open-Loop Blo ck Diagra
Single Elements a single sho wn in Figure 25.8 containing Consider the simple block diagram lysis is ana ram diag k this rather simple bloc process element. The objective of . u(z) to y(z) ting transfer function rela to obtain the z-domain puls e Clearly from this block diagram: y(s) == g(s) u*(s)
resu lt in "sta rred " transforms; from the Next we obta in y"(s) by taki ng Eq. (25.144}, we get y*(s) ::: g*(s) u*(s)
in that: from where we immediately obta y(z)
= gNH(z)u(z)
e, that: If we are now given, for exampl K
g(s)
= -rs +
(25.146)
1
tran sfer us that the corr esp ond ing pul se this block diag ram analysis tells function is: (25.147)
u(t} u(s)
Figu re 25.8.
/
u*(t} u*(s )
g(s)
y(t)
y*(t) .,.
y(s)
y*(s )
le element.
Open-loop block diagram with a sing
921
RETE-TIME SYSTEMS CHAP 25 DYNAMIC ANALYSIS OF DISC
ple 24.6. where 1/J = e-AttT, as obtained earlier in Exam zero-order hold is added to g(s) as the when that Recall from Example 24.7 tion for the first-order process is: is usual practice, the pulse transfer func g
() _ K(l z - 1-
4!) z- 1
cpz
(24.101)
I
Series Elements in Figure 25.9 containing two continuous Consider now the block diagram shown an intermediate sampler. Again, the process elements in series separated by is to obtain the z-domain pulse transfer objective of the block diagram analysis function relating y(z) to u(z). The analysis proceeds as follows: (25.148)
y(s) = g2(s) v*(s)
and
(25.149)
v(s) = g 1(s) u*(s)
(25.149), intro duce the resu lt into We now wish to obta in v*(s) from Eq. consolidated expression. Eq. (25.148), and then find y"(s) from the Eq. (25.149}, we obtain: App lyin g the result from Eq. (25.144) in (25.150)
= g*1(s) u*(s)
v*(s)
gives: which whe n introduced into Eq. (25.148) (25.151)
, we finally obtain: and upon applying the Starred" transform 11
(25.152)
= g*2(s) g* 1(s) u*(s)
y*(s)
We now straightforwardly obtain the requ
ired z-transfer function relation as: (25.153)
= Kw/..z) KtNJ..z) u(z)
y(z)
on either sampler. where we emphasize that there is no hold all puls e transfer function for the over the that is here on The implicati puls e transfer functions of the the of process in Figure 25.9 is the prod uct if: indi vidu al elements. Thus, for example,
Kt
Kt
~u*(tl u(s)
Figu re 25.9.
u•(s)
gt(s)
(25.154a)
= -rls +
v(t)
v*(t)
v(s)
v•(s)
~
g,(s) y(s)
y•(s)
ents in series with an inter medi Open-loop block diagr am for two elem sampler.
ate
COM PUT ER PROCESS CON TRO L
922
~ u*(t)
__;,_; ._
u(s)
gl (s)
u*(s)
v(t)
g2 (s)
y(t)
~
y(s)
v(s)
y*(s)
series with no ram for two continuous elements in Figure 25.10. Open-loop block diag intermediate sampler.
and
(25.154b)
will be given in this case by: then the overall pulse transfer function
(25.155)
each indi vidu al z-transfer functions for obtained by simp ly multiplying the first-order process. s whe n the two elements in series are A completely different situation arise as indicated in Figure 25.10. Let us g, continuous, with no intermediate samplin e transfer function relating y(z) to u(z) puls now proceed to obtain the z-domain for this case. From the block diagram: (25.156a)
and
v(s)
= g 1(s) u*(s)
so that:
(25.156b)
(25.157)
ed ects y(s)'to u•(s) in Eq. (25.157) (and inde We mus t now observe that wha t conn sfer tran us inuo cont , two of bination in the block diag ram itself) is a com one single - but still continuous into d bine com be may ch whi s function ind will refer to as g28'1(s) simply to rem composite transfer function, which we as: ten writ be may 57) (25.1 , i.e., Eq. us of its individual component elements (25.158) y(s) = g-zg 1(s) u*(s) whe re We may now apply the star transform
(25.159)
to Eq. (25.158) to obtain:
RETE-TIME SYSTEMS CHAP 25 DYNAMIC ANALYSIS OF DISC
and finally:
923
(25.160)
) repr esen ts the z-tra nsfo rm of the It is imp orta nt to note that g 2g 1 NH(z tion mad e up of the prod uct
nsfer func discretized version of the composite s-tra ) is the prod uct of the indi vidu al NH(z (z)g1 g2NH , hand r othe g 2 (s)g 1(s); on the of g 2(s) sepa rate ly, and g 1(s) ions z-tra nsfo rms of the disc retiz ed vers separately. In general: (25.161) We therefore have that: is not always the same as the The z-transform of a product of functions product of their individual z-transforms. ession intro duce d in Eq. (24.102) when This is a more general form of the expr deal ing with the ZOH element. e the impl icati on of Eq. (25.161), To conclude, as well as to driv e hom tran sfer func tion s are as give n in obse rve that if, in Figu re 25.10, the Eq. (25.154), thet;t, first, we have that:
te version of this second-order, composi and the z-transform of the discretized transfer function is given by:
nsform (for -; :1- -r1 ), we then have that and upo n eval uatin g the indicated z-tra be given in this case by: the overall puls e transfer function will (25.162)
in Eq. (25.155) for the sam e tran sfer whic h is not the sam e as that obtained ent block diag ram of Figure 25.9. function elements arra nged in the differ the situa tion in Figure 25.9 and in Let us repe at the com pari son between inpu t samplers to have zero-order the Figure 25.10 except that now we require 01) and see that the overall tran sfer holds. In this case we can use Eq. (24.1 function in Figure 25.9 takes the form: (25.163)
COMPUTER PROCESS CONTROL
924
where 1/J; =e-Al/~,; =1, 2. This can be compared with Eq. (25.155), the situation without a ZOH. Following a similar analysis, we see that if the single sampler on the input to g 1(s) in Figure 25.10 has a ZOH, then the overall transfer function in Figure 25.10 becomes (cf. Appendix C):
(25.164)
In practice, Eqs. (25.163) and (25.164) which include the ZOH are the relevant
ones for discrete-time block diagrams of real processes. The next example illustrates in detail the block diagram with and without a zero-order hold. Example 25.5
THE EFFECf OF THE ZOH ELEMENT ON SAMPLED-DATA SYSTEMS.
Obtain the continuous-time response, y(f), of the process indicated in Figure 25.10, given that the input, u(f), is a unit step function. and that g1(s) and g2(s) are first-order processes given by Eq. (25.154). Determine the continuous-tim e response y{f) for two cases 1. Wheng1(s) includes a zero-order hold 2. When there is no zero-order hold
Solution: The unit step response with the zero-order hold can be found easily because the transfer function for the continuous process including the hold is: H(s) g 1(s) g 2(s) = ( 1 -
K- , K,-)(- e-slu)(s + -r s + 2
S
1
1
T2
)
1•
(25.165)
and recall that the sampled unit step input is: u*(s)
= 1 1-s4t -e
(25.166)
so that:
(25.167)
.
f.'
"
925
CHAP 25 DYNAMIC ANALYSIS OF DISCRETE-TIME SYSTEMS (a)
K1K y
I
0
11t
311t
211t Time
(b)
y
KtK2 ~~-Tt
11t
311t
211t Time
Figure 25.11. Continuou s-time response of two first-order processes in series to a sampled unit step function: (a) with the ZOH element; (b) without the ZOH element or in the time domain: (25.168)
which is sketched in Figure 25.11(a). The response without the zero-order hold can be found from removing H{s) from Eq. {25.167) to yield: (25.169)
Recall that u*(s) can be written: (25.170)
Introducing Eq. (25.170) into Eq. (25.169) now gives! y(s) =
~)(1 (~)( 1 't'2.1' + 1 't'S
+
+
e-sllr
+
e-2s111
+ ... )
(25.171)
COMPUTER PROCESS CONTROL
!ILb
in s merely introduces and if we recognize that the endless sequence of exponentials function obtained by se -respon impulse the into delays of the indicated magnitudes easily inverted to give is (25.171) Eq. in ion express entire the term, first the g invertin the following rather interesting response: O
K K
_1_2_ [ (e-r!T,- e-t/<1) '~"t - 1"2
y(t)
+
(e-
ll.t < 1 < 2ll.t
(25.172)
with time behavior shown in Figure 25.1l(b).
25.3.3 Closed-Loop Block Diagrams Chapter 14, we will If we refer back to our discussion in the early portions of
feedback control recall that the components of the feedback loop in a continuous ring device, a measu the itself, s proces the as: system were identif ied comparator, the controller, and the final control element. different; For the sample d-data control system, the situati on is slightly the old of some of ter charac the and added, been some new components have which the in 23.3 Figure to back refer we If ed. modifi been have components identify the sample d-data contro l system was introdu ced, we may now follows: as system control d-data sample a of components of the feedback loop 1. The process itself 2. The measuring device another for 3. A sampler for discretizing the continuous measurement, and discretizing the set-point signal ) 4. A comparator (performing its operations on discrete signals e) discret tely comple (now 5. The controller 6. The hold element 7. The final control element ns, not Of these components, the third and the sixth are the new additio fifth the and fourth the A; IV being part of the continuous feedback loop of Part ers. charact e discret have acquired new, completely
Transfer Function Relations for the Elements of the Block Diagram in Chapte r 14, in In the same manne r as we did for the contin uous system
n relations for Eqs. (14.1) throug h (14.5), we will now write the transfer functio . system control d-data the elements of the sample
(
927
SYSTEMS CHAP 25 DYNAMIC ANALYSIS OF DISCRETE-TIME
The Process:
y(s) = g(s) u(s) + gjs) d(s)
(25.173)
and the proce ss outpu t can We assume here that the process itself is continuous be made coontinuous; and can input s proces the that be measu red continuously; that the disturbance variable is continuous. The Measuring device (or sensor): Ym(s)
h(s) y(s)
(25.174)
The Sampler: is Y..m· Performs a discretization operation on Ymi its outpu t The Comparator: Is part of the discrete controller mechanism: E*(s) = y*Js)- y*m(s)
(25.175)
The Controller: Being completely discrete, operates according to: (25.176)
The (Zero-Order) Hold Element: Lapla ce transf orm Conv erts the discrete control comm and signa l (with orm c8 (s): transf ce Lapla c..(s)) to the (piecewise) continuous signal with cJ.s)
= H(s) c*(s)
(25.177)
The Final Control Element: signa l outpu t of the Converts the piecewise continuous control comm and le: variab input ss proce hold element to the actual (25.178)
result is the closed-loop If we now put all these eleme nts together, the 25.12. Figure block diagram show n in
ck control system Figure 25.12. Typical block diagra m of a digital feedba
.
COMPUTER PROCESS CONTROL
928
Closed-Loop Transfer Function Relations We are now in a position to use the same principles applied in developing openloop transfer function relations to analyze the closed-loop system in Figure 25.12. The objective here is to find z-transfer functions that relate the "sampled" process output, y• to the sampled set-point, y•d, and also relate the "sampled" process output, y• to the disturbance variable d (which we should keep in mind is not a sampled variable). Transfer Function Relating y(z) to y4 (z) In order to determine the response to set-point changes, let us begin with the process model in Eq. (25.173) and set d(s) = 0; the process input, u(s), is determined by Eq. (25.178), but since cn(s) itself is determined by Eq. (25.177),
we have: u(s)
= 8v(s) H(s)c*(s)
which, when introduced into Eq. (25.173) for u(s) gives: y(s)
= g(s) gJs) H(s)c*(s)
(25.179)
From this point on, we have two main tasks:· (1) determine y"'(s), and (2) obtain a closed-form expression for y"'(s) by eliminating c"'(s). By taking the usual star transformation in Eq. (25.179), we obtain: y*(s) =
(ggp] •(s)c*(s)
(25.180)
where the product of the three continuous transfer functions g(s)g11(s)H(s) has been combined into the single, composite, continuous transfer function ggvH(s), with "starred" Laplace transform indicated in Eq. (25.180). Next, we observe from Eqs. (25.176) and (25.175) that c•(s) is given by: (25.181)
•
In order to eliminate y•,.(s), we must now exercise some caution, because the only related expression we have is in Eq. (25.174), and it involves the continuous signal, y,., not y•,.. We must first reintroduce Eq. (25.179) for yin Eq. (25.174) to
give: Ym(s)
'
= h(s)g(s) 8v(s) H(s)c*(s)
(25.182)
and then take the star transform in order to generate the required expression for y*,.(s). Here we make the product h(s)g(s)g 11 (s)H(s) into the composite hgg-~(s), and take the star transformation to give: y*m(s)
= (hggJf] * (s)c*(s)
(25.183)
We may now safely introduce Eq. (25.183) into Eq. (25.181) and solve for c"(s} to yield: c*(s) = [
g*c(s)
•
]
1 + (hggJf] (s)g*c(s)
y*,/..s)
(25.184)
CHAP 25 DYNAMIC ANALYSIS OF DISCRETE-TIME SYSTEMS
929
If we now eliminate c•(s) from Eq. (25.180) by introducin g Eq. (25.184) we obtain the starred transfer function relationship:
y*(s)
(gg.HJ* (s)g*c(s)
=[ 1
+[hgg.H]
*
]
y*J.s)
(25.185)
(s)g*c(s)
Let us now simplify our notation by introduci ng the following composite continuous transfer functions, the product of all the continuou s transfer functions in the forward part excluding the controller: gj.s)
= g(s)g.(s) H(s)
(25.186a)
and B!(s) = h(s)g(s) g.(s)H(s)
(25.186b)
the product of all continuou s transfer functions in the feedback loop (again, excluding the controller); then Eq. (25.185) may be written as: g*j..s)g*c(s)
y*(s)
Jy*J.s)
= [ 1+g*l,s)g*c(s)
(25.187)
We may now simply recast Eq. (25.187) in the z-transform notation to obtain the required closed-loop transfer function relation: (25.188)
The introduct ion of the composite transfer functions gj.s) and g1(s) is more than just a notationa l convenience; it permits the developm ent of a simple, error-proo f procedure for obtaining closed-loop transfer functions for sampleddata systems without having to go through a lengthy derivation every time. This procedure is now outlined as follows: 1. Obtain the product of all the continuous transfer functions in the forward path from the set-point signal to the process output signal. Be careful not to include the controller; it is discrete, and in any event, its transfer function is always presented separately in closed-loop transfer functions even for continuou s feedback control systems. Call this consolidated continuous transfer function gj.s). 2. Obtain g•j.s), the starred transform of this consolida ted transfer function.
3. Also obtain the product of all the continuou s transfer functions in the feedback loop (again, excluding the controller); let this be g1(s); also obtain the starred transform of this transfer function, g»1(s).
930
COMPUTER PROCESS CONTROL wil l be giv en tion for the closed-loop sys tem is eas ily 4. The star red tran sfo rm rela tion rela n ctio fun the z-tr ans fer by Eq. (25.187) fro m wh ich ). obt ain ed as given in Eq. (25.188
) to d(.z) Tra nsf er Fun ctio n Relating y(.z
iving the tran sfer ve ma y now be app lied in der The pro ced ure sum ma rize d abo put to disturbance changes. cess out put function relating the process out dis turb anc e sig nal and the pro n The for war d pat h bet wee the all tha t the rec r, eve how (s); g e transfer function, 4 st contains onl y the dis turb anc mu the refo re tinu ous , not sam ple d, and we dis turb anc e sig nal is also con the composite g4 d(s). cisely as in combine it wit h gd(s) to obtain ns in the feedback loo p are pre res pec t to The con tinu ous transfer functio h wit t, tha ly, ate we hav e, imm edi the las t der iva tion : thu s, disturbance changes:
[g4 d] •(s) y*(a)
= I + g*t_s)g*,Js)
so tha t in z-transform notatio y(z)
n:
= 1 + gt.z)gc(t.)
We ma y now combine the two obt ain :
closed-loop z-transfer function
(25.189) expressions to
(25.190) the corresponding ce bet wee n this expression and Observe the stri kin g resemblan r 14 for continuous systems. expression obtained in Ola pte Let us not e tha t (25.190) are mia ls in bot h por tion s of Eq. 1. The den om ina tor pol yno ide ntic al. al (because it is arate out the dist urb anc e sign sep not can we ugh tho n Eve 2. g d(s) can ed form for d(s), the composite 4 continuous), given any specifi can the n be obtained. . be formed, from which gd d(.z) t res pon se to det erm ine closed-loop tran sien to } 190 (25. Eq. ng usi In 3. anc e, the a cha nge in the inp ut dist urb eith er a set- poi nt cha nge , or solely by d t response will be det erm ine nat ure of the observed tran sien polynomial, ie.: the roots of the den om ina tor . (25.191) 0 1 + gf,:r.) Kc(Z)
=
··~
...:
.
·.
931 RETE-TIME SYSTEMS CHAP 25 DYNAMIC ANALYSIS OF DISC c is rem inis cent of the char acte risti 4. Obs erve that this expr essi on in ems syst back feed closed-loop equation obtained for continuous-time -dat a feed back con trol system pled sam the fact, in is, it Cha pter 14; isely the s3m e role as its prec s characteristic equation, and it play continuous-time counterpart.
with the follo win g example. We shall illustrate closed-loop analysis Exam ple 25.6
A FIRS T-O RDE R SYSTEM CLO SED -LOO P BEH AVI OR OF L CON TRO L. ITA DIG AL UND ER PRO POR TION
25.12, find se block diag ram is show n in Figu re Given the digit al control system who are given tions func fer set-point whe n the trans the response to a unit step change in the as follows: K h(.r) = I g.(s) = I; g(s) = - - ; TS + I H(s) = (
I
e-sllt) (theZOHelement)
- s
nal and the controller is a digital prop ortio
controller, i.e., g*c(s) = Kc.
Solu tion: cont inuo us transfer func tions in In this case, the consolidation of the 86) path in this case gives, from Eq. (25.1
the forward
= _ KI (1 -se"'"") TS
which is the same as g1(s) since h(s) =
1.
Discretizing the composite transfer func z-transforms, we obtain:
whe re If>= e"Mh . Since g*c(s)
tion in Eq. (25.192) and taking
= Kc' we have immediately that
fer function From Eq. (25.188), the closed-loop trans
y(z)
(25.192)
+
relation we need is:
COMPUTER PROCESS CONTROL
932 which simplifies to:
(25.193) To obtain the response to a unit step change in the set-point, we let yti
y(z) =
{
KKc(l - ~)z- 1 1 + (KKc-1,6(1 +KKc)]
}
z-1
1
----1
(25.194)
1-z
Before carrying out a z-transform inversion it is instructive to simplify the expression in winged brackets first, as follows:
Let (25.195) be the closed-loop transfer function pole in Eq. (25.194); then, solving for t/1 in terms of pgives:
so that
1 -t/1
=
1- p 1 + KK
(25.196) c
Introducing Eqs. (25.196) and (25.195) into the winged brackets in Eq. (25.194) now gives: 1 KetO- p)z- 1] y(z) = [ 1 _ P z-1 1 _ 4 -1
(25.197)
where (25.198) is the closed-loop gain. The z-transform indicated in Eq. (25.197) is now easily inverted (d. Appendix q to give: (25.199)
Some comments about this step response are now in order: 1. Observe now that Eq. (25.199) is analogous to Eq. (14.42) obtained for the continuous system under classical proportional control. 2. Further observe that Eq. (25.198) is identical to Eq. (14.41a); however, Eq. (25.195) does not bear the same resemblance to Eq. (14.41b). 3. The fact that Eq. (25.195) is not analogous to its continuous-time counterpart expression is a critical point that provides us a glimpse into the major difference between continuous and sampled-data feedback control systems. As we will soon see, this is a difference with serious implications for the stability of sampled-data control systems.
933
CHAP 25 DYNAMIC ANALYSIS OF DISCRETE-TIME SYSTEMS
STABILITY
25.4
A major recurring theme throughout this chapter is that once we have made the modifications required by the special character of discrete-time systems, all the techniques for continuous-ti me system analysis that we learned earlier carry over nicely for the analysis of discrete-time systems. This is especially true for stability analysis. As was the case for the continuous system, we are often concerned with whether or not the output sequence of a discrete system remains bounded in response to a bounded sequence of values for the input. While there are other means of defining system stability, this concept of "bounded-inp ut, boundedoutput" (BIBO) stability is usually sufficient. By analogy to the continuous-ti me definition of BIBO stability, we may now state that in response to a bounded input sequence, u(k), the dynamic output sequence of a system, y(k), remains bounded as k ~ oo, then the system is said to be stable; otherwise, it is said to be unstable.
If
It is important to remember that, strictly speaking, this definition has nothing to say about the behavior of the output of sampled-data systems in between sampling points. However, it requires a special pathological situation for an unbounded continuous signal to give rise to a bounded sampled sequence.
Therefore, it is standard practice to assume that a bounded sampled sequence implies a bounded continuous output signal
25.4.1 Conditions for Stability Recall that a continuous system is considered stable if the roots of its characteristic equation all lie strictly in tl1e left half of the complex s-plane. For the open-loop system, this translates to having all the poles of the openloop transfer function in the left-half plane; for the closed-loop system, it is the roots of the more complicated closed-loop characteristic equation that must lie in the left-half plane. Thus the stability region in the continuous domain is clearly the left half of the s-plane, with the imaginary axis as the boundary. From our discussion in Section 25.2.3, it was established, using the fundamental relationship between the variables s and z, that the region in the z-plane that corresponds to the left half of the s-plane is the interior of the unit circle (Figure. 25.2(b)). Thus, we are therefore able to deduce that the region of stability in the z-plane is the interior of the unit circle, with the circle itself as the boundary. We may therefore state that: A discrete system is stable if the roots of its discrete characteristic equation all lie strictly within the unit circle in the z-plane. Let us now discuss what this translates to in the open-loop and closed-loop cases-
Open Loop
For the general linear discrete system whose open-loop transfer function was given earlier as: (25.46a)
L COMPUTER PROCESS CONTRO 934 or
(25.46b)
hled as: the characteristic equation is def A(.1;- 1)
= 1 + a1z-1 + ¥
ll, the roots of which, we may reca of g(z). Thus:
2
+ ... + anz..,.
=0
have been previously referred
(25.200)
to as the poles
is n-loop pulse transfer function g(z) The discrete system with an ope of g(z) lie strictly within the unit s open-loop stable if all the pole circle.
For the multivariable system wh
en earlier ose time-domain model was giv
as: y(k )
= «
it can be shown tha t the charac
+ Bu (k- 1)
(25.31)
teristic equation in this case is:
141- Ul = 0
;:,_
(25.201)
mial in A., wit h es rise to an Nth-order polyno which, for an N x N system, giv stability condition is that: roots, A.1, i =1, 2, 3,..., N. The (25.202) IA.,I < 1; i =1, 2, ... , N AN IM PO RT AN T QU EST ION
relate the stability nt question that enables us to orta imp an ask now st mu We ing continuous systems to tha t of the underly pro per ties of a sampled-data system:
openes from sampling a continuous, Can the discrete system that aris unstable? op loop stable system ever be open-lo 25.2.3 and r back to our discussion 1n Section es of an To answer this question, we refe pol the are n , ... de tha t if s =s, i = 1, 2, z =f!IJ. are recall the earlier statement ma n ctio fun fer ans z-tr onding poles of the stable, is s-transfer function, the corresp tem follows: if the continuous sys d-data The implications here are as ple sam the t the case, observe then tha ction fun then s1 < 0 for all i; this being fer ans z-tr a e this system will hav g plin sam from ng ulti We res 0. 1 system if s1 < the uni t circle, since tf/J < 1 whose poles will all lie within therefore conclude that:
opensystem can never give rise to an An open-loop stable continuous em. loop unstable sampled-data syst
935 DISCRETE-TIME SYSTEMS CHAP 25 DYNAMIC ANALYSIS OF tion of the statement is true, the actu al loca Observe, how eve r, that while this e. tim the sam plin g the uni t circle will dep end on h.t,
poles within
Closed Loop feedback n relation for the typ ical dig ital The closed-loop tran sfer functio equation tic eris ract cha Eq. (25.190) wit h the control system was obta ined in given as: (25.191) 1 + 8/Z) 8c(Z) = 0
ites-transfer tion corr esp ond ing to the compos where g1(z) is the z-transfer func back loop, feed the in s ous transfer function function mad e up of all the continu the roots all le, stab be to em syst closed-loop exclusive of the controller. For the in the uni t circle. of Eq. (25.191) mus t lie strictly with AN om ER IMP OR TAN T QUEST
Let us now ask another important
ION
question, related to the pre vio us
one:
closed-loop stable under continuous Can a continuous system which is under digital control with the same control become closed-loop unstable controller parameters? ple, and stion by con side ring a very sim We shall ans wer this crucial que familiar, exa mpl e. A FIR ST- ORD ER SYSTEM CLO SED -LO OP STABILITY OF L CON TRO L. ITA DIG NAL UND ER PRO POR TIO g a first-order a digital control system involvin Investigate the stability properties of ortional control. process with a ZOH under digital prop
Exa mpl e 25.7
Solution: In this case, since K
g(s) = - - ; 'fS
+ 1
and
H(s)
=(
1_
I) e-SA s
we have back loop apart from the controller, are the only other elements in the feed that (25.203)
tion is: so that the corresponding z-transfer func EJ{z) =
K(l - l,&)z- 1 1 _ ~z- 1
(2:5.204)
' '~
COMPUTERPROCESSCONTROL
936
with~= e-Mir. And now, since g.(z) = ~,the characteristic equation for this closedloop system is given by:
which simplifies to yield:
(25.205) an equation whose single root is located at
z = p =f-(1-,)KKc
(25.206)
(recall Eq. (25.195) in Example 25.7). Let us observe the following about the nature of this root 1.
2. 3.
When K, = 0 (the open-loop case), the root is located on the real axis at z == ' == e-Mir, and since i-llt/r is always less than 1, we therefore have that 0 < ~ < 1, and the system is stable. As I<,; increases, the value of this root shifts to the left along the real axis. At the critical point when Kc = r, , where:
K* = c
1 ... ..
_:__;__z_
K(l-')
(25.207)
z = -1 in Eq. (25.206), and the root lies on the boundary of the unit circle; for values of Kc > K•,, the root falls outside the unit circle, and the system becomes unstable.
This last observation is quite significant recall that a continuous first-order system under continuous proportional control am never be unstable; we have just shown that ~e same system under digital proportional control can only be stable for controller gain values less than the critical value shown in Eq. (25.207).
Let us therefore note very carefully from this example that It is possible for a conHnuous system that is closed-loop stable under
continuous control to become closed-loop unstable under digital control, even with the same controller parameters. It must also be observed that in the simple example just:considered, not only is it possible for this system to go unstable, the critical controller gain value required for this system's closed-loop stability depends on the sampling time (through ~}. The influence of sampling time on the stability of this system is illustrated in the next example. Example 25.8
EFFECT OF SAMPLING TIME ON THE CLOSED-LOOP STABILITY OF A FIRST-ORDER SYSTEM UNDER PROPORTIONAL DIGITAL CONTROL
Examine the influence of sampling time on the stability properties of the closed-loop digital control system of Example '15.7.
CHAP 25 DYNAMIC ANAI.YSIS OF DISCRETE-TIME SYSTEMS
937
Solution : root of the From the expressi on in Eq. (25.206) for the location of the single K,, the gain r controlle of value fixed a for that observe we , equation characte ristic by: given is -1 critical value of 'for which the root becomes 'critical
=
'<
KK - 1 KK: + 1
(25.208)
'critical' the system will be \UlStable. Since Thus, for all values of 'for which value for the samplin g time Alaitical for which critical the e determin can we • = e-~>th, r gain: controlle this system is stable for any fixed
KK -
Atcrilical
1)
= - r In ( KK: + 1
(25.209)
Thus forM > AI critical the system will be WlStable.
rs Let us try to underst and this result in physical terms. Recall from Chapte ous continu a to hold der zero-or a adding of effects the of one that 24 23 and transfer system was effectively to add a unit time delay, which appears in the is delay time e effectiv this of 1 size the Since factor. zfunctio n as an extra II that Part from recall we since and At, time, g samplin the to ional proport unstable adding a time delay will cause a continuous first-order system to go results the then K,), large ntly sufficie (for control k under proport ional feedbac ize to general results These . andable underst quite are es exampl two last of the means time g samplin the ng increasi any order system and serve to wam us that systems that, for stability, we must "detune " the controllers for discrete-time in order to ers controll system ous continu " "detune to d require were we as just preserv e stability as time delays were increased.
25.4.2 Stabili lyTest s nation We have just established that, as with continuous systems, the determi the ating investig than more no s involve systems discrete of of the stability is It z. variable x comple nature of the roots of a polynomial equatio n in the to has one if nient inconve larly particu be clear, howeve r, that it will than a explicitly evaluat e the roots of characteristic equatio ns higher in order several are there , quadrat ic. Thus, as was the case for continu ous systems evaluat ing techniq ues for testing the stability of a system withou t explicitly a purely test, Routh the used we , systems ous continu for that the roots. Recall positive algebraic test that identifies the number of roots of a polynomial with if any test to used was it , analysis real parts. In its application to stability in the lie s, variable the in ial polynom a n, equatio eristic roots of the charact is the region stability the right-half plane. For the discrete system, because can that one be course, of will, test onding interior of the unit circle, a corresp of exterior the in lie that n equatio ristic characte in z-doma the identify roots of Refs. (see this to hes the unit circle in the z-plane. There are several approac es: [1-4]); however, here we will fOL""US on two of_the most common techniqu 1. The bilinear (Mobius) transformation technique 2. The Jury test
Each of these will be discussed in turn.
938
L COMPl.ITER PROCESS CONTRO
ation Technique The Bilinear (Mobius) Transform
Consider the following transfor
mation:
z+1 z- l
w =--
(25.210)
be sho wn tha t or Mobius transformation. It can which is kno wn as the bilinear the set of into nte d by I z I < 1 gets map ped rior of inte eve ry com plex num ber rep rese the s map ) 210 by I w I < 0, i.e., Eq. (25. complex num ber s represented e. lan w-p the left hal f of the the uni t circle in the z-plane into the variable ows: a polynomial equation in foll as is this of The implication the bilinear by z , z , Z:v ..., zit, can be converted z of the form P(z) =0, with roots 1 2a diff ere nt pol yno mia l equ atio n in the ) to tran sfo rma tion in Eq. (25.210 if the roots z 1, 0, wit h roots w1, w2, W:v ..., wit; = ) ll(w variable w, of the form true tha t the t circle, the n it will also be z 2, z 3 , ... , zit lie wit hin the uni of half the w-p lan e. , ••• ,wit will lie in the left cor resp ond ing roo ts w1, w2, w3 also be use d for usly for continuous systems, can Thus, the Routh test, used previo t half of the righ the in are ts w11 w2, w3, ..., wit det erm inin g if any of the roo of the roots equivalent to determining if any w-plane, and this will be entirely of the uni t circle in the z-plane. z1, z2, z31 ... , Znr is in the exterior w, gives: ), whe n solved for z in terms of The transformation in Eq. (25.210
w + 1
-z= w- l
(25.211)
for usin g the sho uld be noted. The strategy whe re the interesting sym met ry d: ility analysis is now outline bilinear transformation for stab n, P(z) = 0, ) for z in the characteristic equatio 1. By substituting Eq. (25.211 =0; convert it to the equation ll(w) respond to any roots of ll(w) in the RHP cor 2. Use the Routh test on ll(w); le. circ uni t roots of P(z) in the exterior of the s a substantial of P(z) to ll(w ) frequently require Unfortunately, the conversion al amo unt of usu the by on; this is the n followed am oun t of algebraic manipulati technique this lt, tesu a .As . ting the Routh test directly com put atio n involved in conduc tell can niques (see below) by which we is not as pop ula r as oth er tech ts inside the uni t circle or not. if a polynomial in z has all its roo
The Jury Test s-time" Routh e-time" version of the ucontinuou The Jury test is a truly "discret a pol yno mia l for ons and sufficient con diti test; it pro vid es the necessary 1 in absolute than less are t to hav e roots tha equ atio n (with rea l coefficients} on an array, or the uni t circle); it is also based value, (i.e., roots tha t lie within of the Jury tion and· the generation and applica table, just like the Rou th test;
939 TEMS SIS OF DISCRETE-TIME SYS CHAP 25 DYNAMIC ANALY tion and application of e resemblances to the genera table bears some remarkabl the Routh array. t. ure for applying the Jury tes The following is the proced " fonn: c equation in the "fo rw ard 1. Write the characteristi (25.212)
, is positive. where the leading term, a0
t of 2. Carry ou t the first par
the Jur y test:
.212) determine: By substituting into Eq. (25 (25.213a) II
P(-1) =
.L (-1 )"- i a. t=O
(25.213b)
I
I I
· 1. a,. < a0 , 2. P(1) > 0, and 1) < 0, for n od d 3. P(-1) > 0, for n even, or P(the n we can immediately ditions are not satisfied, con ee thr se the of any If it is no t necessary to ts outside the un it circle, and se tests are satisfied, conclude tha t P(z) has roo the if table. However, uns is tem sys e Th r. the proceed fur then proceed to Step 3.
and then test if
3. Generate the Jury table:
rs of rows making a
pai of n + 1 columns and n - 1 Th is is a table consisting oks, the Jury table is tbo tex st mo in that
uld be noted total of 2n - 2 rows. (It sho explicitly include the rows; we hav e cho sen to 3) (2n pre sen ted wi th cle e ar.) sons that will soon becom additional-final row for rea gen era ted from the in the Jur y tab le are s row the of nts me ele The stic polynomial as follows: coefficients of the characteri nts of the eve n ine d in pairs; the eleme erm det are s row the All the elements in 1. are always the reverse of num ber ed row of the pai r the odd numbered row. fficients of s (rows 1 and 2) are the coe row of r pai t firs of nts me ele The 2. reverse order. P(z) arranged in forward and ained from the uent pai rs of rows are obt The elements of the subseq ording to the acc 3. s row ly p~ding pai r of elements in the immediate las: following determinant formu
COMPUTER PROCESS CONTROL
940
TIIEJURYTABLE
Rowl Row2
Row3 Row4
RowS
en- 2
Cn-3
en -4
en -5
Row6
co
cl
c2
c3
•
• • •
Row2n-5 P3
P2
Pt
Po
Row2n-4 Po
Pt
P2
P3
qz
ql
qo
qo
ql
q2
• •
1Rnw2n-3 Row2n-2
bk =
ck
=
I
an
an -1-k
ao
ak+
I
I; k
cn-2
= 0, 1, 2, ..•, n -1
1
bn-2-kl ; k == 0, 1, 2, ..., n- 2
bn-1 bo
bk+
1
•
• •
qk = IP3 Po
co
P2-k Pk +
1
I
; k == 0, 1, 2
941
SYSTEMS CHAP 25 DYNAMIC ANALYSIS OF DISCRETE-TIME first colum n: 4. Deter mine stabil ity from the eleme nts of the
that all three tests in Step 2 The first neces sary condi tion for stabil ity is it is furth er neces sary that ity stabil for then true, is this above are satisfied. If elem ents in the first ated calcul the follow ing cond itions relati ng pairs of colum n be satisfied:
•
• •
ional row 2n- 2 allow s us to We may now obser ve that havin g the addit of elements in the first colum n. consi der the stability test as one invol ving pairs the neces sary and suffic ient are 4 Step The comb ined tests in Step 2 and unit circle and thus deter mine condi tions that all the roots of P(z) are inside the syste m stabil ity. following example. Let us illust rate the Jury test proce dure with the TAL CONT ROL STAB ILITY OF A CLOS ED-L OOP DIGI . TEST JURY THE G USIN EM SYST
Exam ple 25.9
digital control system is given as: The characteristic equati on for a certain closed-loop (25.214) 3 0.032z-4 = 0 2 P(z) = 1 + 0.4 z- 1 - 0.69[ - 0.256z- + Determine wheth er this system is stable or not. Solut ion: The equati on is not in the form requir ed by Eq. we obtain:
(25.212), but by multip lying by z
4,
(25.215)
0 P(z) = z4 + 0.4 z3 - 0.69 i- 0.256z + 0.032 = given by: which is in the required form, with the coefficients
= 1;
llo
a1
= 0.4;
a2
= - 0.69;
a 3 = - 0.256;
a4
= 0.032
in mind that n = 4 which is even. We may now carry out the first part of the test; keep 1. 1a4 I =o.o32 < 1 2. P(l) = 0.486 > 0 condition) 3. P(-1) = 0.198 > 0 (because n =4, we apply this are satisfied; we must now test the of part first the of tions condi three Thus, all the tesl the ete compl to proceed to construct the Jury table, ~'
J
\
COMPUTER PROCESS CONTROL
942
The table will consist of three pairs of rows; the elements of the first pair of rows are already known from the characteristic equation; so the elements we need to detennine are b., bl' b2, b31 for the second pair of rows, and for the last pair of rows, c0 stabilil:'f test; for and~· We may calculate c1 if we wish, but it is not necessary for the . below. shown table the in included is value its ss completene After going through the required determinant evaluations, the following Jury table is obtained:
-0.256 0.4
-0.69 -0.69
0.4 -0.256
-0.9990 0.2688
-0.4082 0.6679
0.6679 -0.4082
0.2688 -0.9990
0.9255 -0.5575
0.2283 0.2283
-0.5575 0.9255
Rowl Row2
0.032 1.0
Row3 Row4
RowS Row6
1.0 0.032
Examining the pairs of calculated elements in the first column of this table, we find that
0.9990 > 0.2688;
and
0.9255 > 0.5575
indicating that no roots of the characteristic equation lie outside the unit circle, from which we conclude that the system is stable. It is, perhaps instructive to note that P(z) may be factored as follows: P(z)
= (z -
0.8)(z + O.S)(z - 0.1 )(z + 0.8)
(25.216)
from where we see that indeed no root lies outside the unit circle.
As with the Routh test, it is possible to conduct the Jury test with unspecified values for controller parameters. The results of such tests will be the range of values of the controller paramete rs over which the closed-loop system will be stable (see Problem 25.10).
Other Methods It should be noted that other methods exist for studying the stability properties of discrete-time systems. Some of these other methods include:
1. The Root Locus Method (see Ref. [3]) 2. The Nyquist method (see Refs. [1, 3]) 3. Lyapunov's direct method (Ref. [1]). Another obvious choice is to use polynomial root extraction computer programs. When all the paramete rs in the characteristic equation are specified, and we are only interested in the roots, this is perhaps one of the most efficient ways to investigat e closed-loop stability.
RETE-TIM£ SYSTEMS CHAP 25 DYNAMIC ANALYSIS OF DISC
25.5
943
SUMMARY
vior of in som e deta il, the dyn ami c beha In this chap ter, we have expl ored g the usin s, ition cond oop ed-l clos as as well discrete processes und er open-loop pter Cha in d e tran sfer func tion intro duce tools of the z-tra nsfo nn and the puls 24. Lap lace tran sfer func tion , the By ana logy with the con tinu ous the tion wer e disc usse d extensively and characteristics of the pulse transfer func e Thes ed. blish esta tion ain tran sfer func rela tion ship to the cont inuo us dom open the ying stud in ks bloc ding buil as z-do main tran sfer functions wer e used ram diag k bloc pled -dat a proc esse s via and clos ed-l oop beha vior of sam rete in dete rmin ing the stab ility of disc lved invo es issu key analysis; then the systems were discussed. be summa..-ized as follows: The mai n lessons of this chap ter may bly simi lar to thei r cont inuo us-t ime 1. Disc rete syst ems are rem arka been have s tion ifica necessary mod dom ain counterparts so that once the char acte risti cs, nearly all of the ial spec r thei for unt acco mad e to ch are appl icab le in cont inuo uswhi lts concepts, techniques, and resu disc rete -tim e analysis. time analysis carry over dire ctly into arise by the proc ess of sam plin g a 2. How ever , whe n disc rete syst ems have a discrete syst em existing in a cont inuo us process, the fact that we analysis be don e with grea t care , cont inuo us envi ronm ent requires that . as illus trate d by seve ral examples ain resu lts that do not carr y over into 3. The re are certain cont inuo us dom the area of stab ility of clos ed-l oop in the disc rete dom ain, especially e is that whi le som e cont inuo ussyst ems . The mos t imp orta nt of thes ally , can nev er be clos ed-l oop time syst ems exist whi ch, theo retic -data· syst ems beca use of the pled sam unst able , this is not the case for the hold element. unit sam ple time delay intro duce d by red in this chap ter will become even The imp orta nce of the mat eria l cove desi gn we take on the issu es invo lved in the mor e evid ent in the next chap ter as of digi tal controllers. REFERENCES AND SUGGESTED
FUR THE R REA DIN G
, puter Controlled Systems, Pren tice- Hall Astr6m, K. J. and B. Wittenmark. Com Englewood Cliffs, NJ (1984) ) ms, Prentice-Hall, Englewood Cliffs, NJ (1981 2. Ogata, K., Discrete-Time Control Syste Control of Dynamic Systems, Addison-Wesley, al 3. Franklin, G. F. and J.D. Powell, Digit Reading MA (1980) ms, Discrete-Time and Computer Control Syste 4. Cadzow, J. A. and H. R. Martens, ) Prentice-Hall, Englewood Cliffs, NJ (1970
1.
944
COMPUTER PROCESS CONTROL
REVIEW QUESTIONS 1.
What determines the order of a pulse transfer function?
2.
How are the poles, the zeros, and the steady-state gain of a pulse transfer function determined?
3.
What does the time-delay term contribute to the pole-zero distribution of a pulse transfer function?
4.
What aspect of a pulse transfer function is responsible for contributing additional zeros at the origin?
5.
What is the fundamental relationship between the complex Laplace transform variable s and the z-transform variable?
6.
1he imaginary axis in the complex s-plane maps into what region in the z-plane?
7.
The entire left half of the complex s-plane maps into what region in the z-plane? What does this imply about the region in the z-plane into which the entire right-half plane is mapped?
8.
Why is the relationship between the z-plane and the s-plane not unique?
9.
How are the poles and zeros of a Laplace domain transfer function related to the poles and zeros of the corresponding z-domain transfer function?
10. Why is the number of zeros of a continuous process usually different from the number of zeros of the transfer function of the equivalent discrete process incorporating a ZOH?
11. A discrete process whose pulse transfer function has a zero outside of the unit circle will exhibit what type of dynamic behavior? 12. Why does the process of sampling a continuous inverse-response system not always produce a discrete system that exhibits inverse response? 13. How do the following characteristics of a discrete system's pulse transfer function affect its dynamic behavior? (a) Positive real poles within the unit circle (b) Negative real poles within the unit circle
(c) (d) (e) (f)
(g) (h)
(i)
G)
Real poles on the unit circle Complex conjugate poles within the unit circle Complex conjugate poles outside the unit circle Complex conjugate poles whose real parts lie within the unit circle but whose imaginary parts are multiples of± 1r Complex conjugate poles on the unit circle A pole outside the unit circle A zero outside the unit circle A time delay
14. What distinguishes the block diagram of a sampled-data feedback control system from that of a continuous feedback control system?
CHAP 25 DYNAMIC ANALYSIS OF DISCRETE-TIME SYSTEMS
945
15. What is the "starred " Laplace transform, and what is it used for? the same as those 16. Which components of the sampled-data feedback control system are common to both are which system; control feedback us ccntinuo nding of the correspo unique to the ely complet are which and but modified for the sampled-data system; sampled-data system? s for sampled-data 17. What is the procedu re for obtaining closed-loop transfer function systems? 18. When is a discrete system stable? p unstable 19. Can a continuous, open-loop stable system give rise to an open-loo system? data
sampled-
us closed-loop controlle r identical with even control, digital under control to become unstable parameters?
continuo 20. Why is it possible for a continuous system that is stable under
techniqu e for 21. What is the basic principl e behind the bilinear transfor mation determining the stability of a discrete system? 22. What is the procedure for applying the Jury stability test?
PROBLEMS 25.1
er system Given the following pulse transfer function model for a first-ord incorporating a ZOH element
y(z)
=
2.0(1- 1/!)z- 1 1 - ,z-1 u(z)
(P25.1)
Obtain the system's unit step response for the following values of 1/J : (a) (b)
(c) {d)
¢= 0.5 ¢=0.8 ¢=-0.5 ¢=1.5
of a firstPlot these responses and comment on the effect of ¢on the step response order system.
u and output y of a 25.2 Each of the following pulse transfer functions relates the input case: each For element. ZOH a ating incorpor process sampled (a) Evaluate the process steady-state gain (b) State the location of the poles and zeros (c) Write the corresponding difference equation process model {d) Obtain the process unit step response; and (e) Identify the process type (e.g., first-order, inverse-response, etc.)
COMPUTER PROCESS CONTROL
946
(3)
0.5z- 1 g(z) = 1- o.sz- 1 o.sz- 1 g(z) o.sz- 1 g(z) 1 - z- 1
(4)
g(z)
(5)
. g(z)
(6)
g(z)
(7)
g(z)
(8)
g(z)
(1) (2)
25.3
4.5z- 1 - 4z- 2 I- O.Sz 1 6.0z- 1 - 0.375z- 2 I + z- 1 + 1.25z- 2 - 0.43 ~z-t + 0.6093z- 2 I - 1.4252z- 1 + 0.4965z 2 (0.0995z- 1 + 0.0789z- 2)z- 6 1 - 1.4252z- 1 + 0.4965z- 2 0.5z- 1 I - 1.2z- 1
In Chapter 7, it was established that a system composed of two first-Qrder systems in opposition , i.e., whose transfer function is given by: (P25.2)
will exhibit inverse response, for K1 >
~~
when:
(P25.3) (a) Obtain the equivalent discrete-time result by deriving the conditions under which the system whose pulse transfer function (with ZOH element) is given below will exhibit inverse response: btz-1 g(z)
=
b2z-t
1-ptZ-1 -1- P2Z-I
(P25.4)
(b) By relating Eq. (P25.2) to Eq. (P25.4), show that in the limit as the sampling time ll.t tends to zero, the conditions derived in part (a) reduc~ to the conditions in Eq. (P25.3).
25.4
Establish the result given in Eq. (25.35).
25.5
For each of the block diagrams shown in Figure P25.1, determine the open-loop transfer function between y(z) and u(z). In each case:
1 s 5 3s + 1
the unit of time is minutes, and the sample time M =0.5 min.
947
SYSTEMS CHAP 25 DYNAMIC ANALYSIS OF DISCRETE-TIME y"(t)
u*(t)
t(t)
~--~ t( s)
lit
y"(s)
u*(s)
y"(t)
u*(t) t( s)
lit
....
y"(s)
u•(s)
Figure P25.1. 25.6
valve and measu ring device A process whose transfer function model (including as: ed dynamics) has been obtain 1.5 5.0 (P2S.S) y(s) 4.5s + 1 u(s)+ 2.ls +Td(s ) ck controller, including a ZOH 25.11 for this process and Figure in type the of m diagra block a Draw element. ns. relatio n obtain the closed-loop transfer functio
is to be controlled using a digital proportional feedba
l system. Obtain the closed-loop 25.7 Figure P25.2 shows a digital cascade contro en y(z) and d2(z). betwe and ;.z), y and y(z) n betwee transfer functions
Figure P25.2.
A digital cascade control system.
a thermo 25.8 In Problem 24.5, the transfer function model for as: () ~ 0.9(0 .3s-l ) () Y s - s (2.5s + 1) us
siphon reboiler was given
(P24.7 )
with the input and output variables defined as:
"
:::
y
=
(F s- F s *) (lb/hr) F s * (lb/hr) (h - h*) (ins) h* (ins)
-state operating conditions. Here, h• (ins) and F5* (lb/hr) represent nominal steady The time constants are in minutes.
948
COMPUTER PROCESS CONTROL Under digital proportional feedback control incorporating a ZOH element, with a sample rate of Ill = 0.1 min, obtain the dosed-loop pulse transfer function given that Kc = - 0.5. From the closed-loop transfer function, write the corresponding difference equation and obtain the process response to a unit step change in the normalized level set-point. Plot this response.
25.9
A proportional-only controller was designed for a first-order process by direct synthesis, in the continuous-time domain; the controller gain has been specified as: '!" (P25.6)
K'!",
where the K is the process steady-state gain, '!"is the process time constant, and '~"r is the time constant of the desired dosed-loop reference trajectory. (a) In attempting to implement the control system on a digital computer, a young engineer selected '!"/ '~"r = 3.0. A more experienced control engineer recommended that with such a selection, the sampling time, Ill, should not exceed 0.7'!", otherwise the closed-loop system might become unstable. Confirm or refute this recommendation. (b) Because of hardware limitations, it is not possible to sample this process any faster than l!t = '!". What is the maximum value of '!"/ '!", for which the closed-loop system will remain stable if At = '!"? 25.10 A process consisting. of two CSTR's in series is reasonably well modeled by the followi."1g transfer function model: y(s)
= (12.0s+
1.5 1)(5.0s+ l)u(s)
(P25.7)
The time constants are in minutes, and the valve and sensor dynamics may be considered negligible. (a) Show that under proportional feedback control in continuous time, the closedloop system is always stable, for all values of proportional controller gain KC" (b) Under digital proportional feedback control, incorporating a ZOH, find the range of Kc values for which the closed-loop system will remain stable if the sample lime Ill =1 min.
(c) Repeat part (b) for At= 5 min. 2-5.11 An approximate model for the reactor temperature response to changes in jacket cooling water flowrate was given for a certain reactor in Problem 24.4 as: -0.55 ("F/gpm) + 1)
g(s) = (5s- 1)(2s
(P24.6)
The time constants are in minutes. First show that the closed-loop system is stabilized under proportional feedback control in continuous time, with Kc = -4.0. Next, investigate the closed-loop stability of the digital control system employing the same controller (incorporating a ZOH element) with Ill = 0.5 min. 2.5.12 The dosed-loop transfer function for a digital feedback control system has been obtained as:
+ gjz)Kc
(P25.8)
CHAP 25 DYNAMIC ANALYSIS OF DISCRETE-TIME SYSTEMS with Kc = 2.0, and:
949
0.15z- 1 - 0.29z- 2 + 0.32z- 3 - 1 - 1.6z- 1 + 0.5z- 2 - 0.4z 3
,1 ) _
8J'z
(P25.9)
Investigate the stability of the closed-loop system: (a) Using the method of bilinear transformations and the Routh (b) Using the Jury test
array
25.13 For the first-order system with the transfer function:
0.66
g(s) = 6.1s +
(P25.10)
with the following a continuous-time-domain design has yielded a PI controller parameters:
6.7 0.66.il 6.7 rating a ZOH element, If this controller is now implemented in digital form, incorpo tuning parame ter .il the of values ble admissi of range the and with .O.t = 1, find digital PI controller the for function required for closed-loop stability. The transfer is: (P25.11)
a ZOH element, and first25.14 A closed-loop system consists of a proportional controller, function betwee n y(z) transfer pulse op open-lo The system. -delay order-plus-time by: given and u(z) (incorporating the ZOH) is (P25.12)
(a) What is the characteristic equation for this closed-loop system? the maximu m value of (b) For the specific case in which b = 0.09, and~= 0.86, find 0. = m if Kc for which the closed-loop system remains stable of time delays on (c) Repeat part (b) form= 1, and form =2. Comme nt on the effect . stability oop closed-l the range of Kc values required for ced in Problem 8.5, is the 25.15 The process shown below in Figure P25.3, first introdu facility. production end of a certain polymer manufacturing the polymer product The main objective is to control the normalized melt viscosity of s are defined as variable process t pertinen The . F to fy of ratio the 5 g adjustin by values: tate steady-s ate appropri from s follows, in terms of deviation ) u = ratio of the transfer agent flow to inert solvent flow (Fy/F5 ing pipe v = concentration of transfer agent measured at the inlet of the connect inlet reactor the at d measure agent transfer of ration w = concent y = normalized melt viscosity of polymer product at reactor exit
COMPUTER PROCESS CONTROL
950
Catalyst
Monomer
PIPE PREMIXER
REACTOR
Figure P25.3. The following transfer functions have been given for each portion of the process:
=
k:t..1_ 1 Os + 1
Premixer.
gl(s)
Connecting pipe;
g2(s)
e-6s
Reactor:
g3(s)
_2_5_ 12s + 1
the time unit is in minutes, and all the other units are normalize d units conforming with industry standards for this product. (a) We want to control this process using a digital controller, gc(z), incorporating a ZOH. Draw a block diagram of the type in Figure 25.12 for this process and obtain the closed-loop transfer function. (b) Under proportion al control with L!.t = 3 min, find the maximum value of Kc for which the closed-loop system remains stable. (c) By increasing the sample time to M =6 min. the delay is reduced to one sample time. Repeat part (b) for this choice of the sample time. In terms of the range of Kc values required for closed-loop stability, is there an advantage to increasing the sample time in this manner in order to reduce the delay time?
CHAPTER
26 DE SI GN OF DI GI TA L CO NT RO LL ER S r control ventional analog and digital com pute The major distinction between con by the ed rict conventional con trol ler is rest syst ems is that the con tinu ous , as the h suc s, form on simple, prespecified available hard war e elements to take ed mit unli y uall virt has digi tal con trol ler P, PI, or PID; by con tras t, the . take can rithm trol algo flexibility in the possible forms a con We digital controllers are designed. how with ed cern con is pter cha This a with g alon lf, digi tal con trol ler itse the star t with an intr odu ctio n to the hes: roac app ign des ler digital con trol discussion of the two fund ame ntal rete app roac h invo lves con stru ctin g disc rect indi The ct. dire gn indirect and the desi ous trollers obta ined by con tinu app roxi mat ions to con tinu ous con this er und fall that trollers and the othe rs methodologies; discrete Pill con discrete the direct app roac h, a com plet ely h Wit . first category are disc usse d ctly to dire s lead gn desi ler trol con ess, and repr esen tatio n is used for the proc full take ally techniques in this category usu e discrete controllers. The desi gn quit e efor ther and r by the digital com pute adv anta ge of the latit ude offered the than e ctur stru in ed icat mor e sop hist often resu lt in controllers that are on of cha pter concludes wit h a discussi The ers. troll con l sica discretized clas s. esse proc le tal controllers for multivariab issues involved whe n designing digi
26.1
NS PRELIMINARY CONSIDERATIO
shall book, unle ss othe rwis e stat ed, we As we hav e don e elsewhere in this ng suri final con trol elem ent and the mea con side r that the dyn ami cs of the one into ess with the dyn ami cs of the proc device hav e all bee n com bine d outp ut be designated as g(s). The inpu t and to overall process transfer function vely , ecti resp , y(t) and , desi gna ted as u(t) of this "ov eral l proc ess" shal l be in case the lly usua is This y(s). and sforms u(s) with corr espo ndin g Laplace tran data put a proc ess mod el by inp ut/ out prac tice bec aus e in iden tify ing valve separate out the contributions of the to correlation, it is usu ally difficult Ot::1
·~ 952
COMPUTER PROCESS CONTROL
~~Jl
dynamics, and those of the measuring device, from the collected input/outp ut data; thus it is precisely this overall transfer function, g(s), that is identified. Under digital feedback control, recall that the continuous input, u(t), received by the overall process is actually a discrete signal from the discrete controller that has been "made continuous " by the hold element; in particular, with a ZOH element, u(t) will be the piecewise constant input signal generated from the discrete sequence u(k), the control command signal from the controller. The controller itself is considered as receiving discrete error information, E(k), the difference between the sampled, desired set-point value, Yd(k), and the sampled process output, y(k). This digital feedback control system is shown in Figure 26.l(a). (The sampler at the input of the ZOH element is not explicitly shown because the block represents a combinatio n sample-and -hold device.) Observe that with the exception of u(t) connecting the hold element and the overall process, every other signal indicated in this diagram is sampled. If we now combine the ZOH element and the process, and refer to the composite transfer function as g~s), i.e.:
I
gn(s)
H(s) g(s)
l _ = (
e-'At) g(s)
s
(26.1)
then y(s)
= gn(s) u*(s)
(26.2)
and by taking "star" transforms, we obtain: y*(s) = gif.s) * u*(s)
and the equivalent
~-transform
(26.3)
representation is easily obtained:
y(z)
= g(z) u(z)
(26.4)
With this maneuver, all the explicitly indicated signals will now be discrete, and Figure 26.1(a) can be represented in the completely equivalent form shown in Figure 26.1(b). Once again note that we use g(z) with no subscripts to denote the discrete-time process having a zero-order hold, because this is the true equivalent of g(s) in control system design. Henceforth in our discussion, a reference to the "process" is to be understood to mean that entity represented by g, the overall process (plus valve and measuring device dynamics) incorporati ng the ZOH element. In a digital feedback control system, the only other component in the loop (as indicated in Figure 26.l{b)} will be the digital controller g, with discrete input e(k) and discrete output u(k). With these ideas in mind, let us now proceed to the task at hand: the design of digital controllers.
953
CHAP 26 DESIGN OF DIGITAL CONTROllERS (
u(k)
u(t)
ZOH
g(l)
u(o)
u*(a)
(a)
y d(k)+ y .
-
£(k)
•W
r.
u(k)
g(z)
u(z)
y(k) y(z)
(b)
Figure 26.1.
26.2
Two equivalen t fonns of a digilal feedback control system.
THE DIGITAL CONTROLLER AND ITS DESIGN
We begin our study of the issues involved in the design of digital controllers with an introduc tion to the digital controller itself, and the philosophies behind its design.
26.2.1 The Digital Contro ller A digital controller accepts a discrete sequence of error signals, e(k), and computes the discrete sequence of corrective control action, u(k), according to a discrete. control law that may be represented in the time domain, or in the z-domain.
z-domain Representation In the z-domain, the controller has the following pulse transfer function representation (see Figure 26.1(b)): u(z)
= gc(z) f(z)
(26.5)
In its most general form, the digital controller transfer function, gc(z), has the form:
(26.6)
COMPUTER PROCESS CONTROL
954
1 z-domain discrete control ·(i.e., a ratio of two polynomials in z- ) so that the law takes the form:
(26.7a)
or
eo + (} 1Z-1
( 1 u(z) =
+ lp'IZ-1 +
9
-2 2Z 'lf2Z-2
+
(}
-r
) + ··· + ,.Z E(z) + ... + 'l'qZ-q
(26.7b)
in Chap ter 25, the digita l As with the pulse transfer functions considered n as a ratio of polynomials controller pulse transfer function could also be writte shortly, the "back ward" shift in z as oppos ed to z-1; however, as we will see form in Eq. (26.6) is the more useful form.
Poles and Zeros of the Digital Controller note that the q roots From our discussion in Section 25.2 in Chapter 25, we polynomial equation:
of the (26.8)
of: are the poles of the digital controller, while the r roots
9(.z- 1) = 80+ 81z- 1 + 82z-2 + ... + e,.z-r = 0
(26.9)
other transfer functions, are the zeros of the digital controller. Again as with ss error signa l e(k) is proce to nds how the contr oller outpu t u(k) respo zeros. and poles these of determined by the natur e
Realization of the Digital Controller be convenient for analysis, While z-domain representations migh t sometimes be physically implemented let us keep in mind that the digital controller must given in the z-domain form in the time domain. Thus, when the control law is res that we obtai n the requi as in Eq. (26.7), physi cal imple ment ation times' know n as a timesome is this on; equiv alent time-domain representati doma in realization. ter 24 may be used for The proce dure described in Section 24.4.4 of Chap s. First rearra nge follow as deriv ing the time-domain realization of Eq. (26.7) to obtain: (26.10) or
(1
+
l{l 1z- 1
+
vr2z- 2 + ... + lJiqz-q )u(z) = 2 ( (}0 + e.z- 1 + 82z- + ... + e,.z-') E(z)
(26.11)
ITAL CONTROLLERS CHAP 26 DESIGN Of DIG r, we obtain ransform in the usu al ma nne Then by taking inverse z-t do ma in realization:
=
-- 2) +- .. + 'I'.,U(k- q) u(k) + llf1u(k - 1) + llf2u(k (k- 2) + ·-· 6oe(k) + e,e (k- 1) + 62e
which may also be written
+ 9,e (k- r)
955
the time-
(26.12)
in the recursive form:
+
u(k)
- q) = - ljf1u(k - 1) - l/f2u(k - 2) - -...2)-+l/f·-·9u(k + 6,e (k- r)
6oe(k) + e,t '(k - 1) + fJ2e(k
about this tim Let us note the following
e-domain form of the discre
(26.13}
te controller:
transfer function is ard to obtain if the controller 1. It is more straightforw form. given in the backward shift es past values of parts: the first par t involv ct tin dis two of ts sis con current and past 2. It the second par t involves the control sequence, while values of the error sequence. ues of the control u(k), dep end s on pas t val ue, val t ren cur the se y be considered 3. Becau portion of the control law ma this ), .13 (26 Eq. in ce uen seq ov ing average" of a t; the second par t is a "m the "autoregressive" par e current error ues of the err or sequence (th the "m ov ing total of r + 1 consecutive val as d ere pa rt ma y be con sid and r pa st values); this the str iki ng by d ate tiv mi nol ogy is mo ter ch Su t. par e" rag ave th the ARMA .10) and (26.13) bea r wi res em bla nce tha t Eqs. (26 s of time series average) sta tist ica l mo del {autoregressive, mo vin g ana lys is. " par t is determined by 'l'i, m the "autoregressive ~o on uti trib con e es of g,(z); the 4. Th directly rel ate d to the pol i = 1, 2, ... , q, wh ich are the oth er han d, is ov ing average" par t, on contribution from the "m ated to the zeros rel ly 2, ..., r, which are direct determined by fJ1 , i 0, 1, influence the es pol on cti ller tra nsf er fun tro con the us Th z). g,( of uence, while the pas t values of the control seq dependence of u(k) on the e on the error sequence. zeros influence its dependenc
=
Physical Realizability .12), or Eq. (26.13), the that as presented in Eq. (26 ed erv l obs n bee y ead alr It has u(k), the cur ren t con tro es the det erm ina tio n of law l tro con the d Ha dig ita l con tro l law requir n. y current and pas t informatio action, on the basis of onl uld have required tha t wo s thi 0, > i ere wh t), + E(k ing tain con ms ure (an d cur ren tly involved ter culated on the basis of fut cal be ion act l tro con t cur ren controller is said to be Un der such conditions, the n. atio orm inf le) lab vai una physically unrealizable. as follows: realizability may be sta ted The condition of physical
COMPUTER PROCESS CONTROL
956
The digital controller whose transfer function is as given in Eq. (26.6) is physically realizable if and only if the highest power of z in the numerator polynomial 8(z-1) is less than or equal to the highest power of z in the denominator polynomial, 'l'(z- 1 ). Thus, if RN represents the highest power of z in the numerator polynomial of g,(z), and R0 represents the highest power of z in the denominator polynomial, then for g,(z) to be physically realizable requires that: (26.14)
It is very important to note that the realizability condition can be checked directly from the backward shift form; it is not necessary to reexpress g,(z) in the forward shift form. Let us illustrate with the following examples. Example 26.1
PHYSICAL REALIZABILITY OF VARIOUS DIGITAL CONTROLLERS .
Test the following digital controller pulse transfer functions for physical realizability. (a)
g,(z)
(b)
g,(z)
(c)
g,(z)
(d)
g,(z)
3 + 2z- 1 + 3z- 2 1 + 4z 1 z + 3 + 2z- 1 + 3z- 2 I + 4z- 1 2z- 1 + 3z- 2 I + 4z- 1 z 2 + z + 3 + 2z- 1 + 3z- 2 z. 2 + 1 + 4z 1
(26.15) (26.16) (26.17) (26.18)
Solution (a) The highest P.ower of z in the numerator of Eq. (26.15) is 0 (note that the constant 3 is the same as 3z0), i.e., RN = 0; the highest power in the denominator is also 0, i.e., R0 =0. Thus, this controller is physically realizable, because RN =R 0 . Note that this controller is a special case of the one presented in Eq. (26.7). A time-domain : realization of Eq. (26.15) is easily obtained as: u(k)
= - 4u(k- 1) + 3E:(k) + 2E:(k- 1) + 3E:(k- 2)
(26.19)
which does not require any future information. (b) For the controller in Eq. (26.16), observe that the highest power of z in the numerator is 1, i.e., RN = 1, while for the denominator, R 0 · 0. Since in this case RN > R 0 , the physical realizability condition is violated, and the controller is not realizable. To confirm this conclusion, the time-domain realization of Eq. (26.16) may be obtained in the usual manner; the result is:
=
u(k)
= - 4u(k- I)+ E:(k + I)+ 3E:(k) + 2E:(k- I)+ 3E:(k- 2)
(26.20)
which is immediately recognized as being unrealizable because of the presence of the E:(k + 1) term.
957
CHAP 26 DESIGN OF DIGITAL CONTROLLERS R = 0; since in this case RN < R0 , (c) For the controller in Eq. (26.17}, RN = -1 while 0 domain realization in this case timewe conclude that the controller is realizable. The is easily obtained as: (26.2 1)
u(k) = - 4u(k- 1) + 2£(k- 1) + 3e(k- 2)
which is, of course, realizable. since RN =RDt we conclude that (d) For this controller, RN =2 and also R0 = 2 and ation in this case might appear realiz in the controller is realizable. The time-doma ion back into the time domain, we confusing at first; observe that upon the usual invers obtain, from Eq. (26.18): + 1) + 3e(k) + 2e(k- 1) + 3e(k- 2) u(k + 2) + u(k) = - 4u(k -1) +e(k + 2) + e(k
terms requiring future information. which, upon first examination appears to contain back by two, we obtain the entirely term each in However, by shifting the time index equivalent fonn: u(k) + u(k- 2)
- 4u(k- 3) + e(k) +e(k - 1) + 3E(k- 2) + 2£(k-
3) + 3e(k- 4)
or u(k)
= -u(k- 2) - 4u(k- 3) + e(k) + E(k- 1) + 3E(k- 2) + 2£(k- 3) + 3E(k- 4)
(26.2 2)
information. Note also that which no longer involves terms requiring future2 ;z-2 would have eliminated the zby on functi er multiplying the original pulse transf (26.22) could have been obtained positive powers of z, and the realization in Eq. directly.
er Des 26.2.2 Two Approaches to Digital Controll
ign
oller desig n are no different from Fund amen tally, the objectives of digital contr each case the aim is to obtai n a those of conti nuou s contr oller desig n: in rman ce criteria (typically that perfo d contr oller that satisfies some presp ecifie be no steady-state offsets, and that the closed-loop syste m be stable, that there e"). In digit al contr oller desig n, the dyna mic respo nse beha vior be "acceptabl oller. howe ver, the end resul t is a discrete contr one of two ways: 1his discrete controller can be obtai ned in ain desig n and then discretize 1. Carr y out the familiar conti nuou s dom or oller, contr the resulting continuous time, and obtai n the discrete 2. Carr y out the desig n directly in discrete contr oller directly. is as follows: with samp led-d ata The philo soph y behi nd the first appr oach a truly discr ete contr oller with a contr ol syste ms, even thou gh we have envir onme nt is still fund amen tally ss discretized view of the process, the proce can be obtai ned by carefully oller contr ete discr conti nuou s; thus a usefu l oller desig ned for the conti nuou s cons truct ing the discrete equivalent of a contr is the conti nuou s system; the oach process. The prim ary focus in this appr implementation detail. an dary, secon is discrete natur e of the controller
958
COMPliTER PROCESS CON TRO L
discrete controller is obta ined This is the indirect approach, since the us design, and has the advantage of indirectly from a fundamentally continuo which we are already familiar. with s relying on controller design principle show, lies in the fact that controllers The main disadvantage, as we shall soon well as the continuous controllers from designed this way may not perform as rollers are also limited in form to whic h they were obtained. These cont rs. discretized versions of continuous controlle perspective is switched, and the gn desi the , With the second approach roller with its discretized view of the prim ary focus is now the discrete cont n of the control system is now Figure process; the operational representatio ete. It is the direct appr oach beca use 26.1{b), whe re everythi11g appears discr directly. It has two main advantages: the design yields a discrete controller ation are already directly incorporated all the effects of sampling and discretiz rollers are only limited in form by cont into the design, and the resu lting broa d latitude in the designs that can realizability conditions. Thus there is result from this approach. oach is that the fundamentally The mai n disadvantage of the direct appr easily taken into account in this strictly continuous natu re of the process is not possible to obtain dose d-lo op system discrete-time approach; it is therefore ctives at sam plin g poin ts whil e beha vior that mee ts perf orm ance obje samples. exhibiting undesired behavior between
e Tim e 26.2.3 From Con tinu ous Tim e to Discret p control system to a sampled-data, The transition from a continuous closed-loo certa in issu es with very imp orta nt com pute r cont rol syst em invo lves implications for digital controller design.
The Effect of Sampling and Holding action on a piecewise continuous basis, Qualitatively, the application of control ess output, affect the control loop in and the intermittent sampling of the proc the following manner: actually operates in "open-loop" 1. In between samples, the control loop control action held constant by ied fashion, with the previously appl point when.the inpu t "jum ps" the ZOH device until the next sampling for the sampling duration. to another value at which it is, again, held is, in actual fact, exactly m Thus, the behavior of a sampled-data syste s. · onse resp step the same as a series of open-loop is available to the controller. Such 2. No intersample process information critical if the process outp ut loss of process information may become it is sam pled , are such that signal, and the frequency at whic h largely undetected at sampling unacceptable intersample behavior goes points. pter 23, the effect of the sampleQuantitatively, as was discussed in Cha m is approximately equal to addi ng and-hold device on the sampled-data syste of the process. To illustrate, let us a time dela y of llt/2 to the dynamics in solid lines in Figure 26.2; sampling consider the sinusoidal function show n
959
ITAL CONTROLLERS CHAP 26 DESIGN OF DIG
the sam ple d value time un its an d ho ldi ng t:.t of als uous erv int at on cti this fun indicated ste pw ise contin ng period produces the n of pli sio sam ver d the er fte ov shi a nt as sta con ction "ap pea rs" fun d ple sam the hed t tha das ve the imated by function. Obser on, which ma y be approx cti fun us uo tin con al the origin following lin e. ically by con sid eri ng the lyt ana d ate str on dem be This fact ma y H device: nsfer function of the ZO approximation to the tra 1 - e-s AI ~__;:_.-
s
J
~ + ... ( / "' -1 I - 1 + s6 t2! s =
6t(l- s~t
+ ... )
(26.23)
a Eq. (26.23) cor res po nd to in the par ent hes is in ms on ter s o ion tw t cat pli firs im e the t Th tha No te gn itu de t:.f/2. , a time delay of ma s: series expansion of e-st.t/2 be summarized as follow y ma d an significant, closed-loop stability are
dynamics of the e delay contributed to the The additional, effective tim s roM/2 radians sample-and-hold device add y reducing the sampled process by the reb the the process phase lag, (or 18 0ro / ro5 degrees) to rees), where ro,0 is deg (1) ol ians (or lBOroc 5 rad /2 M roc by 0 n rgi ma phase quency. , and ros is the sampling fre the crossover frequency
sed -lo op sta bil ity res po nsi ble for the clo ly ed nd ha gle sin is the first-order system This fac tor 25.8 of Ch ap ter 25 for ple am Ex in ved ser ob s propertie control. un de r digital proportional
al· Computer Control The Advantages of Digit
-loop control to conclude that a closed ing ego for the m fro d n un de r digital One might be tempte de r continuous control tha un ter bet m for per ays l ha s on e single, system will alw however. Digital con tro e, tru m fro we r far is is Th control. l: the computational po over conventional contro age trol ant con adv of n ng tio mi nta hel me overw allows the imple ter pu com l ita dig alo the en tio na l an g an d versatility of im ple me nt wi th co nv to ble ssi po im are t falls associated wi th str ate gie s tha un der sta nd ing of the pit r pe pro a th wi us, Th controllers.
Fig ure 26.2.
by the sam ple -an d-h old effective delay of l'lt/2 The introduction of ancontinuous signal. . operation applied to a
960
COMPUTER PROCESS CONTROL
digital process control, it is possible to exploit its advantages of available computing power and versatility in designing sampled-data control systems that will consistently outperform the conventional types.
26.3
DISCRETE PID CONTROLLERS FROM THE CONTINUOUS DOMAIN
The simplest, and the most familiar, digital controllers are the discrete PID controllers. These arise from approximating classical continuous PID controllers. Thus let us begin our study of digital controller design by investigating the form these controllers take, and the strategies available for their design.
26.3.1 Digital Approximation of the Analog PID Controller The continuous analog PID controller, as we may recall, operates according to the following equation in the time domain: (26.24)
where p, is the controller output when e(t) is zero. By defining u(t) as the deviation variable (p(t)- p5 ), Laplace transformation in Eq. (26.24) gives: u(.v) = gc(s) e(s)
(26.25a)
where the indicated controller transfer function, as we well know, is given by: (26.25b)
There are various ways of obtaining digital approximations to this controller. A popular method involves approximating the integral with the rectangular rule for numerical integration, and approximating the derivative with a finite difference, i.e.:
f
1
0
e(t) dt =
.f
e(i) llt
r= I
(26.26a)
and de e(k)- e(k- 1) dt "' llt
(26.26b)
The digital PID controller may be obtained by discretizing Eq. (26.24), using Eq. (26.26). Depending on how the result is presented, this digital controller can take one of two distinct forms: the position form, or the velocity form.
961
CHAP 26 DESIGN OF DIGITAL CONTROLLERS
The Position Form (26.26) directly we have: By discretizing Eq. (26.24) and substituting Eq. u(k)
/:it k .L E(i) = Kc {E(k) +1:1 r=l
1:D + -:< [e(k )- e(k- 1)]
}
(26.27)
u.t
samp ling point, this control This is know n as the position form because at each outpu t directly. oller contr law gives the actual value (position) of the be obtained by takin g may oller contr this for ion The pulse trans fer funct ve the z-tran sform of invol will z-transforms in Eq. (26.27). Observe that this e in simplifying this devic ing follow the y the indicated finite sum; let us emplo . aspect of the z-transform i.e.: Let S(k) represent the k term error sequence sum, k
S(k) ==
(26.28)
L E(i) i= I
then, clearly:
k-l
S(k- 1) =
(26.29)
_L E(i)
r= I
), we obtai n straig htforw ardly , and by subtr actin g Eq. (26.29) from Eq. {26.28 that: (26.30) S(k) = S(k- 1) + E(k)
If we now take z-transforms, we obtain: S(z) = z- 1S(z) + E(z)
easily rearra nging to:
S(z) =
C~ z-1)
(26.31)
E(z)
immediately obtain: We may now take z-transforms in Eq. (26.27), and u(z) = Kc [ e(z)
+ M1:1 ( 1 _1 z-1 )
e(z)
!:it ( I - z-1 )e(z) + 1:v
and by factoring out the common E(z) term, we obtai representation:
J
(26.32)
n the pulse transfer function (26.33)
by: with the controller pulse transfer function given (26.34)
COMPUTER PROCESS CONTROL COMPARISON WITH THE GENERAL DIGITAL CONTROLLER
The digital PID controller given in Eq. (26.27) may be expanded and rearranged to yield: 'T:o u(k) = Kc ( 1 + !it +
----;;;- e(k- l) -:r;-- Kc-cD)
(Kjl.t !it) 7: e(k) + 1
K/1t +-[e(k- 2) + e(k- 3) + ... + e(l)]
(26.35)
'CI
which takes the general form of a digital controller given in Eq. (26.13), with the following parameters:
Thus, the digital PID controller is seen to be a special case of the general digital controller presented earlier.
The Velocity Form Observe that by shifting the discrete-time index appropriately, we obtain from Eq. (26.27) that u(k - 1) is given by: u(k-1) = Kc {e(k- 1)
Jlt
k-l
+ - .I. e(i) + 7:/r=l
'CD A•
[e(k- 1)- e(k- 2)]
}
(26.36)
ill
and by subtracting Eq. (26.36) from Eq. (26.27), we obtain: !lu(k)
= Kc {[e(k) -
'Co !it e(k- 1 )] + 7:1 e(k) + !it [ e(k) - 2e(k- 1) + e(k- 2)]
}
(26.37)
where
ilu(k) = u(k)- u(k- 1)
(26.38)
This may be further rearranged to give:
This is known as the velocity form, since it represents the "change" in the position of the control variable. The pulse transfer function representation of the velocity form is easily obtained by taking z-transforms in Eq. (26.39); the result is:
963
CHAP 26 DESIGN OF DIGITAL CONTROLLERS
(26.40)
or, if we wish to repres ent this in terms of u(z), instea z-transform of Eq. (26.38) to yield:
d of ~u(z), we can take the
-1 u(z) --~ 1
-z
so that:
with g,{z) given by:
(26.41)
which is precisely the same expression one obtains COM PARI SON WITI I TilE GENERAL DIGIT AL
by rearra nging Eq. (26.34).
CONTROLLER
corres pondi ng expressions If we now comp are Eqs. (26.39) or (26.41) with the form for the digita l PID ity Eqs. (26.13) and (26.6), we see that the veloc ller, with the following contro l digita al controller is a special case of the gener param eters: lf/1
=-1;
60
= K, (1 + ~ + ~:}
~
=
lfli = 0; i > 1
Kc(~}
along with:
61 = - K,
c:~ + 1) ;
6;=0 ;i>2
l PID controller: The following points may now be noted about the digita or the velocity form. 1. It is physically realizable in either the positi on and the deriv ative in 2. If the appro ximat ions used for the integr al ple, we had used the exam for Eq. (26.24) had been differ ent (say, ard difference for the backw the and al, integr the trapez oidal rule for have been obtained derivative) completely different expressions would for the digita l PID controller. the positi on form; the 3. The velocity form has certai n advan tages over windu p. reset of most obvious is that it eliminates problems l PID controller may be A discussion of several opera tional aspects of the digita found in Ref. [1], p. 183, and Ref. [2], pp. 616-619.
964
COMPUTER PROCESS CONT ROL
26.3.2 Digi tal PID Controller Tun ing The most comm on appro ach to twtin g digit al PID controllers is to empl oy the same heuri stic rules used for tunin g conti nuou s PID controllers, i.e., the Cohe n and Coon , or the Zieg ler-N ichol s tunin g form ulas. The fund amen tal justi ficat ion is that for smal l samp ling times , the digit al PID contr oller beha ves much like the conti nuou s controller; thus conti nuou s controller settin gs may be conv erted for use with the digit al versi on. How ever, it is impo rtant to reme mber that the inclu sion of the ZOH adds an effective time delay of t:.f/2 to the proce ss time delay. For the situa tions when 6.t is not small, it is neces sary to adjus t the process time delay from a to (a+ t:.f/2) before carry ing out the conti nuou s design; this will ensu re that when the conti nuou s contr oller is discr etize d and impl emen ted in digit al form , the desta biliz ing effect of samp ling will be taken into account. It shou ld be noted that if the proce ss react ion curve is gene rated from the samp led-d ata proce ss befo re using the Cohe n and Coon tunin g meth od, the effect of the samp le-an dhold opera tion will alrea dy be inclu ded in the expe rimen tally gene rated data. Thus , we have that:
In general, digital PID controllers are tuned using the same classical techniques used for tuning continuous PID controllers, but with additional compensation for the effect of sampling time delay. Rega rdles s of the meth od used for tunin g, it is often good practice to have a first evalu ation of the controller perfo rman ce via simu lation when ever possi ble.
26.4
OTHER DIGITAL CONTROLLERS BASED ON CONTINUOUS DOM AIN STRATEGIES
The strat egy of desig ning digit al contr oller s for samp led-d ata syste ms by conv ertin g conti nuou s controllers originally desig ned for conti nuou s syste ms is not limit ed to PID contr oller s alone. In this section, we take a more gene ral appr oach to the subject: we pose the prob lem as that of obtai ning digit al appr oxim ation s to any arbit rary s-tra nsfer funct ion; the appr oxim ation form ulas gene rated there by may then be used for the specific appli catio n of conv ertin g conti nuou s contr oller trans fer functions (obta ined via conti nuou s dom ain designs) to digit al forms for use with samp led-d ata systems. I
26.4.1. Tech niqu es for Digi tal Approximat ion of Con tinu ous Transfer Functions · In Chap ter 25, we estab lishe d that the Lapla ce trans form varia bles (on whic h conti nuou s transfer functions are based ) and the z-transform variable (on whic h discr ete pulse transfer functions are based ) are relate d by: (26.42)
In usin g this to obtai n the discr ete equiv alent of an s-tran sfer function, g(s), it shou ld be recalled that the proc edur e calls for a Laplace inver sion to obtai n g(t), follo wed by discretization, to obtai n g*(t); only after this step can we take
CHAP 26 DESIGN OF DIGITAL CONTROLLERS
965
z-transforms, a process which we have shown to be exactly equivale nt to taking Laplace transfor ms to obtain g*(s), and then converti ng to the z-domai n via Eq. (26.42). Such a procedu re provides exact discrete-time equivalents, but it is clearly very tedious. It turns out, howeve r, that by replacin g Eq. (26.42) with approximations for e-sA1, we obtain relations between s and z that may be used to convert from the s-domai n to the z-domai n by direct substitution. Three of the most common approximants are now presented below: 1. Expansion of e-5~ 1 : A series expansio n for e-sM truncate d after the first two terms gives:
so that, Eq. (26.42) may be approxim ated as:
z- 1 =1-sM which rearranges to give: (26.43)
2. Expansion of 1/e~t: An alternative approxim ation may be obtained from a series expansion for the reciprocal function tfAt instead, viz.: ~ .. I +sM
(26.44)
so that e-slll is approxi mated by the reciproc al of the right-ha nd side of Eq. (26.44), with the result that z-1 =
1 +sM
which rearrang es to give: (26.45)
3. Pade Approximation: A final alternative may be obtained by using a firstorder Parle approxim ation for e-sll.t, i.e.: e-sAI ,
1 - s11tl2 1 + s!J.tfl
e-sAI ,
2-sM 2 + s/1t
(26.46)
2-sM 2 +sM
(26.47)
or
so that: z-1
COMPUTER PROCESS CONTR OL
966
and solving for s in terms of z, we obtain the Tustin approx
imation [3]: (26.48)
las may be obtained A more rigorous justification for these approximating formu differential equati on by considering the problem of numerically integrating the ce appro ach is differen rd backwa repres ented by the s-transfer function; if the d difference forwar the if result; the is (26.43) used, the appro ximat ion in Eq. and if the result; the is (26.45) Eq. in ion ximat appro the appro ach is used, ion in ximat appro the trapezoidal numerical integration appro ach is used, Eq. (26.48) is the result. ts have been The variou s prope rties of each of these appro ximan note that merely We 7). thorou ghly investigated in Ogata (Ref. [3], pp. 308-31 the most also is it te; accura most the Tustin 's approximation (Eq. (26.48)) is (26.43) is Eq. in n imatio approx nce differe ard backw complicated to use. The transfer pulse stable a easy to use; and, for a stable g(s), it will always produ ce function. known as Euler's The forward difference approximation in Eq. (26.45) (also er, it can be shown approximation) is almost as easy to use as Eq. (26.43); howev s-plan e into the the of half that because it maps certain regions of the left replaced by an be might g(s) stable a e, exterior of the unit circle in the z-plan arity with famili some with reader (The on. functi er unstab le pulse transf nown well-k the with ction numer ical metho ds will immediately see the conne ry ordina g solvin of d metho s Euler' stabil ity proble ms associ ated with differential equations.) ard difference Thus it is advisable to use either the Tustin or the backw differe nce ard backw the only appro ximat ion; for simplicity we will use s. follow what in approximation Eq. (26.43)
26.4.2 Trans lating Analog Cont roller Desig ns to Digital Equiv alent s la to translate some We will now use the backward difference conversion formu lents. equiva digital typical continuous controllers into
The PID Controller Given the PID controller, with the transfer function:
), we obtain the by replac ing s accord ing to the expres sion Eq. (26.43 appro ximat e digita l equivalent as: g ( z) = Kc [ 1 c
_ 1- + -,;D -I:J.t ( 1 - z 1) -rl + t:..t 1 - z-1
J
(26.49)
967
LERS CHAP 26 DESIGN OF DIGITAL CONTROL
tran sfer func tion obta ined earli er in whic h is, in fact, iden tical to the a verifiably appr opri ate approximation Eq. (26.34). The fact that Eq. (26.49), the Laplace transfer function shou ld from y to g,(s), coul d be obtained so easil the reasons why this appr oach is very not be lost on the reader; it is one of attra ctiv e.
The Direct Synthesis Controller t ral form ula for gene ratin g the direc Recall that in Cha pter 19, the gene be: to d foun ence trajectory was synthesis controller with a first-order refer
1 1 g (s) = 'f,S g
(19.6)
c
e the process with open -loo p transfer This is the controller whic h will caus ctory represented by a first-order lag function g(s) to follow the closed-loop traje with a time constant 'f,. me in Eq. (26.43), the digi tal Acc ordi ng to the appr oxim ation sche equivalent of this controller is: g (z) c
~ (-1-8 )1 • At t, 1 - z
=
=
1-z-•
(26.50)
/il
particularly simple: we take the process To apply this in a specific situation is lt = (1 - z- 1 ) I At, and inse rt the resu tran sfer func tion , g(s), subs titut e s trates this procedure. in Eq. (26.50). The following example illus Example 26.2
DIRECT SYNTHESIS DIGITAL APPROXIMATION TO THE CESS. PRO DER T-OR CONTROLLER FOR A FIRS
oller the cont inuo us direct synthesis contr Obtain the digital approximation for is given by : ion funct fer trans e whos m syste designed for a first-order g(s)
=
K TS
+ I
Solution: rearrangement Substituting s =(1- z-1) I M gives, upon some
..M L + 6t
T
g(s>l. = (' ·~r) =
{26.5 1)
(_T)z-1
I
1'
+ l'lt
desired controller as: and, by applying Eq. (26.50), we obtain the _
g,(z) -
1'
+
K
M(I- bz-
T,
l
- Z
-I
1)
(26.5 2)
COMPUTER PROCESS CONTROL
968 where
b
=
The time-domain realization of this controller is easily obtained as:
+lit)
("' )
1' - e(k)- u(k) = u(k-1}+ ( -
K1',
KT,
e(k-1}
(26.53}
which is recognized as a PI controller in the velocity form; it is, of course, also of the general digital controller form in Eq. (26.13).
The Digital Feedforward Controller In Chapter 16, we obtained the result that the controller required for feedforward compensation is given by: gj..s)
gjs)
= - g(s)
where g4(s) is the disturbance transfer function, and g(s) is the process transfer function. By simply substituting Eq. (26.43) for s in this expression, we would obtain gu(z), the digital feedforward controller. In particular, for the purpose of illustration, when g 4(s) and g(s) are assumed to take the first-order-plus-time-delay form, we recall that gff reduces to a lead/lag element, possibly with a time delay, i.e.: (16.20)
Assuming that the indicated time delay is an integral multiple of At, say, r =MAt, then, by observing that the substitution of Eq. (26.43) for ('B + 1) results in something of the form a (1 - bz-1), it is a trivial exercise to establish that the digital lead/lag form for the feedforward controller will be: _ K8 z-M(l - bz- 1) gjz) -
(1 - cz-t)
(26.54)
It is left as an exercise for the reader to ded_uce what the c~tants Kff, a, b, and
c are. Note that even this digital feedforward controller transfer function is a special case of the general form given in Eq. (26.6).
The Discrete Smith Predictor Algorithm The Smith predictor, first introduced in Chapter 17, is one of the earliest model-based control schemes. As we recall from the earlier discussion, with tb.e continuous domain control law given by: (26.55)
CHAP 26 DESIGN OF DIGITAL CONTROLLERS
969
the Smith predictor improves the closed-loop behavior of processes with transfer function g e-as by eliminating the delay from the closed loop. Here, g, is the classical controller designed for g, the process without the delay. It should be noted that this control law is not easy to implement in continuous time (cf. Ref. [1J, p. 238, and Ref. [4], p. 228). By substituting Eq. (26.43) for s, however, Eq. (26.55) can be converted to a digital control law that is quite easy to implement on the digital computer. To accomplish this, first rearrange Eq. (26.55) to give: u(s)
[1 +g._.g(!- e~]
= gAs)
(26.56)
Let us now consider, for the purpose of illustration, the situation in which the process transfer function is of the first-order-plus-time-delay type, so that g, the transfer function without the delay, is: g(s)
= - K- -rs + I
Further, suppose g, has been designed for g such that: 1 gg, = f:,S
(from the discussion in Chapter 19, we will recall that such a g, will be a PI controller with parameters as indicated in Eq. (19.11)). Under these conditions, Eq. (26.56) reduces to: u(s\ [ 1
,
+
(I -
1 e-as)] = -E(s)
r,s
gT:,s
which rearranges to:
•
(26.57)
If we now substitutes= (1-z-1)/ I::J from Eq. (26.43) and assume the time delay a = Ddt, where D is an integer, the digital approximation to Eq. (26.57) is obtained straightforwardly as: (26.58)
with. time-domain realization:
(26.59) Note once again that this control law is of the general form given in Eq. (26.13) and is very easy to implement on the digital computer.
COMPUTER PROCESS CONTROL
970
26.5
DISCRETE DIGITAL CONTROLLERS BASED ON DOM AIN STRATEGIES
lating ·analog designs to digital As note d earlier, the problems with trans control of sampled-data systems are equivalents and employing these for the to take the effect of the sample-andfail twofold: (1) pure ly continuous designs the trans latio n proc ess invo lves hold oper ation into cons idera tion; (2) digital controllers may work well if approximations. Thus, these "translated" ling is faster and the approximations the sampling time is short because samp ons will be more accurate; however, tituti involved in the s and z variable subs continuous originals. they are not likely to perform as well as the takin g the direct appr oach , i.e., by lts resu r bette in obta It is possible to discrete framework, either in the in carrying out digital controller design with Some· of the approaches for ain. dom ime the z-domain, or in the discrete-t in this section. carrying out such designs will be discussed
in 26.5.1 Direct Syn thes is in the z-D oma domain results derived in Chapter Rather than approximating the continuous borrow the concepts and use them to 19, as was done in the last section, let us r from first principles. deriv e a digital direct synthesis controlle m show n in Figure 26.1(b) whic h syste rol cont ata Consider the sampled-d een y(z) and yiz) as: has the closed-loop transfer function betw y(z) =
g(z) Sc(Z) y tz) I + g(z) g c(Z) t1'
(26.60)
p behavior (the reference trajectory) If we now represent the desired closed-loo q(z), then by following precisely the by the puls e transfer function y(z) /yiz) = 19.1, we arrive at the conclusion that same arguments as presented in Section to prod uce the desir ed closed-loop the digit al controller which is requ ired response will be given by: q(z) I Kc(z) = g(z) 1 _ q(z)
(26.61)
transfer function q(z) is, of course, The choice of the desir ed closed-loop cont rolle r mus t be phys icall y restr icted by the fact that the resu lting reali zabl e. rical note at this point. One migh t It may be inter estin g to inject a histo el-based controllers that these direct conclude from the current literature on mod the conc ept of usin g refer ence synt hesi s idea s are relat ively new and rse, 1/g( z), mdesigning high · inve el mod trajectories, q(z), and the process lopm ent. In fact, this is a design perf orma nce controllers is a rece nt deve for one can find the curr ent procedure that is m·are than 35 years old, in the 1958 textbook by Ragazzi 1) philosophical discussion and even Eq. (26.6 al computers in the mid-1950s, it is a and Franklin [5]! Given the state of digit nced. won der the controller designs were so adva roller design techniques that fit into cont al digit rent diffe ral There are seve differ only in their choice of they this gene ral direc t synthesis scheme; reference trajectory, q(z).
971
TROLLERS CHAP 26 DESIGN OF DIGITAL CON
Deadbeat Controller for any is base d on the requ irem ent that, The dea dbe at controller (d. Ref. [6]) onse sho uld exhJ."bit: set-point change, the closed-loop resp • Min imu m rise time
• Zer o steady-state offset • Finite settling time
set-point syst em is requ ired to follow the in othe r wor ds, the closed-loop is past, y dela e any peri od of una void able exactly at each sampling poin t onc i.e.: (26.62) r 1y,f..z) y(z)
=
that this bee n incorporated. Thus, observe where the unit sampling delay has the form: translates to requiring that q(z) take q(z)
(26.63)
= z-1
and the resulting deadbeat controll
er will be given by:
z-1
I
gc(z.)
= g(z)
1-
(26.64)
z- I
for q(z) of D sample periods, the expression When the process has a time delay : read to y itional time dela is modified to account for the add (26.65) z-D- 1 rt_z.)
=
and the dea dbe at controller will be: I
Bc(Z)
= g(z)
z-D- 1
1 _ z-D -I
(26.66)
a troller for a first-order system with Thus, for example, the dea dbe at con ZOH will be obtained by using: g(z)
=
in Eq. (26.64), whe re we recall that controller:
K( l- f)C 1 1- ;z.-1
'=
e-At/-r.
This prov ides the dea dbe at
1- fz- 1 ;)( 1 - z- 1) K(l g.(z.)
(26.67)
ion as: (26.67) is obtained in the usu al fash The time-domain realization of Eq. (26.68)
972
COMPUTER PROCESS CONTROL
whic h, again has the form given in Eq. (26.13 ). A very impo rtant point to note abou t the deadb eat contr oller (and indee d all other contr ollers based on the direc t synth esis schem e) is that it depen ds on the inver se of g(z); thus the zeros of g(z) becom e the contr oller' s poles . This imme diate ly creat es a probl em for proce sses with inver se respo nse (zero outsid e the unit circle) becau se the proce ss zero becom es an unsta ble pole in the contr oller. Thus dead beat contr ollers canno t be used for proce sses with inver se respo nse. An intere sting situat ion arises when the proce ss has a zero locat ed at z = - [3, wher e 0 < f3 < 1, so that the zero, even thoug hg(z) negat ive, lies withi n the unit circle . Unde r these condi tions , this negat ive proce ss zero becom es a nega tive contr oller pole. The contr ibutio n of such a pole to the dyna mic respo nse of the contr oller will be of the type 4 discu ssed in Chap ter 25, and illust rated in Figur e 25.5; conse cutiv e value s of the contr oller outpu t will altern ate in sign, a situat ion referr ed to as "ring ing." The effect of contr oller ringing on the proce ss outpu t y(k) is to produ ce intersample rippling; i.e., oscill ations in the outpu t betw een samp les. This can be illust rated with the follow ing exam ple. Example 26.3
DIGIT AL DEADBEAT CONTROLLER RING ING AND
PROCESS OUTP UT RIPPLING.
Consider the continuous underdamped second-order process: g(.s)
=
1
82
+ .s +
(26.69)
If we convert this to a discrete-time process havin g a zero-order hold and sample time, Ill =0.3, the pulse transfer function is:
g
( ) _ 0.040 52 z- 1 + 0.036 65 z- 2 z - 1- 1.664 z- 1 + 0.740 8 .:- 2
(26.70)
Note that this has poles Pi= 0.8318 ±0.221 i and a zero at Z; =- 0.9045. Design a deadbeat controller and determine the closed -loop response to a unit step set-point change. Solution: Since there are no time delays (other than the unit delay due to the hold), the deadbeat controller requires a reference trajectory given by Eq. (26.63). Employing the design Eq. (26.64), one obtains the controller design : gc(z) =
)(1-
1 ( z- . 1 1 - z-
1.664 z- 1 + 0.740 8 z- 2) 0.040 52 z- 1 + 0.036 65 z- 2
(26.71)
which can be realized by inverting the pulse transfe r function to: u(k)
=
24.68 [0.0039 u(k- 1) + 0.03665 u(k- 2)
+ ff..k)- 1.664 ff..k- l) + 0.7408 ff..k- 2)] (26.72) When this controller is applied to the process, the closed -loop respon se, in terms of the continuous and discrete outputs y, well as the discrete mput u, is shown in Figure 26.3. Note that the controlfer pole as at Z; =- 0.9045 (coming from the process
CHAP 26 DESIGN OF DIGITAL CONTROLLERS
973 a)
y
0.5
0.0 0
5
6
40 b)
;·
' 20
' '
u(ld 0
'
-20
·, ' '.
. ·-
-·
'
-40
0
Figure 26.3.
.
,·.'
''
3
4
An illustration of controller "ringing" and intersample "rippling."
zero) causes ringing of u(k), and this produces the rippling of the continuous output between samples. Obviously if we did not measure the continuous output and had only the sampled output we would think the controller was outstanding because it caused the sampled process to reach the new set-point in one sample time. This example illustrates one of the major problems with deadbeat controller s and indeed any other controller with very aggressiv e controller action and poles close to -1: the sampled process may follow the discrete-time reference trajectory perfectly and yet the actual process is wildly oscillating. See Refs. (3, 6, 7-9] for more discussion of deadbeat controllers.
Dahlin Algorith m It is possible to improve the performan ce of the deadbeat controller by choosing a less aggressiv e reference trajectory ; this is the purpose of the Dahlin algorithm . With Dahlin' s algorithm , the closed-loo p behavior is desired to be of the first-orde r-plus-tim e-delay type, with the familiar continuou s-time represent ation:
If the delay is an integral multiple of the sampling time (i.e., then this translates to a q(z) given by: q(z) =
(I _
e-IJ.tt~,)
I - e
r= MM, say),
z-M-l
All~, z-l
(26.73)
COM PUT ER PRO CESS CON TRO L
974
with the first -ord er-p lus- time -del ay whic h incl udes the ZOH elem ent be obtained from Eq. (26.61) as: dynamics. The Dahlin controller may now 1 [
Kc(Z)
= g(z)
(1- e·d/IT,) z-M-1
z-M-1 1_ e-611r, z-1 _ ( 1 _ e Atlr,)
J
(26.74)
abou t the Dahlin algorithm: The following are some points to note time delay M, and the time constant 1. It has two tunin g parameters: the is chosen so that the controller is term -r, in the reference trajectory. M delays; -r, determines the spee d time ess realizable whe n there are proc of the closed-loop response. , we have the oppo rtun ity to avoi d 2. It is clear that with this algorithm that is possible with the dead beat n actio the type of excessive control as conservative a controller as controller since we can choose -r, to give the inve rse of g(z) mea ns the we wish; however, the depe nden ce on to cont rolle r ring ing. It is le Dah lin algo rithm is still susc eptib effects of ring ing in the Dah lin som etim es possible to mini mize the othe r tech niqu es for avoi ding algo rithm by choo sing -c, carefully; [8]. ringing may be found, for example, in Ref. ess inverse, any process zeros outside 3. Because the controller uses the proc pole s in the Dah lin controller. the unit circle will become unst able used with proc esse s havi ng Thu s the Dah lin cont rolle r cann ot be inverse response. ible with the Dah lin algo rithm by Let us illus trate the detu ning poss considering the following example. Exam ple 26.4
DAHLIN IMPROVED RESPONSE WITH THE CON TRO LLE R.
secon d-ord er syste m of Exam ple 26.3, Let us again cons ider controlling the time using the Dahlin algorithm.
but this
Solu tion: is only slightly less agres sive than that If we choose a reference traje ctory that es: 0, -r, = 0.3 =At, so that Eq. (26.73) becom used by the dead beat controller, i.e.,
r=
0.6321 z- 1 0.36 79 z- 1 1 q(z) =
(26.75)
then the Dahl in controller is:
21 z- 1 ( 0.63 z- 1 I = Ec(Z)
2 1.66 4 z- 1 + 0.74 08 z- ) 2 z1 665 0.03 + 0.04 052 z-
)(•-
(26.76)
which can be realized as u(k)
=
2) + 0.0039 u(k- I) 15.60 [e(k )- 1.664 E(k- I)+ 0.7408 e(k-
+ 0.03665 u(k- 2)]
(26.77)
975
ITAL CONTROLLERS CHAP 26 DESIGN OF DIG a)
1.0
y 0.5
b)
40
20
··-,
.- ...
' ''
:'
: ·__. :.FLru·-~--
'
u(k) 0
··' -20
-·
--·
second-order process of Dahlin controller for the nge , (b) controller action Closed-loop response of resp cha nt onse to set-poi Example 26.3; (a) out put requiied. lier dea dbe at con trol ler Eq. (26.77) wit h the ear No te tha t by com par ing only a detuned deadbeat is ler > 0, the Dahlin control -r, h wit t tha s see one 72), Eq. (26. (26.77) is shown in controller. the Dahlin controller in Eq. The closed-loop response of rippling, the effects are less le there is still ringing and Figure 26.4. Note that whi However, the response rov output response is imp ed. ous tinu con the and d, nce pronou is still not very good.
Figure 26.4.
trollers to permit them
deadbeat and Dahlin con g. This It is possible to modify the se and · to eliminate ringin
inverse respon to han dle processes with ller does not strive rs so tha t the resulting contro filte ng uni det u and Morari [9] involves add ing irio Zaf r Edgar [8} and late and gel Vo os. zer s ces pro to cancel se dehming filters. We roaches for the design of the app c cifi spe ed pos pro e hav and Edgar controller here. will discuss only the Vogel
Vogel-Edgar Controller Dahlin's algorithm by pro pos ed modifications to would me an Vogel and Ed gar [8] have ics from the controller. This am dyn tor era num del mo the Vogel-Edgar removing the cel the process zeros; thu s can to try not s doe ller tro the con cesses with inv ers e ringing and can han dle pro to t jec sub not is ller tro trajectory so tha t con is add ed to the reference response. Th e modification Eq. (26.73) becomes:
COMPUTER PROCESS CONTROL
976 "') _ -
tt\Z
(1-
(
1_
e-IJ.ttT,) e-IJ.tiT,
z-•)
B'·-•'] B(l)
[~
z
-M-1
(26.78)
1
I
where
is the numerator polynomial of the process model given in
B(z-1)
Eq. (25.46).
With this modification, the Vogel-Edgar controller will be: (26.79)
Let us illustrate with an example. 1.5
a)
1.0
y
0.5
0.0 -f--,-,-,-,-,--,-,-,-.,....,. --,-T"T".,--,-,-T"T"'"T" ""11-,-I.,-,.-,-IT"T"I.....-.--,or-,1 6 5 4 3 2 1 0 b)
----------------------------..·--------------.
0
Figure 26.5.
1
2
3
4
5
6
Closed-loo(> response of the Vogel-Edgar controller for the second-order process of Example 26.3; (a) output response to set-point change, (b) controller action required.
'
977
CHAP 26 DESIGN OF DIGITAL CONTROLLERS Example 26.5
CLOSED-LOOP RESPONSE WITH THE VOGEL-EDGAR CONTR OLLER .
Let us again control the s..ocond-order system of Example 26.3, but now EdS:U controller.
use the Vogel-
Solution : 1 d in If we modify the reference trajectory by the factor B(z- )/B(l) as indicate Eq. (26.78), then forM = 0, 'fr = 0.3:
0.6321 z- 1 () _ q Z - 1-0.36 79
(0.0405 2 z- 1 + 0.03665 z- 2 ) 0.07717
ZI\
(26.80)
and the Vogel-Edgar controller becomes: 8c(z)
=
8.19- 13.6 z- 1 + 6.07 .z- 2 1 - 0. 700 z- 1 - 0.300 z 2
(26.81)
which can be realized as: u(k)
= 0.700 u(k- 1) + 0.300 u(k- 2)
+ 8.19 £(k) - 13.6 E(k- 1) + 6.07 £(k- 2)
(26.82)
much The closed-loop response to a unit step in set-poin t (Figure 26.5) shows for Thus time. rise delayed slightly only and ringing no with improve d control action real parts, the discrete processes with zeros outside the unit circle, or with negative algorithms. Vogel-Edgar controller is far superior to the original deadbea t or Dahlin
Zafiriou and Morari [9] provide a review of these and other SISO digital controllers.
26.5.2 Time- Doma in Design s discrete-time It is possible to design the discrete controller directly in the
general domain , using the discrete-time difference equatio n model. The model: process procedure involves starting from the y(k) + a 1y(k- 1) + Q.j)(k- 2) + ... + a~(k- n) - = b0 u(k) + b 1u(k- 1) + b2u(k- 2) + ...
+ b,.u(k- m)
given in with known parameters, and entertaining a control law of the type law is control This ters. parame er Eq. (26.13), with yet undetermined controll obtain to d require ters parame er controll the and model the into then introduced of the a prespecified process response derived. For example, if the control law type: u(k)
= u(k-1) +K0 E(k)+K1 E(k-1)
(26.83)
is to be used for a first-order system whose model is given by: y(k)
= ay(k- 1) + bu(k- 1)
(26.84)
L COMPUTER PROCESS CON TRO
978
observe, from Eq. (26.84) tha t whe re a and b are given, first we 2) + bu( k-1 )- bu( k- 2) y(k )- y(k - 1) = ay( k- I) -ay (k-
(26.85)
kwa rds by wit h its time arg ume nt shifted bac and upo n sub stitu ting Eq. {26.83), one, and rearranging, we obtain: (26.86) + bK0 e(k - 1) + bK1 e(k - 2) y(k) = (1 +a) y(k - 1)- ay( k- 2) finally y(k)) for e(k) and rear ran ge to obt ain We may now intr odu ce (yi k)as: ems closed-loop syst the discrete-time equ atio n for the (26.87)
) is constant. whe re we hav e assu med that yik e will be type s of designs here; two of thes eral sev loy Now , we cou ld emp disc usse d in mor e detail.
Direct Syn the sis Design dom ain; for traj ecto ry in the disc rete -tim e Sup pos e we cho se a reference wit h tim eer ord first the transfer function for exa mpl e, by inve rtin g the pul se obtains: dela y response in Eq. (26.73) one (26.88)
term by term pari ng Eq. (26.87) wit h Eq. (26.88) whe re 4Jr = e-411-r,_ Thu s by com des ired firstthe ieve ach to select K0 and K1 for the case whe n M =0 one can this mea ns selecting: ord er response. In the present case
e exactly. so that Eqs. (26.87) and (26.88) agre
Pole Placement Design If we take the z-transform of Eq.
(26.87), one obtains: b(K0 +K 1 )
y(z)
= 1- (1 +a -b K 0 )z- 1 +( a+ hK 1 )z- 2 Yd
(26.89)
roo ts of the tran sfer function who se pole s are indi cati ng a closed-loop pul se cha ract eris tic equ atio n: (26.90) ctly from the atio n can also be obt aine d dire Not e that this characteristic equ y(k - 2) ng the coefficients of y(k), y(k - 1), discrete-time Eq. (26.87) by inspecti
979
S DIGITAL CONTROLLER CHAP 26 DESIGN OF
. pu lse transfer function e ne ed not calculate the to on us ble Th ssi ). po .90 is (26 it . n, Eq to yield tic eq ua tio poles closed-loop characteris to place the closed-loop Ha vin g ob tai ne d the as so K I KCJ 1 rs ete ram the pa er by oll d ntr ne is de ter mi choose the two co closed-loop res po ns e the c mi ce na Sin dy . ed sh sir wi e the de wh ere ve r we place the poles to achiev can is e we , iqu les hn po tec se lar the cu of This pa rti location un de r feedback control. ned pa ram ete rs are determi behavior of the system er oll ntr co the se cau be ral ent ne cem ge A mo re referred to as pole pla in desired locations. les po op er -lo oth sed ere clo ter 10, wh by "p lac ing " the ailable in Ref. [1), Ch ap av is nt me ce pla le po discussion of o discussed. design methods are als
es to Di 26.5.3 Ot he r Approach
gi ta l Co nt ro lle r De sig
n
ous systems can be techniques for continu n sig de er oll ntr co er ital controller design. Several of the oth ectly applicable for dig dir be n tems. ca y the t tha plicable to discrete sys modified so example, is directly ap ital for dig d, for tho me res us du ce loc t The roo main design pro -do cy en qu fre l er tro oth d con optimal Discussion of this an e-domain techniques of tim e Th . [3] f. trix Re in Ma c nd systems may be fou in Refs. [1, 3]. Dynami lei these are discussed oth er model-based are also directly applicab c Control (MAC), an d mi rith go Al l de Mo ), Control (DMC in Ch ap ter 27. thms will be described digital controller algori
26.6
S IABLE CONTROLLER DIGITAL MULTIVAR
n t that with the exceptio le systems, it turns ou ab re ari du ltiv ce mu pro th n wi sig de ng When deali ional controller these systems, any rat classical of the mo st trivial of ble to implement wi th ssi po im lly ua us are t st be tha mu ollers leads to controllers all mu lti va ria ble contr lly tua vir , ore us ref Th the . is ers able control an alo g controll The issue of multivari m. fo r for l ers ita oll dig ntr in co d igi tal " implemente tha t of de sig nin g "d th wi us mo ny no sy alm os t y be obtained multivariable systems. s, digital controllers ma tem sys ble ria -va gle signs carried ou t As wi th the sin ctly by discretizing de ire ind r he eit ms ste sy signs in the discrete for multivariable ly by carrying ou t the de ect dir or in, ma do s ou ce du re of s, z variable in the continu approach, the same pro ct ire ind the dir ec t the ith W domain. ap ter ap pli es; wi th ch s thi in er rli ea sign in the su bs tit uti on pr es en ted on to carry ou t the de mm co re mo en oft is it n mo de l as basis. approach, however, trix difference eq ua tio ma the ng usi in, ma ssed in Refs. [1, 3]), discrete-time do omain techniques (discu e-d tim le, ab ari ltiv mu Some of these practitioners. lar with process control oth er have not been very po pu MAC, an d IMC, on the C, DM as ch su es iqu hn tec ed no tab le Model-based control cesses an d ha ve enjoy pro le ab ari ltiv mu to in designs ba sed ha nd , are applicable the principles involved s; ion cat pli ap al tri us acceptance in ind xt chapter. ll be discussed in the ne on these techniques wi
26.7
SUMMARY
presented tw o digital controller an d the ed uc rod int ve ha pro ac h, in wh ich In this ch ap ter we sign. The indirect ap de its for ies ph so lm by simple va ria ble ap pr oa ch ph ilo ted" into the digital rea sla an "tr are ns sig de continuous
980
COMPUTER PROCESS CONTROL
substitution, makes it possible to convert to digital form virtually any controller designed by the controller design techniques discussed in Part IVA. By this method, continuous PID controllers, feedforward and cascade controllers, time-delay compensation controllers, direct synthesis controllers, ratio controllers, etc., are all easily digitized, and may be used on the sampleddata system. Despite the convenience, this approach has the disadvantage of requiring special compensation for the effect of sampling if the sample time is large; also, the approximations involved in the digitizing process usually result in some loss of performance. With the direct approach, the design is carried out directly in the discrete domain, either using transfer functions (as with the deadbeat and the Dahlin algorithms) or the difference equation model in discrete time. While these tecbniques implicitly take the effect of sampling into consideration, they are unable to deal directly with the fact that the process is inherently continuous; the result, as was demonstrated with the discrete domain direct synthesis tecbniques, is the possibility of a closed-loop system that achieves the desired behavior at sampling points but that exhibits unacceptable intersample response. It is important to reiterate, in closing, that the real advantage of digital over analog control is that control algorithms that are impossible to implement because of analog hardware limitations are easily implemented on the digital computer. It is this versatility of the digital computer, more than anything else, which makes the application of advanced control schemes possible. REFERENCES AND SUGGESTED FURTifER READING 1. 2.
3. 4. 5. 6. 7.
8. 9.
Astrom, K. J. and B. Wittenmark, Computer Controlled Systems, Prentice-Hall, Englewood Cliffs, NJ (1984) Seborg, D. E., T. F. Edgar, and D. A. Mellichamp, Process Dynamics and Control, J. Wiley, New York (1989) Ogata, K., Discrete-Time Control Systems, Prentice-Hall, Englewood Cliffs, NJ (1981) Deshpande, P. B. and R. H. Ash, Elements of Computer Process Control with Advanced Control Applications, lSA, Research Triangle Park, NC (1981) Ragazzi, J. R. and G. F. Franklin, Sampled-data Control Systems, McGraw-Hill, New York (1958) Isermann, R., Digital Control Systems, Springer-Verlag, Berlin (1981) Kuo, B. C., Analysis and Synthesis of Sampled-data Control Systems, Prentice-Hall, Englewood Cliffs, NJ (1963) Vogel, E. F. and T. F. Edgar, "A New Dead Time Compensator for Digital Control," ISA/80 Proceedings (1980) Zafiriou, E. and M. Morarl. "Digital Controllers for SISO Systems: A Review and a New Algorithm," Int. J. Control, 42, 855 (1985)
REVIEW QUESTIONS 1.
What is a digital controller, and what are some of the characteristics that distinguish it from a conventional analog controller?
2.
What is the general z-domain form of the digital controller, and how is the corresponding time-domain realization obtained?
3.
Why is the concept of "physical realizability" important within the context of digital controller implementation?
981
CHAP 26 DESIGN OF DIGITAL CONTROLLERS physic ally realizable? What does it mean for a digita l controller to be
4.
"indir ect" appro ach to the design of What is the funda menta l philos ophy behin d the philos ophy behin d the "direc t" the digita l contro llers? How is it differ ent from appro ach?
5.
ach to the design of
6.
the "indir ect" appro What are the advan tages and disadvantages of digita l contro llers?
7.
the "direc t" appro ach to What are the advan tages and disadv antage s of llers? contro l digita
8.
g on the prope rties What are the main effects of sampl ing and holdin feedback contro l loop?
9.
y affect the closed-loop How does the sampl e-and- hold device quantitativel a sampl ed-dat a control system?
tage 10. What is the single most overw helmi ng advan analog contro l?
is it 13. What is Tutsin 's appro ximat ion, and what
of a sampl ed-dat a
stability of
of digita l contro l over conve ntiona l
contro 11. What is the positi on form of the discrete PID velocity form? 12. How are digita l PID controllers tuned in genera
the design of
ller? How is it differe nt from the
l?
used for?
ion discus sed in this chapte r, which is 14. Of the two altern atives to Tutsin 's appro ximat more useful? Why? differe nce" appro ximat ion to conve rt a 15. What is requir ed in using the "back ward l form? digita to analog controller transfer function from design by direct synthe sis in discrete time? 16. What is involv ed in carryi ng out controller Chapt er 19 for direct synthe sis design in Is it any differe nt from what was discussed in n? the continuous-time domai contro ller? Why is this not a practical 17. What are the requir ement s for a deadb eat contro ller for most applications? menon 18. What is "ringing," and how does this pheno
arise?
thm 19. What strateg y is emplo yed in Dahlin's algori ller? the deadb eat contro
for impro ving on the perfor mance of
of the 20. What are some of the basic characteristics
Dahli n controller?
's algori thm, and in what way does it 21. What is the Vogel-Edgar modification to Dahlin impro ve the Dahlin controller's performance? almos t synon ymou s with that of design ing 22. Why is the issue of multiv ariabl e contro l "digit al" controllers for multiv ariabl e systems?
L COMPUTER PROCESS CONTRO
982
PROBLEMS 26.1
wing l gas furnace consists of the follo The con!Tol syst em for an indus!Tia to: g acco rdin (a) A digi tal cont rolle r oper atin g u(k)
= O.?Su(k- 1)
8£(k - 1) + 0.25 u(k- 2) + O.Ole(k) - 0.00
elements:
(P26.1)
(b) A ZOH element; (c) A valve, with tran sfer function: gv(s)
75.0 +I = 0 Ols
CFMI . pslg)
(S
(P26.2)
function: (d) A tran sfer line, with transfer e-0.2 •
g,(s)
= O.Ols +
(e) The mai n process, with transfer g•ls) 1'
I (SCFM/SCFM)
(P26.3)
function:
= 0.5s2 ·0+
I
(°F/SCFM)
(P26.4)
The unit of time is seconds. and com bine it sfer func tion g(s) for the proc ess, (a) Obt ain the cons olid ated tran give n that g(z) tion func sfer tran e puls the process with the ZOH elem ent to obta in roller. t.t ::: 0.1 sec. Also obta in g,(z) for the cont obta in the Figu re 26.1(b) for this proc ess; in type the of ram diag k (b) Dra w a bloc ate the stig Inve . tion and the char acte risti c equa clos ed-l oop tran sfer func tion stability of the closed-loop system. er mac hine , u, and the the thick stoc k flow rate to a pap 26.2 The rela tion ship betw een win g tran sfer been app roxi mat ed by the follo basi s wei ght of the pap er, y, has function model:
O.Sse-8•
y(s) ::: 7 .5s + I u(s)
(P26.5)
n tuni ng rule s el, alon g with the Coh en and Coo (a) Use this Lap lace dom ain mod resu lting PI the e retiz Disc r. rolle gt~ a PI cont pres ente d in Cha pter 15, to desi us proc ess inuo cont ent the digi tal cont rolle r on the cont rolle r usin g At = 2. Imp lem the basi s in ge chan step unit a em resp onse to and simu late the clos ed-l oop syst · . weig ht set-point. Plot the response plin g rate At= 4, discretize the sam d ease incr the at ated oper (b) If the procesS is to be e new cond ition s. 4 and repe at part (a) und er 'thes cont inuo us PI cont rolle r usin g At= s. Com pare the closed-loop response y in the proc ess first add At/2 to 'the time dela 4, = At with n atio (c) For the situ cont inuo us PI the in Coh en and Coo n rule s to obta tran sfer func tion befo re usin g the at part (b). repe and 4} = M ng (usi cont rolle r cont rolle r. Disc retiz e this new significant any e controller to that in part (b). Is ther Com pare the perf orm ance of this r? rolle cont last d in obta inin g this adva ntag e to the strat egy emp loye tion of etha nol, y, in an tion mod el relates the top com posi 26.3 The following tran sfer func the feed flow rate, d: and u, rate, flow x to the reflu etha nol/ wat er disti llati on colu mn
983
ITAL CONTROUERS CHAP 26 DESIGN OF DIG y(.r)
=
0.14e-12.0s
0.661!-l.SI
+ 1 d(.r) 6.7 .r + 1 u(.r) + 6.2 .r
The uni t of time h; minute
del s. Observe tha t the mo y(.r)
(P26.6)
is of the form:
= g(s) u(s) + gJ.s) d(.r)
rw ard con tro lle er function for a fee dfo and rec all tha t the transf en by: basis of such model is giv
r des ign ed on the
-gJ .s)
g-' s) 11'
= -g(.r)
e ital form wit h sam ple tim be implemented in dig to is ller the tro m con fro rd z), rwa gj. If such a feedfo nsf er fun ctio n, uired digital controller tra At = 0.5 min, obtain the req ng: usi s, for this proces par tic ula r gj.s) obt ain ed e app rox im atio n enc fer dif rd wa for (a) Th e e app rox im atio n enc fer (b) Th e bac kw ard dif tion (c) Th e Tu tsin approxima transfer function: t-order system wi th the 26. 4 Fo r the gen era l firs (P2 6.7 ) K g(s)
=1:s + 1
uired syn the sis con tro ller req t the con tin uou s direct tha 19 ller. er tro apt con Ch PI in a is wn y it wa s sho erence tra jec tor t-order closed-loop ref ain ed firs obt ied ~ cif wa spe ller a e tro iev con ach sis to syn the ital ver sio n of this dir ect In Ex am ple 26.2, the dig n. tio ima rox app nce ere n for the gen era l using the bac kw ard diff (26.39) - the exp res sio Eq. th wi .5) ula r (26 Eq. ing (a) By com par Ke and -r1 for thi s par tic y obt ain the val ues for Wh r At. lle e, tro tim con ple PID sam te dis cre epe nde nt of the tha t these values are ind controller and confirm t dep end on At? tha rs ete am par troller wi th tha t is it des ira ble to hav e con atio n; com par e the res ult im rox usi ng Tu tsin 's app At? on (b) Repeat Ex am ple 26.2 end dep troller par am ete rs no w sam ple tim es, in Eq. (26.53). Do the con time sys tem s wi th lon g tecre dis for t tha d nde me om the model: rec on n d bee tea ins has It ed {c) if the design is bas ved pro im be can nce ma controller perfor (P2 6.8 ) K 1!-a.r g(s)
=1:s + 1
ller suc h as tha t in 1 in the res ult ing con tro tin g D set n the e un it as pa rt and t, DA wi th a= sam pli ng del ay of 1 tim iva len t to int rod uci ng a pre dic tor equ is ith is .Sm (Th d ). fie .69 odi (26 . "m Eq ref er to thi s as the us t Le .) vel oci ty del (in mo ller s tro of the pro ces l res ult in a PI con suc h an exercise wil l stil wh at t on tha ent ow Sh mm H Co ch. ). roa .53 app wi th the on e in Eq. (26 ller tro con s thi e . par form), and com alternative controller on the par am ete rs of this effect increasing At has firs ttely, con sid er the sim ple of Pro ble m 26.4 concre nts poi in ma the ate 26.5 To illu str er function: ord er pro ces s wi th tra nsf (P2 6.9 ) 0.6 6 6.1 s + 1 g(s)
=
=
984
COMPUTER PROCESS CONTROL (a) Obtain a direct synthesis controller for this process for 1'r = 2.0. Implement this in standard digital form on the continuous process, with a sample time At = 1.0, and obtain the closed-loop system response to a unit step change in the process set-point (b) Implement the same controller on the same process for the same set-point change, but now with sample time At =.4.0. Compare the closed-loop response obtained in this case with that obtained in part (a). Comment on the effect of increased At on the closed-loop system performance. (Recall Examples 25.8 and 25.9 of Chapter 25.) (c) Use the "modified Smith predictor approach" outlined in Problem 26.4(c) to obtain the digital controller for the case when At = 4.0. Implement this controller on the process (with At = 4.0) and obtain the closed-loop response for the same set-point change. Compare the response with that obtained in part (b).
26.6
[This problem is open ended] The following model for a CSTR in which an isothermal second-order reaction is taking place, was first given in Problem 19.12:
(P19.18) The manipulated variable is F, the volumetric flowrate of reactant A into the reactor; the disturbance variable is CAQt the inlet concentration of pure reactant in the feed; and the output variable to be controlled is CA• the reactor concentration of A; V is the reactor volume, assumed constant The nominal process operating conditions are given as:
F
= 7.0 X w-3 m3/s
V
= 7.0 m3/s
/c = 1.5 x I0-3 m3/kg moJo-s CAo = 2.5 kg molelm3 CA = 1.0 kg molefm3 Consider the situation in which the gas chromatograph measurement of CA has a delay of 60 seconds, and that CAO is not available for measurement. (a) Linearize the model around the provided steady-state operating condition, obtain the approximate transfer function model, and use it to design a classical PID controller, using any tuning method of your choice. Carefully justify any design dtoices made. (b) Obtain a discrete version of the controller obtained in part (a); implement it on the original nonlinear system using At = 30 sec, and obtain the closed-loop system response to a changeinCAO from25 to20 kg mole/~ (remember, CAO is unavailable ~~~
.
(c) Use the linearized model to design an IMC controller, justifying any design choices made. Discretize this controller using the approximation technique of your choice,~ At= 30 sec, and repeat part (b). Compare the~ with that of the classical controller you designed and implemented in part (b).
26.7
In Problem 24.5, the transfer function model for a thermosiphon reboiler was given as:
() _ 0.9{0.3s-1)u{) Ys
-
s (2.Ss
+ 1)
with the input and output variables defined as:
s
(P24.7)
CHAP 26 DESIGN OF DIGITAL CONTROLLERS
985
(Fs- F s *) (lb/hr )J. ' F s * (lb/hr )
u
=[
y
= [ (h-h*
h*) (in)] (in)
steady-state operating conditions. Here, h* (ins), and F5 * (lb/hr ), represent nominal The time constants are in minutes. ter to sample the process outpu t It is desired to control this process using the compu and to take control action every 0.1 min. e trajectory: (a) Use the transfer function model and the referec s q()
=
(l-0. 3s) (1
+ 0.3s)( -r,s + I)
ller. What dynamic system can with -r, = 1.0 min, to design a direct synthesis contro ller? Also, what is the closest contro al unusu hat somew be used to imple ment this n? imatio classical controller that can be w;ed as an approx nce approach, imple ment it differe ard backw the using ller contro (b) Discretize the a unit step change in the to se respon -loop closed on the process, and obtain the normalized level set-point. ior might be "missed" if the sample (c) On the chance that the inverse response behav te version of the direct synthesis discre time is increased toM = 1.0 min, rederive the process (using the new sample the on it ment imple ions, condit these controller under unit step chang e in the same the to se respon time), and obtain the closed-loop the longer sample time does s, normalized level set-point. For this particular proces ? antage disadv a or provid e an advan tage 26.8
Dahli n's digita l contro ller design This probl em is conce rned with comp aring que. techni sis synthe direct teclmique with the continuous Given the first-order-plus-time-delay system: K e-ar
g(s) = - -
(P26.1 0)
-rs + I
uous direct synthesis controller and an appro priate reference trajectory, the contin was given in Chapt er 19, in Eq. (19.24). sion for 8c(z) (Keep in mind that (a) Discretize this controller and obtain an expres MM.) a= where the discre tecou nterpa rtofe- as is~ obtain g(z), the corres pondi ng (b)From the transfer function in Eq. (P26.10), first use this to obtain the Dahli n and ZOH; a g oratin pulse transfer functi on incorp are the Dahlin controller Comp ). controller, emplo ying the q(z) given in Eq. (26.79 sis controller. synthe direct uous contin the of n versio with the discretized 26.9
s whose transfer function model (a) Design a Dahlin controller for the paper proces was given in Problem 26.2 as: 0.55e- 85 (P26.5 ) y(s) = 7 .Ss + 1 u(s)
it expression for the controller. for llt =2.0, r= 8.0, and -r,. =3.0. Write out an explic ented by: repres s proces "true" Implement this controller on the y(s)
=
OAOe-lOs S.Os + 1 u(s)
(P26.1 1)
COMPUTER PROCESS CONTROL
986
unit step change in the basis weigh t and obtain the closed-lOop system response to a set-point. closed-loop system respon se with that (b) Repeat part (a) with -r,. = 6.0. Comp are the of the param eter -r,. on the controller effect the on obtain ed in part (a). Comm ent performance in the face of plant/ mode l mismatch. 26.10 [This problem is open ended] trial heat excha nger that utilizes Figur e P26.1 is a schematic diagra m for an indus was first introd uced in Proble m it ; chilled brine to cool down a hot process stream oq, remai ns constant, that the (in rature tempe brine the , 14.2. Assum e that T8 the following transfer function that measu ring device has negligible dynamics, and
relations:
-(1 - O.Se- 108}
(T-TI' )("C)
(P26.12a)
= (40s + l)(lSs +I) (Fs- Fs*) (kgls)
(P26.1 2b)
are reason ably accurate. ss using a techn ique of your (a) Desig n a classical PID contro ller for this proce choice. Justify any design choices made. ed in part (a) using backw ard (b) Discre tize the classical PID contro ller obtain ller on the process and obtain contro this ment Imple differences, withA l = 5 seconds. e of +SOC in the process feedst ream the closed-loop system response to a step chang
temperature.
ability , determ ine &om it an (c) Obtai n a proce ss reacti on cubes t of your this appro ximat e mode l to Use l. mode y e-dela appro ximat e first-order-plus-tim choices made. Imple ment design obtain a Dahlin controller for Al = 5 sec. Justify the Comp are the closed (a). part in as e rbanc distru same this contro ller for the
responses.
t to perfo rm better ? Did the (d) Which contro ller would you norma lly expec in. simul ations confirm this expectation? Expla
Chilled Brine
Heat Exchanger Process
Feed
Stream
Chilled Brine Out
Figur e P26.1.
T,F
ITAL CONTROLLERS CHAP 26 DESIGN OF DIG r functio 26.11 Giv en the tran sfe
n for an ope n-l oop uns tab
987
le process as: (P26.13)
- 0.5 5
g(s) = 5.0~
for s inc opo rati ng a ZO H, r function for the proces sfe tran se pul the (z) (a) Ob tain gHp ation. esponding difference equ M 1 min. Write out the cor digital PI controller: the ng usi led trol s is to be con (b) Giv en tha t this proces (P26.14) -1)
=
u(k)
= u(k -l) -1. 2K e(k )+K e(k
atio n int o the dif fer enc e equ rod uce this exp res sio n int the K, r ain ete obt am nt, par sta con free is wit h the set -po int y4 (a), and ass um ing tha t the val ues tha t of ge ran the mo del obt ain ed in par t tain Ob atio n rela ting y(k) to Yd· loo p sys tem to be stable. closed-loop difference equ tak e in ord er for the closed can K r ete am the controller par ble ms 85 and process intr odu ced in Pro designed for the pol ym er ler trol con ital dig A 12 26. 25.15 has bee n giv en as: k) 0.375Su(k- 2) + 0.325e( u(k) = 0.6 25u (k- 1) + (P26.15) 2) (k99e 0.1 + -1) (k - O.S08e en as At for imp lem ent atio n giv wit h the sam ple tim e en by: giv is s ces pro n for the composite transfer functio 25.oe-6 s + 1) ) = (1 Os + 1 )(1 2s
=3.0 min.
Recall tha t the
(P26.16)
g(s
. the ZO H, for At= 3.0 min r function inc orp ora ting sfe tran se pul the ), g(z (a) Ob tain din g difference equation. atio n Write out the cor res pon 5) into the difference equ exp res sio n in Eq. (P26.1 ller the tro nge con rra the rea uce and rod (b) Int y is con sta nt, um e tha t the set -po int 4 equ atio n to this use ; y to ) obt ain ed in par t (a); ass 4 y(k ting difference equ atio n rela exp res sio n to obt ain a . ility stab p in yd; -loo check for closed ent a uni t ste p cha nge atio n in par t (b), imp lem in equ e lied enc imp fer is dif ller the tro ng con (c) Usi pon se. Wh at typ e of res tem sys the t plo sim ula te and
Eq. (1'26.15)?
pa rt V §fE CKA L
CON TR0 1L TOPKCS In Parts I-IV we have presented key concepts and many importan t tools for
understan ding the dynamics, developin g a model, and designing a control system for a process of interest. However, this material is only a fundamen tal base from which to latmch further forays into deeper and more advanced aspects of Process Dynamics, Modeling, and Control. Even after the extensive and detailed discussions presented so far, there remain a significant number of importan t subjects yet to be explored. To sample some of these, we provide in Chapters 27-29 an introduction to a broad spectrum of "special topics" and truly advanced process control concepts which the engineer will likely encounter in practice. To avoid undue excursions <:Jutside the boundarie s imposed by the intended scope of this book, however, the detailed treatment of these topics must be left for a more advanced course of study. As a finale, a capstone discussion of several case studies is provided in Chapter 30 to illustrate how appropria te concepts and tools are selected and brought to bear in solving real problems.
partV SPJECKAl CONTROl 1rOJPKCS
CHAPTER27.
Mo del Predictive Control
CHAPTER28.
Statistical Process Control
CHAPTER29.
Selected Topics in Advanced
CHAPTER30.
Process Control System Sy nth
Process Control es is- Some Case Studies
s sail, • "'1ie time lias come, ' tfie
fie R.!wwetfi any tfiing, "' Jll.nc{ if any man tliinl(. that
lit to !(pow.' fie R.!wwetli notliing yet as fie oug St. Paul, I Corinthians 8:2
·2
CHAJPTJER
27 E CONTROL M O D E L P R E D IC T IV of new technology is eav or, the dev elo pm ent end ific ent sci of as are In ma ny cer tai nly tru e of classical practical nee d. This is by d s ate tiv mo en oft qu ite of the chemical proces l wh ere the em erg enc e tro of con s ion ces ect pro onn c erc ati int om aut complex pro du cti on volume, an d n ind ust rie s, wi th its lar ge om ati on , which~ in tur aut for d nee the d ate cre . ns, gy tio olo era tro l tec hn sev era l un it op au tom ati c pro ces s con of ent pm l elo tro dev con s the ces mo tiv ate d field of pro l technology wi thi n the tro con s by ces pro stly in mo , d ore ate Furtherm bee n mo tiv icant advances hav e also s itself, we find tha t signif -based control technique del mo the th wi so rly ula tic par is is practical need. Th apters 19, 22, an d 26. l dri ve for mo re already int rod uce d in Ch ind ust rie s, the un ive rsa ied all d an cal mi che In the icient use of energy, an d h pro du ct quality, mo re eff hig of to nt me ain att t ten sis con sibility hav e all combined of env iro nm ent al respon al ion dit tra by t me be an increasing awareness l systems tha n can tro con on s and the dem r to cte impose far stri the se challenges led ind ust ry' s res po nse to tec hn iqu es alone. Th e ic Matrix Control (DMC) nam lly successful Dy ria ust , ind the of ent pm dev elo ol (MAC) [45, 46, 60, 62 - 65] d Model Algorithmic Contr an its 56] for 18, d use [14 are que tw hni tec pu ter sof e of the commercial com of bet ter kn ow n by the nam ies (and subsequent ones teg stra l tro con o tw ese Th . OM es IOC em nsch ol (MPC) im ple me nta tio as Model Predictive Contr d fie ssi cla are ) ure uct str a sim ila r discuss. for reasons we shall soon vid e an ov erv iew of the in this cha pte r is to pro ive tro l Ou r pri ma ry object Control as a family of con s, tive dic Pre del Mo of ce cti ple · pri nci ple s an d pra n on its basic princi we will focus ou r discussio var iou s commercially schemes; and in this reg ard the d an der lyi ng theory, un the of s ect asp nt eva som e rel first MPC schemes we re Also, ev en tho ug h the es. , kag pac C MP ble availa me nta ls of the the ory ins igh t int o the fun da m fro rily ma pri ed ult dev elo ped in ind ust ry, hav e res an d limitations of MPC w implementation details, suc h contributions and ho iew rev ore ref the l wil we ; g ons yin uti pa trib C, nce of MP academic con nti er an d scope-of-influe fro the d ed an ct end tin ext dis ve the y ha MPC as a em erg enc e of no nli nea r the to ion ent att r ula par tic in its.oWn right. im po rta nt subject ma tte r
.SPECIAL CONTROL TOPICS
992
27.1
INTRODUCTION
Model Predictive Control is an appropriate ly descriptive name for a class of computer control schemes that utilize a process model for two central tasks: 1. Explicit prediction of future plant behavior, and 2. Computati on of appropriate corrective control action required to drive the predicted output as close as possible to the desired target value. As a class of control schemes, MPC has enjoyed such remarkable industrial success and popularity that according to recent reviews [28, 78] it is currently the most widely utilized of all advanced control methodolog ies in industrial application s. Before delving into a full-scale discussion of the principles and practice of MPC, we find it instructive first to place this industrial success and popularity in perspective . We will do this by examining the nature of contempor ary industrial processes, and the typical assoCiated control problems; we will then see that MPC in fact addresses a significant number of these problems in a manner that is direct, efficient, and easily Wlderstood.
27.1.1 Contemp orary Industria l Processes and Associate d . Control Problems The typical industrial process is usually complex, having several input, output, and disturbance variables, and processing large volumes of raw materials in Furthermo re, the current continuou s, semibatch , or batch mode. economic/ environme ntal climate dictates that such processes must operate m1der conditions of very stringent demands on: • Product quality • Energy utilization • Safety and environmen tal accountability In most cases, the key product quality variables, by which the product is sold are not available for on-line measureme nt, and in', some cases, even the key indicators of the basic process conditions are not a\iailable for measureme nt frequently enough. In addition, when the same processing units are used to manufactur e several different grades of the same basic product, the plant will undergo frequent transitions or start-ups and shutdownS.
Contemporary Industrial Control Problems As a result of the foregoing, the typical industrial process has associated with · it the following control problems: 1. It is almost always multivaria ble, typically with significan t interactions between the process variables: • Several process variables (y1, y2, ... , Yn) to be controlled • Several manipulate d variables (uv u2, ... , um) available for control • Several disturbance variables (dp d2, ..., dk), some measurable , some nnt mrPl' wh1rh WP hRVP littlf' or no control
993
L EDICTIVE CO NT RO CH AP 27 MO DE L PR
behavior: lon g 2. Difficult dynamic lag thr ou gh pip es, ed by tra ns po rta tio n rde r us ca h-o s hig lay to de s me on Ti ati • de lay , ap pro xim sis aly an d an t en me asu rem systems, etc. havior • Inverse-response be instability op -lo en op al • Occasion no nli ne ar to emical processes are ch all e nc (si s tie ari 3. Inh ere nt nonline erity). varying degrees of sev mized below: · kinds, typically as ite d ou tpu t variables 4. Constraints of all values of the inp ut an ute sol ab the on nts rai • Const inp uts rates of change of the • Constraints on the nts rai nst co ty inequali • Ot he r eq ua lity an d nts rai nst co t sof d an rd • Ha
"I de al Co nt ro lle r" 27.1.2 An at om y of an
s an d M PC Ca pa bi lit ie
tio n uir ed for optimal op era "id ea l controller" req the t s: tha ute ve rib ser att ob ing w no We ma y ve the follow us tri al process mu st ha of the contemporary ind eractions, tim e ltiv ari ab le process int mu le nd ha to le ab r, in pu t/ ou tp ut 1. It sh ou ld be ati c dy na mi c be ha vio erw ise ), an d lem ob pr er oth d an de lay s, le an d oth ba nc es (m ea su rab co ns tra int s, dis tur vior. ha be ar ne nli from no complications resulting ort. ng the us e of control eff above while optimizi the all do ld ou sh It 2. ts um set of me asu rem en wi th the ba res t mi nim inf err ing critical, bu t ll we rm rfo pe ld ou 3. It sh an s of it mu st ha ve a me fro m the pla nts (i.e., ve r is available). ate wh m fro on ati orm unavailable, pla nt inf d measurement e of modeling errors an fac the in t us rob ain 4. It sh ou ld rem noise. s an d sh utd ow ns , ributes du rin g sta rt- up att se the all ain int 5. It sh ou ld ma ady-state operation. . as we ll as du rin g ste ins tru cti ve to ntr oll er exists, it is co l" ea "id ch su no t e controllers an d to W hil e it is cle ar tha ies of mo de l predictiv ilit ab cap l ica typ the su mm ari ze no w ted above. ide al requirements no co mp are these wi th the
es Typical MPC Capabiliti
C scheme: uently, the typical MP As we wi ll sh ow subseq ha nd les ari ab le sy ste ms an d sy to us e for mu ltiv ea ly lar cu rti pa Is 1. th ease. process interactions wi oth er difficult response, as we ll as e ers inv s, lay de e 2. Ha nd les tim ease. process dynamics wi th
994
SPECIAL CONTROL TOPICS
3. Utilizes a process model, but no rigid model form is required (the original MPC schemes are based on so-called "nonparametric" step or impulse--response models). 4. Compensates for the effect of measurable and unmeasurable disturbances (the former directly in a feedforward fashion, the latter by inference in a feedback fashion). 5. Is posed as an optimization problem and is therefore capable of meeting the control objectives by optimizing control effort (if the problem is so posed), and at the same time is capable of handling constraints of all kinds.
Observe now that when these MPC capabilities are compared with the noted "ideal" controller attributes, it is easy to appreciate the industrial success of this class of controllers where others have failed. Let us now give a historical perspective of the evolution of MPC.
27.1.3 A Historical Ovetview of Model Predictive Control Even though the current industrial and academic interest in MPC was primarily generated by the 1978 paper of Richalet et al. [65), and by the 1979 Shell publications [14, 56], what have since become recognized as the central MPC concepts actually predate these first reports of application by some twenty years. The textbooks by Newton et al. [52], and Horowitz [32), the original dead time compensator (the Smith predictor) [73, 74] discussed in Chapters 17 and 26, and the linear programming approach to optimal control presented by Z.adeh and Whalen [83], all contain the essence of the MPC concept Apparently, the first publication to introduce, explicitly, the now standard MPC concept of the finite moving prediction horizon seems to be Propoi [59] (cf. Garcia et al. [28]). The classic text by Box and Jenkins [6) also contains the fundamental concepts of MPC, complete with a statistical theory for optimal handling of measurement and process noise. Nevertheless, according to Mehra [45, 46], Model Algorithmic Control (MAC), as the forerunner of the scheme now commercially ~ted under the name of IDCOM, was in fact originally conceived in the late 1960s by Adersa/Gerbios, subsequently developed, and successfully i\pplied to several multivariable industrial processes (cf. Richalet et al. [62-65]). With the availability of more powerful digital computers in the 197~, it became more practical and economical to apply MAC to more industrial prOcesse:s; this led to its evolution into the computer control algorithm now marketed as IOCOM The Dynamic Matrix Control (DMC) technique first appeared in the open literature in 1979 (after having been applied with notable success on several Shell processes for a number of years), when Cutler and Ramaker, and Prett and Gillette reported its application to a fluid catalytic cracking unit [14, 56]. A reformulation of the original DMC problem as a quadratic program by Garcia and Morshedi [27] subsequently led to the development of its most popular variation to date: Quadratic Dynamic Matrix Control (QDMC). The first attempt to put MPC (primarily as embodied by DMC and MAC) within the same framework as the so-called "classical control schemes" was by,
995
TROL CHA P 27 MOD EL PRE DICT NE CON
Inter nal Mod el Con trol (IMC ) para digm Garcia and Mor ari [23], in whic h the IMC struc ture (in whic h, as note d in was prop osed . They show ed that the t oper ates in para llel with the plan t, plan Cha pter 19, an inter nal mod el of the opri ate inve rse of this plan t model) is and in whic h the controller is som e appr subs eque nt publ icati ons by Mor ari and inhe rent in all MPC schemes. This and lity, robu stne ss and perf orma nce of stabi the cow orke rs prov ided insig ht into MPC schemes [25, 26, 70]. that the IMC struc ture popu lariz ed by It shou ld be note d in this rega rd in fact alrea dy a cent ral part of the 1974 Garcia and Mor ari in 1982 [23] was Youla et al. [80, 81] and Zam es [85] mon ogra ph by Fran k [22]. In addi tion ulation. However,. the unification of form deve lope d the sam e type of prob lem of the vario us struc tures into the one all these concepts and the consolidation ral due to Garcia and Mor ari [23]. Seve now know n as the IMC struc ture is me beco have e som been deve lope d, and addi tiona l MPC techniques have since wed in Section 27.5. revie be will these ; ucts commercial prod since been the prin cipa l subject of at has The theo ry and practice of MPC the shops [43, 58], and several sessions at least three book s [47, 49, 57], two work [1]. ce Fourth Chemical Process Control Conferen on of the pion eerin g pape rs, both Finally, we note that since the publ icati schemes have been appl ied to man y IDCOM and DMC as well as othe r MPC proc esse s with the appr opri ate such indu stria l proc esse s. A sam ple of on. references is prov ided in the next secti
MPC App 27.1.4 A Sam ple List of Doc ume nted
lica tion s
sam ple of appl icati ons of vario us MPC The follo wing list is a repr esen tativ e liter ature since 1975: open schemes that have appe ared in the control [45, 60] 1. Aircraft flight control, jet engine y boile r [34, 75] utilit s, rator gene m stea 2. Supe rhea ter, 3. Transonic wind tunnel [50] 40, 56) 4. Fluid catalytic cracking units [18, 31, [24] tor reac h 5. Batc r indu stry [41, 67] 6. Several processes in the pulp and pape 17] 16, [9, tor reac r 7. Hyd rocr acke 8. Distillation colu mns [29] 9. Polymer extruder[77] 10. Olefins plan t [9, 30]
licability of MPC 27.1.5 Process Characteristics and App MPC for effective perf orma nce (cf., for To be sure , not all proc esse s requ ire ire rtan t to iden tify whic h processes requ example, Ref. [30]). Thus , it is impo . esses proc such izes acter MPC for effective control and wha t char appl icati ons of MPC indic ates that A care ful stud y of the publ ishe d cult able cont rol prob lems invo lving diffi processes with cons train ed, mult ivari rol cont this from t mos the d fitte dyna mics have trad ition ally bene l stria indu the nal cons ensu s amo ng meth odol ogy. Thu s the conv entio MPC that is rs, rche resea l and academic practitioners, as well as both indu stria any com bina tion of the following with s esse proc to d suite best is typic ally char acte risti cs:
,, ' 996
SPECIAL CONTROL TOPICS
1. Multiple input and output variables with significant interactions between SISO loops. 2. Either equal or Wlequal number of inputs and outputs. 3. Complex and Wlusually problematic dynamics (such as long time delays, and inverse response, or even Wlusually large time constants). 4. Constraints in inputs and/ or output variables.
27.2
GENERAL PRINCIPLES OF MODEL PREDICTIVE CONTROL
Chemical processes often have slow dynamics so that, quite often, it takes a substantial amount of time for the full effect of each single control action to be completely manifested in the observable process output. The immediate implication is that it is not possible to obtain the "full picture" of the consequences of previously applied control action from only the current process output measurement In deciding what control action to take at the current time instant therefore, it is useful: 1. To consider first how the process output will behave in the future
further control action is taken,
if no
2. To target control action towards rectifying what remains to be corrected after the full effects of the previously implemented control action have been completely manifested. This is the fundamental motivation behind Model Predictive Control as a controller design methodology.
Basic Elements of MPC The fundamental framework of Model Predictive Control consists of four elements shared in common by all such schemes; what differentiates one specific scheme from the other is the strategy and philosophy Wlderlying how each element is actually implemented. These elements (illustrated in Figure 27.1) may be defined as follows: 1. Reference Trajectory Specification The first element of MPC is the definition of a desired ~et trajectory for the process output, y•(k). This can simply be a step to the new set-point value or more commonly, it can be a desired reference trajectory that is less abrupt than a step. . 2.
Process Output Prediction
Some appropriate model, M, is used to predict the process output over a predetermined, extended time horizon (with the current time as the prediction origin) in the absence of further control action. For discrete-time models this means predicting y(k + 1), y(k + 2), ... y(k + i) for i sample times into the future based on all actual past control inputs u(k ), u(k -1), ... u(k- J).
997
CHAP 27 MODEL PREDICTWE CONTROL Futur e
Past
---------IF
·· ~~>· ••• •
* y*(k + 2} y (k .; ll _...,. ;y*(k V.~--
" ,.( _.• ·0··-·- o-···- -o".. Y
.lf:.---uJi
/(k-2)~/ A
oK-
..n
-,(" •••.o· J(k+ 1)
/ /·~~y
811i
u(k+ m-1)
(k) m
•
y(k-2 )0'/ y.,.(k- 2j
k+m -1
k+p
Horizon
Figur e 27.1.
l: x-x: reference trajectory, Example of elements in model predictive contro ured outpu t, Ym; - - : meas -A: At, y*; o--- -o: predicted outpu control action, u.
y;
3. Control Action Sequence Computation a sequ ence of control mov es that will The same mod el, M, is used to calculate tive such as: satisfy some specified optim izati on objec of the proc ess outp ut from targe t • Mini mizi ng the pred icted devi ation over the pred ictio n horizon, effort in drivi ng the process outp ut • Minimizing the expe nditu re of control to target, ts. This is conceptually equiv alent to subject to prespecified oper ating constrain el inver se, M•, whic h is capable of cons truct ing and utiliz ing a suita ble mod , u(k + m -1) requ ired for achieving .... pred ictin g the control inpu t sequence u(k), steps into the future. the prespecified outp ut beha vior p time 4. Erro r Pred ictio n Upd ate can constitute a perfect repre senta tion of In recognition of the fact that no mod el com pare d with the mod el pred ictio n, is reali ty, plan t meas urem ent, y (k), k)- (k), thus obta ined is used to .y(k), and the pred ictio n error , '1(k) = Ym( upda te futur e predictions. MPC, let us discu ss how lhe Hav ing defin ed the basic elem ents of applied. unde rlyin g process mod el is deve lope d and
y
AfodelFonnsforAfPC l) MPC, the main subject of this We note first that stan dard (con vent iona pora ting nonl inear mod els of any form chapter, utilizes only linear models; incor
SPECIAL CONTROL TOPICS
998
rece nt innovation whic h will be with in the MPC framework is a relatively schemes are implemented on the discussed in Section 27.7. Also, since most MPC the continuous, mod el forms are digital computer, the discrete, rath er than model forms for conventional MPC more natural. Thus the three most popular the finite convolution (or impulseof schemes are the linear, discrete versions ain transfer function mod els, response), the state-space, and the transform-dom a more general context in iously in each of which has been encountered prev e these models more closely below amin reex now will we Olap ters 4, 23, and 24; in the MPC context. 1. Finite Convolution Models
There are two entirely equivalent forms of
this mod el type:
The Impulse-Response Model Form: k
y(k) =
I. g(i) u (k- i)
(27.1)
•=0
ess impulse response function. with the "parameters" g(t) known as the proc The Step-Response Model Form: y{k)
=
k
J./ (i) Au(k- i)
(27.2)
process step-response Junction; and with the "par ame ters" P{t) know n as the 6u(k) = u(k) - u(k- 1). 4, it is easily established that the As we had note d earlier in Olap ter ed according to: step- and impulse-response functions are relat g(l)
= P{i) - /X..i -1)
/X.l)
T. g(}) = }=I
and
i
al systems, both g(O) and p(O) are It shou ld also be noted that for all real, caus ime systems exhibit the man dato ry equa l to zero; hence, all realistic discrete-t one-step delay. nts are typic~y obta ined eithe r The impu lse (or step) response coefficie m [18]), provided the data are Yocu directly from plan t data (e.g., Cutler and ced from othe r ~o-called parametric reasonably noise free, or they are dedu model forms such as the other two listed below. 2.
Discrete State-Space Models
These models may be represented by: k
y(k)
= J.0a(i) y(k- i)
k
+
"J. b(i) u(k- i- m) 0
(27.3)
999 L RO NT CO E TIV EDIC CHAP 27 MODEL PR Average with egressive, M ov in g toR Au r s (fo AX M AR n as wi th th e time serie These are also kn ow ilarity in structure sim e th of e . us (6] ca be ins nk eXogenous inputs) models of Box an d Je ng average (ARMA) vi efficients a(i), b(i) mo co e e, th siv d res an eg m, tor au lay de e th as ch ter s su by reason of The m od el pa ra me to pl an t data. Again l de mo the g tin fit ned by usually m us t be obtai = 0. ) b(O = (0) a causality, r Function Models 3. Discrete Transfe
m: These are models fro (27.4)
o ted as a ratio of tw n ha s been re pr es en 1 alo ng wi th the tio nc fu r fe ns tra ted ), where the indica e, B(z-1) an d A(zre discussion z-transform variabl ters 24 an d 25 for mo po ly no mi als in th e ap Ch e (se es tim le m samp tion m us t also be associated de lay of of the transfer func s ter me ra pa e Th s). s identification. of these m od el form ental da ta via proces rim pe ex m fro d ne determi nd ar d MPC may be model forms for sta us rio va e th at it is th of ns rta nt to re m em be r Ot he r discussio po im is It ]. 69 , ou gh some in Refs. [57 to an ot he r, ev en th found, for example, rm fo el od m e on of ho w to t fro m others. Th e de tai ls po ss ib le to co nv er an th d ar rw fo ht aig or e str ters 4, 23, an d 24; conversions ar e m en discussed in Chap be s ha r he ot an to rm convert one model fo , in Ref. [49]. be found, for example o als ay m ls tai de such
Inverse Obtaining the Model
el inverse" is obtaining the "m od of s es oc pr e th , ns uatio ined) optimization In m os t practical sit of a (possibly constra ion lut so e th as y, all ow n (and we shall carried ou t numeric tion case, it ca n be sh iza tim op ed in tra ns generalized (left, or problem. In the unco verses ar e typically in ng del. lti su re e th at titutes the pl an t mo do so sh or tly ) th al operator th at cons tic ma the ma e th of right) inverses
ictions Updating Model Pred
rved between actual discrepancy is obse r ve ate wh to e , unmeasured ut Many factors contrib model prediction: the effect of unmodeled the model in d rs an ro ts re, or er pl an t measuremen in the model structu rs ro er tal cause from en e on am e nd lat fu ssible to iso disturbances, po im ten of is it s. As th e discrepancy pa ra m et er es tim ate sim pl y to att rib ut e is gy ate str PC M ar d remain constant fo r another, th e sta nd sume this va lu e will as , es nc ba tur dis d re mo de l predictions entirely to un m ea su rizon, an d up da te the ho n io ict ed pr e th ad di ng the cu rre nt ly all future times over therefore by simply ed liz rea is gy ate str accordingly. The edictions. principles ar e y to all the future pr observed discrepanc ons ho w these general cti se o tw xt ne the in MAC, th e tw o Let us no w examine ati on of DMC an d ul rm fo sic ba e th in thodology. ap pl ied specifically neers of the MPC me pio e th as ed er id ns co schemes
1000
27.3
SPECIAL CONTROL TOPICS
DYNAMIC MATRIX CONTROL
27.3.1 Process Repres entatio n Let 13 = [p(1), {3(2), {3(3), ... , f3(n)f represen t the unit step-res ponse function obtained for a process, i.e., as illustrate d in Figure 27.2, the elements of the vector ~ represen t the change observed in the process output at n, consecut ive, equally spaced, discrete-time instants after impleme nting a unit change in the input variable. Also, let the current time instant be k, and let us further assume that, in the absence of further control action, it is predicted that the output of the process in question will take the values: yO(k),
y0(k + 1), yo(k + 2), ..., y0(k + p -1)
over the p-time step horizon whose origin is the current time instant k. Let this vector be represen ted as yO(k), i.e.: yO(k) =
rJD(k), yO(k
+ 1), yO(k + 2),
... , yo(k + p- I)] T
where the argumen t k in y0 (k) is used to indicate the time origin of the sequenti al predictions in the vector, and the superscr ipt "0" is used to indicate a predictio n conditio nal on the absence of further control action. (lf k = 0, for example , this essentially constitut es an initial conditio n on the predicte d plant output; subsequ ent sequence s for k > 0 may be obtained recursiv ely using the rredictio n at the penultim ate instant (k- 1)). Note that the vector notation for yO(k) (and for y(k + 1) and Au(k) below) is special because it denotes a scalar at many different time steps rather than a vector of outputs at one time step as would the usual interpretation. To proceed, we assume linearity, so that the principle of superpo sition applies and the step-resp onse model represen tation Eq. (27.2) indicates that an arbitrary sequence of m control moves, Au(k), Au{k + 1), Au(k + 2), ..., Au(k + m1) will cause the system to change from the noted "initial conditio ns" y0 (k) to a new state:
y (k + 1) =
rJ(k + 1), y(k + 2), y(k + 3), ...• y(k + p)f I
Unit Step Response Unit Step Change ~n)
J
Input
Dynamic System
Output
11<3
~ 1
Figure 27.2.
The unit step-response function.
...
·
...,
1001
CHAP 27 MODEL PREDICTWE CONTROL
d (see Figure 27.3) as given by the followin g equation s, where the appende e collectiv the ts represen p), sequenc e, w(k + 1), w(k + 2), w(k + 3), ... , w(k + output the on ces effect of wuneasu red disturban y(k
+ 1) "' yO(k) + /J(1)Au(k) + w(k + 1)
y(k + 3)
+ /3(3)Au(k) + f3(2)!J.u(k /3(1)Au(k + 2) + w(k + 3)
= y 0(k + 2)
... = ... y(k + m)
y(k + m
+ 1)
+ p)
+ 1) +
+ ...
= y0(k + m- 1)
+ f3(m)!J.u(k) + {3(m- 1)Au(k + 1) + ... 1) + w(k + m) m+ + /3(l)!J.u(k
= yO(k + m)
+ f3(m + l)Au(k) + {3(m)Au(k + I) + ...
+ {3(2)Au(k + m- 1) + w(k + m + I)
... = ... y(k
+ /3(2)Au(k) + /3(l)!J.u(k + 1) + w(k + 2)
y0(k + 1)
y(k + 2) "'
+ ...
= yO(k +p-I) +
f3(p- m
+ fj(p)llu(k ) + f3
+ 1)!J.u(k + m- I) +
1his may be rewritten as: y(k + 1)
= y 0(k)
(27.6)
+ 13 Au(k) + w(k + 1)
where Au(k) is the value of Au at m points in time beginnin g at time step k; i.e.: Au(k) = [Au(k) Au(k + I) ..• Au(k + m - I )]T
and the matrix f3 given by:
/3(1)
0
/J,.3)
W.>
/3(1)
0 0 0
{J(m)
f3(m- I)
/3(m- 2)
/3(1)
{3(m + 1)
{J(m)
f3(m- 1)
/3(2)
f3(p- 2)
{3(p- m + I)
{J(I)
0
/l:l)
0
f3=
A/J)
f3(p- 1)
m is called the system's "dynami c matrix." Observe that it is made up of in down shifted ately columns of the system's step-resp onse function appropri 1) + w(k and moves; control of vector ensional order. Au(k) represen ts them-dim to yet are We ces. disturban led unmode of effect e collectiv the of is the vector ahead ed determin be to is resolve the nontrivi al issue of how this latter vector of time.
JUU'l
SPECIAL CONTROL TOPICS Past
Future Target -----------r-----~0 0
.___ _ _u(k=+m-1)
k+p
Horizon
Figure 27.3.
The elements of DMC: The "reference trajectory" is the set-point line.
27.3.2 The SISO (Unconstrained) Problem
Unconstrained Problem Formulation Expressed in the form shown above in Eq. (27.6) the control problem becomes that of judiciously choosing, and implementing, the control sequence represented as .11u(k) such that the predicted system output is caused to move to, and remain at, the desired trajectory value: y*(k + I) = fy*(k + 1), y*(k + 2), y*(k + 3), ... , y*(k + p)f
(usually set constant at the desired set-point value), i.e., choose .11u(k) such that: (27.7) yO(k) + 8 .11u(k) + w(k + 1) = y*(k + 1)
If we now define e(k + 1), the projected error vector in DMC parlance, as the difference between the desired output trajectory y*(k + 1) and the current output prediction in the absence of further control action, JO(k), corrected for the effect of unmeasured disturbance, w(k + 1), i.e.: e(k + 1) ~ y*(k + 1)- [jO(k) + w(k + 1)]
(27.8)
then the control problem reduces to choosing .11u(k) such that the equation: 8.11u(k) = e(k + 1)
(27.9)
is satisfied. This is the final process model form for the unconstrained DMC formulation. The set of equations represent, on the RHS, the predicted deviation of plant output from desired set-point in the absence offurther control
1003
TROL CHAP 27 MODEL PREDICTIVE CON
d in the d incremental change to be obs erve action, and on the LHS, the pred icte the sequence of control moves, .du(k). enting plan t outp ut as a result of implem
n Unconstrained Problem Sol utio erm ined set of 9) usu ally con tain s an ove rdet Now , the exp ress ion in Eq. (27. trol moves, is con of con tem plat ed num ber equ atio ns since, in DM C, m, the p. Thus, no th leng izon hor n the pred ictio alw ays cho sen to be sma ller than is no vector e of equations in the sense that ther exact solu tion exists for this set tly. mat ch the RHS exac .du(k) that will cause the LHS to " by finding ) may therefore only be "sol ved (27.9 Eq. in ns atio equ The set of .1u(k))ll (d. B 1)som e vector norm: ll(e(k + the vector .du(k) that minimi7.es measures that ric met e som ed by minimizing and the App end ix D), i.e., Eq. {27.9) is solv do) on the LHS (what the process can the difference betw een the vector is required to do). one on the RHS (what the process ares of the chosen nor m· is the sum of squ the re whe case In the specific sam e as the is this (i.e., the Euclidian norm), elem ents of (e(k + 1)- 5 Au(k)) ation problem: solving the unconstrained optimiz (27.10)
+ l)- 8Au (k)] min tf> = [e(k + I)- 5Au (k)n e(k t.u(k)
a well-known, l "least squ ares " pro blem with whi ch, of course, is the classica with resp ect 10) By differentiating in Eq. (27. analytical, closed-form solution. forwardly: to Au{k), we obta in quit e straight . __ lL )] aau(k) = - fiT[e(k + I)- 8 Au(k and by setting this equ al to zero
we obtain the so-called norm al equ
ular, we obta in the wel and now, prov ided 5T5 is nonsing solution:
ations:
l-known least squ ares (27.11)
or Au(k) = fi+e(k + I)
(27.12)
whe re 6 because while: is kno wn as the "left inverse" of
tity idempotent matrix, and not the iden B C + on the othe r han d gives an
matrix I (see App end ix D).
1004
SPECIAL CONTROL TOPICS
Observe therefore that while the model prediction in Eq. (27.9) involves the system's dynamic matrix 1'3, the control action calculation in Eq. (27.11) involves the left inverse of 1'3. It is important to point out here that from the definition in Eq. (27.8), and from the model equation in Eq. (27.6), we see that: e(k + 1)- 1'3 du(k) = y*(k + I)- y(k + 1)
(27.13)
the deviation of the predicted process output from the desired trajectory, which we now define as the "residual error vector" e,(k + 1): E,(k + 1)
= y*(k + 1)- y(k + 1)
(27.14)
so that: e(k + 1)- B du(k) = e,(k + l)
(27.15)
Thus a control sequence du(k) chosen according to Eq. (27.11) minimizes the squared residual error between the predicted process output and the desired trajectory over the p-interval prediction horizon. The difference between the two error vectors e(k + 1) and e,(k + 1) in Eq. (27.15) is subtle but extremely important: e(k + 1) we recall as the '"projected error vector" - the predicted output error that will result if no further control action is taken; e,(k + 1) on the other hand is the residual error left after the control action aimed at eliminating e(k + 1) has been implement ed. Thus e(k + 1) is used to compute control action; the result of the computatio n is conditioned upon minimizing the residual e,(k + 1). In the explicit, unconstrai ned DMC solution, du(k) is determine d analytically using e(k + 1) as shown in Eq. (27.11); in the implicit fmm obtained by solving the optimizatio n problem in Eq. (27.10), e,(k + 1) may be introduced for e(k + 1)- 13 du(k) and du(k) is then determined numericall y so that the residual vector is minimized. In practice, a penalty against excessive control action is often incorporate d into the optimizatio n objective to read: min¢ = [e(k + 1) -1'3 Au(k)f [e(k + 1)- B du(k)] + K2[Au(k)Tdu(k)]
Au(k)
(27.16)
It is easy to show that in this case the resulting control action is: (27.17)
a slight modification of Eq. (27.11).
Unmeasured Disturbance Estimation and Prediction Update The projected error vector e(k + 1) in Eq. (27.8) requires the vector of future values of unmeasure d disturbance effects that are unknown at time instant k; they can only be estimated solely on the basis of currently available information . At the penultimat e time instant (k- 1), on the basis of this same stepresponse model, the value y(k) was predicted as the output value to expect at
1005
CHAP 27 MODEL PREDICTIVE CONTROL
the time instant k. With the actual measure ment y(k) now availabl e, i.e.: n, predictio model the in discrepancy (27.18)
fl..k) :: y(k) - y(k)
also becomes available. In DMC, this discrepancy is assumed to be due to the effect of unmode led is disturbances yet unaccou nted for by the model; it is further assumed that this each Thus, effects. nce disturba such of values the best estimate of the future element w(k + t}, i = 1, 2, ... , p of the vector w(k + 1) is estimate d as: w
= y(k>- .Y
i = 1, 2•...• P
(27.19)
and these values introduc ed for e(k + 1) in Eq. (27.8).
Implem entatio n Strategy not We now note that because of the inevitab le predictio n inaccuracies, it is -1) advisabl e to impleme nt the entire sequence, Au(k), Au(k + 1), ..., Au(k + m n. as calculated from Eq. (27.11) over the next m intervals in automatic successio is it 1), + w(k vector the g estimatin in efforts best our despite This is because the impossi ble to anticipa te precisel y over the next m time intervals , that unavoid able plant/m odel mismatc h, and other unmode led disturba nces to used ns predictio the from differ to state plant actual the cause are bound to may compute this sequence of control actions. Also the process output set-poin t change at any time over the next m intervals. Such a set of precomp uted control moves is therefore inherent ly incapabl e of reflecting the changes that would subsequently occur after the computation. The DMC strategy is therefore to impleme nt only the first move, Au(k), and then: 1. Update the projected error vector e(k + 1) in Eq. (27.8) at the next time instant, i.e.: • Update yt(k + 1) with any new desired set-poin t information. • Update 0 (k) by adding the effect of impleme nting Au(k), and assumin g no other control move beyond this will be implemented. • Using available system measure ment and the correspo nding model prediction, update the w(k + 1} estimates as indicated in Eqs. (27.18) and (27.19).
y
2. Shift the origin of the predictio n horizon forward to (k + 1) by droppin g 0 off the first element in each of the updated vectors y"(k + 1), (k), second the that so w(k + 1), advancin g the other elements in order, element becomes the first, the third becomes the second, etc., and finally filling the vacant last element by linear extrapol ation. The updated and "shifted " vectors now become, respectively, y"(k + 2), 0 (k + 1), w(k + 2).
y
y
3. Recompute the control move sequence using these updated and "shifted" vectors, impleme nt the first one, and repeat the cycle.
SPECIAL CONTROL TOPICS
1006
The discussion given above is easily extended to multivariable systems and to the constrained case. But before demonstrating how this is done, it is importan t to pause and observe the four MPC elements as utilized in the DMC scheme: 1. The reference trajectory is specified simply as a step to the desired setpoint or target value. 2. Process output prediction is carried out using the step-response model as given in Eq. (27.6), with 8, the dynamic matrix as the "main operator" ; this is further rearrange d and simplified to the equivalen t modeling equations in Eq. (27.9). 3. Control action computation is carried out using Eq. (27.11), which involves the use of the generalized (in this case, the left) inverse of the dynamic matrix 8. 4. Model prediction update is achieved by providing estimates for w(k + 1) as indicated in Eq. (27.8), using the single correction term calculated at time instant k as indicated in Eqs. (27.18) and (27.19).
27.3.3 Extensions to Multivariable Systems The DMC scheme as discussed above extends quite straightforwardly to systems with multiple inputs and multiple outputs; the basic form of the modeling equation in Eq. (27.9) remains the same, except that the matrices and vectors become larger and appropria tely partitione d. For example, for a two-input , two-outp ut system, the DMC equations are given by:
(27.20)
where e;(k + 1) is the projected error vector for the ith output variable (i = 1, 2), .6.ui(k) is the sequence of control moves for the jth input varjable (j = 1, 2), and output variable eij is the dynamic matrix formed from the step-respo nse of the 2). 1, = j 2; 1, = (i i to the input variable j By simply expandin g the definition of the vectors and matrices so that the entire partitione d vector on the LHS is represented as e(k + 1), the one on the RHS as .6.u(k), and the partitione d matrix simply as 8, observe therefore that Eq. (27.20) is exactly of the same form as Eq. (27.9), and therefore the leastsquare control move sequences are also given by Eq. (27.11); the only difference is that the matrices and vectors are now larger in dimension.
Scaling With multi variable processes, it often happens that a unit change in one output variable is much more importan t than a unit change in another. A typical example is the two-point distillation control system in which the top product quality (measure d in mole fractions) and a tray temperatu re in the bottoms
1007
TROL CHAP 27 MODEL PREDICTIVE CON t variable, a controlled. In the case of the firs section (measured in °F) are to be betw een 0 be t scale (since mole fractions mus unit change repr esen ts the entire l. Thu s in sua unu red side con s of lO"F are not and 1), whi le tem pera ture change imp orta nt as in temperature may be dee med this part icul ar case, a unit change . as a change of 0.01 in mole fraction suc h that of scaling the erro r vector e(k + 1) nce orta imp the DMC recognizes equally. ted vari ous outp ut variables are trea tuni ng a equally imp orta nt changes in the as r rix mat odu ctio n of a wei ghti ng This is don e thro ugh the intr s: para met er so that Eq. (27.11) read Au(k)
= (er rer 'er re( k + 1)
ents ·are best ght into how to cho se its elem The role of this mat rix and insi it arises how rly clea siderations that sho w und erst ood via the following con wish to fund ame ntal ly (cf. Ref. [53]). W repr esen t the imp orta nce we Let the elem ents of the mat rix others. the in nge able relative to a uni t cha atta ch to a uni t cha nge in each vari : mes beco 9) (27. rix, the DMC Eq. Upo n intr odu cing this scaling mat (27.21) W8 Au( k) =W e(k+ 1)
so that the objective of the least squ to:
ares optimization pro blem is now
(k+ 1)min 4' = [e(k+ 1)- 8Au (k)f WT. W[e
modified
eAu (k)]
Au(l)
or
min ; .Wl)
= [e(k+ 1)- 8Au (k)f r[e( k+ 1)- 8Au(k)J
(27.22)
wit h the mat rix r defined as:
(27.23) ds from whi ch {J#iJAu(k) =0 then yiel Au(k)
the required solution:
= (er rer •er re( k + t)
(27.24)
ng mat rix r is that by definition, the wei ghti It may be obs erve d therefore as sho wn in W rix mat the scal ing positive definite; and it aris es fromr by specifying the elements of W chosen rmine Eq. (27.23). It is thus bes t to dete cts in the various process outp uts. effe ing scal ired des the ieve to ach al theo ry read er familiar wit h the statistic Let us not e in closing that the the stri kin g imm edia tely hav e reco gniz ed of par ame ter esti mat ion wil l C pro blem DM the para met er esti mat ion and similarities betw een leas t squares ted to the rela ctly dire are lts sho wn abo ve formulation,· and how the resu in line ar s blem pro ares squ t leas wei ghte d ord inar y leas t squ ares , and the ch are whi ts cep ion. In fact , man y con stat istic al par ame ter esti mat feat ure s lysi ana al istic ous aspe cts of stat es are trad itio nall y asso ciat ed wit h vari issu e thes of on ussi disc iled C. A deta pro min entl y in the stru ctur e of DM contained in Ref. [53).
1U08
27.3.4 Th e General Co nst rai ned Pro
SPECIAL CONTROL TOPICS
blem
The most general form for spe cifying the DMC problem ma y now be expressed as: Min P (au(k).....ou(H m-1 )) "' ~ 1 e,(k + l)T fe,( k + l) + ~ 1 [u(k + l- 1lF u(k + l - 1) + t.u(k + l- llR t.u (k + ll)]
(27.25)
wh ere the ele me nts of the wei ght ing matrices r, F, and R, alo ng wit h the pre dic tion hor izo n p, and the con tem pla ted num ber of pre com put ed con trol moves m, are the tuning parame ters. Wh en con stra ints are inv olv ed, this pro ble m for mu lati on mu st be aug me nte d wit h the con stra int equations. In this case, if we def ine the collective vector of all the con trol moves as v, i.e.: v = [u(k),u(k + 1), ... , u(k + ml)]T
(27.26)
the opt imi zati on pro ble m can be written as the following stan dar d Qu adr atic Program (QP) (cf., for example, Refs. [28, 84]): (27.27)
subject to:
(27.28)
where the matrices Q, A, are related to the tun ing par am eter s not ed above and to som e har d constraints; the vectors v and 11 on the oth er han d are line ar functions of the out put predic tion vector, the pas t inputs, u(k - 1), u(k - 2), ..., u(k - n), as well as bei ng fun ctions of the tun ing parameter s. There are ma ny efficient algorithms for solving this QP (e.g., Refs. [57, 66, 84]) . It sho uld per hap s be not ed, in conclusion, tha t the origina l DMC scheme rep orte d in the pioneering pap ers was not formulated in this fashion; the above is, strictly spe aki ng, the QD MC formulation. As wil l be not ed in Section 27.5, the commercial DMC pac kag e is bas ed on opt imi zin g an absolute val ue (L 1 nor m) of the res idu al erro r vec tor rather tha n the quadratic fun ction (L nor m) as not ed above.
y,
2
27.4
MODEL ALGORITHMIC CO
NTROL (MA<:;:)
As not ed earlier, MAC is ver y similar to DMC in principl e. Ho wev er, the fun dam ent al similarities the y sha re not wit hst and ing , the re are som e sub tle but important distinctions bet wee n MAC and DMC. We wil l therefore focus on suc h distinctions rath er tha n pro vid e a full treatment compar able to tha t given DM C in the previous section.
27.4.1 Process Re pre sen tat ion The model form for the MAC J(k + 1)
'= y0(k) +
scheme: Gu (k) + w(k + 1)
(27.29)
CHAP 27 MODEL PREDICfWE CONTROL
1009
is very similar to that in Eq. (27.6): the main differences are that this is an impulse-response model involving u, the actual input, whereas the DMC model in Eq. (27.6) is a step-response model involving t..u, the change in the input; the matrix G here is composed of impulse-response coefficients, in precisely the same manner in which the "dynamic matrix" 8 in Eq. (27.6) is composed of the step-response coefficients.
27.4.2 Problem Formulation, Solution, and Impleme ntation via IDCOM Problem Formulation The unconstrai ned problem formulation may then be posed similarly as in Eq. (27.7), i.e., to choose u(k) such that: yO(k) + Gu(k) + w(k + 1) = y*(k + 1)
(27.30)
However, how the elements of the desired trajectory, y*(k + 1) are calculated in this case constitutes what is perhaps the most fundament al difference between DMC and MAC. While with DMC all the elements of the entire vector y*(k + 1) are set equal to the current set-point value, i.e.: y*(k + i) = Ystt·fH1int(k); i = 1, 2, ... , p
(27.31)
with MAC, the elements of the desired trajectory are taken as a reference trajectory, y *(k), based on the current measured value, y(k), and the current setpoint, Yset-point(k) as follows: y*(k + 1) = CX)'(k) + (1 - a)yS
(27.32)
with subsequent values determined according to: y*(k + i) = cxy(k + i- I) + (1 - a)ystt·poinr(k); i > 1
(27.33)
Thus the MAC desired trajectory is a first-order approach to set-point from the current measured value. This is indicated in Figure 27.4. As noted in Ref. [46), it is possible to use higher order trajectories; however, the first-order strategy noted above is used almost exclusively. It is important to note that the parameter a determines the desired speed of approach to set-point; a small value (close to zero) indicates the desire for a swift approach to set-point, while a larger value (close to 1) indicates the opposite: a more sluggish approach to set-point. This parameter is thus the · primary tuning parameter for the MAC controller, and its choice is very closely tied to the robustness of the overall control system (cf. Ref. [54]). As noted in Ref. [28] the parameter a is a more direct, and more intuitive, tuning parameter than the weighting matrices, horizon lengths, etc., utilized in the DMC formulation.
SPECIAL CONTROL TOPICS
1010
,
..:-:...........~ Ysetpo intt----- -------:: .":"
...
.......
MAC Desired Trajectory
/ .......... ·
y*(k+il II
Time
k
Figure 27.4 .
The MAC desired trajectory.
Finally, we also note that in the DMC formulation, the number of control moves m is deliberately chosen to be less than the prediction horizon length p, and both are available as tuning parameters . With MAC m = p and neither is used as a tuning parameter; p is determined by the truncation order of the finite impulse-response function, i.e., for all j > p, h(J) =0.
Problem Solution In a similar vein to the DMC problem, MAC determines the control sequence by
'
minimizing the objective function: p
41
A
= .LI [y*(k + i)- y(k + i)] 2){i)
(27.34)
t=
or
p
41
= L. [e,(k + i)] 2 ){i) i
=I
where the l{i) are (possibly) time-varying weights.
Implementation The model prediction is updated and corrected for the effect of modeling errors and unmodeled disturbances precisely as indicated in Eqs. (27.18) and (27.19) for DMC. The same strategy of implement ing only the first element of the computed input sequence and then repeating the optimizatio n at the next time instant is also adopted in MAC. The constrained problem poses no additional complications; the constraints are simply appended to the objective function and the resulting quadratic program (QP) is solved using a proprietary algorithm resident within the IDCOM software. For obvious reasons, not much has been disclosed about this algorithm; however, it is known to perform a two-step QP when there are more inputs than outputs. Under these conditions, because of the extra degrees of freedom, the objective of the second QP is to minimize the deviation of the
1011 TROL CHAP 27 MODEL PREDICTWE CON valu es in ecti ve pres pec ified idea l rest ing inp ut sequ enc e from thei r resp that the res ensu es of the first QP. This add itio n to mee ting the objectiv con trol of e itur end exp with the opti mum objectives of the first QP are met
effo rt.
27.5
• TIVE CONTROL COMMERCIAL MODEL PREDIC IEW REV SCHEMES: A QUALITATIVE
mer cial are curr entl y ava ilab le as com A wid e vari ety of MPC sche mes ures of feat nt salie The . by various vendors com pute r software packages offered w. belo y ivel litat qua ized mar sum are now several of these commercial prod ucts
27.5.1 IDCOM pac kag e CO Mm and - is the com mer cial IDC OM - for IDe ntif icat ion and Mo del the ng enti Setpoint, Inc. for imp lem mar kete d in the Uni ted States by OM IDC inal orig the ier, me. As note d earl Alg orit hmi c Con trol (MAC) sche OM {IDC ions vers r late ; bios Ger by Ade rsa/ controller was dev elop ed in France e wer } ems IDCOM-M for mul tiva riab le syst S for single variable systems, and oint, Inc. in the Uni ted States. Setp dev elop ed jointly by Ade rsa and
Mo del Form ion of IDCOM is the impulse-response vers The process mod el form utilized by tifie d iden ally usu is el form. The mod el the line ar discrete convolution mod the in ctly dire el mod the her than iden tify from plan t dyn ami c test data . Rat the tify iden to ed end mm reco n r, it is ofte imp ulse -res pon se form, how eve ulse to con vert this to the requ ired imp then and first el mod type ARMAX ulse imp the of n atio bec ause the iden tific e resp ons e form. This is prim aril y larg with ates estim to s lead ally y data usu resp onse function directly from nois se pon -res e of the fact that the imp ulse vari anc es - a dire ct con sequ enc elated. corr ly coefficients are all fund ame ntal ine for mod el identification. rout a s ude incl The IDCOM package
Fundamental Objective ence of controller is to determine the sequ The prim ary objective of the IDCOM , the rest inte of zon hori n ictio ove r the pred in con trol mov es that will minimize, es, iabl Var pred icte d outp uts (Controlled sum of squ ared dev iatio ns of the er rath nds bou n whe points (or zon e limits, IDCOM parl ance ) from their set-ofrate and , lute abso both to ified) subject than prec ise targ et valu es are spec ance). nipulated Variables in IDCOM parl (Ma ts inpu the on change, constraints able s, vari led vari able s than con trol Wh en ther e are mor e man ipul ated ues Val ting Res l ewo rk is the concept of Idea inco rpor ated in the IDCOM fram ary prim the to n itio add In this case, in for the man ipul ated vari able s. ared squ of sum the e imiz min to then tries objective, the IDCOM con trol ler rest ing able s from thei r respective idea l vari ated ipul man the of dev iatio ns g the rdin rega es ng the prim ary objectiv valu es, but still subj ect to sati sfyi con trol led variables.
1012
SPECIAL CONTROL TOPICS
Thus the IDCOM strategy involves a two-step optimization problem: the primary problem involves choosing the control sequence required to drive controlled variables close to target; the second involves optimizing the use of control effort in achieving the objectives of the primary problem. This two-step optimizati'4l problem is solved using a quadratic programming (QP) approach. Even when there are no excess manipulate d variables, the ideal resting values concept is still particularly valuable when, for operationa l and/ or economic reasons, there is some benefit in having a manipulated variable at a specific steady-state value. No other MPC scheme incorporates this concept explicitly.
Tuning The major tuning parameter in the IDCOM controller is the "reference time" by which the desired closed-loop speed of response is specified. A smaller "reference time" (corresponding to an a value in Eqs. (27.32) and (27.33) close to zero) provides faster closed-loop response, but the manipulate d variable is moved more vigorously; a larger "reference time" (corresponding to an a value close to unity) provides a slower but smoother response requiring less vigorous control action. By virtue of this fact, a larger "reference time" also improves the robustness of the overall control system since then the controller becomes less sensitive to plant/mod el mismatch.
Implementation Platform ·Even though a version of IDCOM (IDCOM-B) is currently available for implement ation directly on the Bailey DCS, the IOCOM software typically resides in the process control computer and communicates with the distributed control system (DCS) database tht9ugh some interface. A common hardware implementation strategy recommended by Set-point requires linking IDCOMresident in a Digital VAX - with the Honeywell TDC 3000 DCS system through Honeywell's CM-50s interface and a generic scanner program, called the Phoenix interface, written by Set-point. Of course, with the appropriate interface, any other available DCS system could be used in place of the IDC 3000.
Example Industrial Applications I
Industrial application s of IDCOM include the ·control of reactors and regenerato rs of Fluid Catalytic Cracking (FCC) and coking units; cutpoint control of crude· distillation units; reactor control in i reforming and hydrocrack ing units; control of C2 splitters in ethylene uni~; and control of various distillation columns.
27.5.2 DMC The Dynamic Matrix Control (DMC) scheme was originally developed at Shell and is currently being marketed by Dynamic Matrix Control Corporation. It is also available from other vendors under license from DMC Corporation. As noted earlier, even though they differ in certain details, the basic control philosophies of DMC and IDCOM are similar.
..•·.
CHAP 27 MODEL PREDICTWE CONTROL
1013
Model Form DMC utilizes the step-response model form usually obtained from plant dynamic test data. The DMC package includes an identification software package - Dynamic Matrix Identification (DMl) - developed specifically for identifying step-response models for multivariable processes. The strategy employed remains undisclosed for proprietary reasons.
Fundamental Objective The original version of the DMC algorithm finds the sequence of control moves that minimize the squared deviation of the predicted output from their respective set-points. This is done by first solving the unconstrained optimization problem with the quadratic objective function explicitly, obtaining the least square solution. The constraint handling capability is then added by iteratively checking for constraint violation and resolving the modified problem if violation occurs. In the subsequent Shell versions of DMC, constraints handling is incorporated more directly by formulating the problem as a Quadratic Program. This version, as noted earlier is known as Quadratic Dynamic Matrix Control (QDMC). The DMC package marketed by DMC Corporation is different from QDMC in that the controller objective function requires the minimization of the absolute value of the vector of errors between the predicted process output and their respective set-points or zone limits. This absolute value formulation allows the constrained optimization problem to be solved by the less computationally intensive linear programming (LP) approach. Since only a single-step optimization is performed, ideal resting value optimization is not an explicit part of the DMC algorithm. In order to keep manipulated variables close to their prespecified economic optimum values (in situations when there are more manipulated variables than controlled variables), additional terms are introduced into the overall objective function. The relative importance of the various aspects of this composite objective function (minimizing prediction error, versus penalty against excessive control action, versus keeping manipulated variables at the economic optimum) is indicated by the values introduced for the various weighting matrices associated with each individual component.
Tuning The main tuning parameters are known as the move suppression factors (the scalar K in Eq. (27.17) or the matrix R in Eq. (27.25)); they indicate the tradeoff between the amount of movement allowed in the manipulated variables and the rate at which the output deviation from set-point is reduced over the prediction horizon. The prediction horizon as well as the number of control moves computed at each optimization cycle are also available for use as tuning parameters. As earlier explained, the weighting matrix r in Eqs. (27.23) and (27.25) is used primarily for scaling in the multivariable case; it permits the assignment of more or less weight to the objective of reducing the predicted error for the individual output variables; the matrix F in Eq. (27.25) is primarily for
SPECIAL CONTROL TOPICS
1014
from prespe cified penaliz ing the movem ent of manip ulated variabl es away ble. reasona and desired is policy a such when values economic optimu m
Implementation Platform l compu ter. Some The DMC softwa re will typically reside in the process contro in the VAX resides DMC where cases DMC Corpor ation applica tions include s. CM-SO h throug 3000 TOC well Honey with nicates compu ter and commu
Example Industrial Applications if the 15 or more DMC appear s to have the largest industr ial applica tion base heless, DMC Nevert ered. consid is ny years of applications at Shell Oil Compa the oil and in ty majori the with 's, IDCOM to similar very applica tions are e sbme includ now tions petroch emical industr ies. More recent DMC applica s. chemic al and polyme rizatio n reactor
27.5.3 OPC is curren tly being Optim um Predic tive Contro l (OPC} was develo ped, and form, and the model the t, concep control The Inc. ls, Contro Treiber market ed, by DMC. by ed fundam ental objectives are all similar to those employ
Model Form ion. Howev er, like DMC, OPC uses the step-re sponse model for output predict y a transfe r identif to s analysi ries time-se ing this model is obtain ed by employ sponse step-re the to ted conver then is this data; plant from functio n model which in y strateg ication identif model. This is in direct contra st to the DMC DMI. using directly ied identif is se respon the so-called nonpar ameter ic step permit s the Furthe rmore the identif ication modul e of OPC only ariable multiv a of ts elemen identif ication of the compo nent input/ output le to possib is it DMI with s wherea time, a transfe r functio n matrix one at y. neousl simulta ts identif y these elemen
Fundamental Objective the original DMC; The OPC objective function is essentially the same as that of mance index. ;perfor tic contro l action is calcula ted by minim izing a quadra on smaller OPC run. still and ints constra Howev er, in order to be able to handle ly cast as the ~tural more is which m, proble zation machin es, the optimi be reform ulated. compu tationa lly intensi ve Quadr atic Progra m (QP), had to tic objective quadra l origina the es, By the introdu ction of two artificial variabl additio nal one with n functio ve objecti linear a into functio n is transfo rmed less us~g aints equali ty constr aint; this permit s the handli ng of constr can OPC that so ch, approa (LP) compu tationa lly intensive Linear Progra mming es. indeed run on smaller machin
Tunin g DMC: the penalty The major tuning parame ters in OPC are the same as with ion horizon , predict the as such es variabl Other moves. l contro the weight s on ters. parame tuning as le the numbe r of control moves, etc., are also availab
. I
:: I
1015
E CONTROL CHAP 27 MODEL PREDICTW
Implementation Platform
ula tion task s are all & controller des ign and sim ldin bui del mo the C OP th des ign , the OPC Wi ible per son al com put ers . By multifunction car ried out on IBM com pat C03 MF s ley' be carried out on Bai mu nic atio n com controller implementation can nal itio add e vid the nee d to pro controller. This eliminates the DCS system. between the hos t computer and
s Example Industrial Application n Setpoint, Inc. and at of a smaller company tha Treiber Control, Inc. is somewh tions as there are lica app C OP ny re are not as ma n app lied on DMC Corporation. Thus the bee tion s. Ho we ver , OP C has ty dis till atio n IDCOM or DMC app lica uri h-p hig ds ext rac tion cells, san tar ts, uni g kin rac hyd roc ble pol yet hyl ene , pul p mills, and mu ltiv aria col um ns, pol ym er ext rud ers reactors.
27.5.4 PC
. In ma ny ways it ma rke ted by Profimatics, Inc Predictive Co ntro ller (PC) is h those of DMC. wit y teg stra aspects of the IDCOM s iou var e bin com to s ear app
Model Form IDCOM. Like IDCOM ally similar to tha t use d by Its mo del form is fundament e constant determines defined by a filter wh ose tim it use s a reference trajectory p response. the des ired spe ed of closed-loo mo del upd atin g the oth er MPC schemes, the of any Ho we ver , unl ike tion strategy is rec istic. The model prediction cor trends can be ed scheme is som ew hat mo re real erv obs t diction errors so tha pre t pas ing lud inc by ed enh anc . inc orp ora ted systematically
Fundamental Objective iterative strategy for ction utilized by PC and its The qua dra tic objective fun orithm.. Ho we ver , alg cent of the original DMC con stra int han dlin g is reminis re control mo ves futu le ltip schemes in which mu C MP er oth the ike unl in, aga only the first one is zation cycle (even tho ugh are com put ed at each optimi y: each optimization e ado pts a single mo ve strateg implemented), the PC schem s policy may affect Thi ve. ing only one control mo put com h wit ned cer con is are active. cycle ly especially wh en constraints controller performance adverse
Tu nin g ine the desired closedrence trajectory is used to def In PC, as in IDCOM, the refe ain ing the refe ren ce obt time con sta nt for er filt the h suc as se; pon loo p res parameter. trajectory is the major tuning
Implementation Platform PC is imp lem ent ed on the sam
C. e platforms as IDCOM and DM
1016
SPECIAL CONTROL TOPICS
Example Industrial Applications Published applications of the PC algorithm have been mostly in oil operations, particularly on FCC units.
27.5.5 HMPC Horizon Predictive Control (HPC) is marketed by Honeywell as a single loop (multi-input, single-output) scheme. The multivariable version, Honeyw ell Multivariable Predictive Control (HMPC), is relatively new on the markel
Model Form Both HPC and HMPC are flexible in the model form they can accept for carrying out model prediction. However, the identifier included with these packages identifies parametric ARMAX or transfer function models from plant data.
Fundamental Objective The objectives of HPC (and of HMPC) are fundamentally different from that of the other MPC schemes. A correction horizon (the main tuning parameter) is chosen by the designer as the time after which the prediction error is to be reduced permanently to zero; as there is an infinite set of control move sequence s that will achieve this nominal objective, the HPC objective is therefore to find the sequence that corresponds to a minimum expenditure of control efforl It should be noted that the quadrati c objective function of the DMC algorithm may be reformulated to resemble the HPC objective. For proprietary reasons, there are several other aspects of the HMPC/H PC algorith m that are currently unavailable.
Tuning The major tuning parameter is the correction horizon. It is defined as the length
, of time within which the controller must retUrn the variable to its set-poin t or nearest limit. It is claimed that even in the multivariable case, all that is required is the specification of this correction horizon for each controlle d variable . ·
Implementation Platfor m The model building, controller design, and simulation mod~ for HMPC/H PC are implemented on the personal computer. Estimation of model parameters from plant dynamic test data is carried out using MATLAB's system identification toolbox. The controller coefficients are transferred from the PC to the Honeywell DCS. The control algorithm is implemented directly in the Honeywell application module so that no process control computer is needed for implementing HMPC/HPC.
Example Industrial Applications Since HMPC/ HPC are relatively new addition s to the commercial MPC market, publicly documented industrial applications are still relatively few.
CHAP 27 MODEL PREDICTIVE CONTROL
1017
ACADEMIC AND OTHER CONTRIBUTIONS
27.6
Since the publication of the original DMC and MAC papers, the general subject matter of MPC has received considerable attention from academic as well as industrial researchers. The result is that substantial contributions have been made to the advancement of the theory and practice of MPC. What follows is a representative - rather than exhaustive - review of the various aspects of MPC that have received attention.
27.6.1 Fundamental Understandin g As originally conceived and presented in the pioneering publications, DMC and MAC were clearly empirical techniques based on technically sound, but heuristic, arguments. Primarily because a strong theoretical framework was not yet available for these techniques therefore, the remarkable industrial success they enjoyed (especially where others had failed previously) was initially difficult to explain. Garcia and Morari [23] provided some theoretical results, putting these techniques as well as others which, at best appeared only vaguely related, into one unified structure they subsequently referred to as the "Internal Model Control" (IMC) structure (see Figure 27.5; see also the series of papers that followed [25, 26, 70, 201). More fundamental theoretical results and insight into the stability, robustness, and other properties of MPC appeared later in the papers by Rawlings and coworkers [44, 51, 61]. In the same year that the original Garcia and Morari paper was published, the first paper on the basic theoretical properties of MAC was published by Rouhani and Mehra [71] in which was discussed, among other things, the theoretical basis of how problematic dynamics (particularly inverse response) are handled by MAC. Seborg and coworkers (e.g., [10, 39]) connected the concepts of optimization via linear programming for constrained multivariable control with MPC; they also provided some fundamental analysis of the concepts involved in the design of both the predictor and the control elements of MPC. In the paper by Maurath et al. [42], the concept of principal component analysis was introduced for the design of MPC schemes.
Setpoint+
~
F
Plant
Controller
Filter
f-.
Q
u
p
yd
W> \..
Model
"d The IMC structure.
+
-
p
Figure 27.5.
y
1018
SPECIAL CONT ROL TOPICS
d to the initial eluci datio n of Brosilow and coworkers [7, 8] also contribute as well as to the use of linear the fund amen tal struc ture now know n as IMC, control. ble :varia prog ramm ing withi n the concept of multi was first intro duce d by MPC to oach appr ing The quad ratic prog ramm cons train ed MPC prob lem as a Garcia [24] and Ricker [66]. By posin g the arity betw een the prob lem simil Quad ratic Program, and by recognizing the possible to take adva ntage is it , MPC ard solved at every time insta nt in stand for solvi ng such optim izati on of effic ient algor ithm s that alrea dy exist problems. strat egy was prese nted by A statis tical inter preta tion of the DMC n the DMC fram ewor k reside withi that s lishe Ogunnaike {53]. This work estab proven statistical concepts as least the same principles upon whic h such time-Mar quart nonl inear regre ssion squa res parameter· estimation, the Leve nberg entia l estim ation are base d, sequ sian Baye meth od, Ridge regression, and ding DMC's success. thereby prov iding another vehicle for unde rstan ry of time -seri es analy sis, Usin g argu ment s from the statis tical theo the theoretical basis for the s, thing other MacGregor [38] established, amon g reference trajectory. He show ed first-order filter used to generate the MAC beha vior (due to mode l error s and that if the unmo deled aspects of the plan t as a rand om walk process observed unme asure d disturbances) can be represented which is reasonably close to the ption with white meas urem ent noise (an assum nce pred ictor of the effect of these obse rved reality), then the mini mum varia age of Section 27.3, is obtai ned by unmo deled dynamics, w(k + 1) in the langu path , as advo cated by the MAC utiliz ing a first-order fl.lter in the feedback scheme. ut of this filter is easil y MacG rego r also estab lishe d that the outp ng average (EWM A) of past movi rearr ange d to give an exponentially weighted easy to dedu ce that unde r mes beco then it value s of the disturbance sequence; ignored, the EWM A control charts conditions in which the process dynamics are me identical to the MAC strate gy used in Statistical Process Control (SPC) beco led discu ssion of this and other detai incor porat ing this first-order fl.lter. A 28. ter Chap in related issues may be found
Schemes 27.6.2 Add ition al Stru ctur ally Sim ilar MPC tural similarities with DMC and Several control meth odolo gies beari ng struc of the differences betw een these MAC have since been prop osed . Mos t subtle, but, in some cases, these are es strate gies and the original MPC schem ctions. The following is a distin rtant impo to subtl e differences can lead ol strategies: representative selection from this class of contr 1.
Generic Model Control [35, 36]: ar or nonli near, dyna mic or In which any available proce ss mod el (line desig ned to calculate the ithm algor static) is incorporated directly into the follow the trajectory to ss proce the e caus contr ol actio n requ ired to case, the reference syste m has prescribed by a reference system. In the SISO titute the tunin g parameters. cons two poles and one zero whose locations MPC (see Chap ter 19). ard stand with e Lee [37] has compared this schem
CONTROL CHAP 27 MO DEL PREDICTIVE
1019
ive Control [11, 12]: 2. Adaptive Generalized Predict e control embedded in a self-twling/ adaptiv is m adig par In which the MPC y) are gor similar techniques in this cate y be environment. This (and oth er ma ems syst le nsions to multivariab are largely limited to SISO cases; exte ails det ns atio ent lem but the imp ess con cep tua lly stra igh tfor war d, ustn rob review of the issues regarding daunting. Clarke [13] presents a rk. ewo this controller design fram and parameter estimation within Control [2-4]: plified by 3. Simplified Model Predictive ects of the standard MPC are sim asp nal atio put com In which the the base as e ons inal open-loop system resp iou s the device of specifying the nom obv The . tem sys trol ed- loo p con nde case req uire me nt for the dos hpa are discussed by Arulanan and Des comparisons with standard MPC . found in Tu and Tsing [76] [2-4]. The original concept may be [21, 55]: 4. Forward Modeling Control tha t control plicity is achieved by requiring sim nal atio put com In which poi nt in the le sing the error at only one action be calculated to minimize of stan dar d y teg stra on zati oin t optimi future, as opp ose d to the mu ltip that of Marchetti et al. [39]. MPC. The strategy is similar to
27.6.3 Robustness Issues en tha t model a central role in MPC, and giv Since the process model plays the face of , how MPC schemes perform in uncertainty is an unavoidable fact e importance. pla nt/m ode l mismatch is of prim MPC schemes ility and robustness of standard stab the A general analysis of specific issues te horizon formulation. Certain is not possible because of its fini nique (in the tech robust performance for the IMC concerning robust stability and ; particular (47] u irio Zaf and ussed by Morari disc n bee e hav ) case ned trai ons unc troller design nt issues surrounding robust con emphasis was laid on the importa Ref. [57]). also uncertainty descriptions (see effect of wit h explicit incorporation of the s usse disc d MPC, Zafiriou [84] Within the framework of standar . ility stab and on the robustness general tuning parameters and constraints 61] have presented a completely [51, ers ork cow Rawlings and horizon nite infi an robustness of MPC using analysis of the stability and representation.
me nta l Ele me nts 27.6.4 Im pro vem ent s on Fu nda the model, the C, as noted in Section 27.2, are The fundamental elements of MP dar d MPC as in IMC, or implicit as in stan approprinte model inverse (explicit blem), and the disturbance estimation, or pro whe n pos ed as an optimization · me. sche g atin upd ion dict pre el mod tation aspects of MPC esen repr el the mod The issues involved in improving by Muske and e, by Morari and Lee [48], and hav e been discussed, for exampl l be discussed wil els to accept nonlinear mod Rawlings [51]; extending MPC late r.
1020
SPECIAL CONTROL TOPICS
The constrained optimization approach to implementing the approximate process model inverse as the controller is not without its complications. For multivariable problems with long prediction horizons and requiring computation of a large number of future control moves, the resulting QP can be quite formidable. Strategies for improving this aspect of MPC have been proposed by Brosilow and coworkers [8]. It involves a two-step approach utilizing the less computationally taxing LP formulation. For good reason, the disturbance estimation strategy of MPC has received the most criticism. Recommendations for posing the MPC problem as a classical state estimation and regulation problem, and taking advantage of the. rich heritage of these subject matters have been made by several authors (cf. Refs. [ 44, 48, 68, 69, and 82]).
27.6.5 Nonlinear Extensions Since all chemical processes are nonlinear to varying degrees of severity, extending the standard MPC concept to systems described explicitly by nonlinear models has been the subject of intense research. To date there have been essentially three approaches: 1. Scheduled Linearization (as exemplified in Ref. [24]) in which the nonlinear model is linearized around several operating steady states and the appropriate linearized model used within the ~ear MPC framework as the process moves from one operating condition to the other.
2. Extended Linear MPC [33] in which the basic linear MPC structure is augmented to reflect the true nonlinearities captured by an explicit nonlinear model; the recommended control moves then become perturbations around the basic linear MPC controller recommendations. 3. Explicit Nonlinear MPC in which the fundamental MPC problem is posed as a full-scale nonlinear problem and the nonlinear controller obtained either explicitly by analytical means (as proposed in Refs. [19, 20]) or implicitly as the solution of a nonlinear program (NLP) complete with the full nonlinear model and (possibly nonlinear) constraints (cf., for example, Ref. [5]). '
We consider the issues involved with the nonlinear ~xtensions of MPC important enough that they will be discussed separately in: the next section.
27.7
NONLINEAR MODEL PREDICfiVE CONTROL
If one considers the basic concepts of MPC, there is nothing in the MPC structure that fundamentally forbids the use of a nonlinear model. In fact, the conceptual extension of the intrinsic MPC concept to nonlinear systems has been discussed by Frank [22] in 1974.
However, some very serious practical issues arise that make the nonlinear extension of MPC a nontrivial exercise.
CHAP 27 MODEL PREDICTWE CONTROL
1021
that the 1. Availab ility of Nonlinear Models. It is general ly believe d which with ease relative fue success of standar d MPC is due in part to on models, r nonlinea ; obtained be can models se step- and impulse-respon the other hand, are much more difficult to construct, either from first principles or from input/ output data correlation. 2.
Nonlinear Model Inversion. The procedu re for carrying out fue model inversi on require d for the implem entation of the standar d MPC can control ler is itself not trivial; the inversio n in the nonlinear case ated. complic only be expected to be even more
need for These factors notwith standin g, there are strong factors motivating the ions. applicat control nonline ar control in certain chemical process
27.7.1 Motiv ation of the control It is true that in many classica l.indust rial processes, the role state as system is to hold the process output as close to the operatin g steady , and problem ry regulato classic the is This nces. possible in the face of disturba
state, by definition_ the process will be operatin g in the vicinity of a steady e. adequat be fact, and therefore a linear representation will, in general Howev er, there are some very importa nt excepti ons to this · conception of chemical processes: out in 1. For batch and semibatch processes, the entire operatio n is carried n." operatio state "steadyas thing such no transien t mode, and there is 2.
3.
and Continu ous processes that experience frequent start-ups, shutdowns, any from away time of period tial substan a transiti ons spend identifi able steady-state operatin g region. the There are processes for which the overall nonlinearities (even in to critical so and severe, so neighbo rhood of steady states) can he e. adequat be will model ying time-var stability, that no linear
r industry ) For such process es (which are common in the chemical and polyme will be ers controll ar nonline e; effectiv very linear control lers will not be class of latter the of e exampl ar particul A ance. perform ed improv for essential model ar nonline the which for systems is the reactor studied in Ref. [19], linear no is fuere that found was It gain. process the in exhibits a sign change n of this operatio stable permit will which action) integral (with ler control process.
27.7.2 Techn iques for Nonlin ear MPC nonline ar The various techniq ues that have been propose d for implem enting d. reviewe versions of the MPC concept will now be briefly
Scheduled Linearized MPC as the With this techniq ue, a lineariz ed model whose states are updated coefficients ponse step-res the e generat to used is change ns conditio process
SPECIAL CONTROL TOPICS
1022
tation ; the mode l neede d to imple ment the linear QDMC contro l compu nonlinear model ale full-sc prediction is however carried out by integrating the well for a batch d worke has ure proced This on-line, in parallel with the plant. reactor [24].
Extended Linear MPC [33], is to reformulate The approach here as presented in Herna ndez and Arkun the original DMC problem in Eq. (27.6) to read: yd(k + l) = yO(k) +
J! du(k) + w(k + I) + d"1(k)
(27.35)
d"1(k) is exactly as where everyt hing else but the newly introd uced vector are compu ted by d"'(k) vector the of nts described for standa rd DMC. The eleme tion obtain ed 1 predic t outpu the 1), + (k en betwe nce minimizing the differe predic tion the 1), + y(k from the extended linear model shown above, and device, this by Thus plant. the of model obtain ed from a full-scale nonlinear orated incorp are model ear nonlin the by ed captur as s the process nonlinearitie al origin the ving preser direct ly into the DMC formu lation while still framework. then becomes a The solution to the extended DMC proble m so formulated term) aroun d d"'(k) onal pertur bation (predicated by the presence of the additi ated via illustr have [72], al. et inger the standa rd. linear DMC solution. Simm e. schem this of veness effecti ial simulation studie s the potent
r
Bilinear MPC a bilinear model can As an appro ximat ion of the ·nonlinear plant behav ior, model; it can also linear a often provid e a more accurate representation than ear model. An nonlin ale full-sc a than n provid e a more tractable representatio presen ted by been has ns entatio repres s proces r bilinea MPC strategy based on · Yeo and Williams [79]. rmations were The results presented were for SISO systems, and some transfo it in the same explic be might thm algori ng resulti emplo yed in order that the be easier to might s vein as the IMC results. Particularly because bilinear model hold some to se.ems ach appro obtain than full-scale nonlin ear models, this relatively ms ~syste adable multiv to ed promise, especially if it can be extend il}ts. constra handle to lated formu be can it ed easily, and provid
Nonl inear MPC system s have been Strategies for extend ing the IMC conce pt to nonlin ear of generating an issues the lar particu in 20]; presen ted by Economou et al. [19, enting it as the implem of that and model ear nonlin the of appro priate inverse · (nonlinear) IMC controller were carefully discussed. MPC al origin the that recall ach, As an altern ative to the IMC appro to take full advantage problem was posed as a QP (or an LP) primarily in order in the standa rd MPC of these optim ization techniques. If the linear model of the type: model ear scheme were then replaced by a full-scale nonlin dx
dt = f(x, u, d; 9)
(27.36)
1023
TROL CHAP 27 MODEL PREDICTWE CON g(x, u, d) y
(27.37)
=
if necessary, d to ente r in a non line ar fashion and the constraints are perm itte : then the resulting problem becomes (27.22)
min tfr[u(t), x(t), y(t) ] u(r)
subject to:
=0
dx
dt - f(x, u, d; 9) y -
g(x, u, d) = 0 h(x, u) = 0 q(x, u) :s; 0 x(to)
= Xo
t e [t0, t0 + 11
state vector, uts, u is the inp ut vector, x is the Her e y is the vector of process outp the curr ent is the vector of mod el para met ers; d is the disturbance vector, and 9 T. by iction horizon is indi cate d time is indicated at t()t and the pred pro gra m C problem becomes a non line ar MP ar line Posed this way , the non line ar non t cien effi of t men elop rap id dev ables (NLP). As a resu lt of the vari of bers capable of han dlin g large num ve. pro gram min g (NLP) algorithms abo ed pos as blem pro e to solve the NMPC e dat and constraints, it is now possibl to e don k wor the of ew revi a very careful also Biegler and Rawlings [5] pro vide are e thes ; course, still rem ain unr eso lved in this regard. Several issues, of rence. refe the ver y carefully considered in
27.8
CLOSING REMARKS
of MP 27.8.1 Str eng ths and Weaknesses ':,
C
marize the del Predictive Control, we now sum To conclude our discussion on Mo ventional con By . mes sche of conventional MPC MAC, ma in stre ngth s and deficiencies and C that, in the original sense of DM and n, MPC, we mea n those techniques ictio pred licit -response mod el for exp utilize the (linear) step or impulse . lem prob n atio miz opti a (constrained) calculate control action by solving
Strengths success in unp rece den ted pop ular ity and Con ven tion al MPC has enjo yed g reasons: indu stry primarily for the followin .~.: .
1. Model Form e, easi ly onse model, a physically intuitiv It use s a step (or impulse) resp e or no littl g irin requ ric mod el form und erst ood , so-called non para met e. ctur stru el mod ter, mat that for or, a priori decision abo ut process order,
I
SPECIAL CONTROL TOPICS
!
../
/2. Control Computation Its strategy of utilizing long-range prediction for the computation of corrective control action is also intuitively appealing and easy to understand. Many otherwise difficult problems created by difficult dynamics (dead-time, inverse response, etc.) are handled with remarkable facility with this approach.
3. Constraints It allows the explicit handling of constraints through on-line optimization. This aspect, in particular makes conventional MPC the only methodology that, in one package, allows the typical performance criteria of importance in the process industries to be addressed directly and not in the ad hoc fashion typical of most other schemes.
J)eficiencies Ironically, most of the currently identified deficiencies of MPC are associated directly or indirectly with the very attributes that constitute its strength.
·,
..
:
:
1. Model Form There are several industrial processes of importance for which an approximate linear model provides a poor representation of the relevant plant dynamics. In this case, the attractiveness of the step- (or impulse-) response model is supplanted by the unacceptable inaccuracies of the naively simple representation. Also, the conventional MPC model form is not directly applicable to processes with integrating elements; under these conditions special modifications noted in Morari and Lee [48] are required. The issue of model identification could alSo be raised here; however, model identification is a universal problem in process control and in general is not localized to MPC Slone. ·
2. Tuning The control computation strategy adopted by MPC, even though fundamentally appealing, contains a substantial number of tuning. parameters; and it is not always obvious how these pllfameters should be chosen. In this regard, as noted earlier, MAC is far 1~ cumbersome than DMC; but by the same token, the latter has more qegrees of freedom available for Achieving the often conflicting objectives of robustneSS and performance. · 3. Model Prediction Updating The model prediction updating strategy is often extremely inadequate because it assumes that the currently observed discrepancy between the model prediction and plant measurement is due only to unmodeled disturbances; it also assumes further that such discrepancy will remain constant over the prediction horizon. This often leads to poor performance, especially in disturbance rejection.
4. Analysis As attractive and as useful as conventional MPC has been, a systematic analysis of its stability and robustness properties is not possible in its
)!
. :';i
·;~'
CHAP 27 MODEL PREDICTWE CONTROL
1025
in general, timeorigin al finite horizo n formulation. The control law is, ented in the repres be t canno case, ained constr the in varying, and especially e horizo n infinit The closed form requir ed for such genera l analyses. 61]). [51, Refs. (cf. is analys such formulation is more amenable to of MPC along with A more detailed discussion of the strengths and weaknesses i and Lee [48]. Morar in found be may some recommendations for improvements that the areas of is ncies deficie these izing recogn of uence A natura l conseq are summ arized These ied. MPC in need of further work are more easily identif next.
27.8.2 Furth er Work with regard to the Despite the fact that significant advances have been made l system design contro a as l Contro tive theory and practice of Model Predic rily (but not prima done be to work r furthe still is metho dolog y, there exclusively) in the areas reviewed below.
Model Identification of MPC (or any other· Mode l identif ication is clearly the "Achilles' heel" ). Devel oping and matter that model -based contro ller design techni que for and most timetant impor most the remain still s evalua ting approp riate model requir e more also steps consu ming steps in the implem entatio n of MPC; these expertise from the user. on well in the Robus t model identi ficatio n metho ds that will functi concerning issues , regard this In nonide al indust rial enviro nment are needed. condit ions oop, open-l to ed oppos as -loop, closed model identif ication under use (step, pulse, to signal test what ); ication identif on-line versus e (i.e., off-lin deal effectively with pseud o-rand om binary sequence, or others); how to proces s during data the enter idably unavo that ances unmea surabl e disturb proces s dynam ic retain collection; how to reject proces s noise but still sed within the addres be to need and tant information; etc., are all very impor MPC. ·framework of
Unmeasured Disturbance Estim ation and Prediction tion errors remain the Most MPC schemes assum e that all future model predic ed prediction error is observ any , course Of error. tion predic t same as the curren ance, model ing disturb e surabl compo sed of compo nents contributed by unmea noise. t remen measu and ral), structu error (parametric as well as alone, it would Were all the contributions due to unmea sured disturbances analysis and series time from results some be possib le to take advan tage of predic tion past and t curren the using ing model ance carry out on-line disturb hither to (and sured unmea errors . Predic ting the future effects of these with and y aticall system more out carried be unmod eled) disturbances can then be much thus will se respon load -loop closed The ainty. reduc ed uncert ily due to fundam ental impro ved. If, however, the contributions were primar ing" will not be as model rbance "distu such 't:hen re, errors in the model structu effect ive.
102 6
SPECIAL CON TRO L TOPICS
t
men n error was due entirely to measure On the othe r hand, if the predictio erve Obs ry. essa is nec spe akin g, no mod el correction
noise, then, stri ctly ing wha t is e-of f betw een closely esti mat ther efor e that ther e is a trad han d and one the on e anc urb eas ure d dist con side red as the effect of unm the effect that other (not to mention the fact measurement noise rejection on the ibed to ascr tly rrec el may end up bein g inco still of stru ctur al erro rs in the mod ject sub a is e thes as es to resolve such issu unmeasured disturbances). How und er active research.
Error and Uncertainty Sys tem atic Treatment of Modeling ciated with always be some uncertainty asso No mat ter how derived, there will has been inty controller design und er uncerta any model. The problem of MPC be resolved. studied, but man y issues remain to achieving rely on tun ing par ame ters for es kag pac Com mer cial MPC sho uld be ious how these tuning parameters robustness, but it is not always obv d for a foun ers timal" set of tuning paramet pletely selected optimally; besides, an "op com or al" tim nd to become "su bop set of ope rati ng conditions is bou lly. tica dras nge ons were to cha inadequate if the operating conditi
ol Nonlinear Model Predictive Contr ar MPC are practical implementation of nonline Most of the issues involving the rop riat e app g inin obta of that ains cal rem still unr eso lved ; but the mos t criti els are nonlinear models. fairly accurate first principle mod For complex chemical processes, es the mak s Thi in. obta to time con sum ing usu ally difficult and / or very from plan t al nonlinear inp ut/ out put models possibility of identifying empiric indu stri al practitioner. data attractive particularly to the be obtained using: may els Nonlinear inp ut/ outp ut mod
• Dynamic neural networks ive moving average) models • Polynomial ARMA (autoregress radi al A) models using, for example, • Oth er NARMA (Nonlinear ARM basis functions ponse ization of the linear impulse-res • Volterra Series models (a general convolution models) how to mos t critical unr eso lved issue is Reg ardi ng neu ral networks, the that way ha networks most effectively in suc h wit introduce dyn ami c elements into out ied requ ired by MPC, can be carr mul tiste p out put prediction, as reasonable confidence. und the els, the major obstacles center aro For the polynomial ARMA mod not widely adequate model structures are still fact that guidelines for choosing erlying und the using radial basis functions, available. As for NARMA models based; is g elin mod e on which neu ral netw ork ke the concepts are very similar to thos unli r, eve How ns. tatio re similar limi the two approaches therefore sha s of term in as muc h has bee n pub lish ed cern neu ral netw ork app roa ch, not con ary prim g radial basis functions. The of ber developing NARMA models usin num e larg uire they typi call y req wit h Vol terr a mod els is that . tely qua linear processes ade parameters to represent most non
ICTIVE CONTROL CHAP 27 MODEL PRED
27.9
SUMMARY
1027
l reviewed in some detai tive Control has been dic its Pre l C, de MP Mo of of es te ipl sta nc The current the basic pri e main issues regarding un de rly ing theory of sta nd ard in this ch ap ter . Th the of ls an d some detai es av ail ab le for the historical evolution, e commercial pa ck ag Th d. ing sse cu dis en reviewed, while stress MPC ha ve be C schemes have been the MP to us ns rio tio va of ibu n ntr tio co implementa The academic er. oth the e m lin fro cip e eering dis wh at differentiates on ledge within the engin ow kn of dy as C bo a MP as ar C ne advancement of MP ject matter of nonli gling ou t the critical sub right. In have been reviewed, sin worthy of separate consideration in its ow n y further log of do ed tho ne in me C an emerging er areas of MP oth of on ssi cu dis a r, ve addition to this, howe sented. pre en be o als s ha rk wo from this chapter th at ar cle be It sh ou ld joy ed remarkable methodology ha s en ol ntr co te, a as C MP marily because, to da 1. St an da rd others have failed pri ere ce wh an s rm ces rfo suc pe al nt tri rta indus im po dology tha t allows the sig n de er oll ntr co the it is the on ly metho o po rat ed dir ec tly int cri ter ia to be inc or formulation. sim ple to MPC ar e rel ati ve ly of es ipl inc pr tal me nta tio n are 2. Th e fu nd am en req uir ed for its im ple ls de mo sic ba the ge of advances in un de rst an d, d it takes full ad va nta an n; tai ob to sy ea the av ail ab ili ty of reasonably hn olo gy as we ll as tec re wa rd ha r ute co mp . optimization software literature attest to available in the op en ns tio n ca pli ap us ro me as a co ntr oll er de sig 3. The nu ectiveness of MPC ble eff ria tal va lti en mu am d nd fu ine the co ns tra larly for large-scale, me tho do log y particu tics. ris cte ara ch c mi dyna processes with complex ial • fact tha t the commerc cations also attest to the all pli ap e s ar rou s me me nu he sc ese M PC 4. Th fo r im ple me nti ng tal pa ck ag es av ail ab le the sa me fu nd am en ve ha all y the te; ua m eq ad fro e ly on tal tinguish fu nd am en various factors tha t dis the d on an ati se, tiv ba mo al ry gic technolo of the prima essentially as a result d the oth er have arisen ter. However, DMC an rke ma or d/ an er lop ve de ng the eri of ne an d preferences ions since, as the pio cupy preeminent posit the y IDCOM continue to oc ailable the longest: av ha ve be en y the es, tri al ag us ck pa ind d ial co mm erc do cu me nte lar ge st sh are of the the ve ha e or ref the ap pli ca tio ns . nefit from the not all processes will be , ses ces suc d an s gth or no interactions, Yet for all its stren variables exhibit little e os wh ses ces Pro se which are se ldo m po we r of MPC. characteristics, an d tho c mi na MPC: dy al rm no th fit significantly from processes wi mo st likely no t bene ll wi s int tra ns co to subject as well. just as likely to perform MPC are: simpler techniques are ed ed ne is rk wo further The main areas where c test data, dels from plant dynami mo of on ati fic nti Ide • ns, • Nonlinear extensio
1028
SPECIAL CONTROL TOPICS
the former because to a large extent, the performance of the MPC scheme is really only as good as the model used, and the latter because nonlinearities are an integral part of all realistic processes, and they can still constitute significant problems in certain cases. REFERENCES AND SUGGESTED FURTIIER READING Arkun, Y. and W. H. Ray, Eds., Proceedings of Chemical Process Control- CPC IV, AIChE (1991) 2. Arulalan, G. R. and P. B. Deshpande, "Synthesizing a Multivariable Prediction Algorithm for Noninteracting Control," Proc. Am. Control Conf., Seattle, WA (1986a) 3. Arulalan, G. R. and P. B. Deshpande, "A New Algorithm for Multivariable Control," Hydrocarbon Processing, 51, (1986b) 4. Arulalan, G. R. and P. B. Deshpande, "Simplified Model Predictive Control," Ind. Eng. Chem. Res., 26, 356 (1987) 5. Biegler, L. T. and J. B. Rawlings, "Optimization Approaches to Nonlinear Model . Predictive Control," in Proceedings of CPC W, 543-571 (1991) 6. Box, G. E. P. and G. M. Jenkins, Time Series Analysis: Forecasting and Control, HoldenDay, San Francisco (1976) 7. Brosilow, C. B., "The Structure and Design of Smith Predictors from the Viewpoint of Inferential Control," Proc. Joint Aut. Control Conf., Denver (1979) 8. Brosilow, C. B., G. Q. Zhao and K. C. Rao, "A Linear Programming Approach to Constrained Multivariable Control," Proc. Am. Control-Conf., San Diego, 667 (1984) 9. Caldwell, J. M. and G. D. Martin, "On-line Analyzer Predictive Control," Sixth Annual Control Expo Conf., Rosemont, IL, 19-21 May (1987) 10. Chang, T. S. and D. E. Seborg, "A Linear Programming Approach to Multivariable Feedback Control with Inequality Constraints," Int. J. Control, 37, 583 (1983) 11. Clarke, D. W. and C. Mohtadi, "Properties of Generalized Predictive Control," Proc. 10th IFAC World Congress, Munich, 10, 63 (1987a) 12. Clarke, D. W., C. Mohta:di and P. S. Tuffs, " Generalized Predictive Control - I and II," Automatica, 23, 137-160 (1987b) 13. Clarke, D. W., "Adaptive Generalized Predictive Control," in Proc. ofCPC W, 395417 (1991) 14. Cutler, C.JI.. and B. L. Ramaker, "Dynamic Matrix Control- A Computer Control Algorithm," AIChE National Meeting, Houston (1979) 15. Cutler, C. R. (1983). Ph. D. Thesis, U. of Houston 16. Cutler, C. R. and R. B. Hawkins, "Constrained Multivariable Control of a Hydrocracker Reactor,• Proc. Am. Control Conf., Minneapolis, 1014 (1987) 17. Cutler, C. R. and R. B. Hawkins, "Application of a Large Predictive Multivariable Controller to a Hydrocracker Second Stage Reactor," Proc. Am. Control Conf., Atlanta, 284 (1988) 18. Cutler, C. Rand F. H. Yocum, ''Experience with the DMC Inverse for Identification," in Proc. of CPC IV, 297-317 (1991) 19. Economou, C. G., M. Morari and B. Palsson, "Internal Model Control- 5. Extension to Nonlinear Systems," Ind. Eng. Chern. Process Des. Dev., 25, 403 (1986) 20. Economou, C. G. and M. Morari, "Internal Model Control - 6. Multiloop Design," Ind. Eng. Chem. Process Des. Dev., 25, 411 (1986) 2.1. Erickson, K. T. and R. E. Otto, "Development of a Multivariable Forward Modeling Controller," I. and E C Research, 30, 482 (1991) 22. Frank, P. M., Entwurf von Regelkreisen mit Vorgeschriebenem Verhalten, G. Braun, Karlsruhe (1974) 23. Garcia, C. E. and M. Morari, "Internal Model Control -1. A Unifying Review and SOme New Results," Ind. Eng. Chern. Process Des. Dev., 21, 308 (1982)
1.
CHAP 27 MODEL PREDICTIVE CONTROL
1029
24. Garcia, C. E., "Quadratic Dynamic Matrix Control of Nonlinear Processes. An Application to a Batch Reaction Process," AIChE AnnUR/ Mtg, San Francisco (1984) 25. Garcia, C. E. and M. Morari, "Internal Model Control - 2. Design Procedure for Multivariable Systerr.s," Ind. Eng. Chem. Process Des. Dev., 24, 472 (1985a) 26. Garcia, C. E. and M. Morari, "Internal Model Control - 3. Multivariable Control Law Computatio n and Tuning Guidelines," Ind. Eng. Chern. Process Des. Dev., 24, 484 (1985b) 27. Garcia, C. E. and A.M. Morshedi, "Quadratic Programmin g Solution of Dynamic Matrix Control (QDMC)," Chern. Eng. Commun., 46, 73 (1986) 28. Garcia, C. E., D. M. Prett, and M. Morari, "Model Predictive Control: Theory and Practice- A Survey," Automatica, 25, 335 (1989) 29. Georgiou, A., C. Georgakis, and W. L. Luyben, "Nonlinear Dynamic Matrix Centro! for High-purity Distillation Colwnns," AIChE J., 34, 1287 (1988) 30. Gerstle, J. G. and D. A. Hokanson, "Opportunit ies for Dynamic Matrix Control in Olefins Plants," AIChE Spring Meeting, Houston, Texas (1991) 31. Grosdidier, P., A Mason, A. Aitolahti, and V. Vanhamaki, "FCC Unit Reactorregenerator Control," submitted for presentation at ACC, Chicago (1992) 32. Horowitz, I. M., Synthesis of Feedback Systems, Academic Press, London (1963) 33. Hernandez, E. and Y. Arkun, "A Nonlinear DMC Controller: Some Modeling and Robustness Considerations," Proc. Am. Control Omf., Boston, 2355 (1991) 34. Lectique J., A. Rault, M. Tessier, and J. L. Testud, "Multivariable Regulation of a Thermal Power Plant Steam Generator," IFAC World Congress, Helsinki {1978) 35. Lee, P. L. and G. R. Sullivan, "Generic Model Control (GMC)," Comp. and Chern. Eng. 12, 573 (1988) 36. Lee, P. L., R. B. Newell, and G. R. Sullivan, "Generic Model Control- A Case Study," Can. J. Chern. Eng., 67,478 (1989) 37. Lee, P. L., "The Direct Approach to Nonlinear Control," in Proceedings of CPC IV, 517-542 (1991) 38. MacGregor, J. F., "On-line Statistical Process Control," Chern. Eng. Progress, October, 21 (1988)
39. Marchetti, J. L., D. A. Mellichamp, and D. E. Seborg, "Predictive Control Based on Discrete Convolution Models," Ind. Eng. Chern. Process Des. Dev., 22, 488 (1983) 40. Martin, G. D., J. M. Caldwell, and T. E. Ayral, "Predictive Control Applications for the Petroleum Refining Industry," Japan Petroleum Institute -Petroleum Refining Conf., Tokyo, Japan, 27-28 October (1986) 41. Matsko, T. N., "Internal Model Control for Chemical Recovery," Chern. Eng. Progress, 81, (12), 46 (1985) 42. Maurath, P. R., D. E. Seborg, and D. A. Mellichamp, "Predictive Controller Design by Principal Components Analysis," Proc. Am. Contml Conf., Boston, 1059 (1985) 43. McAvoy, T., Y. Arkun, and E. Zafiriou Model-based Process Control: Proceeding of the IFAC Workshop, Pergamon Press, Oxford {1989) 44. Meadows, E. 5., K. R Muske, and J. B. Rawlings, "Constrained State Estimation and Discontinuo us Feedback in Model Predictive Control," Proc. European Control Conference, Groningen, Netherlands, 4, 2308--2312 (1993) 45. Mehra, R. K., et al. "Model Algorithmic Control Using IDCOM for the FlOO Jet Engine Multivariab le Control Design Problem," in Alternatives for Linear Multivariable Control (ed. M. Sain et td.), NEC, Chicago (1978) 46. Mehra, R. K. and S. Mahmood, "Model Algorithmic Control" Chapter 15 in Distillation Dynamics and Control (ed. P. B. Deshpande), ISA, Research Triangle Park, NC (1985) 47. Morari, M. and E. Zafiriou, Robust Process Control, Prentice-Hall, Englewood Cliffs, NJ (1989) 48. M•rari, M. and J. H. Lee, "Model Predictive Control: The Good, the Bad, and the Ugly," in Proceedings of CPC IV, 420-444 (1991)
SPECIAL CONTROL TOPICS
1030
Prett, Model Predictive Control, (in press) 49. Morari, M., C. E. Garcia, J. H. Lee, and D. M. (1992) l Dynam ics,
Transo nic Wind Tunne 50. Morea u, P. and J. P. Littna un, "Euro pean (1978) ios a/Gerb Aders ," Simplified Model tive Control with Linear Models," 51. Muske, K. R. and J. B. Rawlings, "Mode l Predic
AIChE J, 39, (2), 262 (1993) , Analytical Design of Feedback Controls, 52. Newto n, G. C., L. A. Gould , and J. F. Kaiser Wiley, New York (1957) l: A Non-stochastic Indust rial Process 53. Ogunn aike, B. A., "Dyna mic Matrix Contro Chem. Fund., 25, ics," Ind. Eng. Contro l Technique with Parallels in Applie d Statist
712 (1986) H. Ohno, ''Robust Stability of Model 54. Ohshi ma, M., I. Hashimoto, T. Takamatsu, and
55. 56.
57. 58. 59.
Predictive Control," Int. Chem. Eng., 31, (1), 119 (1991) rehensive SISO Controller," Otto, R. E., "Forw ard Model ing Controllers: A Comp (1986) ber Annual AIChE Mtg., Novem ained Multivariable Control Prett, D. M. and R. D. Gillette, "Optimization and Constr on, Texas; also Proc. Joint Houst Mtg., al Nation AIChE Unit," ing of a Catalytic Crack Aut. Control Conf., San Francisco (1979) l, Butterworths, Stoneh am Prett, D. M. and C. E. Garcia, Fundamental Process Contro (1988) Second Shell Process Control Prett, D. M., C. E. Garcia, and B. L. Ramaker, The Workshop, Butterworths, Boston (1990) ed-data Automatic Systems," Propoi, A. 1., "Use of LP Method for Synthesizing Sampl
Control, 24,837 (1963)
Automn. Remote Auto Adapt ive d'Un Avion ," 60. Rault, A., J. Richalet, and P. LeRoux, "Com mands Aders a/Gerb ois (1975) ty of Constr ained Receeding Horizo n 61. Rawlings, J. B. and K. R. Muske, "The Stabili (1993) Press) (in Cont. Control," IEEE Trans. Auto. n des Systems Discrets Linearines Mono62. Richalet, J. A. and B. Bimonet, "Identificatio Sructure," Elec. Lett., 4, (24) (1968) de ce Distan d'Une variabies Par Minimisation el, "New Trend s in Identi ficatio n, Humm P. and us, Lecam F. A., J. et, 63. Richal Topology," 2nd IFAC Symposium on Weak ce, Distan ural Minim ization of a Struct Identification, Pragu e (1970) Identification des Processus par Ia Methode 64. Richalet, J. A., A. Rault, and R. Pouliquen, du Modele, Gordo n and Breach (1970) Papon , "Mode l Predictive Heuris tic 65. Richalet, J. A., A. Rault, J. D. Testud , and J. atica, 14,413 (1978) Control: Applications to Industrial Processes," Autom Constrained Intern al Model for mming Progra atic Quadr of 66. Ricker, N. L., ''The Use (1985) 925 %4, Contro l," Ind. Eng. Chem. Process Des. Dev., Studies of Model Predictive Control 67. Ricker, N. L., T. Subramanian, and T. Sim, "Case Control, (ed. T. J. McAvoy, Y. Process in Pulp and Paper Produ ction," in Model Based (1989) Oxford Press, on Pergam u), Arkun, and E. Zafirio Estimation," Ind. Eng. Chem. Res., 68. Ricker, N. L., "Mode l Predictive Control with State 29, 374 (1990) of the Art," in Proceedings of CPC IV, 69. Ricker, N. L., "Model-predictive Control: State 271-2 % (1991) nal Model Contro l - 4. PID 70. Rivera, D. E., M. Morari, and S. Skoge stad, "Inter 252 (1986) %5, Dev., Des. Process Chem. Eng. Ind. ," Design ller Contro Control (MAC): Basic Theoretical 71. Rouhani, R. and R. K. Mehra, "Mode l Algorithmic Proper ties," Automatica, 18, (4), 401 (1982) Schor k,"A Constrained Multivariable 72. Simminger, J., E. Hernandez, Y. Arkun, and F. J. on Iterati ve QDMC," Proceedings Based ller Contro tive Predic Model near Nonli (1991) er Octob ADCHEM IFAC, Toulouse, Time," Chem. Eng. Progress, 53, 73. Smith, 0. J. M., "Closer Control of Loops with Dead (5), 217 (1957)
1031
TROL CHJ\P 27 MODEL PREDICTIVE CON
Journal, Febr uary (1959) er to Ove rcom e Dea d-tim e," IS/\ 74. Smi th, 0. J. M., ~'A Con troll on de Rec uper atio n de Ball du le riab tiva Num eriq ue Mul 75. Test ud, J. L., "Co mm ande 9) Vap eur, " Ade rsa/ Ger bios (197 m for Opt imiz ed "Syn thes izin g a Digi tal Alg orith g, Tsin H. Y. J. and 76. Tu, F. C. Y., Con trol, " In. Tech., May (1979) an Indu stria l Extr uder ," p, "Int erna l Mod el Con trol of 77. Was sick J. M. and D. T. Cam Proc. ACC, Atla nta, 2347 (1988) re Nee ds: The View from imot o, "Pre sent Stat us and Futu 78. Yam amo to, S. and I. Hash 1) (199 ngs of CPC IV, 1-27 Japa nese Indu stry ," in Proc eedi trol, " Ind. Eng. Chem. "Bil inea r Mod el Pred ictiv e Con , iams Will C. D. and Y. K. 79. Yeo, Res., 26, 2267 (1987) Hop f Des ign of Opti mal and H. A. Jabr , "Mo dem Wie ner80. Youla, D. C., J. J. Bongiorno, Aut. Control, AC-21, 3 s. Tran IEEE ," put- outp ut Case Con troll ers - I. The Sing le-in (197 6a) £ Des ign of Opti mal J. ]. Bongiorno, "Mo dern Wiener-HopCon 81. Youla, D. C., H. A. Jabr , and trol, AC- 21, 319 Aut. riab le Case ," IEEE Trans. Con troll ers - II. The Mul tiva (197 6b) g an Obs erve r for Loa d rg, "Pre dict ive Con trol Usin 82. Yua n, P. and D. E. Sebo 6) (198 669 tle, Conf, Seat Esti mati on," Proc. Am. Control ar Prog ram min g," IRE len, "On Opti mal Con trol and Line 83. Zad eh, L. A. and B. H. Wha
45 (1961)
Trans. Auto. Cont., 7, (4), ers," in Proceedings of ess of Mod el Pred ictiv e Con troll 84. Zafi riou , E., "On the Rob ustn CPC IV, 363- 393 (1991) renc e Tran sfor mati ons, Opt ima l Sens itivi ty: Mod el Refe 85. Zam es, G., "Fee dbac k and s. Aut. Control, ACTran IEEE rse," Inve mate App roxi Mul tipli cativ e Sem inor ms, and 26, 301 (1981)
REVIEW QUESTIONS for wha t two cent ral tasks? In MPC the proc ess mod el is used y to bene fit from cs of thos e proc esse s mos t likel Wha t are the typi cal char acte risti MPC ?
1. 2.
MAC and IDC OM?
3.
Wha t is the rela tion ship betw een
4.
Wha t four elem ents cons titut e the
5.
Wha t is the difference betw een an
6.
? What mod el form is emp loye d in DMC
7.
The dyna mic matr ix in DMC is mad
8.
9.
basic fram ewo rk of all MPC sche
mes ?
impu lse-r espo nse and a step -resp
onse mod el?
e up of wha t elements?
actio n com puta tion mic matr ix 13 is used for cont rol Wha t type of inve rse of the dyna res min imiz atio n squa t leas a as prob lem is pose d whe n the unco nstr aine d DM C prob lem? + 1) and the resid ual the "pro jecte d erro r vect or" e(k Wha t is the diffe renc e betw een erro r vect or e,(k + 1) in DMC?
upda 10. Wha t is the DM C strat egy for
ting mod el pred ictio ns?
cont rol mov es calc ulate d at leme nt the entir e sequ ence of m 11. Why is it inad visa ble to imp vals ? ession over the next m time inter time instant k in auto mati c succ
1032
SPECIAL CONTROL TOPICS
12. Why is scaling important in using DMC for multivariable control problems posed as least squares optimization problems? 13. What role does the scalar K play in the unconstrained DMC formulation? 14. In the general constrained DMC formulation, explain the roles of the tuning matrices r, B,andD. 15. What model form is employed in the MAC methodology? 16. What are the main differences between DMC and MAC? 17. What role does the parameter a play in MAC? 18. What differentiates the commercial package OPC from DMC? 19. What characteristics set the commercial package PC (marketed by Profimatics) apart from the others? 20. What property makes the Honeywell's HMPC different from the other commercial MPC packages? 21. What is the main tuning parameter in HMPC7 22. What approaches are currently available for nonlinear MPC?
C H A PT ER
28 L ST AT IST IC AL PR OC ES S CO NT RO (1) the man ipula ted variables of a Thus far, we have tacitly assu med that: action as frequently as we desire, rol process can be adju sted to implement cont e"; and (2) the cont rolle d proc ess and that such adju stme nts are "cost-fre , and that such meas urem ents are variables can be meas ured just as frequently ciate d unce rtain ty, or inhe rent asso avai lable "noi se-fr ee" (i.e., with no practice, howe ver, the most impo rtant "variability"). Quit e often in indu stria l ity variables who se meas urem ents variables to be cont rolle d are prod uct qual meas urem ents are available only mus t be obta ined in the laboratory. Such mea sure men t is an inhe rent each infre quen tly, and asso ciate d with rence betw een a cont rolle d process "variability." As such, any observed diffe ly be due to inhe rent meas urem ent variable and its desir ed value may simp action is necessary; howe ver, the ctive "variability" - in whic h case no corre real, systematic depa rture from target observed difference may also be due to a necessary. With in this framework, -in whic h case corrective action may be parts: ive process control must now consist of two
effect
devi ation of the process variable 1. An objective analysis of the obse rved
from its desir ed value. do to minimize such deviation. 2. A rational decision regarding wha t to ity Control mov emen t spea rhea ded by At one extreme, with its roots in the Qual tiona l Stati stica l Proc ess Cont rol tradi , Shew art in the 1920s (cf. Ref. [22]) first part, findi ng appl icati on mos t (SPC) focuses almo st exclusively on the esses for whic h the cost for mak ing appr opria tely in those manufacturing proc the othe r extre me, stan dard (or proc ess adju stme nts is significant. At ses on the second part, findi ng focu lly tiona deterministic) Process Control tradi h little or no cost is associated with appl icati on most ly on processes for whic taking control action. ent SPC in its broa dest and more The objective in this chap ter is to pres the objective analysis and ratio nal mod em sense: as the use of statistics for egies, in the face of inhe rent process desig n of effective process control strat rol action into cons idera tion. Our "var iabil ity," and takin g the cost of cont not be limited to- classical SPC, will but discussion will therefore incl ude charting. i.e., the meth odol ogy of Quality Control
SPECIAL CONT ROL TOPICS
1034
INTR ODU CTIO N
28.1
by measu remen t at time Whenever the value of a process variable is observed this measu remen t consists instant k, say, as y(k), it is generally understood that of two inseparable parts: (28.1) y(k) = Y*(k) + e(k) process variable, and e(k) is where y*(k) is the true, but unknown, value of the a sequence of y(k) values, Given m. rando ly the "meas ureme nt error," usual data, while e(k) repre sents the y*(k) represents the "explainable" part of the ility associated with the rando m, "unexplainable" part - the inherent variab measurement. to maintain the process In the face of such inherent variability, if we wish , Yd(k), the following value variable as close as possible to its desired (target) two questions must be answered: ficant"? Is the observed difference between y(k) and Yd(k) "signi taken? be d shoul action 2. If the difference is "significant," what
1.
sis, while the secon d is Since the first quest ion is conce rned with analy former as the analysis the concerned with control strategy, we shall refer to m. proble y problem, and to the latter as the control strateg
28.1.1 Com mon Caus e and Spec ial Caus e Vari ation d value Yd(k) is said to be Any observed differences betwe en y(k) and its desire if: ion due to "common cause" variat y(k)- yjk) = e(k)
(28.2)
ility due entire ly to where e(k) is nothi ng more than the inher ent variab that the implication from rando m measu remen t errors. In this case, observe le is actua lly at its variab Eq. (28.1) is that y*(k) = yAk), i.e., the process · desire d target value. desired value will be of More generally, the difference between y(k) and its the form: (28.3) y(k)- yjk) = li(k) + e(k) is said to be due to "special and if O(k) is nonzero, then the observed difference the inhere nt common cause to n addiHo in O(k)) by cause" variation (represented the true value of the variat ion. The impli cation is therefore that y*(k), O(k). by value target d process variable, differs from its desire is therefore that of m proble is analys the in ed The prima ry issue involv y(k) and Yd(k) is due solely decid ing wheth er the observed difference betwe en an additi onal special (or is to comm on cause variation, or wheth er there "assignable") cause component.
28.1.2 Two Trad ition al Appr oach es devel oped to solve the The traditional Quality Control (QC) metho ds were ics and proba bility statist ying emplo by ly analy sis probl em system atical
CESS CONTROL CHAP 28 STATISTICAL PRO
1035
common
unavoidable se variations in the midst of theory to det ect special cau strategy problem is trol of approach to the con y oph los phi The n. iatio var cause variation is to be any confirmed special cau se mo re vague: the source of n is that the process ." The underlying ass um ptio "identified" and "eliminated h only occasional wit for long per iod s of time, equent "special tends to rem ain "on-target" infr by sed cau tha t such shifts are t"; rge f-ta "of ts shif t} rup (ab tha t significant costs and rectified at source; and events" that can be identified ula ted variables. ments are ma de in the ma nip pha sis on the are inc urr ed wh ene ver adjust em re mo ce refore nat ura lly pla Tra diti ona l QC schemes the analysis problem analysis problem. process control addresses the On the oth er hand, sta nda rd ays negligible alw ost cause variations are alm ociated with ass by ass um ing tha t com mo n ies teg stra trol iations. The con inate all elim to compared to special cause var ed thu s fun dam ent ally des ign jected sub ays sta nda rd process control are alw is s assumption is that the proces ain rem not re deviations from target. The refo the l wil and s, unknown source . tem sys l tro to disturbances of known and con al int erv ent ion fro m the ing ent lem imp "on -ta rge t" wit hou t ext ern in ed tha t little or no cost is inc urr places more Furthermore, it is ass um ed s control therefore nat ura lly ces pro rd nda Sta . ion act con trol y problem. emphasis on the control strateg me tho ds dea l with t while the traditional QC tha e erv obs We ma y now control strategy the atically, the QC app roa ch to se. is true for the analysis problem system ver con The l. and often impractica tic plis sim rly ove is m ble pro h too cavalierly, but analysis problem is dealt wit sta nda rd process control: the re systematic and control strategy problem is mo the sub seq uen t approach to the nal approaches itio trad , nei the r of these two arly Cle ic. list rea re mo usu ally y. Nevertheless, ade qua tely and simultaneousl ns stio que both rs we ans ne alo which the sol utio n of practical imp ort anc e in the re are ma ny situ atio ns som e situ atio ns, a ch is app rop riat e, and for pro vid ed by eac h app roa ches is best. combination of the two approa
llow 28.1.3 The Di scu ssi on to Fo
mo st wid ely use d org ani zed as follows: the The res t of the cha pte r is 28.2; the underlying l be reviewed first in Section traditional QC techniques wil er which they are und rly so that the conditions assumptions will be stated clea en one of the key wh s pen hap d objectively. What ine erm det be can ble lica app discussed in Section QC techniques breaks dow n is assumptions underlying the rd process control t, a case is ma de for the sta nda ering approach 28.3; wit hin this same contex ine eng r ula und erly ing this pop y oph los phi the and , gm par adi rop riat e is discussed wh en traditional SPC is app is pre sen ted . The issue of explicitly in Section 28.4. s dynamics and how our knowledge of proces In Section 28.5 we discuss with statistics in ely riat rop app can be combined ing del mo s ces pro tic inis erm det stra teg y pro ble ms lysis as well as the con trol dea ling wit h both the ana eralizes both the QC atically. The discussion gen sim ulta neo usl y and system ework of "Stochastic fram trol, presenting this con s ces pro rd nda sta and methods nal QC phi los oph y hyb rid bet we en the trad itio e tru a as ol" ntr Co s ces Pro ored and practiced sta nda rd process control fav ry of some of the favored by statisticians, and ma tion 28.6 provides a brie f sum routinely by engineers. Sec topics. mo re adv anc ed multivariate
1036
28.2
SPECIAL CONTROL TOPICS
TRADmONA L QUALITY CONTROL MEmODS
28.2.1 Preliminary Concepts Let us start by considering the situation in which the following holds: 1. y•(k) the true value of a process variable (observed by measurement as y(k)) is constant.
2. e(k), the measurement error associated with y(k), is a sequence of independent, and identically distributed, random variables with mean . value of zero, and variance til.
3. The underlying probability distribution from which the observed "sample" e(k), k = 1, 2, 3, ... , is assumed to have been drawn is the Gaussian (or normal) distribution. The immediate implication of these assumptions is that the operating model explaining each observation is: y(k)
= y* + e(k)
(28.4)
i.e., that the observed process measurement y(k) varies around its true, fixed, constant, mean value, y•, in a random fashion that follows the Gaussian probability distribution function. Thus the probability of obtaining a value of y lying in any given interval is obtained from the probability density function: j{y)
1 exp [- !. (~)~ = -~
2
u
u
(28.5)
One of the many advantages of employing this probability distribution function to describe the process variation is that its very well characterized theoretical properties greatly simplify statistical analysis. It is known, for example, that there is a probability of 0.00135 that a data point y(k) drawn at random from such a distribution will exceed the true mean value of y• by 3u, i.e.: Pr [y(k) > (y* + 3o)] = 0.00135 (28.6) and by the symmetry of this probability distribution function, we also have that: Pr [y(k) < (y* - 3u)] = 0.00135 (28.7) Thus the probability that y (k) will fall outside the limits y» ± 3u is the sum of the probabilities in Eqs. (28.6) and (28.7), or 0.0027. With this simple fact, we may now observe that whenever the process is truly "on-target," it is highly unlikely that the discrepancy between the observed value y(k) and its desired target value y4 will exceed the value 3u, three times the measurement error's standard deviation; any deviation exceeding these bounds is very likely (with probability 0.9973) to be due to a "special cause."
CHAP 28 STATISTIC.1L PROCESS CONTROL
1037
Thus the properties of the Gaussian distributio n function permits us to test the hypothesis that the discrepan cy between each observed value y(k) and its
desired target value Yd is due solely to inherent measurem ent variabilit y (common ly known as the null hypothesis, H 0 ), as opposed to the alternative hypothesis, H., that it is due to a special, assignable cause.
Risks and Errors in Hypothesis Testing Observe from Eqs. (28.6) and (28.7) that there is a finite, nonzero probabilit y that an observati on randomly drawn from a Gaussian distributio n will deviate from the true mean by more than± 3a. Thus in testing the hypothesi s that such a deviation is due solely to common cause variation, setting the "acceptan ce limits" at ± 3a carries with it a probabilit y of 0.0027 of falsely rejecting the hypothesi s when in fact it should be accepted. A Type I error is committe d when an otherwise true hypothesi s is falsely rejected; the probabilit y of committin g such an error is referred to as the a risk. A Type ll error, on the other hand, is committe d when a false hypothesi s is inadverte ntly accepted; the probabilit y of committin g such an error is referred to as the f3 risk It should be noted that attempts to lower the a risk are usually accompan ied by an increase in the f3 risk, and vice versa.
28.2.2 The Shewar t Chart What is traditiona lly referred to as the Shewart Quality Control chart (see Refs. [22, 23]) is a graphical method for testing the hypothes is that the observed process measurem ent y(k) does not differ significantly from its desired target value y d against the alternativ e hypothes is that it is significan tly different. The theoretica l basis is found in Eqs. (28.6) and (28.7): that true, purely random variation of y around Yd can be expected to exceed 3uonly about two or three times in 1,000 observatio ns. The a risk associated with this procedure is therefore 0.0027. Thus, given Yd the desired target value, and CJ, the standard deviation o( the inherent measurem ent error, the Shew art Chart in essence monitors:
z=-- -
(28.8)
(sometim es called the "signal-to -noise" ratio); the process is considere d as being "on-targe t" or "in-control" when:
z < 3.0 but when:
z
~
3.0
(28.9)
(28.1 0)
a "special event" is declared to have occurred. Thus the classical Shewart Chart consists of a sequentia l time plot of process data y(k), on which is superimp osed a centerline correspon ding to the target value Yd along with upper and lower control limit (UCL, LCL) lines set at ± 30" from this centerline.
SPECIAL CONTROL TOPICS
1038
~...,....,..., ,....,....,.....,....,....,.....,....,....,....,........ 52.000 .-..-,..-,.....,.-,-,.....,....,.....,....
51.500
1
I t
i
y 49.500
Lower Control Limit
(LCL}
--l -----19.0 ----25.0 22.0 16.0 13.0
-~-,.._ -.4.0 '-2.0 48.0000.0 6.0 8.0 10.0
Time Sequence
Figu re 28.1.
le 23.1 the Mooney viscosity data of Tab Shewart quality control cha rt for ). trol" con "iness proc a (a typical Shewart Cha rt for
hou rly rt sho wn in Fig ure 28.1 is for ired For example, the She war t Cha des The osity of an industrial elastomer. on iati dev measurements of the Mooney visc d dar stan for this grade is 50.000; a ed ciat targ et Mooney viscosity value asso lity iabi var c characterize the intrinsi trol Con value of CT = 0.5 is kno wn to y alit Qu ve siti sen er and the rath wit h the sam plin g pro ced ure Table 23.1 obtaining these measurements. for d use ent ipm et line is lab ora tory equ targ The which the plo t was obtained. C1 =0.5. e contains the original dat a from sinc 1.5 50± at limits lines are dra wn cess is . dra wn at y4 =50 , and the control pro the its; lim trol con outside the ± 3C1 Observe tha t no dat a point falls therefore said to be "in con trol "
wart Chart Constructing and Using The She
the Shewart ure for constructing and using The following is a typical proced . trol Cha rt for Statistical Proce~>'S Con ive of "usual" process operation. 1. Collect historical dat a indicat resentative al subgroup" - the dat a set rep 2. From this, extract a "ration establish to d use is set a dat s Thi ance. of periods of "rational" perform e of a, mat value, as well as a good esti the operating "base": the mea n trol con the ing sett variation nee ded for the measure of intrinsic process lim its. ence of a desired targ et val ue (in the abs 3. Dra w the centerline at the rational the from an value esti mat ed specified targ et value, the me its at lim trol con er low the upp er and subgroup may be substituted); set ± 3CT from tlili? centerline. tially in time on this chart. 4. Plot process dat a y(k) sequen the control er an observation falls out side 5. A "signal" occurs whenev "corrective take and se, cau assignable limits; in suc h a case, find an action."
1039
L L PROCESS CO NT RO CH AP 28 ST AT IST ICA
TABLE23.1
.1 sity Data For Figure 28 Hourly Mooney Visco
Time Sequence (in hours)
1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0 15.0 16.0 17.0 18.0 19.0 20.0 21.0 22.0 23.0 24.0 25.0
Mooney Viscosity
Units) (Standard Ind us try
49.763 50.050 51.079 49.310 49.855 51.056 49.887 49.806 49.735 50.799 50.699 50.469 50.007 50.341 49.798 50.767 48.678 50.372 50.782 49.648 49.889 49.669 49.544 50.472 50.837
Western Electric Rules tru ly " wh en the process is
ala rm risk of raising a "false " lim its While the a risk (the art Ch art , the "3-sigma ew Sh c ssi cla the th wi k of reased J3 ris k- the ris n-t arg et" ) is very low
"o of the inc red too wide, because ic ex am ple are sometimes conside "off-target." (A specif is s ces pro the en wh rm ala an no t rai sin g s point.) ssic subsection illustrates thi considered in the next a risk employed by the cla th low the for ion cat tifi jus wi ociated The most compelling cations, the costs ass t in its original appli s therefore wa tor fac ng idi err Sh ew art Ch art is tha nificant. The ov sig ite qu re we ne ces sar y ts un en t tm expensive bu ma kin g adjus probability of ma kin g the ble ssi po as low to keep as at the W est ern process adjustments. th the Sh ew art Ch art wi e nc rie pe ex cal cti luded for use wi th the As a res ult of pra al rules ha ve be en inc ion dit ad r fou y, an Electric Co mp
1040
SPECIAL CONTROL TOPICS Shew art Chart . These are now comm only know n as the "Wes tern Electric" rules. The rules state that a "signa l" is declar ed when: 1. 2. 3. 4.
A single data point falls outsid e the 3-sigma limits . 2 out of 3 consecutive points fall outsid e the 2-sigm a limits. 4 out of 5 consecutive points fall outsid e the 1-sigm a limits. 8 consecutive points fall on one side of the media n line.
The first rule is of course recognized as the stand ard Shew art "one point outsid e the 3-sigm a limits " criterion. Toget her these four rules reduc e the (3 risk considerably, at the expense of slightly increasing the a risk.
Other Shewart Charts Altho ugh the y (or y-bar) chart discus sed above is the most popul ar of the Shew art Chart s, there are many oti1er Shew art Chart s: the R-cha rts (for ranges), used to monit or the intrinsic proce ss variab ility, CY, itself; m-charts for monit oring media ns, p-cha rts for monit oring variat ions in data involv ing percen tages (e.g., perce nt defective parts in a sampl e), etc. In fact, any statistic that can be comp uted from process data can be presen ted in Shew art Chart form, with a line for the nomin al value, and one or two other lines indica ting limits of acceptable "norm al" variability.
28.2.3 The CUS UM Char t The Shew art Chart is partic ularly good for detect ing large shifts of the order of 30" or higher; it is less sensitive to shifts of small er magn itude. The concept of the average run length (ARL) is often used to illustr ate this point better . The ARL is define d as the numb er of seque ntial obser vation s expec ted to pass before a "signa l" is declar ed. For examp le, for the classical Shew art Chart with its 3-sigm a limits, when the proce ss is truly "on-ta rget," the proba bility that an obser vation from this proce ss will fall outsid e the control limits is 0.0027 (see Eqs. (28.6) and (28.7)). Thus, on the average, we would expect 1/0.00 27"' 371 observations to pass before a first "signa l" is declared. For this Shew art Chart therefore, the ARL :;:: 371 (370.3 7 round ed up to the neare st intege r). Upper Control Limit
~+3cr~------------------------
*
Yt r
a
- - -.----- -
f
N~wLe;,l
2a
5a
~-3crr-~----------------------
Lower Control Limit
Figure 28.2.
Implication of a positive shift of 2a in the mean level of a process measurement
1041
CHAP 28 STATISTICAL PROCESS CONTROL
Let us now consider a situation in which there is a positive shift of 2cr in the mean level of the process measurement (i.e., the true mean has shifted from y* to y* 1 = y* + 2cr). Under these circumstances, for an observation y (k) to trigger a signal by falling outside the upper limit, normal variation around the new mean will have to exceed one standard deviation, i.e., (y- Y\) >.cr; for the observation to fall outside the lower limit will require that (y\- y) >Sa (see Figure 28.2). Now from the properties of the normal distribution with mean y* 1, and variance cil, we know that: Pr
[(y- y* 1) >a] = 0.1587
(28.11)
while the Pr [(y\ -y )>Sa] is negligibly small. Thus for such a shift in mean, the ARL = 1/0.1587 = 6.301, implies that on the average, seven observations will pass before we can expect a signal to be triggered on the Shewart Chart. Since it is not unusual for observations to be made every hour, this implies that we may not see the real upset in y* of 2 standard deviations until perhaps 7 hours after the event occurred. This may be an unacceptably long time for such a significant deviation in the process output to go undetected. The CUSUM (for CUmulative SUM) chart, first introduced by Page [18, 19], is a procedure that is designed to detect smaller shifts in mean value more quickly. The operating model for the CUSUM technique is the same as in Eq. (28.4): (28.4) y(k) = y* + e(k) By subtracting the target value from either side, we obtain: [y(k)- Yd]
or
(28.12)
8+ e(k)
where 8 represents the discrepancy between the true mean value of the process variable, and the desired target value. Now define S(k) as: k
S(k) =
I [y(i)- YJ] i= I
(28.13)
a cumulative sum of the deviation of the observation from the desired target value. The CUSUM chart is a plot of S(k) against the time index k. If the true mean value of the observation equals the desired target value, then o = 0 and from Eq. (28.12): k
S(k) =
I e(i) i= I
(28.14)
in which case S(k) will appear as a random walk, wandering randomly around zero. For any nonzero discrepancy 8: k
S(k) =
k8 +
.I e(i) r= I
(28.15)
1042
SPEClAL CONTROL TOPICS
, aine d, syste mati c incre ase or decrease and the plot of S(k) will show a sust or negative. depe ndin g on the whe ther 8 is positive ty betw een the Shew art Cha rt and itivi sens in e renc diffe To illus trate the viscosity data in Table 23.1 and ney Moo the CUSUM chart, let us retu rn to the y n level at k = 10 by addi ng 0.6 to ever simu late a delib erate shift in the mea the for rt Cha art Shew The resu lting obse rvat ion afte r the nint h one. set, y, are supe rimp osed and shown data nal origi the as well "per turb ed," Yp as the original data ; the solid circles ate in Figure 28.3a. (The emp ty circles indic ), the shift is relatively sma ll (0.6 = 1.2a indicate the pert urbe d data.) Because no and ds, boun art Shew in the 3-sigma the pert urbe d data still rema in with . ered signal is trigg show n in Figu re 28.3(b), whe re the The corr espo ndin g CUSUM char t is for the orig inal data , S, and the solid emp ty circles indi cate the CUSUM urbe d data , SP. Note that whe reas the circles indicate the CUSUM for the pert inspection of the CUS UM chart, the mere simu lated shift is quit e noticeable by the Shew art Cha rt. The chan ge in the sam e is not true for sequ entia l plot on the tenth obse rvati on on, prov ides a slop e of the CUSUM plot, visible from of nt" has occurred, but also an estimate clear indic ation not only that an "eve whe n it migh t have occurred. ing whe ther or not a true change in For the purp ose of objectively ascertain it is cust oma ry to emp loy the so-called slop e has occu rred in a CUSUM plot, the Shew art Cha rt emp loys the parallel "V-mask" muc h in the sam e way that is cons truct ing and usin g this "V-mask" UCL and LCL lines. The proc edur e for may er read ested inter ussed here. The som ewh at invo lved and will not be disc herill and Brow n [24]. In any event, Wet or 10], [9, s Luca ple, consult, for exam ly supp lant ed by an equi vale nt, large such a grap hica l proc edur e has been disc usse d, for exam ple, in Luca s and prim arily com puta tion al, appr oach ly in MacGregor [15]. Crosier [12, 13], and also mentioned brief perf orm s wha t is kno wn as a Theo retic ally, the CUSUM met hod ) T): i.e., it tests the null hypo thes is (H0 Sequential Probability Ratio Test (SPR If 0. -:;: 8 that {H.) is thes alternative hypo that c = 0 in Eq. (28.12), agai nst the as: T we define SPR r Ha Pr[y (l); y(2); ... ; y(k)] unde (28.16) --" :--unde --'...-----y(2); SPR T = -:-(l); r H0 y(k)J ; Pr[y e of SPRT exceeds a prespecified a risk then H 0 is rejected if the com pute d valu a pute d valu e of SPRT is sma ller than valu e, and H. is rejected whe n the com pres peci fied f3 risk value. mus t specify 8 (a mea sure of the Thu s, to use the CUSUM meth od one dete ct quickly), and values for a to like sma llest shift in the mea n one wou ld the yd, and a. For this and othe r reasons, and f3 .risks, in addi tion to specifying the than use to ted y as mor e com plica CUSUM meth od is cons ider ed by man Shew art meth od. the CUSUM meth od (incl udin g a Ther e are man y othe r vari ation s of UM) that we will not disc uss here. The meth od com bini ng Shew art and CUS cople, to the publ icati ons by Lucas and inter ested read er is referred, for exam the , form c basi t mos its in that is to note work ers [11-13). The impo rtan t poin t ad inste h on the Shew art Cha rt in whic CUSUM char t is prim arily a variation e valu et targ its from the obse rvat ion y of eval uatin g the actu al devi ation of ed. plott is s ation devi ve sum of these agai nst control limit lines, the cumulati
1043
CESS CONTROL CHAP 28 STATISTICAL PRO 52.000 oy
eyp
51.500 51.000 50.500 y
50.000 49.500 49.000
Shi ft Imp lem ent ed
- -Lim-it -trol -er-Con - - - - - - - -Low
48.500
48.000 10.0 13.0 16.0 0.0 2.0 4.0 6.0 8.0 Tim e Seq uen ce
19.0
22.0
25.0
(a)
14.000 13.000 12.000 11.000 10.000 9.000 8.000 7.000 s 6.000 5.000 4.000 3.000 2.000 1.000 0.000 ·1.000 0.0
• sp
os
Shi ft Imp lem ent ed
~ 2.0
4.0
6.0
8.0 10.0
13.0
16.0
19.0
22.0
25.0
Tim e Seq uen ce (b)
Fig ure 28.3.
shifted (•) process for an "on-target" (o) and (a) Example Shewart plots ts. plo ing CUSUM variable; (b) the correspond
ne nti all y W eig hte d 28.2.4 EWMA: Th e Ex po
Mo vin g Average
far uses process dat a technique discussed thu s g rtin cha e l tro con lity Each qua y use s e(k), the dif fer enc Sh ew art Ch art ess ent iall e tim in nt poi h eac at differently: the classical ing it ire d tar get value, com par us Th d. tea ins bet we en y(k) and the des e(i) L~~ 1 , CUSUM cha rt use s the sum aga ins t ± 3a limits; the mo st cur ren t inf orm atio n, the on ly ire ent s use foc d s while the Sh ew art me tho the CUSUM me tho d pay oev er to pas t information, pay ing no atte nti on wh ats
SPECIAL CONTROL TOPICS
1044
equal attention to the entire data history as it pays to the most current information. There is a class of "moving average" techniques that fall somewhere in between the Shewart and the CUSUM methods in the manner in which historical data is utilized; the Exponentially Weighted Moving Average (EWMA) method, first proposed by Roberts [20], is the most widely used in this class. The EWMA of the observation y(k) is given by the expression: y(k) =
A.y(k) + (l - A.)y(k - 1)
(28.17)
(with 0 < A. S 1) that is easily recognized by engineers as the computational equivalent of a digital, first-order filter. In terms of e(k) = y(k)- yd, and defining: (28.18)
then it follows immediately that Eq. (28.17) may equally well be written as: ~(k) =
A.e(k) + (1- A.)~(k- 1)
(28.19)
By recursive application of this expression, it is easy to show that Eq. (28.19) becomes: k
L w(i) e(i) = i=O
(28.20a)
w(i) = 1..(1-A.)k-i
(28.20b)
~(k)
with the weights w(i) given by:
Note how the expression for ~(k) naturally falls in between e(k) used by the Shewart method (corresponding to w(i) = 1 fori= k; and zero otherwise), and k
I, e(i) used by the CUSUM method (corresponding to w(i) = 1 for all i ). i
=1
Now, if the errors e(i), i = 1, 2, ... , k, are considered as usual to be independent and identically distributed Gaussian random variables with zero then it can be shown that the variance of ~(k) is mean and constant variance given by:
cr,
(28.21)
that has the asymptotic limit (for reasonable values of k): (28.22)
The parameter A. that, from Eq. (28.20}, determines the memory length, and that from Eq. (28.22) also strongly influences the EWMA variance, is to be chosen by the user. Procedures and guidelines for determining "optimum" values for A. are presented, for example, in Hunter [5].
1045
CHAP 28 STATISTICAL PROCESS CONTROL
Plott ing and Using the EW.M:A r [5] sugges ts that y(k) For the purpo ses of plottin g the EWMA statistic, Hunte st" of y(k + 1), say, foreca ead tep-ah "one-s in Eq. (28.17) be consid ered as a zed by setting y_,(l) initiali is plot EWMA The such. as d y1 (k + 1), and plotte l limits for the contro igma equal to the target value, i.e., y1 (1) = Yd· The three-s i.e.: , (28.22) Eq. EWMA are obtain ed from
YJ± 3aEWMA
= Yd
± 3a (
~)
(28.23)
associ ated with the raw where a is the standa rd deviat ion of the error, e(k), process measurement. ity data of Table 23.1 An examp le plot of the EWMA for the Moone y viscos used to indica te the are circles empty is shown in Figure 28.4. Again , the te the EWMA for indica circles solid the while data, al EWMA for the origin that for this Recall case. each the "pertu rbed" data; A. is chosen as 0.5 in and that for 0.5, a= ion, deviat rd standa the =50, proces s the target value is Yd 9. = k after ented implem was 0.6 of shift the data, the pertur bed a limits at: For the choice A. = 0.5, Eq. (28.23) is used to set the 3-sigm 50.00 ± 3
X
0.5
~
= 50.00 ± 0.87
for the pertur bed data Obser ve that the EWMA forecast trigger s a first signal two observ ations after 12, = k at limit) l contro upper the e outsid (the point falls 15 EWMA forecasts the of out 5 the disturb ance was implem ented; and in all, f-control" signals. "out-o trigger ance disturb the of made after the introd uction d to combi ne a mende For the purpo se of compa rison, it is often recom forecasts (cf. EWMA g pondin corres the with Shewa rt plot (for raw y(k) data) 52.000 0 Yewma
51.500 51.000 50.500 Yewma
50.000 49.500 49.000
LCL
Shift Implem ented
48.500 _._.._._ _,_....__ .
48.000 l-...J.-L --'--'--L ....I-'--- '--'--L... .I-'--'-.. ._........_.__,_.. 0.0 2.0 4.0 6.0 8.0 10.0 13.0 16.0 19.0 Time Sequen ce
Figure 28.4.
22.0
The EWMA plot for the Mooney viscosity data.
25.0
SPECIAL CONTROL TOPICS
1046
y
Shift Imple mente d
49.000
LCLf orEW MA (~k=-)---t
48.500 1--------------LC~L~ti=-or-y
.._.~_,__,
__,_....._...._._.__,_..
._..__.~_._..I....-J.__.
48.000 0.0 2.0 4.0 6.0 8.0 10.0 13.0 16.0 Time Seque nce L....L_...._._..__.._.__
Figure 28.5.
19.0
22.0
25.0
An example combined Shewa rt and EWMA plot.
for the pertu rbed Mooney Hunt er [51). Such a plot is show n in Figur e 28.5 by Hunt er [5], and with the viscosity data only, plotte d as recom mend ed emph asize s once more the plot respective contr ol limits as indicated. This n in the Shew art plot does vatio obser l actua point noted earlier: whereas the r several signals. not trigger a signal, the EWMA forecast does trigge with the specific choice of A It has been show n by Hunt er [6] that the EWM porating the Western incor t Char art Shew A= 0.4 is virtually equivalent to the A and its vario us EWM the t abou n matio infor l Electric rules. Addi tiona rtant point s to impo The [5]. properties are available, for example, in Hunt er note are: • It is just as easy to use as the Shewart plot, e in between the Shewart and • In its use of process data, it falls somewher
the CUSUM methods, priately, it is possible to • By choosing the "tuni ng" param eter A appro the classical Shew art than obtai n a proce dure that is more sensitive level. mean in Char t in picking up smaller shifts ent context in Section 28.5. We will have cause tq meet the EWMA in a differ
28.3
NDA RD SERIAL CORRELATION EFFECTS AND STA PROCESS CONTROL
Dist urba nces 28.3.1 The Natu re of Indu stria l Processes and of an interconnected network of The typical industrial chemical process consists reactors, distillation columns, ical chem as indiv idual processing units such inertial components prese nt in heat exchangers, mixing tanks, etc. The inherent , the transportation lag due to each of these units, the presence of recycle loops many process variables of that fact the flow throu gh connecting pipes, and
CESS CONTROL CHAP 28 STATISTICAL PRO
104 7
spi re to gua ran tee me asu red frequently, all con t obs erv atio ns. importance are sam ple d and pas to l be stro ngl y rela ted wil ns atio erv obs t ren cur tha t re be expected to be process variables will therefo ented reasonably Measurements of controlled such correlations can be repres dy of process strongly serially correlated, but stu the s: del am ic process mo dyn tic) inis term (de h wit we ll ated upo n this very fact. dynamics in Par t II was predic le variations in however, of the una voi dab s in am bie nt There is the add itio nal factor, tion tua fluc t impurities, con stan of up ld bui the als, teri raw ma , tha t combine to n, hea t exchanger fouling, etc. conditions, catalyst deactivatio ible to pre dic t, or to ys tha t are virhtally imposs "di stu rb" the process in wa e deterministic model. represent wit h any reasonabl and the con stan t inh ere nt process dyn am ics, the These two factors es - mean tha t presence of process disturbanc naturally tend to e measurement, y(k), wil l The typical process variabl in addition it with previous observations; be very stro ngl y correlated " get. -tar wander and not remain "on will also naturally tend to ted in Eq. (28.4), an quality control mo del pre sen Thus within the context of the has: the typical chemical process observation y(k) obt ain ed from t is har dly eve r exp lain abl e par t, y .. (k), tha 1. A "de term inis tic, " or dynamics. - because of inherent process constant -o r unc orr ela ted refer to as d(k), ainable part, tha t we will now xpl une or " stic cha "sto A 2. se," e(k); d(k) the unc orr ela ted "w hite noi tha t is har dly the sam e as a nonstationary drift. will usually take the form of
Co rre lat ion 28.3.2 Co pin g Wi th Se ria l
s dat a is tha t all the of serial correlation in proces The mo st imp ort ant effect ds bre ak down. The tho ind traditional charting me underlying ass um ptio ns beh so-called "no rma l the on ed the EWMA, are bas as ll we as art, Ch rt wa She error, e(k), being an y strongly on the me asu rem ent The seq uen tial theory test" tha t dep end s ver ce. dis trib ute d Gaussian sequen bas ed on e(k) ind epe nde nt and identically alsQ is d tho in the CUSUM me out ried car test o rati ility probab ce. being such a Gaussian sequen statistical basis of ng eno ugh to und erm ine the stro is tion When cor rela ploy one of two em to trol methods, it is customary g "ba nd- aid s" these traditional qua lity con lyin app to ts oun ch essentially am approaches. The first app roa rt Ch art are wid ene d s: the limits of the She wa to the trad itio nal technique negative correlation; correlation, or nar row ed for "ap pro pria tely " for positive app rop riat ely " to ted jus "ad M and EWMA are SU CU the of rs ete am par the e of the se issues are relation on the ARL. Som account for the effect of cor egor, Hu nte r and lish et al. [3], and also in MacGr discussed, for example, in Eng to con fro nt the fail r, aid " approaches, how eve ependence of Ha rris [17]. The se "ba ndind on ed bas s test istical hypothesis fundamental fact tha t all stat the pre sen ce of com ple tely inv alid ate d by seq uen tial obs erv atio ns are correlation. ons in y*( k) are is mo re systematic: var iati ch roa app tive rna alte The ed in the sys tem atic reflect the dynamics inv olv mo del ed app rop riat ely to
1048
SPECIAL CONTROL TOPICS
(explainable) component of the data; disturbance models that go beyond setting d(k) = e(k) are also developed to reflect the nature of the typical disturbances
experienced by the process. The use of such techniques specifically for the purpose of developing quality control charts is discussed in detail in Keats and Hubele [7], and also in Harris and Ross [4]. In Section 28.5 we will discuss how this same approach is used for controller design.
28.3.3 Standard Process Control To be sure, the presence of serial correlation and systematic drifts in the observed value of a process variable severely limit the applicability of traditional QC methods on most chemical processes. But a more serious impediment is the assumption of the traditional QC methods that making adjustments in the manipulated variable to correct for observed deviations from target values always has significant associated costs. In most industrial chemical processes, not only are adjustments in the manipulated variables cost-free, but because of a natural propensity for the process to drift away from target, it is not making timely adjustments to correct for observed deviations that has associated costs. This is the motivation for the standard process control paradigm: that the natural dynamics of the process, and the persistent nature of the disturbances, are such that waiting to ascertain the "significance" of an observed deviation before taking corrective control action is often Wlacceptable. Corrective control action is therefore taken after every observation is made, employing any of the control algorithms discussed in detail in Part IV of the book, the most popular being feedback control, using the PID control algorithm (cf. Chapters 14 and 15). A well-devised standard control strategy can therefore significantly minimize the effect of persistent disturbances on the process variable of interest, but at the expense of making continuous adjustments in the manipulated variable. However, since the net result of having a key process output variable drift away from desired target value can mean significant financial loss; and since it is relatively easy to make the required changes in the manipulated variables to correct for these process excursions; and since the resulting variation in the manipulated variable value is of no real consequence, it has been said that:
The primary aim of standard process control is to transfer variations from where it "hurts" (in the process output, y) to where it does not hurt (in the manipulated variable, u) (cf. Downs and Doss [2]). The most serious criticism of this standard process control philosophy lies in the fact that when the observed deviations from target are truly random,
and not statistically significant, the continuous controller adjustments actually make the situation worse. These, and other related issues, have been discussed, for example, in MacGregor [16].
28.4
WHEN IS TRADITIONAL SPC APPROPRIATE?
Under the appropriate conditions, traditional SPC has provided very powerful tools for improving product quality. That these traditional SPC techniques
1049
CHAP 28 STATISTICAL PROCESS CONTROL
ing opera tions is a testimony have enjoyed wides pread use in many manu factur tant to know when these impor is it ver, Howe . to their simplicity and power tools are appro priate and when they are not.
28.4.1 Thre e Basic Process and Cont rol Attri butes ques may be applicable in any In deciding wheth er or not traditional SPC techni the status of the follow ing partic ular situat ion, it is helpfu l to invest igate three process and contro l attributes:
s response time)
1. Samp ling interv al (as a ratio of the natural proces a sampl ing interval that When the proce ss outpu t variable is measu red at time of the process, the is consid ered large relativ e to the natur al respo nse be manif ested in the to likely less natur al dynam ics of the proce ss are y correlated. The seriall be to likely less are ts remen observations, and measu e to the natur al relativ small converse is true when the sampl ing interv al is process response time. 2. Noise or disturbance structure mostl y to measu remen t When the "unex plaina ble" part of the data is due noise signal s are often such be), noise (no matte r how significant this might ian distrib ution with Gauss a from s signal m rando quite well appro ximat ed as le disturbances dictab wtpre zero mean. When the process is subject to additi onal y inade quate grossl be will ure struct noise of more complex struct ure, a Gaussian ically. realist s signal in repres enting such 3. Cost of implementing control action ss is substa ntial, it is When the cost of makin g adjust ments on the proce ved devia tions from obser any of icance reasonable first to ascert ain the signif are cost-free, such a ments adjust when ; action tive correc target before taking shoul d still be action ol contr h philo sophy is less justifi able, even thoug imple mente d judiciously.
28.4.2 Whe n Trad ition al SPC is More Appr opria te Tra~tional
1.
2.
3.
SPC is more appro priate :
e to the natura l When the sampl ing interv al is consid ered large relativ process mean is the that ption assum the process respo nse time (for then able). reason is ics dynam of free and nt essentially consta bances, so that any When the process is not subject to significant distur tially due to essen is t obser ved variab ility in the proce ss outpu ian with Gauss is e(k) that ption assum the measu remen t noise (for then bance s" are distur ess "proc the when i.e., able), reason is zero mean domin ated by measurement noise. When the cost of makin g adjustments is substantial.
"find " and "elim inate" the Cond ition 1 also permi ts the opera tor time to ophy. assignable cause, as requir ed by the SPC philos
SPECIAL CONT ROL TOPICS
1050
Mor e App ropr iate 28.4.3 Whe n Stan dard Proc ess Con trol is Stand ard process control is more appropriat
e:
ve to the natur al proce ss Whe n the samp ling inter val is small relati dyna mics are in evidence, ss respo nse time {for then the natur al proce to persist). tend will t targe from and uncorrected deviations
1.
, significant distu rbanc es, so 2. Whe n the process is subject to persi stent ss outp ut will likely be due proce the that any obse rved variability in to the effect of zero mean than es rbanc distu such more to the effect of the "proc ess distu rbanc es" Gaus sian meas urem ent noise (i.e., when domi nate measurement noise). 3.
28.5
gible. Whe n the cost of making adjustments is negli
STO CHA STIC PROCESS CON TRO L
28.5.1 Basi c Prem ise appr oach to the prob lem of process "Stochastic process control" is a systematic ltane ously with the dual issues of - as well as quali ty - control; it deals simu that are more comp lex than ces rban proc ess dyna mics and stochastic distu with reasonable mode ls for that, is ise prem basic Gaus sian whit e noise. The well as the unex plain able (i.e., the expla inabl e (i.e., deter mini stic), as decisions that satisfy reaso nable ol stochastic), part of the process data, contr . Ther e are there fore three nally ratio made perfo rman ce objectives can be process control paradigm: essential elements required for the stochastic l 1. A deterministic dyna mic process mode · l mode e rbanc 2. A stochastic distu 3. A performance objective rve that the tradi tiona l SPC With in this context, it is instr uctiv e to obse constant), for the deterministic part techn iques empl oy the mode l y*(k) =y* {a noise for the stoch astic part; the of the data, and e(k) = Gaus sian whit e tments, subject to the constraints adjus the perfo rman ce objective is to minimize that Yr.CL < y(k) < YuCL· not empl oy any explicit mode l Classical proce ss control apparently does es {we will see later that it rbanc distu eithe r for the process dynamics or for the appa rent perfo rman ce the and ls); mode icit impl actua lly does empl oy some also see later that the classical PID objective is to make y(k) = yd(k). We will has a more subtl e stoch astic contr oller 's perfo rman ce objective in fact inter preta tion.
28.5.2 Mod els for Stochastic Proc ess Con trol , linea r difference equa tions models With in the context of the curre nt discussion mode ls) are the most comm only {and the equiv alent pulse trans fer funct ion outp ut as y(k), as
the process employed deterministic models. Representing
1051
PROCESS CO NTR OL CHAP 28 STA TIS TIC AL
u(k ), the following are (m ani pul ate d variable) as ut inp s ces pro the and usual, some example models:
(28.24)
(y( k) - y0) = K u(k - 1)
for a pur e gain process: I) - y 0) + (y( k) - y0 ) = Jr 1 (y( k-
t; 1u(k - m- 1)
(28.25)
times. (Note that for a time del ay of nz sam ple h wit s ces pro r rde t-o firs for a of dev iati on of y(k) from e been pre sen ted in terms convenience, the modeL<> hav omes: a nom ina l val ue y0.) the model in Eq. (28.25) bec In transfer function form, (28.26)
of a "ba ckw ard t IVC, z-1 pla ys the role Par m fro all rec y ma we wh ere , as del will be of the form: lly the transfer function mo era gen re Mo r. rato ope shift" (28.27a)
u(k - I) (y( k) - y0 ) = P(z-')z:m
wh ere
(28.27b)
ynomials in z-1. and t;(z-1) and tr(z-1) are pol
Disturbance Models kin s [1]) for
Box and Jen y time ser ies mo del s (cf. : It is cus tom ary to em plo mple, the following model stic disturbances. For exa representing the stocha
d(k) = If> d(k - I) + e(k)
(28.28)
t-order autoregressive, or ite noise, is kno wn as a firs wh ian uss Ga is ) e(k ere wh (28.29) AR(l), model, while: = e(k )- ee(k - l) d(k)
l model. For reasons we wil mo vin g average, or MA(l), stic cha sto y nar tio is kno wn as a first-order sta of two mo del s are exa mp les no t go int o her e, the se m walk" model: ndo "ra the : are s del mo ary processes. Two nonstation (28.30) d(k) = d(k -1) + e(k) IM A( l)) model: rder mo vin g average," or and the "in teg rat ed first-o ) - Be( k -1) d(k) = d(k -1) + e(k
(28.31)
(p, D,q ) model, the ser ies mo del is the AR IMA e tim ear lin l era gen st Th e mo , wit h pa s the ord er of the d, Mo vin g Average model AutoRegressive, Int egr ate
1052
SPECIAL CONTROL TOPICS
autoregressiv e part q as the order of the moving average part, and D as the· degree of differencing (or integration). It has the form: (28.32)
where 1/J(z-1) and O(z-1 ) are, respectively, pth-order and qth-order polynomials in the backshift operator z-1, and \1° is the Dth difference operator defined as: V 0 d(k) = d(k) -d(k-D)
The interested reader is referred to Box and Jenkins [1] for further details; for our purposes here, we only note an important result due to MacGregor [14] that as the interval between observations increases, the behavior of an ARIMA(p,1, q) model- for any p or q - approaches that of the IMA{l,1) model shown in Eq. (28.31). Titis is the motivation for restricting our attention to the model in Eq. (28.31).
28.5.3 Minimum Variance Control: General Resultc; The overall model used for stochastic process control is of the form: (y(k) - y 0 ) = P(r 1)r"' u(k -l) + d(k)
(28.33a)
(y(k) - y 0 ) = P(z- 1) u(k- m- I) + d(k)
(28.33b)
or
with appropriate form chosen for P(z-1), and for d(k); and an appropriate value chosen for m, the process delay. The typical objective is that control action, u(k), should be determined to minimize the expected squared deviation of y(k) from its desired target value Yd· Since E[(y- yd) 2] is the theoretical definition of the variance of y (given that its mean value is yd), this objective is commonly referred to as the "minimum variance" control objective. To determine the "minimum variance" control action, without loss of generality, we take the nominal value y 0 around which the model was obtained to be the target value yd, and note from Eq. (28.33) that: (y(k +m +I)-
= P(z- 1)u(k) + d(k + m +I)
yd)
(28.34)
It can now be shown (cf. Box and Jenkins [1), MacGregor [15]) that the control action, u(k), that minimizes E([y(k + m + 1) - yd]2) in Eq. (28.34), is given by: 1
•
u(k) "' P(z-•) [-d(k + m + Ilk)]
(28.35)
where d(k + m + 11 k) is the minimum variance forecast of d(k + m + 1) given information up to the present time k. Such a forecast is obtained using procedures discussed in detail in Box and Jenkins [1], and some illustrative examples will be given below. For now, we simply note that the procedure is
CHAP 28 STATISTICAL PROCESS CONTROL
1053
equivalent to applying a "forecast filter" on the currently available disturbance information, d(k), i.e.: d(k + m +Ilk)
= F(z- 1) d(k)
(28.36)
and that the specific form taken by F(z- 1) is determined by the disturbance model. Whenever an observation y(k) becomes available, we may use Eq. (28.33) to obtain the corresponding value of d(k) as: (28.37a)
where (28.37b)
is the dynamic model prediction of the deterministic part of the observed data y(k). Thus, Eq. (28.35) may now be rewritten with the aid of Eqs. (28.36) and (28.37) as: (28.38)
In diagramatic form, the strategy represented by Eq. (28.38) is as shown in Figure 28.6 (cf. MacGregor [15]), and is structurally the same as the IMC form developed apparently under the strictly deterministic, standard control paradigm in Chapter 19. However, it is important to observe that a crucial part of the IMC strategy is the requirement of an estimate of the unknown disturbance d, to be determined from plant output data and the process model. Whenever unknown information must be deduced from data, there is always a statistical underpinning, whether explicit or not.
28.5.4 Minimum Variance Control: Specific Results For certain specific simple forms of dynamic process and disturbance models, the nature of the resulting minimum variance controller can be very instructive. We shall consider four examples.
d(k) +
Forecast Filter Deterministic Dynamic Model
Figure 28.6.
Block diagram of the minimum variance control strategy.
SPECIAL CONTROL TOPICS
1054 1. Pure gain process with Gaus sian disturbanc
e.
The opera ting mode l is: (y(k) -
Yd)
= Ku(k -1) + e(k)
(28.39)
and the mini mum variance control is given by: u(k)
(28.40)
I"e(k +Ilk) =-K
of e(k + 1) is obtained as E[e(k + 1)], e(k + 11 k), the mini mum variance forecast a zero mean Gaus sian sequence, i.e., its expe cted value. Now , if e(k) is truly then: (28.41) E{e(k + 1)]
=0
and the mini mum variance control is: u(k)
(28.42)
=0
i.e., no control action shou ld be taken. exam ple are preci sely those Obse rve that the cond ition s impl ied in this the Shew art Char t is base d. This impl ied by the assum ption s upon whic h ation to "do noth ing" when ever justifies the tradi tiona l Shew art recom mend = E[e(k + 1}1 = 0). k) 11 + ~(k the process is "on-t arget " (implied by e(k) takes on a "sign ifican t" error the of value If howe ver, the obse rved that there has been a "shif t" or value , say, b, the inter preta tion is usua lly is assum ed to be constant, then shift distu rbanc e of the same amount; and if this r these circumstances, the Unde 8. , value ero E[e(k + 1)] is now equa l to the nonz mini mum variance control is: (28.43) u(k) = - _!. 8 K e. 2. Pure gain process with IMA (l,l) disturbanc The opera ting mode l in this case is: (y(k )-
with
Yd) = Ku(k -1)
+ d(k)
d(k) = d(k- I) + e(k) - () e(k- 1)
(28.44) (28.31)
mum variance control is obtai ned and e(k) is zero mean Gaussian noise. The mini from: 1 (28.45) u(k) = - K d(k + l I k) A
forecast of d(k + 1), is its expe cted Now , J(k + 11 k), the mini mum varia nce s: from Eq. (28.31): value, E[d(k + 1)], which is comp uted as follow d(k+ l)
= d(k)
+e(k +l)- Be(k)
(28.46)
1055
S CONTROL CHA P 28 STA TIST ICA L PROCES
so that: - 6 e(k) d(k + I I k) = E[d( k + 1)] = d(k)
(28.47)
a kno wn ing bee n observed, is con side red ion for since E[e(k + 1)] = 0 and e(k), hav ress exp the in obta 7) from Eq. (28.46) we quantity. By subtracting Eq. (28.4 r: the "one-step-ahead" forecast erro ) e(k+ l) = d(k +l) -d( k+ llk
from which we obtain:
e(k) = d(k )- d(k I k- 1)
(28.48)
7) yields: Introducing this now into Eq. (28.4 - () )d(k) d(k + Ilk) = 6 d(k lk- l) + (l
(28.49)
as an EWMA er filter on d(k), or equivalently, recognizable eith er as a first-ord 1\ plot does of d(k). nt (in the sense that the EWMA Thus, if d(k +11 k) is not significa ssary; nece is on acti 45) implies that no control be not ,Vigger a signal), then Eq. (28. to trol con e ianc var then the min imu m if d(k +ll k) is sign ific ant, 5). implemented is as given in Eq. (28.4 E GAI N IANCE CONTROLLER FOR PUR Exa mpl e 28.1 MIN IMU M VAR .. CE TURBAN PROCESS WIT H IMA (l,l) DIS process who se model imu m variance controller for the Obt ain an expr essio n for the min has been identified as : (28.50a) = 5.0u (k- I) + d(k) (y(k ) - y
d)
with
d(k)
d(k - I) +e(k ) - 0.6 e(k - I)
(28.50b)
Solu tion : in the requ ired para met ers in Eq. (28.50), we obta From Eq. (28.45) and the mod el as: ession min imu m vari ance controller expr u(k) = - 0.2
The min imu m vari ance forecast
d(k
J (k + Ilk)
requ ired in this specific case is obta
ined according to:
+ Ilk)= 0.6J (k I k - I) + 0.4d(k)
rban ce, d(k), whi ch is an EWM A of the distu d(k)
as: itself obta ined from Eq. (28.50a)
= [y(k) - ydl - 5.0u(k - I)
SPECIAL CONTROL TOPICS
1056
3. Pure gain process with IMA(l,l) disturbance: (Control action to be implemented at every time instant k). Jn this case we wish to write an explicit expression for the minimum variance controller we have just derived in Eq. (28.45). First, the forecast formula in Eq. (28.49) is rewritten as: (I- f)z-1) d(k + 11 k) = (1- fJ)d(k)
which can be written in the transfer function form: d(k + I I k) :::: F(r1)d(k)
(28.5la)
{1-fJ)
(28.51b)
with 1
-
F(r) - (I - (}z-1)
(Note that both the parameter f) and the form of this "forecast filter" F(z-1) arise naturally from the IMA(l,l) disturbance modeL) The minimwn variance control expression now becomes: u(k) =
1(1-fJ)
-K (1- (}z-1) d(k)
or (1 - 9r 1)u(k) :::: -
1 (1 K
(} )[(y(k) - yd)- Ku(k- 1)]
(28.52)
where we have made use of the model in Eq. (28.44) to write d(k) in terms of known process information. If we now note that Yd- y(k) is E(k), the familiar feedback error, then Eq. (28.52) rearranges to give: u(k)-u(k-1) = (1
~ (} ) E(k)
or u(k) :::: (1 - (})
K
(28.53a)
±
E(i)
(28.53b)
i=l
recognizable as a pure integral control algorithm. Example 28.2
MINIMUM VARIANCE CONTROLLER IMPLEMENTED AT EVERY TIME INSTANT k FOR A PURE GAIN PROCESS WITH IMA(l,l) DISTURBANCE.
Obtain an explicit expression for the minimum variance controller derived for the process given in Example 28.1 if the controller is to be implemented at every time instant k. Solution: Recalling from the model in Eq. (28.50) that the process parameters are K = 5.0 and £J = 0.6, then from Eq. (28.53b), the required controller is the pure integral controller: k
u(k) = 0.08
L £(i) i= I
1057
CHAP 28 STATISTICAL PROCESS CONTROL : 4. FiiSt-order process with IMA( l,l) distur bance
(Control action to be imple mente d at every time instan
t k).
Tne mode l in this case is: (28.54)
with (28.31)
d(k) = d(k-1 ) +e(k )- ee(k -l)
and the minim um variance controller is given by: [ u(k) = -
} - 1r I
~~
z- I
J
(l - (} )
(1 _ (}z-') d(k)
(28.55)
This rearra nges to give:
rearrangement, we obtain: upon using the mode l to replace d(k). After furthe r u(k)- u(k-1 ) =
] (l-fJ ( )[ e(k)- n1€(k-l )
(28.56)
1
ssion is recognizable as where e(k) is the feedback error Ya- y(k). This expre rearra nged to give the r the velocity form of a PI controller; it may be furthe familiar positi on form: u(k) =
)[ (l-fJ E(k) +(I- n 1) ,. ':>!
.I E(i)J
k-1
•= I
(28.57)
a secon d-ord er model, with The reade r shoul d show, as an exercise, that for ller is the digita l PID contro IMA( l,l) distur bance , the minim um varian ce controller. Examp le 28.3
MENTED AT MINIM UM VARI ANCE CONT ROLL ER IMPLE R PROCESS -ORDE FIRST A FOR k EVERY TIME INSTA NT CE. RBAN DISTU ,l) IMA(l WITH
The deterministic model for a process has been obtain (y(k) -
ed as:
yd) = 0.5 (y(k- I) - yd) + 0.8u(k - I)
with the accompanying stochastic disturbance model
given by:
(28.58)
SPECIAL CON TROL TOPICS
1058 d(k)
= d(k -I)
+ e(k) - 0.6 e(k- I)
(28.59)
um variance controller for this process if Obta in an explicit expression for the minim instant k. time the controller is to be implemented at every Solut ion:
param eters are {1 =0.8, n1 = 0.5, and Obse rve that for this process, the mode l controller is the PI controller: 8 =0.6. Thus, from Eq. (28.57), the required u(k)
= 0.5 [ e(k) + 0.5
.L E(i) J
k- 1
(28.60)
ao:l
this stochastic process control We may now note the following with in framework: algorithm is: 1. Implicit in the classical PID control
mic model • A first- or second-order deterministic dyna el mod ce rban distu • An IMA(l,l) stochastic tive • A minimum variance performance objec
t control action, then implicit in 2. If the EWMA char t is used to impl emen such a strategy is: • A pure gain deterministic mod el el • An IMA(l,l) stochastic disturbance mod tive objec ce rman • A minimum variance perfo sponds to: 3. The Shewart Charting para digm corre el • A pure gain deterministic mod rbance model • A Gaussian white noise stochastic distu tive • A minimum variance performance objec
28.6
TECHNIQUES MORE ADVANCED MULTIVARIATE
likely to face a situa tion in which Realistically, the process engineer is more are to be mon itore d and controlled seve ral process and qual ity variables ess control, extending the ideas we simultaneously. As with multivariable proc ate case is fraug ht with man y have pres ente d thus far to the mult ivari mult ivari ate equi vale nt of the ient effic complications. Nevertheless, a very ented in Kresta et al. [8]. It is based Shewart plot has been developed and pres l analysis as Principal Com pone nt on such tools of mult ivari ate stati stica Structures (PLS). A full discussion of Analysis (PCA) and Projection to Latent outside the intended scope of this these multivariate SPC monitoring tools lies ed to consult the cited reference. chapter; the interested reader is encourag techniques to the desig n and The application of these mult ivari ate SPC nce controllers has also been varia mum implementation of multivariable mini industrial polymerization process has carried out. A specific application to an h the interested reader is referred. been reported in Roffel et al. [21], to whic
CHAP 28 STATISTICAL PROCESS CONTROL
28.7
1059
SUMMARY
ess and quality control in the face of The indu stria lly impo rtant issue of proc focus of this chap ter. We have inhe rent varia bilit y has been the main (QC) meth ods - the Shew art, trol revie wed the tradi tiona l Qual ity Con ing the salie nt poin ts and the basic CUSUM, and EWMA charts - high light The role of stan dard proc ess control assu mpti ons unde rlyin g each technique. tical process cont rol (SPC) was also with in the fram ewor k of traditional statis in all situa tions , and neith er is cable appli discu ssed . Trad ition al SPC is not unde r which each appr oach is most stan dard process control; the circumstances appr opria te have been carefully note d. d in this chap ter as a technique in Stochastic process control was pres ente mic mod els are con1bined with whic h appr opri ate dete rmin istic dyna els and appr opri ate perfo rman ce appr opri ate stoch astic distu rban ce mod control decisions. It was show n nal objectives for the purp ose of mak ing ratio sed tradi tiona l char ting meth ods and that the appa rentl y diametrically oppo y inter preta tion with in this unify ing the classical PID cont rolle rs find read ivari ate tech niqu es were brief ly fram ewo rk. High er dime nsio nal, mult the read er inter ested in purs uing this men tione d with references prov ided for rapid ly deve lopin g topic further. REFERENCES AND SUGGESTED FUR
THER REA DING
Analysis: Forecasting and Control, HoldenBox, G. E. P. and G. M. Jenkins, Time Series Day, San Francisco (1976) Statu s and Futur e Needs: The View From 2. Dow ns, J. J. and J. E. Doss, "Pres ent CPC IV, (Ed. Y. Arku n and W. H. Ray), trolCon ss Indus try," in Chemical Proce AIChE, New York (1991) s T. Sastri, "Qua lity Monitoring of Cont inuou 3. English, J. R., M. Krishnamurthi, and ) (1991 251 20, , eering Engin Flow Processes," Computers and Industrial elate d "Stat istica l Proce ss Cont rol for Corr 4. Harr is, T. J. and W. H. Ross, ) (1991 48 Observations," Canadian f. Chern. Eng., 69, , 18, ng Average," Journal of Quality Technology 5. Hunt er, J. S., "The Exponential Movi 203 (1986) ric alent to the Shewart Char t with Western Elect 6. Hunt er, J. S., "A One-point Plot Equiv Rules," Quality Engineering, 2, 13 (1989) Statistical Process Control in Automated 7. Keats, J. B. and N. F. Hube le, Eds. ) Manufacturing, Marcel Dekker, New York (1989 "Multivariate Statistical Monitoring n, Marli E. T. and , 8. Kresta, J. V., J. F. MacGregor . Eng, 69, 35 (1991) Chern f. ian of Process Oper ating Performance," Canad Technometrics, 15, 833 (1973) e," Schem rol Cont sk V-Ma 9. Lucas, J. M., "A Modified Schemes," Journal of Quality rol Cont sk of V-Ma 10. Lucas, J. M., "The Design and Use Technology, 8, 1 (1976) l of USUM Qual ity Cont rol Schemes," fourna 11. Lucas, J. M., "Com bined Shewart-C Quality Technology, 14, 51 (1982) rol Initial Response for CUSUM Quality Cont 12. Lucas, J. M. and R. B. Crosier, "Fast 24, 199 (1982a) ics, ometr Techn ," -start Head a M Schemes: Give Your CUSU A CUSUM," Communications in Statistics, Part 13. Lucas, J. M. and R. B. Crosier, "Robust - Theory and Methods, 11, 2669 (1982b) rol," of Samp ling Inter val for Process Cont 14. MacGregor, J. F., "Opt imal Choice ) Technometrics, 18, 151 (1976 ) Process Control," Chern. Eng. Prog., 21 (1988 15. MacGregor, J. F., "On-line Statistical
1.
SPECIAL CONTROl. TOPICS
1060 16. MacGregor,
J.
F., "A Different View of the Funnel Experiment," Journal of Quality
Technology, 22, 255 (1990)
17. MacGregor, J. F., J. S. Hunter, and T. J. Harris, SPC Interfaces, unpublished course notes (1993) 18. Page, E. S., "Continuous Inspection Schemes," Biometrika, 41,100 (1954) 19. Page, E. 5., "Cumulative Sum Charts," Technometrics, 3,1 (1961) 20. Roberts, S. W., "Control Chart Tests Based on Geometric Moving Averages,"
Technometrics, 1, 239 (1959) 21. Roffe!, J. J., J. F. MacGregor, and T. W. Hoffman, "The Design and Implementatio n of a Multivariable Internal Model Controller for a Continuous Polybutadiene Polymerization Train," Proceedings DYCORD+ 89, IFAC Maastricht, 9-15 (1989) 22. Shewart, W. A., "The Application of Statistics in Maintaining Quality of a · Manufactured Product," JASA, 546 (1925) 23. Shewart, W. A., Economic Control of Quality, Van Nostrand, New York (1931) 24. Wetherill, G. B. and D. W. Brown, Statistical Process Control: Theory and Practice, Chapman and Hall, London (1990)
REVIEW QUESTIONS 1.
What is Statistical Process Control (SPC) in its broadest sense?
2.
Within the context of maintaining a process variable steady in the face of unavoidable, inherent variability, what is the analysis problem and what is the control strategy problem?
3.
What is ''common cause" variation, and how is it different from "special cause" variation?
4.
Why do the traditional Quality Control (QC) methods pay more attention to the analysis of process variability and not so much to control strategy?
5.
Why does standard process control pay more attention to control strategy and not so much to the analysis of process variability?
6.
How is the Gaussian probability density function used in the traditional QC methods?
7.
In hypothesis testing, what is the difference between a Type I error and a Type II error?
B.
What is an a risk and what is a jJ risk?
9.
What is a classical Shewart Chart, and on what premise is it based?
10. When does a "signal" occur in a ShewartChart?
11. What is the recommended plan of action when a "signal" occur in a Shewart Chart?
12. In employing the standard "3-sigma" limits on a Shewart Chart, what is the risk of raising a false alarm? 13. What is the motivation behind augmenting the Shewart Chart with the Western Electric rules? 14. What is the average run length, (ARL), and how does this concept help in assessing the usefulness of a QC method?
1061
CHAP 28 STATISTICAL PROCESS CONTROL 15. What process variable is plotted on a CUSUM chart?
chart is likely to be more 16. Other things being equal, why do you think the CUSUM shifts? process smaller up picking in Chart t Shewar the than sensitive how 17. Theoretically, on what test is the CUSUM method based, and
does the test work?
data, how does it stand in 18. What is the EWMA, and in terms of how it uses process s? method CUSUM and t relation to the Shewar and the EWMA parameter, 19. Given the inheren t standar d deviation of raw process data chart? EWMA how are the "3-sigma" limits set for the ent to the Shewar t Chart 20. When does the EWMA chart become virtuall y equival incorporating the Western Electric rules? ility of traditional QC 21. What is serial correlation and how does it affect the applicab methods? and the "stocha stic" 22. What are the typical characteristics of the "determ inistic" ment? measure variable portions of a typical industrial process y aim" of standar d 23. As summa rized by Downs and Doss [2], what is the "primar process control? es should be investigated in 24. The status of what three basic process and control attn'but situation? given a in le deciding whethe r or not traditional SPC is applicab 25. When is traditional SPC appropriate? 26. When is standar d process contrbl appropriate? , and what are the three 27. What is the basic premise of Stochastic Process Control m? paradig this for essential elements required stochastic process control 28. What models are typical used for the deterministic part of models? stochastic process control? 29. What models are typical used for the disturbance models in control? 30. What is the performance objective of "minim um variance" represe ntation of the 31. What are the primary elemen ts in the block diagram matic the primary elements of minimu m variance controller, and how do they compare with the IMC strategy discussed in Chapter 19? "perform 32. Within the context of stochastic process control what is the ? method t the Shewar
ance objective" of
er become 33. Under what condition does the minimum variance controll ? method Shewart
equivalent to the
er become 34. Under what condition does the minimum variance controll EWMA method?
equivalent to the
er become 35. Under what condition does the minimu m variance controll er? controll classical PI
equivalent to the
CHAPT1EJR
29 SELECTED TOPICS IN
NT RO L AD VA NC ED PROCESS CO trol and cha pter s to Model Predictive Con y of Even after dev otin g ind ivid ual arra t vas a still is e ther in Par t V, d. Statistical Process Control her e usse disc trol topics that we hav e not yet d ippe imp orta nt adv anc ed process con equ are s, s, and many existing processe data However, almost all new processe er put com ital dig ems (DCS) so that As a wit h Distributed Computer Syst par t of the plan t env iron men t. gral inte an are d logg ing and control ente lem trol methods are now bein g imp e thes consequence, Advanced Process Con ng igni des rs stries. While the enginee , .'ling broadly throughout the process indu trai. ial spec and rees hav e advanced deg ts advanced control systems usually cep con c basi the and erst und t rations mus all engineers involved in plan t ope on and chapter, we will introduce the jarg this in s Thu s. hod met trol beh ind these con cess pro h some of the adv anc ed qua lita tive idea s associated wit plants. methods being installed in today's the use advanced process control involve of s hod met the Essentially all of er to ord in (e.g., a detailed process model) dge of quantitative process knowledge wle kno ess lem. For example, this proc the solve a difficult process control prob with l dea to ts, men of on-line measure to , can be use d to overcome the lack time h wit nge cha tics eris ami c charact mal pro blem of processes whose dyn opti w esses with spatial profiles, to allo provide control systems for proc of failure ntain safe process operation in case economic performance, and to mai each of In or). sens e, valv system (e.g., pump, trol of a key component of the control con ed anc adv t eren diff a ribe shall desc a the sections of this chapter, we with e clud it is designed to solve. We con met hod and the special problem . process control technologies brief discussion of some emerging
29.1
OF GO OD ON-LINE CONTROL IN THE ABSENCE ESTIMATION ME AS UR EM EN TS - STATE
key process process indu stry that there are It is very often the case in the It is eve n s. rval inte d on-line at frequent time basis. variables that can not be measure tine rou a on le ilab ava at all are possible that no mea sure men ts
1064
SPECIAL CONTROL TOPICS
Sometimes these measurements can be taken only very infrequently (as in the case of on-line gas chromatography with long elution times) or perhaps samples must be sent to the lab for analysis. In both these cases the measurement result is known only after a significant delay. For these very common situations, the process time constants may be short relative to the time between measurements, and in addition, the measurement result is delayed, indicating the state of the process .some time in the past. Hence, direct feedback control based on these measurements is impractical. In such situations, a State Estimator may be designed to estimate the values of these process variables between measurements. This state estimator is used to "observe" the values of unmeasured variables and is often called an "observer." Another type of problem that arises less frequently in process control is a situation where the process variable is measured on-line, but there is a high level of noise in the measurement signal. If the frequency of the noise is widely separated from the frequency of the process measurement itself (as in the case of 60 cycle noise superimposed on slowly varying temperature measurements}, then simple filters such as described in Chapter 2 may be used. However, if there is significant overlap of frequencies in the noise signal and in the process measurement, then more sophisticated model-based filtering may be used as part of the state estimator. The most common of these filters is based on the work of Kalman in 1960 [cf. Refs. 1-3] and is termed a Kalman Filter.
29.1.1 State Estimator Structure The general structure of a state estimator is shown in Figure 29.1. components of the estimator are
The
1. A dynamic model for the states of the system x having dimension n:
dx
dt = f(x, u, a) + ~(t)
(29.1)
where ~(t) is some model error. The model depends on a knowledge of the process inputs u and model parameters a. 2. Initial conditions: x(O) = x 0
+
~O
(29.2)
where ~ represents initial condition error. 3. Measurement devices producing an l vector of signals y: y = h(x, u, j3) + 11
(29.3)
where 11 represents measurement error. Usually there are fewer measurements than states (l < n). Here the model for the measurement devices h(x, u, j3,) depends on a set of parameters j3. The actual data y and the model h(x, u, j3) differ by the error term 11·
1065
CHAP 29 SELECTED TOPICS IN ADVANCE D PROCESS CONTROL
When on-line measurem ents are available continuou sly (as in the case of a temperatu re, level, or pressure measurem ent), these componen ts may combine into a state estimator of the form:
dx dt
f(x, u, a) + K(t)[y(t) - h(x, u, ~)]
(29.4) (29.5)
x
where K(t) is ann xI dimension al correction gain matrix and denotes an estimate of the true state x. Note that the last term in the state estimator equation provides a correction to the process model based on the difference between the actual measurem ent, y(t), and the value of the measurem ent signal predicted by the model, h(x, u, ~)- Figure 29.2(a) illustrates a typical state estimator trajectory in the case when y(t) is continuou s and is the measured value of x(t). When some of the measurem ents are available only at discrete time intervals tl' t 2, t 3, ••• , tk and may arrive with some significant delay, then the state estimator consists of two parts. The first part has the form: (29.6)
State Model
:k =f(:r.:,u,o:) + ~(t)
State Estimator
Initial Condition
i
x(O) =Xo +~
= f(i,u,o:) + K(t) [)(t)- h(i,u,j3))
Estimate
x(O} = Xo
Output data y =h(:r.:,u,j3) + 11
Known:
To be estimated optimally:
1. Model with uncertain
1. Process states x(t).
initial condition. 2. Mean and covariance of model errors (~(t), ~ ). 3. Mean and covariance of output errors (ll(t)). 4. Inputs, u(t), and outputs, y(t). Figure 29.1.
The structure of a state estimator.
i{t)
SPECIAL CONTROL TOPICS
1066
0
(a) Continuous data
~(t)
tl
ts
ts
(b)
Figure 29.2.
t,
-tDiscrete
ts
te
data
s data, and (b) discrete
nuou Typical state estimator trajectories for (a) conti data.
een discrete samples tk-l < t < tk. Here and prov ides estimates for the time betw are continuous. The second part of the y 1(t) represents those measurements that sure men t resul ts beco mes know n at estim ator is activ ated whe n discr ete mea according to: t =tk to prov ide an instantaneous correction (29.7) u, ~>J + ~
x(tt> x
2(x,
ents available at t =tr The correction Here y1 (t.t} deno tes discrete meas urem rding to the type of estim ator one gain s K 1(t), K 2(tk) may be defin ed acco state estim ation trajectory for the case employs. Figure 29.2(b) show s a typical discrete data whe n y(tJ is a measured of no continuous meas urem ents and only valu e of x(t).
29.1.2 Applications of the State Estimator are two princ ipal functions that can be As indic ated in the last section, there perfo rmed by a state estimator:
s, and 1. Observation of unm easu red process state measurements. noisy from s state ess proc the of 2. Extraction ervability cond ition s" be satisfied in The first task requ ires that certa in "obs ble of observation. For example, if we orde r for the unm easu red state to be capa measure only the temp eratu re history have a closed pres sure vessel, and we can estim ate the pres sure histo ry inside of the gas insid e the vessel, can we also use of an equa tion of state such as: the vessel? This ough t to be possible beca
PV = nRT
(29.8)
1067
ANCED PROCESS CONTROL CHAP 29 SELECTED TOPICS IN ADV
fixed, and quan tity of gas in the vessel are Thus, by kno win g that the volu me this In . sure pres the rve obse we may also and by mea suri ng the temp erat ure, wed gas allo also we if , ever How . fied case the observability condition is satis d not , then the pres sure in the vessel coul flow into the vessel in an unk now n way ility rvab obse the use beca t mea sure men be estim ated base d on a tem pera ture of an ion rvat obse ul essf succ for that is here cond ition is not satisfied. The lesson e ain enou gh information to uniquely defin cont t mus el mod the , state red easu unm rs, Filte an Kalm as well s of obser-vers, as that unm easu red state. Man y type to easu red states. The read er is referred unm of ion rvat obse for have been used Refs. [1-3] for further discussion. y ator to extract process state s from nois To be successful in using a state estim For ess. proc the of stics abo ut the stati data requ ires deta iled info rma tion tities and covariance for all rele vant quan n mea the ire requ ld wou example, one men t sure mea initial condition error, ~ and such as process mod elin g error, ~(t)i n utio evol l stica stati ld be prov ided to erro r, 11 (t). This info rma tion wou ces choi mal opti ugh Thro ). (29.4 K(t) in Eq. equa tion s used in the calculation of The can be extr acte d from the data y(t). x(t) of ates estim mal opti of K(t) , the of form e som this task usua lly invo lves part icul ar state estim ator used for Kalm an Filter (see Refs. [1-3]). REACTOR (ADAYfED A CONTINUOUS STIRRED TANK FRO M REF. [1]) reactions: us stirred tank reactor (CSTR) for the Let us consider an isothermal continuo
Exam ple 29.1
The rates for each of the reactions are reactor:
c in the given in terms of the concentrations cA, 8
eling equations for the reactor where kl' k2 are rate constants. The mod de;. V
= F(cA f- c;.) - Vk 1c;. c;.(O) = c;.0
-;g des
V
take the form:
dt
= F(c81 - c8 ) + V(k 1cA
- ~c8 )
c8 (0)
= c80
are the of A and B respectively and cAo- c80 Here CAf, c8! are the feed concentrations ible to poss is it that ose supp Now at start-up. initial concentrations in the reactor sure mea ot cann we but B continuously on-line, mea sure the concentration of species to wish we Thus e. valu its know to is important the concentration of A even though it using a state estimator. estimate the concentration of species A F, cAf' noting that c81 = 0 and the quantities V, by tions equa the lify simp First let us rs: mete para less nsion dime the e defin can k1, k2 are all constant. Then we 2V
k 1V
Da 1
=F ; CA
xl
CAref
Da2
k =r:
l=[ i
en
u; ~
X2=-
CArtf
t'V
CAref
1068
SPECIAL CONTROL TOPICS
where cAre[ is the nominal initial charge of species A to the reactor. With these definitions the model becomes: dxl
dt
= -(1 +Da 1)x1 +u
If we have a continuous measurement of species B, then our sensor model is: y(t) = xp) + 77(1)
where 77(t) is the measurement error. Then going to Eqs. (29.4) and (29.5) for our state estimator equation, we obtain:
To illustrate the performance of this state estimator, numerical computations were carried out for the parameters Da 1 = 3.0, Da 2 = 1.0, tt= 2.0, true initial conditions x 10 = 1.0, x20 = 0; and inlet feed concentration u = 0. The state estimator was given erroneous initial conditions 1 = 0.85, ; 2 = 0.15. The values of k 11 • k 21 were determined from Kalman filter equations [1). Gaussian measurement errors having zero mean and standard deviation 0' = 0.05 were simulated by a random number generator and added to the x 2 values to produce the sensor signals, y(t). The state estimatesx1, 2 are shown in Figure 29.3 along with the "true" values x 1, Xz- Note how the unmeasured and measured states both converge to the "true" values with time.
x
x
LO
_ "true" states - - state estimates 0.5
LO
t__..
Figure 29.3.
Comparison of "true" states and state estimator estimates for continuous data. 77(1) is the actual measurement error used (0'= 0.05).
CHAP 29 SELECTED TOPICS IN ADVANCED PROCESS CONTROL
Figure 29.4.
1069
Feedback control loop in which a state estimator is used to provide "measurements" to the controller.
29.1.3 Use of State Estimation in Feedback Control Now that we understand how to generate state estimates, we may use these estimates in a feedback control loop. For example, suppose that we have the chemical reactor of the last section and we wish to configure a control loop to keep the concentration of species A at its set-point. However, since we cannot measure species A directly, we must use a state estimator to provide these "measurements" to the controller. The control loop is shown in Figure 29.4. Obviously one must have great confidence in the state estimator in order to implement such a control scheme. However, plant experience has shown that with good models, careful instrument calibration and regular control system maintenance, state estimators can be successfully used to improve product quality and control system performance.
29.2
CONTROL IN mE FACE OF PROCESS VARIABILITY AND PLANT/MODEL MISMATCH -ROBUST CONTROLLER DESIGN
One of the issues that has always arisen in control system design is how sensitive the controlled system is to expected variations in the process parameters. For example, if we have tuned a PI controller for a particular loop, how will this control loop behave if the process gain changes by 20% or the time delay changes by 30%? This is a question of process sensitivity and the robustness of the control system design. New design methods have been developed for addressing this issue, and we shall discuss some of them in this section.
29.2.1
SISO Sensitivity and Robust Controller Design
Let us begin our discussion with SISO systems because we can readily illustrate the important concepts. To have a specific example in mind, suppose that we consider the conventional control loop shown in Figure 29.5. If we were to apply classical tuning of a proportional controller to the loop, we would construct a Bode plot of g(s) and determine the process gain at the crossover frequency me (i.e., when the phase lag is 180°), as shown in Figure 29.6. The critical process gain takes the value A, and a proportional controller gain of Kcu = 1/A, would bring the control loop to the verge of instability. Thus, depending on the
SPECIAL CONTROL TOPICS
1070
Figure 29.5.
A convent ional SISO control loop.
phase margin and particu lar controller tuning strategy selected, we use various e, Ziegler-Nichols exampl For gain. tional propor the select to gain margin rules tional gain of propor a that tuning would call for a gain margin of 2, so rules involve tuning our of many that Note K, = 1/2A is recomm ended. le and then unstab go to process the causes which gain ler control detel'll'Uning the timeThese safety. of reduci ng the gain by some factor to provid e a margin ff trade-o a always is there that fact simple the tested design rules recognize (usually lity instabi to ess robustn and ance, perform system l betwee n contro contro l system termed · robust stability). Higher contro ller gains to favor that robustness so y stabilit for safety of margin perform ance always reduce the proper balance the seek always must one 29.7, Figure in shown As decreases. betwee n these two factors for the proble m at hand. one would like In order to determine the best margin of safety for robustness, se the true Suppo g(s). in lity variabi ed expect and ainty uncert to know the process can be represented exactly by: g(s)
Kctzs
= 1:S +
1
(29.9)
a, which can then we have a process gain K, a time consta nt 1', and a time delay I in Figure g(s) I curve entire the vary. Variations in process gain K will cause consta nt 't time the in ns variatio factor; same the 29.6 to move up or down by mediu m at vary to g(s) L and cies frequen high at vary to I will cause I g(s) I g(s) I on effect no have will frequencies; finally, variations in the time delay a tes illustra This cies. frequen higher at vary to and will cause the curve L g(s) Note ters. parame s proces the in ons variati to plot Bode the the sensiti vity of frequency around that loop stabilit y is threate ned only by changes at higher ined by process determ be to tends y stabilit robust the crossover frequency. Thus r function in transfe the for that means This cies. frequen variabi lity at higher , while critical most are gain Eq. (29.9), variations in the time delay and process ant import so variations in the time constant are not ms with There are two practic al situati ons that lead to proble arise as a and tch misma robustness. Both could be said to lead to plant/m odel consequence of the following situations: no longer 1. Proces s Variab ility: in which an otherwise adequa te model itself has process the e matche s the observ ed plant behavi or becaus les examp two are fouling ger exchan heat and change d. Catalyst decay lity. variabi process such ying underl nisms of mecha an inadeq uate 2. Inade quate Mode ling: in which the model is e the model becaus be may This or. behavi plant true of represe ntation case, for the is (as n imatio approx poor entally fundam a is re structu ar nonline y severel a nt represe example, when a linear model is used to ters parame model the of es estimat poor of e becaus process), or it may be in an otherwise adequa te model structure.
1071
L ADV ANC ED PRO CES S CON TRO CHA P 29 SELECTED TOPICS IN
Lg(s )
~~~
~~~~~~~~~~
-180~~~~~~
.. Figu re 29.6.
Bode plot for g(s).
Process Var iab ility model, a r e>.:periment, or the use of a goo d Sup pose that thro ugh trial and erro service. into put and ility stab st robu of gin loop is tune d wel l with a certain mar y. In bilit insta rs in the process to thre aten Then, ove r time, some chan ge occu hea t y, deca lyst cata ., (e.g the process gain y this case, the chan ges cou ld be in dela time the in or t, stan con in the time me exch ang er surf ace fouling, etc.), assu us let flowrate, etc.) In this case (change in feed pipe diameter, feed are t but that the vari atio ns AK, Aa ican gnif insi that vari atio ns in -r are nds bou the by n give on regi y fuzz g(s) lies in a significant so that the true process on the transfer function (K + AK)e- (a+ t.a).< (29.10) g(s) =
-rs + 1
er sign, er variations 11K, Aa can be of eith We will assu me that the para met and vary between: $;IlK~
-IMmaxl
-l11amaxl ~
Figu re 29.7.
IMmaxl
11a $;
jl1amaxl
control syste m perf orm ance and The ever-present balance between stability in control system design.
robu st
SPECIAL CONTROL TOPICS
1072
The bounds of this fuzzy reqion can be seen in Figure 29.6. The curve for I g(s) I while the curve for L g(s) has possible has possible variabilit y± I t.Kmax Note the large potential variabilit y in the variabilit y ± ro t.amax crossover frequency roc and correspon ding critical gain, 1/ A, caused by the variability in K and a. It would be useful to have a transfer function for the bounds on this region of variability. Let us call this transfer function the variability factor, lf/(s). Then we could say that the true process, g(s), varies from the nominal process, gm(s),
I
I.
by:
I,
g(s) = gm(s)~s)
(29.11)
-- K +Kt.K e -!J.as "''s) .,..~
(29.12)
Hence for our example here:
Thus, the nominal process when LlK =t.a = 0 has a variability factor of unity. We mar view the Bode plot of this variability factor for b.K = ± t.Kmax ,, Aa = ± b.amax to see how it influences the frequency response of the nominal process, gm(s) (cf. Figure 29.8). If one were to convert the Bode plot in Figure 29.6 into a Nyquist diagram (see Figure 29.9), then we can see the uncertainty in gain and phase angle in the same graph. Notice that the variability factor lf/(s) causes the possible domain of g(s) to appear as wedge-sh aped regions of uncertain ty around gm(jro) when there is variability in only K and a. For example, see the wedge formed around the point g(jro1) as a result of the uncertain ty in the actual values of L g(jro1)
I
I
lljl (s) I
A.K,.,
1.0
-&.,..,.
I (II
(II
Figure 29.8.
Bode plot for the variability factor V'(s) given by Eq. (29.12); liK lia= ±2, K = r= a= 5.
=± 1,
CHAP 29 SELECTED TOPICS IN ADVANCED PROCESS CONTROL
-3
-2
1073
-1
Real Axis
Figure 29.9.
Nyquist diagram for g(s), gm(s) given by Eqs. (29.11) and (29.12).
by and I g(jOJ1) I. The envelop e of all these regions is the band given phase g involvin rules K ± AKmax fihO~ in the figure. Notice that tuning margin and gain II,l'argin are designed to make sure that no part of the possible domain of g(s) encompa sses the point -1 in the Nyquist diagram . The gain to margin rules ensure that the gain variations K ± AKmax do not cause g(s) that ensure hand other the on rules margin phase the OJ,; include -1 when OJ = not variation s in phase lag due to time-delay variabili ty (a± Aamax )OJ do how see can one Thus figure. the in cause g(s) to encompa ss -1 for some m < m, of PID controller tuning rules address the question of robust stability in the face process variations.
I
I
I
I
I
I
Inadequate Modeling of Suppose that a linear process model, gm(s), was develop ed from a set are there r, Howeve data. test pulse or test step experim ental data such as to always inadequ acies in such experim ental data sets. This could be due noise ment measure or unmode led nonlinea rities, poor experim ental design, problem s that prevent the model from represen ting all features of the process. part of In normal process identification experim ents it is the high-fre quency /model process the is This the model which is usually in greatest error. mismatc h problem . In this situation, the robust stability of a control system depends on how sensitive the control system design is to model inadequacy. In practice, one finds that the variability factor lfl(s) resulting from process identification experim ents has the general shape shown in Figure 29.10. Note is that the variabili ty factor is close to unity until the failure frequency m1 to ate inadequ are data ental reached. Above this frequency, the experim identify reliable model paramete rs. If this failure frequenc y is well beyond for the crossover frequency m1 >>m,, then obviously the model will be adequate to dose is y frequenc failure the if , conventi onal control system design; however stability serious to lead may model the using designed OJc, then control systems problems. We shall discuss some possible remedies for this problem below.
SPECIAL CONTROL TOPICS
1074 .
l'l'(s)l
1.0
/ ~====::::---1 \
Ill--
L'l'(s)
variability factor, ~s), resulti ng from Figure 29.10. Typical frequency depen dence of the . Here m1 repres ents the failure ments experi n ficatio proces s identi inadequate. frequency beyon d which the identification experiments are
imes useful to neglect For the analysis of more complex systems, it is somet Figut e 29.9 and to in the specific shape of the variability region g(jof) d by: define ((J)) I radi11S with 4 approximate them with a circular disk (29.13)
f.<
pass the exact shape Thus we choooe the radius t») large enough to encom in Figures 29.9 and shown g(s) in ions variat ted g(jt»). Note that ~r the expec d be relatively small at low 29.10, the radius 14 ((J)) as a fraction of gm shoul ncies. Hence: freque frequencies and increase dramatically at larger
I I
-l ((J)) m
T.c
ro> = .,.........::..:......;....,. -
(29.14)
lcmU(J)>I
Q)
-
passing disk size I 4 { ro) as a fraction of Figure 29.11. Frequency dependence of the encom the nominal process lgm(jm} I.
1075
TROL IN ADVANCED PROCESS CON CHAP 29 SELECTED TOPICS
ure 29.11. Note endent behavior sho wn in Fig factor IJI(jm), should have the frequency-dep ility iab var tha t in terms of the 14) (29. and 13) (29. . Eqs from · Tm(m) mu st satisfy: (29.15)
Ro bu st Controller Design and of mo del effects of process var iab ility s a controller With this bac kgr oun d on the ign des one how r position to conside ure 29.7, we uncertainty, we are now in a Fig m ance and robust stability. Fro rov e the imp THAT provides good perform to n gai pro por tion al con trol ler factor one is recall· tha t inc rea sin g the re the r, eve How ity. ess to instabil trol con d goo performance reduces the robustn lly, trade-off somewhat. Genera y. onl cies tha t allows us to improve this uen freq low at hig h controller gains near gain ler sys tem performance requires trol con the by d ine ility is determ Conversely, the question of stab response of our we could shape the frequency if s, Thu cy. uen and a sharp the crossover freq cies uen h controller gains at low freq controller so as to provide hig d, we could che roa app is cy the crossover frequen as gain ler trol con in ion uct red our controller. ance and robust stability from the n guarantee both high perform 2. 29.1 curved balance beam in Figure This would correspond to the ler for the system trol con PI ust rob a ign des To illustrate this po~t, let us (29.12). Let us Eq. by en giv iability factor 'l'(s) var ·the h wit 9) (29. Eq. by en giv the controller so ent weighting function W(s) in intr odu ce a frequency-depend tha t: (29.16)
uency in order to the controller gain at high freq uce red to ) W(s like uld wo We !J.a. This means wo rst parameter variations !J.K, gua ran tee stability und er the in Figure 29.13, so a Bode plot of the type sho wn tha t ideally W(s) should have frequencies. h phase angle increases at hig tha t the gain drops off and the ~
II ~
~ ~ ~
Po.
s
s
~ "ll
.!!
8
f.
~
~
j
$
il
5.
!
em performance and rob ust balance between control syst Fig ure 29.12. Altering the hav e the pro per freq uen cy to ler con trol stab ility by des igni ng the dependence.
1076
SPECIAL CONTROL TOPICS
·~"I 1.0
.,
'"· · I
.,
~I
j
Figur e 29.13. Ideal form of contr oller weighting to achieve high perfo rman ce at low frequencies and robus t stability at high frequ encies.
Ther e are diffi culti es in impl emen ting this ideal cont rolle r weig hting because simple forms such as:
efi.,s W(s) = (-r,.s
+ l)"
(29.17) whos e Bode plots have the desir ed shap e, are not causal. How ever , there are convenient appr oxim ation s such as: (29.1&a)
or W(s) =
( -r s + 1)" + K (I - e P..s) w w
(29.18b)
whic h may be used. Let us illustrate with a particular numerical exam 10
1o-•+ -or-rT rnrnt- --r-rn rnrd- r-r.,.. ,.mnt 10-·
--r-rT Jrrm!
10
to•
Figur e 29.14. Bode plots for the control weightings W(s) given by Eq. (29.19).
ple.
l
CHAP 29 SELECTED TOPICS IN ADVANCED PROCESS CONTROL Example 29.2
1077
ROBUST CONTROLLER DESIGN FOR A PROCESS WITH TIME DELAYS.
Let us suppose that K = 5, t = 5, and a = 5 in the process given by Eq. (29 .9). If we allow AK = ±1 and Lia = ±2, then the process variability has already been plotted in Figures 29.6, 29.8, and 29.9. It can be shown that if we choose W(s) to be of the form: W: · 5s+l (s) = 5 s + I + 2(1 - e- 5 •)
(29.19)
then W(s) will have the frequency response shown in Figure 29.14. This is similar to the ideal form in Figure 29.13 for frequencies w < 0.5. The overall control scheme for the robust controller is represented in Figure 29.15. The actual process is given by the model g (s) combined with the variability factor as in Eq. (29.11). In a similar way, the controller is a combination of a PI controller and the input weighting function W(s) as in Eq. (29.16). For the W(s) chosen (Eq. (29.19)), the Bode plot shown in Figure 29.14 is not as effective in decreasing amplitude and increasing phase lag at high frequencies as the idealized form in Figure 29.13. Nevertheless, as we shall see, it does decrease the process gain and phase lag in the region close to the critical frequency that aids both performance and stability. To see the loop shaping effect, the nominal (lfl(s) = 1) ueffective" process Km(s) W(s) seen by the PI controller has the Bode plot shown in Figure 29.16 for W(s) =1 and for W(s) give11 by Eq. (29.17). Note how much the amplitude ratio has decreased at llJc. In fact; 'the gain margin has gone from 0.45 for the uncompensated plant to 1.18 for the compensated,plant. This should allow the PI controller gain to be much lower for the same performance or the gain to be increased to improve performance with no cieterioration in robust stability. To illustrate the control system performance the closed-loop step response of the nominal plant, Eq. (29.9), with uncompensated PI controller (W(s) = 1) tuned optimally to minimize Integral Time Squared Error (ITSE) for Km
- -
r
--
r
Process g(s) -- - -
-
I
Nominal
I
Process y
L
- -
- -
-
-
_]
L
-
-
-
_I
Figure 29.15. Block diagram for a robust controller Kc(s) consisting of a PI controller and input weighting, W(s). The process consists of the nominal process, Km(s), and the variability factor 'l'(s).
SPECIAL CONTROL TOPICS
1078 10
:
~
IW(s )gm( s)l
W (s)g0
lgm (s)l
1
gm (s)
---- - ••••
~ ··········z;_ .....____.,
: 'I
1
10-3
~~~---------.
0~--------~~~~== LW( s)g111 (s)
~
------r----~~~
Lgm (s)
~00~--------~r----
~
J 1
-loop frequency pensated and uncompensated open Figu re 29.16. Bode plots of the com ). gm(s W(s) response of the nominal plot,
Nominal
1.25 •
1.00
0.75 y
0.50
0.26
0.00 0
10
20
30
40
50
er PI control onse for the process in Eq. (29.9) und Figu re 29.17. Closed~loop step resp tuned to be r rolle cont ed mpensat with no parameter variations: (a) unco pensated com (b) 6); 0.12 = 1/r 4, 1 ITSE optimal for W(s) = l(K, = 0.18 given by is W(s) n response whe controller tuned "manually" for good . Eq. (29.19)(Kc = 0.45, l/r1 = 0.06)
1079
CONTROL IN ADVANCED PROCESS CHAP 29 SELECTED TOPICS AK= l,ll a.= 2
2.0
1.5
y
1.0
0.5
50
40
30
20
10
0
t
control cess in Eq. (29.9) und er PI p step response for the pro ures -loo Fig sed in Clo as 8. ing 29.1 tun 2; ure = Fig ons AK = 1, Aa wit h par am ete r var iati 29.17(a) and (b).
AK a-l ,lla =-2
y
0
10
20
t
30
40
50
9) und er PI control wit h onse of the process in Eq. (29. resp step p -loo sed Clo 9. ing as in Fig ure s Figure 29.1 AK = -1, Aa = -2; tun par am ete r var iati ons 29.17(a) and (b).
1080
SPECIAL CONTROL TOPICS 10 0
:a
I W (s)gm (s) I
P2
"""'
~ ~"" 10-1 10--1
0 LW(s)gm (s)
...."' ~
. g::
"'.,
-200
-400 10--1 (I)
Figure 29.20. Open-loop frequency response of the compensated plant for various process parameter variations. For parameter variations that cause the plant to be less stable (M< = 1, 11a =2), the two closed-loop step responses are shown in Figure 29.18. By contrast, parameter variations that cause the plant to be more sluggish (M< =-1, 11a =-2) are applied and the two closed-loop responses shown in Figure 29.19. Observe that the performance of the compensated PI controller is noticeably better for all parameter variations. Thus the compensator chosen has indeed improved both performance and robust stability when the process gain varies by 20% and the process time delay changes by 40%. The reason can be seen from the Bode plots of the compensated process shown in Figure 29.20. In addition to the fact that the amplitude ratio is reduced by the compensator close to the critical frequency me there is another valuable feature. Close to the critical frequency me there is some significant variation in phase lag with parameter variations, but the amplitude ratio is relatively flat. Thus there is robust stability for reasonably large process parameter variations. Although there are many possible choices for weighting functions W(s) and optimization methods can be used to find good ones, the choice we made in Eq. (29.19) was found by using the equations for a Smith Predictor linked to a proportional controller. This turns out to have the very nice properties noted above.
There is a broad literature describing various approaches for synthesis of robust controllers for specific types of set-point changes or disturbances and for specific forms of model nncertainty, Ym( m). Those wishing more details can begin with Refs. [4-7].
29.2.2 MIMO Robust Controller Design When we consider the design of multiple input/multiple output (MIMO) systems, it is much more difficult to characterize the uncertainty in the process
CHAP 29 SELECTED TOPICS IN ADVANCED PROCESS CONTROL
1081
and to design robust controllers. To understand the reasons for this, consider the 2 x 2 MIMO system with process model: y = G(s)u
where
y
= [~:]'
G(s)
=
u =
e-a,.,s]
K II e-«u•
K 12
[ -r11 s + I
'rl2S
K2Je-«:.•• -r21 s + I
[:J
+ I (29.20)
K22e-«tt' 'rzzs + I
As compared with the SISO system in Eq. (29.9), where everything could be represented by a Bode or Nyquist plot, this MIMO system has four elements gr (s), each one with a different frequency response. Thus, in order to design a controller G c (as shown in Figure 29.21) that will achieve good performance and robust stability for this system, more complex methods must be applied. In keeping with the concept of shaping the frequency response of the control Gc- Doyle and Stein [5] proposed the use of the singular values to construct a Bode-like plot for a MIMO system. Recall from Chapter 22 and Appendix D that the singular values of a matrix may be defined as the positive square root of the eigenvalues of the product G 8 G where G 8 is the complex conjugate transpose of G -termed the ~ermitian of G. That is:
MIMO
a; (s)
= --J .it;(GH(s)G(s)); i = I, 2, •••, N
(29.21)
Thus there are N singular values for an N x N matrix, and the largest and smallest of the singular values provide norms for the matrix G(s): a,_(s) = II G(s) 11 2
(29.22) (29.23)
-~I Figure 29.21.
.. y
A conventional block diagram for a MIMO control system.
SPECIAL CONTROL TOPICS
1082
Figure 29.22.
Use of O"mJn. O"max to construct a fuzz
y "Bode plot " for IIYII/IIuU 2.
riable "Amplitude Ratios" for this multiva It can therefore be shown that the system may be bounded by: (29.24) s of the vectors y and u. Here IIYlb, llulh denote the Lz norm Figure e the top half of a Bode plot (see wer it if as 4) If we plot Eq. (29.2 een betw Ratio" of the MIMO system lies 29.22), we see that the "Am plit ude the as b /llul view the frequency response of llylh a O"max and O'min so that we can out ked wor e hav [5] . Doyle and Stein shad ed region between O'max and amin the of onse resp cy uen freq the that shapes design procedure for MIMO systems s at uct GG c has sufficiently high gain prod the that ee rant gua y controller Gc to uenc freq high and sufficiently low gains at low frequency for good performance do To d. ecte exP. range of model uncertainty to guarantee robust stability for the Figure ular value plot for II(GG,))II (see sing a ct stru this, Doyle and Stein con t be mus cies uerl freq low at amin er design, 29.23). To achieve the proper controll ll. sma ntly frequencies mus t be sufficie st sufficiently large, and ama x at high robu for nt icie that this desi gn is suff Alth oug h Doyle and Stein prov e
y "Bode plot" for valu es of GG , to cons truc t a fuzz Figu re 29.23. Use of the sing ular IIG G,D2 •
NTROL IN ADVANCED PROCESS CO CHAP 29 SELECTED TOPICS
1083
roximations tha t are vative because of all the app stability, it is often too conser poo rer performance e giv n designs tha t ofte ler trol con in ults res this ma de blem the larg er the usly, this is even more of a pro tha n one would want. Obvio e of this, the ratio of ama x ami n for G(s). Becaus fuzzy region between ama x and and amin for G(s), i.e.: x
(29.25)
O"ma
I(=--
(Jmin
of the sensitivity of , is often used as a measure know.n as the condition number control structures le sib fact, when evaluating pos the process to uncertainty. In eliminate highly to le iab var use d as a screening be can K s, tem sys O MIM for ue analysis that sensitive structures. servatism of the singular val To overcome some of the con for example, en, (ev ) over all elements of G(s y poorly), ver s averages the model uncertainty hap per (s) g very precisely and 12 wn kno be ht mig (s) g en wh 11 " and the concept of of the "structured nncertainty Doyle [6, 7] proposed the use as oth er ideas are Designs using these as well "str uct ure d singular values." ately, the cur ren t tun and Zafiriou [4]. Unfor discussed in detail by Morari l pro duc e rather stil s tem design for MIMO sys ler trol con ust rob for s che approa mance is not the best. cases so that controller perfor ny ma in ults res e ativ serv con ng sha rpe r analysis ains to be don e in ord er to bri Thus, important research rem of stru ctu re can ails lag information and more det to the problem so that phase . be used in the controller design
29.3
OF IL ES - DISTRIBUTED CONTROL OF SPATIAL PR S ER PARAMETER CONTROLL
we have assumed control problems to this point, of ion uss disc our t hou oug Thr ns of time. However, asurements were only fnnctio that all states, inputs, and me iables are functions ms for which the process var there are process control proble urgical processing tall as· ~e. For example, in me of position in space as well s and sheets there slab tal or oth er types of me ; um min alu l, stee for ons operati in the metal. Figure pro per temperature profile are furnaces for creating the ire d lon git udi nal one furnace in wh ich a des 29. 24 sho ws a typical 3-z tion of the firing ula imposed on the slab by manip ons the slab is temperature profile is to be rati ope e the furnace. In som of es zon ual ivid ind the in rates g through the furnace it is a continuous strip movin motionless, and in some cases opt ica l pyr om ete r t the re are con tin uou s wit h vel oci ty v. No te tha ace. Figure 29.25 furn at five fixed positions in the measurements of temperature ual tem per atu re act an and temperature profile nt poi setired des the tes illustra d controller. e through application of a goo profile history tha t could aris s wo uld be in the ces pro the for del riate mo For this problem, the approp ations of the form: form of partial differential equ ox(z. t)
iJt
= a
o2x(z. t) + v ox(z az. t) + {Jx(z, t) + u(z. t) ; 0 az2
s: z :;; L
(29.26)
with boundary conditions: 0
(29.27)
SPECIAL CONTROL TOPICS
1084 3 Furnace Heating Zones
11111111111111.1111111111111.11111111111111
~ 5 Optical Temperature Sensors
Figure 29.24. Heating of a metal slab in a 3-zone furnace having 5 temperature sensors.
Here a is a thermal conduction parameter, u.is the velocity of the slab through the furnace, f3 represents the convective cooling heat transfer coefficient, and u(z,t) is the radiant heat flux from the three zones of the furnace. The boundary conditions Eq. (29.27) indicate that there is negligible heat transfer from the ends of the slab. The measurements are taken at five points Z; where the optical sensors are located:
= x(z;*• t)
Y,
= 1, 2, 3, 4, 5
Physical System
(29.28)
t-0.20
1.0 Temp Sensors
0.8
!
I
r r r1 Metal Slab
tc 0.05
~
...
jlllllllllllllll lll
0.6
... .. -------· ..• .
Heating Zones
y(z,t)
.
0.4
-·
t=0.02. --_............... t=O.Ol
0.2
___ ... .....
-
.......... --------·-......... -... -··
0.0 0.0
0.2
0.4
0.6
0.8
1.0
z/L
Figure 29.25. Control of the temperature profile of a slab moving through the 3-zone furnace. Start-up from a cold slab.
CHAP 29 SELECTED TOPICS IN ADVANCED PROCESS CONTROL
1085
Note that u(z,t) has the special form: u 1(t); 0
u(z,t)
;::
~z~~
< 2L u2(t); b.< 3- z - 3 < u3(t); 2L 3 -
z <-
(29.29)
L
where we can manipul ate u1{t), u 2(t), u 3(t). The task of the distribut ed paramet er controlle r could be posed in two ways: 1. The simple- minded approac h: Forget that there are spatial profiles and simply design a MIMO controller that adjusts u 1, u 2, u 3 in order to bring the five measure ments, Y;(t), to their set-poin t. This approac h will work for some problems, but will not in general give the best results because so much information about the spatial structure is neglected.
t
II
2. The more enlighte ned approach : Plan to use all the informat ion at hand to design a distributed parameter controller that will control spatial profiles. There are several ways in which this mjly be done (see Ref. [1] for a discussio n). If the model equation and paramet ers (such as Eqs. (29.26- 29.29)) are known, then the first principle s PDE model may be used to design the controll er (see Ref. [1] for some example s). Alternat ively, if the model equation s are unknow n, then a spatially distribut ed transfer function model of the form:
(where
1086
29.4
SPECIAL CONTROL TOPICS
CONTROL IN A CHANGING ECONOMIC ENVIRON MENT- ON-LINE OPTIMIZATION
So far in our discussions of controt we have focused on the individual control loops of a multivariable process unit. In practice, of course, the objective of any process operation is to make a profit for the organization. This requires many levels of process scheduling, optimization, and control. To illustrate this in the context of an oil refining company, let us consider Figure 29.26. The activities at the different levels are as follows: Level 1: At the highest level, the parameters and goals of a multirefinery operation are defined. This could include the expected total production of each product (gasoline, jet fuel, home heating oil, etc.) based on market forecasts, the availability of a variety of crude oils, the capacity of each refinery, operating cost parameters, etc. Level II: At the second level, mid- and long-term (e.g., 1 month, 3 month, 6 month, 1 year) economic scheduling is carried out using optimization and optimal scheduling algorithms. This scheduling uses geographic market
Figure 29.26. The multilevel nature of process operations for an oil refining company (adapted from Ref. [10]).
OCESS CONTROL PICS IN ADVANCED PR CHAP 29 SELECTED TO
1087
ete rs, cru de oil inery models, cost pa ram ref ns, tio dic pre er ath the refineries for varying forecasts, we on schedules for each of cti du pro set to ., etc s, edules wo uld call for shipment . For example, these sch ure fut the o he ati ng oil int ds rio pe time summer an d higher ho me the in es rat on cti du facture of these higher gasoline pro ally allocating the manu tim op ile wh r nte wi the an op tim al pro du cti on production in refineries. In this way, us rio va the g on am eters suc h as cru de oil pro du cts generated. Because param pa ram ete rs change is ry ine ref h eac for le schedu refinery ma rke t forecasts, an d prices an d availability, weekly to mo nth ly basis. a on d ise rev les have to be frequently, these schedu led ste ad y-s tat e an d one begins to use detai el, lev s thi At : III l Le ve ind ivi du al process units optimize the operation of to s del mo s ces pro ic dynam ents coming from Level ll. an d production requirem rs ete am par ject to catalyst the on ed bas alytic reforming un its sub cat , ills est pip t uc rod ized so as to meet Thus, mu ltip ng operations are all optim cki cra tic aly cat d an , This pro du ces the setdeactivation the mo st efficient way. in s ule ed sch on cti du the pro le. it during the scheduling cyc points for each process un s I-m , Level IV is tion completed in Level iza tim op the th Wi : Level IV cess control schemes histicated advanced pro sop re mo el the nt me ple use d to im -points to the lower lev troL These provide set con e abl ari ltiv mu ing includ loops. an d maintained. al control loops are tun ed du ivi ind el, lev s thi At l system or through Level V: d via a distributed contro nte me ple im be y ma ps These loo It is at this level that an l controller hardware. ita dig or log ana al du ind ivi ial. trol system design is essent understanding of SISO con VII) consists of the ace wi th the pla nt (Level erf int al fin e Th : VI ors suc h as valves, Level cess variables an d actuat pro g rin asu me for nts ins tru me ou t control action. motors, etc., for carrying only discussed cess operation, we ha ve pro of e tur pic ll era ov From this have presented a few this book; however, we in pth de y an in VI d Levels V an tha t wo uld no rm all y be cess control strategies pro ed nc va ad of les examp off-line an d implemented at Level IV. t at Level m can be do ne ou d rie car n tio iza tim alternatively can be The process op IV from time to time, or vel Le to tes da up e vid da ys for significant mu st only pro a timescale of ho urs to th wi e tim l rea in d timization methods are im ple me nte IV. A wide variety of op vel Le , to s int -po set in es chang of nonlinear programming gramming, various forms h pro suc ear of lin vey ing sur lud A inc ds. d, use n metho an d dynamic optimizatio pe ak seeking algorithms, ]. -13 Refs. [11 olve mixed Linear, methods ma yb e found in ks of Level ll often inv tas ng uli ed sch c mi no The eco nted off-line an d the n ms. These are impleme gra Pro ar ntrol ne nli No d an Integer, . These ap pe ar to the co eters to the lower levels st ram mu pa n ted sig da de up e tem vid sys pro t the control tha es nc ba tur dis ic" sys tem as "econom found in Refs. [13-14]. iew of these ideas may be accommodate. An overv
I
1088
29.5
SPECIAL CONTROL TOPICS
CON TRO L IN THE FACE OF COM PON ENT FAI LUR EABNORMALITY DETECTION, ALARM INTE RPR ETA TION , AND CRISIS MAN AGE MEN T
In all of our discu ssion s of contr ol syste m desig n, we have assum ed that all senso rs work ed, actua tors did not fail, and electr ic powe r outag es did not cause pump s and compressors to stop, i.e., we designed our control systems for norm al opera tion. Howe ver, an increasingly impo rtant aspect of control syste m desig n is to desig n contr ol strategies for contingencies such as senso r failure, sticking valve s, burnt -out moto rs, electric powe r outag es, and other possi ble but rare occurrences. The princ ipal goals of such crisis control schemes are to maint ain safe process opera tion, to minimize the risk of envir onme ntal pollu tion, to take short -term meas ures to mitig ate the effects of the failure, and to ident ify those steps necessary to restor e norm al operation. From the accounts of badly mana ged crises in the past, we are all aware of the catas troph ic consequences of a major explo sion and fire, and the impac t of the releas e of toxic or pollu ting materials into the environment. Howe ver, even a mino r event not felt outsid e the process unit can dama ge a process so severely as to put it out of opera tion for many months. Thus prope r response to only one such event can save lives, jobs, and the econo mic healt h of the organ izatio n. Clear ly, crisis contr ol schem es are an impo rtant part of process contr ol syste m desig n. Some aspects of a crisis control scheme woul d be:
1. Detec tion of Abno rmal Opera tion: Some types of abnor mal opera tion do not produ ce alarm s and are difficult to detec t. For exam ple, a seriou s reacto r explo sion could be traced to the fact that the heat excha nge surface had becom e fouled by solid mater ial over the cours e of a few hours. The feedback controller on the coolant flowrate had comp ensat ed for this for sever al hours befor e the coola nt flowr ate reach ed its maxi mum and the reacto r temp eratu re began to rise rapid ly. By this time it was too late to take any corre ctive action , and the reacto r explo ded. Had the control schem e been desig ned to detec t abnor mally high-coolant flowrates and raise an alarm, the probl em could have been recognized in time and the explosion preve nted. 2. Inter preta tion of Alarm Signa ls: When there is a crisis, there are usual ly many alarm s that go off casca ding one upon the other . For example, a reacto r coolant pump failure causes high reactor tempe rature alarm s, high react or press ure alarm s, low reacto r feedr ate alarm s, reacto r feedpump failure alarm s, cooling jacke t press ure alarm s, etc. If the plant opera tors have seen this alarm struct ure before, then they can ident ify the prim ary sourc e of the probl em and take the prope r corrective action. Howe ver, if the situat ion is new or too complex, the opera tors migh t attack a symp tom of the probl em rathe r than the source. For exam ple they migh t try to restar t the reactor feedrate pump instea d of deali ng with the coola nt pump failur e. Thus, an advis ory syste m to help opera tors interp ret the alarm s signals woul d be a key part of a crisis contr ol system.
CHAP 29 SELECTED TOPICS IN ADVANCED PROCESS CONTROL
1089
3. Recommendation and Implementation of Control Measures: After the source of the problem has been identified, there is the need to offer the operators recommendations of possible countermeasures and even take some actions automatically. For example, in our runaway reactor, an automatic countermeasure might be to inject a large dose of catalyst poison or reaction inhibitor into the reactor to stop the chemical reaction. Often this must be done quickly to prevent an explosion. Thus the control scheme could implement this countermeasure automatically above a specified reactor temperature. Obviously, the design and implementation of such crisis control schemes require a good knowledge of the process so as to be able to determine all possible combinations of failures, their detection and alarm structure, and the appropriate countermeasures in each case. The development of the methodology and software for these control systems is a subject of current research and development in the field of Artificial Intelligence. See Refs. [15, 16] for an overview.
29.6
SOME EMERGING TECHNOLOGIES FOR ADVANCED PROCESS CONTROL
Although there have been powerful tools at hand for applying advanced process control for more than 30 years, the pace of technology is advancing at an accelerating rate, especially in terms of bringing new developments quickly from the research laboratory into industrial practice. In this section, we will briefly introduce some recent and emerging technological developments and indicate how they are being applied in process control.
29.6.1 Dynamic Flowsheet Simulation For more than 20 years, students in process design courses and engineers involved in process design have had as a major tool steady-state simulation programs such as FLOWTRAN™, ASPEN™, PROCESS™, HYSIM™, etc. This has removed the drudgery of routine simulation calculations and allowed process designers to test potential designs through flowsheet simulation. Unfortunately, until recently, there was nothing comparable available for dynamic flowsheet simulation. Individual companies have built ad hoc dynamic flowsheet simulators that have been applied to specific processes to great benefit, but nothing very general was commercially available. More recently, several new packages for dynamic flowsheet simulation have become available. These are listed in Table 29.1 together with some of their key attributes. Undoubtedly in the years ahead, others will join this list. Such dynamic simulation packages are essential tools for configuring control schemes that span several units in a flowsheet (e.g., measuring a variable in Unit 3 and manipulating a variable in Unit 1}, for studying the propagation of upsets and disturbances through a process, for testing control strategies for transition between product grades in a multiproduct plant, and for designing crisis control schemes for handling alarm situations. Clearly dynamic flowsheet simulation will play an important role in the design of future control systems. A survey of current simulators and some important issues in dynamic simulation may be found in Ref. [17].
SPECIAL CONTROL TOPICS
1090
TABLE29.1 SOM E DYN AMI C FLOWSHEET SIMU LAT ION PACKAGES Packa ge Name DIVA
HYSYS
PROTISS
POLYRED
SPEEDUP
Princ ipal Featu res
Contad
• Preconfigured modules include distill ation columns, packe d bed reacto rs, CSTR, etc. • Successful applic ations in real time for opera tor traini ng
Prof. E. D. Gilles Instit ut fur Systemdynarnik und Regelungstechnik Unive rsitat Stuttg art Pfaffe nwald ring 9 70550 Stuttg art Germ any
• Preconfigured modules include most unit operations • In use by a numb er of companies
Hyptr otech Ltd. 300 Hypro tech Centre 1110 Centr e Street North Calgary, Alber ta T2E 2R2 Cana da
• Preconfigured modu les include many unit opera tions • In use by a numb er of companies
Simul ation Sciences Inc. 601 S. Valencia Avenue Brea, CA 92261 U.S.A .
• Preconfigured modu les include all polym erizat ion kineti cs and most types of reactors, distill ation, flash separ ation, etc. • Hand les solids and partic le size distrib ution for many types of polym erizat ion processes • Successfully comp ared to exper iment al data from many types of polym erizat ion processes ·• In use by a numb er of companies
Prof. W. H. Ray Chem ical Engin eering DeptUnive rsity of Wisconsin 1415 Johns on Drive Madis on, WI 53706 U.S.A .
• Equat ions entere d intera ctivel y • Results comp iled into executable code • In use by a numb er of companies
AspenTech Inc. Ten Canal Park Cambridge, MA 02141 U.S.A .
< ',·
IN ADVANCED PROCESS CHAP 29 SELECTED TOPICS
1091
CONTROL
e 29.6.2 Artificial Intelligenc
optimistic discussion of media attention, hype, and ion los exp an n bee has re 1he logies of the future. ) regarding its role in techno of Artificial Intelligence (AI ch and development in there has been serious resear process control is However, at the same time ate of application. Fortun ly, ds fiel ny ma s ard tow ed AI direct D work so that there n a large amount of recent R& bee has re the ere wh a are one trol problems. We shall of AI methods to process con are many new applications discuss some of these below.
Expert Systems of expert systems. An a of AI applications is that Perhaps the mo st mature are ien dly interface, a r-fr use pro gra m wit h a er put com a is tem sys exp ert to allow the program to ic system. These combine log a and e, bas dge wle kno stio ns bas ed on the ation, and to ans we r que pro vid e advice and inform the system. Today ical rules preprogrammed into knowledge database and log development tools ul erf figured using pow con idly rap be can s tem In process control, expert sys wledge base and the rules. kno the of n atio cre the aid which control system design d to provide assistance in use ng bei are s tem sys ert exp , ala rm handling, failure guiding dat a interpretation (cf. Ref. [20]), as well as in , 21, 22]). ion in real time (cf. Refs. [15 detection, and controller act
Neural Ne tw or ks Based on the idea of is tha t of neural networks. A quite different area of AI rk of inp ut nodes, wo net neural network is a the in, bra an hum the emulating to each nod e in the es wit h weighted inp uts nod put out and , ers lay hid den ing the out put from 9(a}). The equation represent hid den layers (see Figure 29.2 a hid den layer is: (29.30) i = l, 2, ... , Y· = f j =I wIf ) I
(I .u.)
n
usually has a ver y the "squashing" function and led cal is .) nf( ctio fun the Here simple form such as: (29.31) fl.x) = 1 + e-ax ts. Through the use of The wii are the inp ut weigh sketched in Figure 29.27(b). ma y model any thi ng es in each hid den layer, one an appropriate num ber of nod equations that ma y ing del mo trast to normal con In . rks wo net ral neu se with the net wo rk models hav e form wit h parameters, neural aic ebr alg c cifi spe a e olv inv re of the network and e simply specifies the structu no fixed functional form. On antage that if on e adv as parameters. This has the del may be bet ter then fits the inp ut weights mo the re, ral network structu neu l era gen ly ent fici suf a s choose ~ were to be use d as tional algebraic functional fo ven con a if n tha es cas e som in ura l networks have bee n ] for further details. Ne a model. See Refs. [23-24 st successful has been in ma ny ways. One of the mo (d. Ref. [24]). applied to process control in m on-line instrumentation fro a dat er oth and ctra spe interpreting
1092
SPECIAL CONTROL TOPICS
------~F---~~Yn
input nodes
hidden
output nodes
layer
(b)
1.0
f{x)
ot:::::=:===:::___ _ _ __ X
Figure 29.27.
(a) A neural network; (b) a typical squashing function.
Other applicati ons include dynamic modeling, the use of neural network s as controllers, and in-process fault diagnosis (d. Refs. [25-29]). Fortunately, there is a wide variety of software available to configur e neural nets, so that applications are easy to develop.
Learning Algorit hms Perhaps the most exciting aspect of AI methods is the ability of these compute r program s to learn. Learning (or "training ") is a fundame ntal part of a neural net. The net is presente d with data sets and "trained " by adjustin g the weights w ij so as to fit the training data set. Then the net is prepared to recogniz e the characte ristics of new input data and provide appropr iate outputs. For example, it is possible to train a neural net to recognize a set of IR spectra for specific compoun ds and their mixtures. Then the net could be asked to identify the composition of an unknow n mixture of these compou nds from a new IR spectra (see Ref. [24]). There are many different approaches to training neural nets, but the central feature is that the net is trained to interpre t informat ion in a certain way. Expert systems can also be endowe d with learning capabilities. For example, an expert system for control system design could be configured with some basic knowled ge and a fundame ntal set of rules for designin g control systems. However, by "training" the expert system on known successful control system designs, it is possible to add information to the knowledge base and add new rules for decision making. Furthermore, in cases where more than one possible design rule might apply, it is possible to adjust the weights for the most successful rules in order to improve the success of the expert system. Again there are many different algorithms for allowing the expert system to learn. See Refs. [22, 30] for a discussion of these.
CHAP 29 SELECTED TOPICS IN ADVANCED PROCESS CONTROL
1093
29.6.3 Parallel Computing Although process control systems have frequently involved distributed computer architecture with many different CPU's throughout the plant assigned different process control tasks, the communication links have generally required relatively infrequent information transfer. In addition, the tasks allocated to the different CPU's have been well defined and selfcontained. More recently, there have been rapid new developments in the field of parallel computing for simple tasks. There are several commercial machines available that allow a network of very fast CPU chips in a single box to be under the control of a single program. The computer architecture can take various forms (see Figure 29.28), but the ideas are the same: the computations for a particular task are divided among the many CPUs operating in parallel and then combined for the final answer. The goal is to increase the speed of the computations by efficient allocation of the subtasks among the various CPU's. In the process control context, this has the possibility of bringing much higher performance computers into the control room so that all the imaginable realtime tasks can be carried out even for processes with very fast dynamics. With the advent of sophisticated expert systems, real-time dynamic process simulation, state estimation, parameter estimation, etc., as part of the control system, large increases in real-time computing power are essential. The natural division of these real-time tasks makes a parallel architecture particularly attractive. For a projection into the future of real-time parallel computing, see Ref. [31}.
Interconnection Network
(a)
Memory
Memory
I I
Interconnection Network
(b)
Figure 29.28. Parallel computing architecture [29]. Two multiprocessor structures: (a) all memory and 1/0 are remote and shared; (b) all memory and 1/0 are local and private.
SPECfAL CONTRO L TOPICS
1094
29.7
CONC LUDIN G REMARKS
ng brief In this chapter we have only scratch ed the surface in providi that the hoped is It introdu ctions to some areas of advanc ed process control. Will and s method these of l potentia the by reader will be intrigue d and excited through or study ual individ through either subject the probe deeper into be done in pursuin g advanc ed study in process control. There is still much to for the fare as s problem research d applica tions, and there are many unsolve creative mind. REFERENCES AND SUGGESTED FURTHER READI NG Ray, W. H., Advanced Process Control, Butterworth, Boston (1989) Bryson, A. E. andY. C. Ho, Applied Optimal Control, Halsted Press, (1976) New York Jazwinski, A. H., Stochastic Processes and Filtering Theory, Academic Press, (1970) Englewood Cliffs, 4. Morari, M. and E. Zafiriou, Robust Process Control, Prentice-Hall, NJ (1989) Concept s for a 5. Doyle, J. C. and G. Stein, "Multiv ariable Feedbac k Design: (1981) 4 AC-26, Control, Auto. Trans. Classica l/Modem Synthesis," IEEE nty," lEE Proc., 6. Doyle, J. C., "Analysis of Control Systems with Structur ed Uncertai Part' D, 129, 242 (1982) IEEE Conf. on 7. Doyle, J. C., "Structured Uncertainty in Control System Design," Process (1985) ale Decision & Control, Ft. Lauderd ted Parameter 8. Gay, D. H. and W. H. Ray, "Identification of Control Linear Distribu s," in Control Function Singular ed Determin entally Experim of Use the Systems through of Distributed Parameter Systems (H.E. Rauch, Ed.), Pergamon (1987) Method s for 9. Gay, D. H. and W. H. Ray, "Applic ation of Singula r Function ," in Model Systems er Paramet ted Distribu Identification and Model-based Control of (1989) n Pergamo Ed.), , McAvoy T.J. and Arkun (Y. , Workshop Based Control ental Control 10. Garcia, C. E. and D.M. Prett, "Design Methodology Based on the Fundam Prett and M. M. (D. , Workshop Control Process Shell The in tion," Formula Problem Morari, Ed.), Butterworths, Boston (1987) " Advances in 11. Biegler, L. T., "Optimization Strategies for Complex Process Models,
1.
2. 3.
CitE. 18, (1992) Day, San Francisco 12. Hillier, F. T. and G.J. Lieberman, Operations Research, Holden(1974) ms for Process 13. Grossm ann, 1., "MINLP Optimiz ation Strategi es and Algorith 89, 105 (1989) DFOCAP Design, Process aided rCompute of ons Foundati s," Synthesi and Process ng, Scheduli , Planning of on 14. Lasdon, L. S. and T. E. Baker, "The Integrati Elsevier, 579 Ed.), , McAvoy J. T. Morari, (M. III, Control Process Cltemical in " Control, (1986) Control," in 15. Moore, R. L. and M. A. Kramer, "Expert System in On-line Process (1986) 839 Elsevier, Ed.), , McAvoy J. T. ri, (M.Mora Chemical Process Control III, on in Chemical 16. Proceedings IFAC Symposium on On-Line Fault Detection and Supervisi Process Industries, Newark, April 1992 and Future 17. Marqua rdt, W., "Dynamic Process Stimula tion - Recent Progress AIChE Ed.), Ray, H. W. and Arkun (Y. IV, Control Process Chemical Challenges," in (1991) "ing," in Cltemical 18. Taylor, J. H., "Expert Systems for Computer-aided Control Engineei (1986) 807 Elsevier, Ed.), , Process Control III, (M. Morari and T.J. McAvoy Expert System," in 19. Niida, K. and T. Umeda, "Process Control System Synthesis by an 869 (1986) Elsevier, Ed.), , McAvoy T.J. and Chemical Process Control III, (M. Morari
S CONTROL
OCES PICS IN ADVANCED PR cHAP 29 SELECTED TO
1095
stem t System for Control Sy ON SY DE X- An Exper "C y, Ra H. W. d an 20. Smith, R E. d Process , "T ow ard s Im pro ve Design," (in press) nta gu e, an d M.T.Tham l Process ica Mo em A. Ch G. in ," J., ms A. , ste 21. Morris owledge-based Sy Kn d an ms rith go Al (1991) Supervision W.H. Ray, Ed.), AIChE egration of Control W, (Y. Ar ku n and ard s the Intelligent Controller - Formal Int (Y. Arkun ow IV, "T ol G., ntr s, 22. Stephanopoulo in Chemical Process Co y, eor Th ol ntr Co th Pattern Recognition wi hE (1991) d Adoption," in and W. H. Ray, Ed.), AIC iew, Pro gra mm ing , an erv Ov ks or tw Ne ral Ray, Ed.), AIChE (1991) 23. Hopfield, J., "N eu an d Data IV, (Y. Ar ku n an d W. H. Chemical Process Control en , "A pp lic ati on of Ne ura l Ne ts to Sensors AlChE Ed Ow A. an d W. H. Ray, .), 24. Piovoso, M. an d Control IV, (Y. Ar ku n s ces Pro l ica em Ch in Analysis," Control of namic Modelling an d {1991) se of Neural Nets for Dy ''U , voy A Me J. T. d an (1990) 25. Bhat, N. ms," Comp. Ch.E., 14,573 cess Mo del ing Ap pro ach an d its Chemical Process Syste ed Pro bas tal Da "A oy, Av J. Mc and Control of Chemica 26. Qi n, S. J. an d T. C Symposium Dynamics 92), 321 (1992) IFA 3rd s ing ced Pro s," (DYCORD Application lumns and Batch Processes nlinear Ne ura l Ne tw ork Process Reactors, Distillation Co No nt icie Eff g tin rea "C W. H. Ray, Process Control, 3 (1993) ers Based on 27. Scott, G. M. an d del Interpretation," J. del-based Controll Models tha t Allow Mo "Experiences wi th Mo y, Ra H. W. d an M. ntrol, 3 (1993) 28. Scott, G. s Models," f. Process Co cess Fa ult Neural Ne tw ork Proces Me tho do log y for Pro "A Ne ura l Ne tw ork .), AIChE Ed V., y, an, Ra ani H. ram W. d ub 29. Ve nk ats W, (Y. Ar ku n an ol ntr Co s ces Pro l ica em Diagnosis," in Ch nchine Learning, Marge (1991) an d T. M. Mitchell, Ma l, nel rbo Ca G. J. S., 30. Michalski, R w York (1983) dison-Wesley (1989) Kaufman Publishers, Ne mputer Architecture, Ad Co nce ma for Per h Hig 31. Stone, H. S.,
CH AP TE R
30 PR OC ESS CO NT RO L SYS TEM SYN TH ESI S - SO ME CA SE STU DIE S tation s on specific tools usefu l Thus far in this book, we have focused our presen ss mode ls, and desig ning proce ng creati for under stand ing proce ss dynam ics, nted relatively simpl e prese have we er, chapt each In proce ss contro l system s. could be applie d. sion discus exam ples illustr ating how the specific tool under control synthesis the of ent treatm no Howe ver, up to this point there has been contro l system l actua in steps the of all which in probl em for real processes, analys is and priate the appro desig n and imple menta tion are carrie d out, and m. It is proble real a g solvin in sly desig n tools are broug ht to bear simultaneou system l contro of ssion discu a such de provi the goal of this final chapt er to with, and dealt be must s detail cal practi cting distra the synth esis, where all ller powe r, and proce ss real practi cal diffic ulties with measu remen ts, contro and imple ment a contro l n desig to order in under stand ing must be surmo unted system which meets the goals of the project. life has its own uniqu e Since every control system synth esis probl em in real y differ ent contr ol widel have which s studie featur es, we prese nt four case concl ude with a discus sion of system goals and synth esis difficulties. We then order to have guide lines on how to chara cteriz e indus trial contro l proble ms in 1hrou gh this mosai c we em. probl ular select ing appro priate tools for a partic great variet y of tools the of value the ciate appre hope that the reade r will of a proce ss contro l red requi learne d earlie r and the versatility and creati vity . engin eer in apply ing these tools successfully
30.1
THE CONTROL OF DISTILLATION COLUMNS
, distill ation colum ns are Because of the impor tance of chemi cal separ ations these units, the contro l of For try. indus ss widel y used in the chemical proce on variat ions has a large colum n energ y consu mptio n and produ ct conce ntrati enviro nmen tal impac t and y, influence on the economics, ultima te produ ct qualit contro l system s for e rmanc perfo highg of the entire proce ss. Thus, havin distill ation colum ns is very impor tant. 10Q7
SPECIAL CONTROL TOPICs
1098
Figure 3o.l.
A generic multicomponent, multiproduct distillation column.
yed in industry The sheer numb er and variety of distillation columns emplo system design l contro of y variet e infinit an t mean s that there is almos of problems types the problems. In the next few sections we shall try to descn be be applied. can that ies strateg that arise and discuss some of the controller depth of and th bread the er, howev brief; Necessarily the discussion must be in this ure literat ous enorm the lting consu by r furthe this topic can be explored 22]. field. Some good starting points are Refs. [2, 6, 11, 12, 16,
30.1.1 Goals of Distillation Control System Design columns and economic Because there are so many different types of distillation contro l system to be situati ons, one must first clearly define the goal of the have, consider the designed. To illustrate some of the possible goals one might n may be multicolum The 30.1. generic distillation column shown in Figure have auxiliary may and points off drawcomp onent with variou s produ ct profile. rature tempe d desire the e achiev to order heater s or coolers in s it bance distur of Depen ding on the purpo se of the colum n, the types the of mics econo the and , experiences, the requirements for produ ct purity in ted indica system l contro the for goals nt operation, one would have differe what follows: 1. Single-Product Stream Columns .
the overhead If the column has only one produ ct stream - for example, s could be stream ct produ other the then which must meet tight specifications, s. In cation specifi loose very with cts produ or feed material to downstream units ead overh the se only this case the control proble m is relatively simple becau All ility. variab ize minim composition control loop needs to be tuned tightly to n colum from g arisin s bance other loops are able to tolera te the distur here. well work y usuall ds metho interactions. Simple SISO control
CASE STUDIES CHAP 30 CONTROL SYSTEM
1099
ns st me et tigh t pro duc t stre am s tha t mu le ltip mu are re the en Wh ble. With strong problem is truly multivaria specifications, then the control usually the case, then erent pro duc t streams, as is interactions between the diff to me et all of the ed ble controllers are req uir more sophisticated multivaria apters 20-22, 27, Ch of as ide simultaneously. The ons cati cifi spe am stre t duc pro case. and 29 become important in this
um 2. Multiproduct Stream Col
ely hig h (e.g., 3. High-Purity Columns d in any stream are not extrem When pro duc t purities require centrations and the dels relating the pro duc t con below 95%), the n linear mo one or more of the work welL However, wh en manipulated variables often n and dyn am ic gai te n the ste ady -sta the h, hig y ver are s itie pur pro duc t the composition become highly nonlinear as del mo s ces pro the in rs ete param because nonlinear ates the control system design varies. This greatly complic models must be used. Energy Minimization Designs hav ing large y low tem per atu re col um ns For som e ver y high or ver uld include wo les inate the economics. Examp rigeration (ref throughputs, energy costs dom tion g costs) or cryogenic sep ara pro duc t et me cru de oil fractionators (heatin to be uld the control system wo of l goa the e cas this In costs). accomplished by zin g ene rgy costs. This is imi min ile wh s ion cat cifi spe necessary control and coolant while taking the minimizing the use of ste am ity. actions to achieve product pur
4.
Frequent Grade Changes 5. Disturbance Rejection versus uence on the typ e trol system have a strong infl The expected tasks of the con y one set of products le, if the column is to make onl of design selected. For examp its desired steadynge al and wo uld rarely cha from one type of feed materi ed only to reject ign des be control system wo uld the n the nt, poi ng rati ope e stat er hand, sup pos e afflict the process. On the oth whatever disturbances might products every two to make five different sets of tha t the column is designed ry month. In this eve als erent types of feed materi weeks or to handle eight diff a wide range of r ove rate be designed to ope st mu e em sch trol con the case from one operating ve quickly and economically operating conditions and to mo "off-spec" product. avoid significant amounts of poi nt to another in order to controller des ign nt on can require very differe These two extremes of operati stra teg ies .
j
I
rks 6. Distillation Column Netwo ltip le dis till atio n n of a process req uir es mu trai n atio ific pur Often the es the columns cas er oth In wn in Figure 30.2. sho as h suc rk wo net a in ns colum s. In such cases ich greatly increases interaction wh ted gra inte rgy ene be y ma cascade controllers y wish to have multivariable the control system designer ma ariable system. work as a hierarchical multiv which control the entire net been me ntio ned . not e ations which hav situ er oth , rse cou of , are There ed in setting the en a taste of the issues involv giv n bee has der rea the , ver Howe control system. goals of a distillation column
,.
.'I
1100
SPECIAL CONTROL TOPics Cl and lighter
C2
Low-purity ethylene
High-pu rity ethylene
C3
and heavier ClColw nn
Figure 30..2.
C2/C3 Splitter
C2 Olefin/Paraflin Splitter
An example of a purification train for light hydroc arbons
.
30.1.2 Mod eling Issues As we saw from the distillation column models discus sed in Sections 12.3 and 13.5, one may choose to represent the column by a tray-to-tray dynamic model or, alternatively, an approximate input /outp ut mode l. The rigorous tray-totray mode l requires the solution of (N + 2) (M - 1) differential equations for a colum n havin g N trays and M chemical species. Thus for N =80 and M =4 the mode l would have 246 differential equations. For the secon d approach, the input / outpu t models make use of low-order linear mode ls (sometimes with time delays) to repres ent the dynamic relationships betwe en process input s (feed conditions, recycle ratio, bottoms boilup, sidestream draws , etc.) and process outpu ts (prod uct stream composition, tempe rature s on specific trays, etc.). These input /outpu t models are usually the most useful for control system design. If the input /outp ut data show significant nonlin earities, then nonlinear input /outp ut models may be used; alternatively, a set of linear models {one for each produ ct grade) may be appropriate.
30.1.3 Cont rol Syste m Desi gn Strategies The choice of control system design strategies depen ds strongly on the goals of the control system and the dynamic problems being addressed. The influence of control system goals was discussed in Section 30.1.1 . Let us indicate the most common dynamic difficulties challenging the contro l system designer: 1. The process has signif icant time delays. This usuall y results from the highorder tray-t o-tray dynam ics, which appea r exper iment ally as low-o rder dynam ics with time delays. In additi on there may be some analysis delay. The most common solution is to implement some type of time-delay compensator in the feedback control scheme. 2. The proce ss has signif icant loop interactions . This arises from the fact that withd rawin g more or less product, or addin g or subtra cting energy from the column, usually affects all produ ct stream compositio ns simultaneously. The solution in this case is to implement some type of interaction compensator or other multivariable controller design.
CHAP 30 CONTROL SYSTEM CASE STUDIES
1101
3. The process does not have good sensors. It is a common problem that not all stream composition measurements are available on-line; in some cases samples must be sent to the laboratory so that there are long delays in receiving measurement results. The usual solution is to implement some type of inferential control scheme or one based on a composition estimator. The inferential control scheme involves cascade control in which a secondary online measurement (such as the temperature on a particular tray) is used as the output being controlled in the inner cascade loop. The outer cascade loop then resets the tray temperature set-point based on the slower stream composition measurements. An alternative scheme involves estimating the composition from other secondary measurements and the process model. Both strategies have been successful in practice. 4. The process is nonlinear. As indicated above, distillation columns may exhibit nonlinear behavior if high purity is required or if there are many widely differing operating steady states corresponding to diffe~ent product grades or different feed materials. In this case, the solution often can be as simple as incorporating a gain schedule into the controller or designing separate linear controllers for each region of operation. When the nonlinearities involve saturation of some of the manipulated variables, then override or other more complex control strategies may be required.
D ul
Overhead Product Yt
FC E
Sidestream Product
Steam
Bottoms Product
Figure 30.3.
A 19-tray distillation column for the separation of ethanol and water.
I~ :
SPECIAL CONTROL TOPICS
1102
30.1.4 An Example ghtf orw ard disti llati on cont rol syste As an illus trati on of a relat ively strai scale distillation colu mn used for thm desi gn problem, cons ider the 19-tray pilot d in Section 13.5. The column, sho wn; sepa ratio n of etha nol/ wate r discusse for m, and bott oms prod ucts ; how ever , Figu re 30.3, has over head , side strea ms botto and in controlling the over head simplicity here, we are only interested the is it use beca nt prod uct is imp orta prod ucts . Close control of the over head the in ent cont nol etha the of e control feed to othe r high er puri ty columns, whil -up clean nol etha final a to rial mate bott oms is imp orta nt beca use it is feed dela ys, the over head com posi tion is colu mn. In orde r to avoi d analysis eter . Unf ortu nate ly, the bott oms mea sure d with an on-l ine dens itom the dens itom eter has larg e relative com posi tion is so low in etha nol that an inferential control scheme mus t and errors. In this case the sensor is useless, cont ent of the bott oms is accurately be used . It is know n that the etha nol om tray (Tray #19) of the column as corr elate d to the temp eratu re of the bott eratu re is a surr ogat e for the bottoms show n in Figure 30.4. Thus Tray 19 temp com posi tion variable. ng data from the distillation column As discussed in Section 13.5, puls e testi of the form leads to a linear transfer function mod el y(s) = G(s) u(s)
whe re
y
ethanol in overhead] [YI(s)J = [mole fractiontemp erat ure- oc
u =
[u1(s)J [
=
Tray 19
Y2(s)
u2(s)
=
ret1ux flow rate - gpm reboiler steam pressure - psig
J
100
§ Steady state
"'
~
...... "'" ~a-
90
~~
80 0
1.0
2.0
3.0
Botto ms Comp ositio n [%eth anol]
Figu re 30.4.
ms composition and Tray #19 The correlation between colu mn botto temperature.
1103
CAS E STU DIE S CHAP 30 CO NTR OL SYS TEM
G(s )
[ :=
0.66e-2.6s 6.1 s + 1
-0.0049e-• 9.0 6s + 1
-34 .7e -9·2s
0.8 7 (ll. 6s + 1) e-s (3.8 9s + 1) (l8 .8s -t- I)
8.1 5s + 1
] (30.2)
re det ails of the e constants in min ute s. Mo with the time delays and tim Refs. [8, 14]. trol system design are given in process, its modeling, and con both multivariable er this column mu st consid The control system design for ed model-based anc adv an time delays; thu s le ltip mu as l wel as s tion interac par ed wit h sim ple lied to the column and com app be l wil e em sch trol con Figure 30.5, is the ic control strategy, sho wn in multiloop PI control. The bas re G(s) represents He unnaike and Jerome [8, 14]. controller of the multidelay c2_mpensator of Og PI al gon dia del, and Gc(s) a mo s ces pro the ) G(s s, ces the pro form (30.3)
s. The matrix D is ign parameters for the proces The matrices Gr and D are des ays to some of the del apter 22 where we mu st add the sam e as discussed in Ch the pro ced ure ing low Fol control system. our in ty sali cau ure ens to inp uts that outlined in Chapter 22, we see D = [
~ e-~.6s
(30.4) ]
matrix G r is is causal. The des ign of the tem sys trol con the t tha ure will ens . For example, if we ltidelay compensator desired determined by the type of mu choose Gr to be the e performance, then we wo uld (see Ref. [8] for wish to ensure the best possibl out d st delay in each row factore same as GD wit h the smalle the result is design details). In this case, 0.66 ] -0.0049 9.0 6s + 1 6.1 s + I (30.5) [ 1) + 6s 6.6s (ll. .7e7 -34 0.8 GF = (3.8 9s + l) (18 .8s + l) 5s+ l 8.1
Fig ure 30.5.
The multidelay compensator
stru ctur e for the distillation colu
mn.
II ; ' ',.,
1104 0.700
Yt
SPECIAL CONTROL TOPICS ''i
\
0.675
0.650 0
I
I
20
I
40
I
60
80
100
93.0
(\.
I\
92.5
:
Y2 92.0
\
.....J'c:. ....'\_ /·'.··..
91.5
I
0
20
40
60
80
100
TIME (MIN )
Fig ure 30.6.
Res pon se of dist illat ion colu mn to a set- poin t cha nge of -Q.035 mole fraction etha nol in ove rhea d composition. ··-·-··- set- poin ts;- - PI control on ly; -- PI with multidelay compensator of Jerome [8].
Imp lem ent atio n of this design can lead to extremely goo d resu lts as sho wn by the sim ulat ion tests sho wn in Figure 30.6. Earlier ver sion s of the mu ltid elay com pen sato r wer e test ed experimentally on the actu al dist illa tion col um n of Figure 30.3 and sho wed excellent results com par ed to PI control. For example, if we let D == I (no dela ys add ed) and let Gp be the sam e as G wit h all del ays removed, the n the dela ys are completely rem ove d from the clo sed -loo p cha ract eris tic equ atio n of the sys tem . An
z
0.75 1
0
0.60 -1-- -r--- ,..-rr ---r- -rj -20 0 20
n=_ ~
.-
·--- -·-.. e: .._.. ,· .....
c
--.--r,-.--...,.,-..-.,,.--...,--l 40
60
80
100
TIME(hUN)
Fig ure 30.7.
Experimental response to a setpoint change in overhead composi tion. -w ith the delay compensato r; ....... with multiloop PI only.
·:,
CHAP 30 CONTROL SYSTEM CASE STUDIES
1105
example of the experimental results when a set-point change is made in the overhead composition is shown in Figure 30.7. Further experimental results may be found in Ref. [14]. In this example we were required to deal with process time delays, loop interactions, and the lack of an on-line sensor for bottoms composition. However, these difficulties were overcome, and the final control system design gave excellent results [8, 14]. We have only scratched the surface here in discussing distillation control problems. There are promising new strategies (e.g., [9, 26]) and a host of special situations which we have not been able to mention. However, the references cited here provide a starting point for further study.
30.2
THE CONTROL OF CATALYTIC PACKED BED REACTORS
An important class of chemical processes is the catalytic packed bed reactor shown schematically in Figure 30.8. The catalyst is packed in a tube which may be heated or cooled with a fluid-filled jacket. With a strongly exothermic or endothermic reaction, there may be significant radial as well as axial temperature and concentration gradients. Alternatively, if the tube is adiabatic, then there may be only axial gradients. Sometimes the tube can be made sufficiently thin that radial gradients can be neglected. Since most catalytic processes in industry have multistep kinetics, close control of · temperature and composition in the packed bed is essential to achieve the desired reactant conversion and selectivity. Note that packed bed processes are an example of distributed-parameter systems discussed in Chapter 29 and have the special feature that the inputs, states, and outputs can depend on spatial position as well as time. The full control theory for this class of processes is beyond the scope of this book; thus the designs we will discuss here are limited to some of the simpler strategies which are used in practice. For more advanced control system designs, the reader is referred to the references cited in Chapter 29.
30.2.1 Adiabatic Reactors There are many catalytic packed bed reactors which are operated adiabatically as shown in Figure 30.9. Examples include multistage adiabatic reactors for exothermic reactions (e.g., partial oxidation of S02 to 503 or ammonia synthesis) with interstage cooling. Alternatively, for endothermic reactions, multistage adiabatic reactors having interstage heating are used (e.g., for naptha reforming). In each case the process loses most of its distributed character because the manipulated variables are the feed temperatures (T;,, T;,, T;3 in Figure 30.9) while the outputs are the exit temperatures (T11 T2, T3 in Figure 30.9) and compositions from each adiabatic bed. None of these variables depend on spatial position. Thus adiabatic packed bed reactors, while important, are relatively straightforward to control by conventional control system synthesis and will not be discussed here.
SPECIAL CONTR OL TOPICS
1106
(a)
• T (z,r,t)
'1 (z,r,t)
(b)
T C;
Tr
z_..,..
0
Figure 30.8.
L
The catalytic packed bed reactor: a) schematic; b) axial profiles measur ed at the tube centerline.
Heat exchange
Heat exchange
zT
·.
I • •
I
,· .....
~ • ••
·- ... _____ :T2 ·--- ..... __ :Tl ' I • Exothermic reactor
·-. ·------- --- Ta
z
0
Figure 30.9.
Multistage adiabatic reactors.
L
1107
CHAP 30 CONTROL SYSTEM CASE STUDIES
30.2.2 Wall-Cooled Reactors c reactors such as show n More difficult to control are the jacketed, nonadiabati ntration of the desired product in in Figure 30.8. H one considers c2 to be the conce a maxi mum because of side gh Figure 30.8(b), one sees that c2 passes throu res. Thus by adjusting the eratu temp r highe by reactions that are accelerated bed temperature profile one feed and jacket conditions to control the packed input variables are T1, cif, The might maximize the yield of c2 from the reactor. ents must come from urem meas t outpu F, T, (all functions of time only) while the issues for wallrtant impo Some bed. the n withi or sensors placed at the exit cooled packed bed reactors are erature, and press ure • The control of spati al concentration, temp profiles ct • The maximization of the yield of a desired produ the few available of ment place best the • The deart h of sensors and sensors e of manipulated variables, Some possible design methodologies for the choic of a control strategy, etc., ion select the on, locati the choice of sensors and their section. will become clear through the case study of the next
tor for the 30.2.3 Control of a Jacketed Packed Bed Reachyde alde Form to l hano Met of Con vers ion catalytic packed bed reactors is
The conversion of methanol to formaldehyde in rmance engineering polym ers an important step in the production of high-perfo
ss operates near atmospheric based on formaldehyde. A widely used proce catalyst in a jacketed tubul ar oxide pressure over a molybdenum oxide /iron are of relat ively smal l tubes the or, In a plan t react react or. unded by the cooling jacket. (- 2 em) diameter and are usually in a bundle surro with excess air to form s On the surface of the catalyst, meth anol react ng factor is that the licati comp A ct. form aldeh yde, the desir ed produ monoxide via an undesirable formaldehyde may be further oxidized to carbon secondary reaction. The reactions are as follows:
I
, thus a liquid jacket for These oxidation reactions are highly exothermic ed to maximize the yield of cooling surro unds the tube wall. It is desir the temperature profile in the on t formaldehyde which is strongly depe nden nant issue. domi a is ol contr e reactor. Thus temperature profil (70 em long) with a cooling tube single a of sting consi r reacto A pilot scale tor's console schematic). opera jacket is depicted in Figure 30.10 (taken from the n (0.05 mole fraction ositio comp feed d desire Air and methanol are mixed to the of approximately 250°C. The methanol) and heated to the feed temperature is about 250°C. Under these feedrate is 1.4 g/mi n, and the jacket temperature es at the centerline of the profil n ositio conditions the bed temperature and comp 30.11. e Figur in n reactor are similar to those show
1108
SPECIAL CONTROL TOPICS Pre- heat er
Tim e= 0.2 Syst em inpu ts
Methanol Feed
Feed Temp 523.0 Meth 0.0500 Rate 1.400 Oil jack et Temp 523.0 Prod uct J
oa . c k
ie
Temp 535.9 Meth 0.0337 co 0.0508 Form 0.9156
t
Temp #7 m #7 GC
#7
535.9
o.o5os
0.9156 '---- ....;P ro
Figu re 30.10.
A pilot plan t reactor for formaldehyde
production.
As indi cate d above, the objectiv e of the control syst em is to max imize the yiel d of the inte rme diat e (for mal deh yde ) from a reac tion mec han ism of the form A ~ B ~ C. It is desired to com plet e the first reaction whi le kee ping the exte nt of the second reaction low , thus maximizing the conversion of met han ol to form alde hyd e. This may be acco mpl ishe d by mai ntai ning a tem pera ture profile in the reac tor suc h that the reaction rate is fast in the first half of the reac tor whe re reaction 1 is pred omi nan t, and the rate of reaction in the second half of the reactor is slow to min imize the effects of the second reac tion which con sum es form alde hyd e (see Figu re 30.11). The con trol of this pac ked bed reac tor to achieve max imu m form alde hyd e yield can not be acc omp lish ed by sim ply mon itor ing the form alde hyd e com pos itio n of the pro duc t stre am and usin g the max imu m yield as a setpoin t in a control loop. This stra tegy is not useful for two reasons. First, the formaldehyde outlet concentration is at or nea r its max imu m valu e at stea dy stat e, thu s any process dist urb anc es will cause neg ativ e dev iatio ns in the mea sure d variable. Second, the form alde hyd e and met han ol concentration mea sure men ts are from gas chro mat ogra phy with a 12.5 min ute time delay betw een mea surements. Since most syst em dist urb anc es are dam ped out in con side rabl y less time, the GC mea sure men ts are obviously unsatisfactory for sim ple feedback control. The app roa ch to con trol ling the pac ked bed reac tor is to mai ntai n opti miz ed ~;~teady-state tem pera ture and carbon monoxide concentrati on profiles in the reac tor (Figure 30.11), thu s indi rect ly con trol ling the form alde hyd e yield. To control these profiles, tem pera ture and carbon monoxide con centration mus t be mea sure d at select location s in the reactor. Tem pera ture mea surements may be mad e usin g ther moc oup les; carb on mon oxid e con cen trat ions are dete rmi ned usin g infr ared spec troscopy. These mea sure men ts pro vide useful out put s since values are obta ined with out delays. The nee d to mai ntai n entire profiles in the reactor usin g only a few mea sure men ts indicates the importance of carefully selecting sens or loca tion.
CHAP 30 CONTROL SYSTEM CASE STUDIES
1109
In configuring the control system, more than just the maintenanc e of the setpoints of exit variables must be considered . Rather, the effects of the control action on entire profiles must be considered , and the influence of these on the yield of formaldehy de must be understood .
The first issue involves the choice of manipulate d variables. From the available alternative s: Tf
Tc F
YmJ -
Feed temperatur e Jacket temperatur e Feedrate Methanol feed mole fraction
the best choice for inputs seem to be T, and T1 . Both feedrate F and feed compositio n Ymt affect production rate but are often constrained by upstream or downstream units. Thus we will consider them disturbance inputs. The choice of outputs must be made from the available sensors and sensor locations. For example, one might have the possibility of placing sensors at one or more of the seven positions denoted by 10 em increments along the bed (cf. Figure 30.11). Thus with the analytical instrument ation noted above, the possible outputs could be
T(z;*, t) -
Yeo
bed temperature at one of seven sensor locations CO mole fraction (from theIR) at one of seven sensor locations formaldehy de mole fraction (from the GC) at one of seven sensor locations, but with 12.5 min analysis delay PACKED BED REACTOR Temperature (l{)
800
600
0
70 Formaldehyde
1.0
0
0.5
70
co
0.4
0.2
0
70
0
70
Figure 30.11. Typical axial profiles of temperature and composition; sensors may be located at 10, 20, 30, 40, 50, 60, or 70 em along the bed.
SPECIAL CONTROL TOPICS
1110
Ym(Zj*,l:t,-12.5)
Figure 30.12.
Cascade control schemes for packed bed reactor control.
Obviousl y this set consists of 21 possible output variables which must be related to two manipula ted inputs (Tc, Tf) and two disturbances (F, Ymt>· A full analysis would require developin g 84 dynamic models between inputs and possible outputs. However, the use of engineering judgment can pare this task down to something more manageable as we see below.
Control System Synthesis A very sophistica ted control scheme for this process has been reported by Windes et aL [24, 25, 27-29]; however, here we shall discuss only the most basic control system design. Following industrial practice, we shall employ multiple cascade control strategies as shown in Figure 30.12 Note that we choose to use the cooling jacket wall temperatu re as the primary manipula ted variable. This is due to the fact that adjustmen ts in the have the following undesirab le effects: feed temperatu re
r,
• The steady-state position of the "hot-spot " Tmax moves dependin g on the value of r,. • Sensors placed downstre am from the position of T max exhibit an inverse response to changes in 1j. Thus T1 is often a secondary manipula ted variable in packed bed reactor control. l.OOr------------,
0.80
1---+ --+-- -+--- 1 300
Figure 30.13.
320
360
380
Steady-state formaldehyde yield as a function of hot spot temperature.
I
CHAP 30 CONTROL SYSTEM CASE STUDIES (a)
340 r - - - - - - - - ,
320
1111 (b)
-----;--;·-----·
265
r--------,
260
~~~-
255/ 250
T....
245 ~~. .
i --
Estimate Set-point
5
0
10
"---+---+--l
240
240L--+--~-~
15
5
0
Time(min)
Figure 30.14.
T-n Set-point
10
15
Time(min)
Experimental response of C3JICllde controller to set-point change in Tmax·
The control scheme, shown in Figure 30.12, works as follows: 1. A special controller, designed to maximize formaldehyde yield, is used to choose the desired hot-spot temperature T max (cf. Ref. [29] for one such design). The design of this controller is complicated by the fact that YfVS. Tmax has a maximum (as shown in Figure 30.13) so that a simple feedback controller cannot be used.
2. The desired Tmax value, Tmax,..' is sent to a cascade controller that has as its output, T wan,.,' the desired reactor jacket wall temperature. 3. The value ofTwall,.. is sent to a second controller whose output is the heating/ cooling power to the reactor jacket. A jacket wall temperature measurement is used to close the inner loop. (b)
(a)
350
265
340
6
'--
I
!
270
260 330 320
'
r' ..
255
'
310 /
~
250
~,"-- Tmax
- - - Estimate Set-point
240
300 0
10
20
Time(min)
Figure 30.15.
T...ul Set-point
245
30
0
10
20
30
Time(min)
Optimizing controller performance-response ofTmax and Twall·
1112
SPECIAL CONTROL TOPICs
4. The outputs from the tubular reactor are undelayed measureme nts of temperatur e and CO concentrati on (from IR) at sensor positions z(; i = 1, 2, ... These are denoted by T (z;*, t), Yeo (z;*, t). There are also measureme nts of methanol concentrati on Ym (z;*, tk - 12.5) available at discrete times tk, but with a 12.5 minute delay due to the elution time of methanol in the gas chromatog raph. The control system designer must decide the number and location of the spatial sensor points z;* to be used for each type of measureme nt.
1
I li. l '
J
1:
5. In the present design, we shall use only exit concentrati ons of Ym, Yeo every 12.5 minutes, but shall use all available temperatur e sensors sampled rapidly. The concentrati on samples will be fed to the special YF controller in order to adjust the value of Twan every 12.5 minutes. Since the time required to move from one ·~eactor steady state to another is 6-8 min, the outer loop in Figure 30.12 is basically for steady-state control.
6. The first inner loop controlling T max makes use of more frequent ! '
''
Ii
II
temperatur e profile measureme nts, and these are used to estimate T max· This can be done by auctioneeri ng control (cf. Chapter 16) or by simple polynomial interpolatio n between the measureme nts. Care must be taken not to tune this loop too tightly or it will run faster than the next inner control loop - poor practice for cascade control.
II! '1:
(a)
1
~
0
]
lF
..
0.4
r:>.
0.3
.
0.1
~r:>.
0
-~
~ 0.2
-1
~
.!!
-2
0 -3
0 -0.1
-4
-0.2 0
(b)
10 20 Time(min)
30
10
20
30
Time(min)
Methanol
1.0
0
Carbon monllllide
0.05
~., 1ii
.2 0.9 r!
0.04
~
8
)! ·I
t I
' I
iii 0.8 §
1 ""
0.7
o Data -Estimates
0.02 0
Figure 30.16.
0.03
o Data -Estimates
10
20
30
0
10
20
30
Optimizing controller performance in maximizing formaldehyd e yield.
I
CHAP 30 CONTROL SYSTEM CASE STUDIES 7.
1113
The last inner loop regulates the jacket wall temperature and is the fastest of the three loops. It is not instantaneous because of the thermal capacitance of the reactor externals and limited heating/ cooling power.
This control scheme has been applied to an experimental reactor (d. Refs. [27-29]) and has performed quite well. To illustrate, Figure 30.14 shows how T max and T wan respond to a set-point change in T max· When the special optimizing controller was added (d. Ref. [29]), Figures 30.15 and 30.16 show how the maximized yield of formaldehyde was achieved from cold startup in about 10 minutes.
30.2.4 Concluding Remarks Although we have been able to mention only some of the key issues in catalytic packed bed reactor control and provide one experimental example, it is hoped that the reader will have a glimpse of the challenges involved in designing control schemes for this class of processes. Much more can be found in the literature cited in Refs. [24, 25, 27-291 for those interested in reading further.
30.3
CONTROL OF A SOLUTION POLYMERIZATION PROCESS
The production of synthetic polymers has grown to the extent that more than 100 million metric tons per year of polymers are now produced worldwide. These products range from low-volume, high-value specialty polymers at several thousand dollars per kg, to extremely high-volume materials which Purge
Hold Tank Monomer(a)
Monomer(b)
7
'
Inhibitor (z)
l
·~~-~ ~- -~~ ·-·----- -~!
Polymer, Initiator, Transfer Agent
Figure 30.17.
Copolymerization reactor with recycle.
SPECIAL CONTROL TOPICS
1114
macr omol ecula r struc ture and the sell for arou nd one dolla r per kg. The large ly deter mine d by the kinetic are mate rial prop erties of these prod ucts eriza tion reactor. Thus a detai led mech anism and the opera tion of the polym processes is the key to the efficient unde rstan ding and close contr ol of these mers with mini mal oper ating poly red prod uctio n of high -qua lity, tailo in gaini ng this unde rstan ding and problems. One of the most impo rtant tools polym eriza tion process modeL achieving good control of the process is the for good polym eriza tion process ired The second essen tial elem ent requ rs and good process moni torin g contr ol is an adeq uate array of proce ss senso with good mode ls, to have longalgor ithms . It is extre mely difficult, even witho ut adeq uate meas urem ents ce term, high-quality control system perfo rman and good process monitoring. efficient opera tion of a process The final element in achieving the safe and control system design. good is uct, whic h yields uniform, high- quali ty prod in creat ing these three lved invo s issue the of A detai led discu ssion we shall only be able Here 18-21]. essential elements may be found in Refs. [4, rd/fe edba ck control orwa feedf a ning to discuss a particular case study of desig . ss. proce on syste m for a solution copolymerizati , consists of a conti nuou s stirre d The process of interest, show n in Figure 30.17 meth ylme thacr ylate (MM A) of on tank react or (CSTR) for the copo lyme rizati with recycle of unre acted rator sepa a to and vinyl aceta te (VA) coup led mono mer A and VA as mono mer B. mono mer and solvent. Let us denote MMA as n are given in Ref. [4]. Many of the details of this contr ol syste m desig syste m is requi red that perfo rms ol contr a that is em The basic control probl es and can quickly achieve set-p oint well in rejecting feed or recycle distu rbanc prod uct grad e to anoth er. The one from chan ges when there is a trans ition ls of the nonli near model), but it is process is nonlinear (see Ref. [4] for the detai be adeq uate for contr ol syste m thou ght that appro xima te linea r mode ls may rd contr ol to adjus t the fresh orwa feedf design. The control strate gy is to use recycle composition can be corre cted feedrates to ensur e that distu rbanc es in the
Tabl el.
Control System Desi gn Meth odolo gy
Copolymerization Process Model • •
Develop a nonli near process mode l Select a stead y-sta te opera ting poin t
Feedfon.vard Control of Recycle • •
Design feedf orwa rd controllers Evaluate distu rbanc e rejection
Feedback Control of Polymer Properties and Rate
ions Obtain process and distu rbanc e transfer funct lar value singu using ng pairi ture/ struc ol Analyze contr decomposition and relative gain array space mode l • Obtain mini mum realiz ation linea r stateinteg ration by ges chan oint set-p for • Tune PI controllers of state-space mode l on nonli near • Check set-point and distu rbanc e rejection mode l
• •
1115
CHAP 30 CONTROL SYSTEM CASE STUDIES
Figur e 30.18.
~
Gpi
Gar
Yap
Gir
Mpw
Inputs and outputs of solution polymerization
process.
es will be hand led by feedback before they enter the reactor. Othe r disturbanc gy is given in Table 1. In what control. The overall control system design strate design. follows, we will go throu gh the steps of the ted by the following procedure. selec was The stead y-sta te opera ting point prod uct quali ty contr ol are the The impo rtant react or outp ut variables for of mono mer A in the polymer (Y.p), polymer prod uctio n rate (Gpi),mole fraction react or temp eratu re (T,). The and ), weig ht avera ge mole cular weig ht (Mpw mer A (Gaf), mono mer B (Gbf), mono of or react inpu ts are the flowrate into the solve nt (G 5J), inhib itor (Gzj), the initia tor (Gif), chain trans fer agen t (G 1J), temp eratu re of the reactor feed the temp eratu re of the reactor jacket (Tj), and diagr am of Figu re 30.18. At block -loop (T rt>· Thes e are show n in the open conta ined pure solvent prehe ated startu p the reactor, separator, and hold tank l were then varie d in orde r to to 353.15 K. The inpu ts to the nonlinear mode Tabl e 2.
Steady-State Oper ating Cond ition s
Inputs
Monomer A (MMA) feedrate Monomer B (VAc) feedrate Initia tor (AIBN) feedrate Solvent (Benzene) feedrate Chai n trans fer (Acetaldehyde) feedr ate Inhib itor (m-DNB) feedr ate Reactor jacket temp eratu re Reactor feed temperature Purg e ratio
Reactor Parameters Reactor volume Reactor heat transfer area
Outputs Polymer production rate Mole fraction of A in polymer Weig ht avera ge molecular weight Reactor temp eratu re
Gaf =18 kg/h r
Gl!f=90kg/hr Gif= 0.18 kg/h r Gsr= 36 kg/h r Gtf= 2.7 kg/h r Gif=O
1j=336.15K Trt= 353.15 K ~=0.05
V,= 1m3
S,:4 .6m2
Gpi =
23.3 kg/h r
Y.P =0.56 Mpw=35,000 T, "' 353.01 K
1116
SPECIAL CONTROL TOPICS
obtain acceptable steady-state values for the output variables. The steadystate operating conditions are summarized in Table 2. Under these conditions, the reactor residence time is 9, = 6 hr and the overall reactor monomer conversion is 20%. These operating conditions ensure that the viscosity of the reaction medium remains moderate. Table 2 also indicates that the reactor feed temperature T1 is practically equal to the reactor temperature Tr , because we have chosen to simulate reactor operation with a preheated feed where the sole source of heat removal is through the jacket
30.3.1 Feedforwar d Control of Recycle In order to compensate for recycle disturbances, a feedforward controller is
designed based on measurement s of recycle monomer and solvent compositions (pt.® in Figure 30.17) and adjustment of the fresh feed (pt
30 28
.65
';:;
~
26
0.
;..~
~a. 24
-----
22
10
20
II·
30 't
I' i"
40
------ -
.55
50
Molecular Weight
I'
I•
ji
.6
.5
1:
,.H
Polymer Composition
.7
0
10
20
't
30
40
50
Reactor Temperature
360
5
358 0
~4
g 356
0 :::.
E-<~ 354
\.a :::<:
352 2 0
10
Figure 30.19.
20
't
30
40
50
10
20
't
30
40
Open-loop output variable response to a purge disturbance.
50
CHAP 30 CONTROL SYSTEM CASE STUDIES
1117
30.3.2 Feedbac k Controll er Design Recall from Figure 30.18 that there are six possible inputs. If we consider that one of these, the solvent flowrate, is determine d by the total material balance, then we have a five input/fou r output system. By creating an approxim ate linear multivariable system model from step test data, one obtains the transfer function matrix (shown in Table 3) relating the four outputs to the five inputs. In order to determine the best loop pairing, we can use two analysis me~ods presented in the earlier chapters: the relative gain array (RGA) and singular value analysis. Here we will use the RGA and the condition number, amllX/ Gmin• at steady state to suggest the best pairing for multiloop feedback control. Because scaling is importan t in evaluatin g the condition number, both the original scaling and "optimal" scaling was used. Table 5 sununarizes the results for the best pairings. Note that the RGA and condition number together favor the CBDE configuration. This would pair the productio n rate with initiator flowrate, composition with the feedrate of monomer A, molecular weight with the flow of chain transfer agent, and reactor temperatu re with jacket coolant temperature. Obviously, this pairing makes good physical sense also. Through the use of engineeri ng insight, it is possible to improve the feedback controller performance by adding ratio control. This has the effect of reducing loop interactio ns. For example, if one redefines the manipula ted variables as shown in Figure 30.21, then the process transfer function would be as shown in Table 4. Note that column A is replaced by column F corresponding to a change in feedrate of B while all other ratios are kept constant. Applying RGA and singular value analysis to the transfer function in Table 4 produces the results in Table 5. Note that the RGA and condition number associated with the pairing FBDE are now better than those for the CBDE pairing. Thus we shall choose the FBDE pairing for our final control system design. This means that we choose the total flowrate of monomer B to control productio n rate, the ratio of flowrates of monomer s A and B to control polymer composition, the ratio of chain transfer agent to monomer B flowrates to control molecular weight, and reactant coolant temperatu re to control reactor temperature. The other variables Gif/ Gbf and Gsf are kept constant. Note that while the RGA and singular value analysis led us to the loop pairing employed , a physical understan ding of the process would also suggest that this is a good pairing. ~.
api
a.,
Yap
air atr
Mp.. ProceBS
Tr
TJ
a.,
~ iG"..
Figure 30.20. Solution polymerization process with feedforward control on recycle stream.
SPECIAL CONTROL TOPICS
2118
Process
n proc ess usin g ratio uts of the solu tion poly meri zatio Figu re 30.2 1. Inpu ts and outp
control.
Inpu Process Tran sfer Function for Flow
Tab le3.
ts
I""" +-
Gbf
~"""c+.-
G~
P•
+ Yap
= [AB CD E]
M;w
Gif
Tif ._Tj-
._r;_ c
D
E
A
B
0.34063
0.49882(0.498498 + 1} 0.1242.UZ + 0.402426 + 1
0
0.849425+ 1
0.20527 0.41 95s+ l
6.459~0.899686 + 1} 0.06573982 + 0.2970& + 1
-0.41613 2412 7s+l
0.66018 1.5098s + 1
-0.29677 1.4471s+ 1
0
0.795905+1
0.29682 2544 7s+ 1
0.49084 1.54435 + 1
-0.71493 1.3517s+ 1
-0.19626 2.7110s+ 1
-4.7145 0.075213fl + 0.40?98s + 1
0
0
0
0
o.onnzsl + 0.30978s + 1
-3.7235
1.0252!0.22710s + 1}
1119
CHAP 30 CONTROL SYSTEM CASE STUDIES
Process Transfer Function for Ratio Inputs
Table4 .
r-
bf
-c+.-
(G~/Gbft
P' + Yap + Mpw
-
G+
(G if!Gbft
= [FBCD E]
(Gifl~t
- T;-
I-
-
T~ 1
F
B
c
D
E
0.98711(0.120lls + ll 0.06594851 + 0.36662 + 1
0.20527 0.41955 + 1
0.49882{0.498495 + 1} 0.124245' + 0.402425 + 1
0
6.4595(0.8996& + 12 0.065739s2 + 0.2970& + 1
0
0.66018 1.5098s+ 1
-41.296'77 1.4471s+1
0
-3.7235 0.79590s + 1
-41.16099 0.9081655 + 1
0.49084 1.5443s + 1
-41.71493 1.35~7s+ 1
-41.19626 2.7110s+ 1
0.07521~ + 0.40798s + 1
0
0
0
0
1.0252(0.22710s + 1} 0.012732s2 + 0.3097& + 1
TableS .
Structure
ABCD
Analysis of Control Structure and Input/O utput Pairings
Bestdiag (RGA)
-
ABCE ABDE ACDE CBDE FBCD
(0.28, 0.66, 0.57, 1.0) (0.72, 0.72, 1.0, 1.0) (1.95, 1.95,1.0, 1.0) (0.84, 0.84, LO, 1.0)
FBCE
(1.24, 159, 1.79, 1.0) (1.0, 1.0, 1.0, 1.0) (1.0, 1.0, LO, 1.0)
FBDE FCDE
-4.7145
-
Optimal Scaling
Orlstinal Scaling 0'-
0.0 0.09673 0.01629 0.02575 0.03765 0.0 0.1137 0.09755 0.03649
a,...!a-
.. 92.37 546.0 346.0
..
237.3 78.87 9150 245.5
a....,
0.0 0.442 0.231 0.1263 0.3142 0.0 0.2983 0.4796 0.2890
a,.../O'mln
.. 5.57 9.837 18.86 7.951
..
8.321 4.7'77 8.455
-
SPECIAL CONTROL TOPICS
1120 Feedback Controllers
Ratio Controllers
Feed forward Control
;
Figure 30.22.
It ; I,
I. i'
I,
II
I·~'
IF
Overall feedforward/ratio/feedba ck control scheme.
A block diagram of the overall control scheme is shown in Figure 30.22 where the feedback, ratio, and feedforward elements are clearly defined. The tuning parameters for the four PI controllers are given in Table 6. The performance of the control system when applied to a first principles nonlinear model of the process (cf. Ref. [4]) is shown in Figures 30.23 and 30.24. Figure 30.23 demonstrates good performance for a grade change in composition while Figure 30.24 shows the outstanding disturbance rejection capabilities for a significant step increase in inhibitor level in the feed. Thus the control scheme performs very well in simulation.
IJ· ! ~~·
'I
l
Table6. Tuning Constants for Selected Control Structure"
It•
!
:j
Manipulated
Output
1/'lj
K
ij
if; 'I
qf
c; .,
2
4
(Ga~IGtit
Y.+
2
1
(GtJIGttt ·tI
~. '(
-6
1
02
6
*Controller reset time 'C; is reported as a fraction of the reactor residence time.
CHAP 30 CONTROL SYSTEM CASE STUDIES
1121
Polymerization Rate
24.
Polymer Composition
.7
.65
~ c. 0s.
>
23.5
.55 .5
23. 0
5
10
0
20
15
5
10
15
20
~
Molecular Weight
4.
Reactor Temperature
354
:a
~
~ ;:;.353
::E1 3.
5
0
15
10
352-l--+--1'--+----11-+--+-+---1 20 10 0 5 15
20
~
~
Figure 30.23. Response of output variables to composition set-point change. Feedforward and feedback mntrol are "on:"--, output;---, set-point. Polymerization Rate
24
Polymer Composition
.6
1-----.---------
';:;'
~
><~
ti 23
.55
r! .5 -1-~1---+--1---l--+---1--+--~ 0 10 5 20 15
22 0
5
10
15
20
't
~
Molecular Weight
Reactor Temperature
:a
~ :::.
~
0 3.5
353
E-<
j
352
3. 0
5
10 ~
15
20
0
5
10
15
20
't
Figure 30.24. Response of output variables to inhibitor disturbance r =5. Feedforward and feedback control "on:"-, output;---, set-point.
SPECIAL CONTROL TOPICS
1122
It is important to realize that even though the control system evaluation carried out here involved model simulation studies, this provided the vehicle for testing a basic control strategy that later was applied successfully to several polymerization plants.
30.4
CONTROL OF AN INDUSTRIAL TERPOLYMERIZATION REACTOR
Large-scale industrial polymer reactors, like any other industrial processing units, are typically multivariable, exhibit nonlinear characteristics, and often suffer from time delays. However, there are additional unique problems associated with the control of polymer reactors, primarily because polymers are made of 1'fiJlC1'0tn01ecules of nonuniform length- hence nonuniform molecular weight- and possibly nonuniform composition (when more than one monomer is involved). Polymer properties are therefore defined in terms of distributions of chain length, molecular weight, and composition. By altering any of these fundamental properties, it is possible to alter significantly the quality of enduse performance or processing characteristic s of the polymer product. Unfortunately, these fundamental polymer properties are difficult to measure on-line; and their relationship to the end-use performance characteristics (typically available after long laboratory analysis) is not always easy to determine. Furthermore, the typical industrial polymer reactor is used to manufacture a variety of grades of the same basic product, necessitating frequent startups, shutdowns, or at least, frequent grade transitions. Thus, in addition to addressing the typical traditional process control issues, the effective industrial polymer reactor control scheme must, at the very least, also address the following issues: 1. The unavailabilit y of on-line measuremen ts (either the fundamental polymer properij.es, or the end-use performance characteristics, or both). 2. The frequent transitions, startups, and shutdowns.
The first issue is clearly critical, since it is difficult to control what cannot be measured. Thus the development of reliable on-line sensors and analyzers for polymer reactors has been rec~iving much attention (d., for example, Ref. [4], for a review). However, continuous on-line monitoring of polymer properties has not yet become a widely applicable, commercially viable option; to be effective, many real-time polymer reactor control strategies must still rely on fundamental models capable of predicting the required polymer properties online (d. Refs. [1, 5, 9]). The remainder of this section is devoted to discussing the design, implementation, and performance ~f a control system developed for an industrial polymerizatio n reactor.
30.4.1 The Process The specific process involved in this study is a large, evaporatively cooled, continuous stirred-tank reactor used to manufacture 10,000 to 25,000 lb/hr of the terpolymer P from three monomers A, B, and C in the presence of a catalyst. The same reactor is used to manufacture several different grades of_ the same
,,,,;
1123
CHAP 30 CONTROL SYSTEM CASE STUDIES
polymer P. In addition to the production rate, it is desired to maintain at specified values such product quality indicators as "melt" viscosity (a measure of the molecular weight distribution}, and polymer composition (in terms of weight %A and %Bin terpolymer). These product quality measurements are only available after approximately 30-45 min of laboratory analysis of samples taken every two hoursi but reactant composition measurements are available by chromatographic analysis every 5 min. A time delay of approximately 15 minutes is known to be associated with the chromatographic analysis. The process variables that can be manipulated to achieve the desired product quality are the three monomer feedrates, as well as solvent, chain transfer, and catalyst feedrates. The stmdard operating conditions for the reactor are such that the reactor temperature is maintained constant and cannot be used as a manipulated variable. The fundamental control problems associated with this reactor are due to the following factors: • The usual complex, nonlinear, multivariable nature of such processes. • The 15 min of analysis delay associated with measuring reactant composition. • The lack of on-line measurements of relevant product quality indicators. Thus an effective control system will involve a synthesis of the different techniques available for dealing with each of these problems, e.g., a modelbased control strategy with time-delay compensation capabilities to take care of problems 1 and 2, in conjunction with a modeling and estimation strategy to take care of problem 3. The additional considerations necessary for this specific reactor are considered in the next section. CURRENT CAMPAIGN GOALS SECOND TIER (Reactor Product Control) Production Rate and Product Properties PRODUCT CHARACTERISTICS
REACTOR CONTENTS TARGETS
- Production Rate, ·Polymer Composition Y~,o Ya, Yc
FIRST TIER (Reactor Contente Control)
J
:··i.Mr:a··: : Rx Feed Flow
I
Figure 30.25.
- Viscosity
REACTOR CONTENTS ANALYSIS
- etc.
The terpolymerization reactor strategy.
1124
SPECIAL CONTROL TOPICS
PROCESS
Model Based Controller 112
+ y
Intennediate Variables (Measurement)
Figure 30.26.
Block diagrammatic representation of the terpolymerization reactor strategy.
30.4.2 The Overall Control Strategy
i, i I
I '·
~ [
:.
.,
' i
t'r t
i
~
\
j,
I
Clearly the most significant barrier to good control is due to the fact that measurements of the very product release properties we wish to control are not available on-line. L• this particular case, the reactor dynamics and the product quality demands are such that taking control action once every two hours - on the basis of informatio n delayed by 30-45 minutes - will always be inadequate . However, "auxiliary" informatio n in the form of reactant composition measurements is available on-line, and it is possible to exploit this fact for improving control system performance. The broad concept of the overall control scheme proposed for the process therefore involves a two-tier system in which the monomer, catalyst, solvent, and chain transfer agent flowrates into the reactor are used to regulate reactant composition in the reactor at the first tier level, every 5 minutes; at the second tier level, at a less frequent rate, set-points for the composition of the reactor contents are used to regulate final product properties. At the heart of the second tier will be an on-line, dynamic first principles model (cf. Chapter 12) running in parallel with the process, supplying estimates of these product properties in between the unacceptab ly infrequent two-hour samples. An on-line state estimator (cf. Chapter 29) is used to update the model predictions when laboratory measurements become available. This multirate (and multivariable) cascade-type scheme is represente d in Figure 30.25; the corresponding block diagram (cf. Chapter 14) is shown in Figure 30.26. Thus, the scheme proposes to tackle the chronic problem of controlling polymer product release properties whose measurements are unavailable as follows: 1.
Indirectly by focusing first on controlling the more frequently measurable auxiliary variables, and then
2. At a less frequent rate, adjusting the set-points for these auxiliary variables on the basis of intersample estimates of the product release properties provided by an on-line dynamic first principles model.
CHAP 30 CONTROL SYSTEM CASE STUDIES
1125
3. Because laborato ry analysis results are 30-45 minutes behind by the time they become available, they are used primaril y to update the model predictions and never directly to determin e control action.
30.4.3 Model Develo pment and On-Lin e Implem entatio n . The salient features of the first principles model and its developm ent are now summari zed. Full details are available in Ref. (13]. 1. Basic Dynamic Model: On the basis of a detailed kinetic scheme, the basic dynamic model was obtained by carrying out material balances on the reactor contents {three monome rs, catalyst, cocataly st, chain transfer agent, and inhibitors). Populati on balances on growing and dead polymer chains are manipul ated in standard fashion to produce a set of moment equations (cf. Ref. [17]). Finally, the producti on rate and product properti es - polymer composition, the number average molecular weight Mn, and the weight average molecular weight Mw - are obtained directly in terms of the bulk moments and the molecular weights of the three monomers. The complete model consists of 29 ordinary differential equation s (seven material balance equation s for the reactor contents. and 22 moment equations) and five algebraic equations for the polymer propertie s (cf. Ref. [13]). 2. Empiric al Correlat ions: The most importan t product release property is a certain "melt" viscosity indicator variable (MVIV) (which we shall represen t as T]) obtained by laborato ry analysis accordin g to the polymer P industry standard s; it is somehow related to the molecular weight and molecular weight distribut ion (MWD) but in no discernibly fundame ntal manner. Thus, to predict this MVIV from the kinetic model requires correlati ng MWD data obtained by gel permeat ion chromat ographic analysis with correspo nding MVIV data. A power-la w relation of the type: (30.6)
was found to be adequate. Thus, estimates only the kinetic model prediction of Mw.
A
1)
of the MVIV are obtained using
3. Paramet er Estimati on: The set of unknow n paramet ers contained in the model fall into the following categories: • 14 kinetic rate constants • two power-la w viscosity-molecular weight correlati on coefficients A small subset of the rate constants and some reactivity ratios were available in the open literatur e; the remainin g rate constant s, along with the other paramet ers, were estimate d from plant startup data using standard principle s of paramet er estimatio n in differential equation models (d. Chapter 12). Some of the actual off-line results indicating the match between the plant data (represe nted by the triangles) and the predictio ns obtained from the complete model (represented by the solid lines) are shown in Figure 30.27.
'l
l
'I
1126
\·."1.
SPECIAL CON TRO L TOPICS
X105 25000
2
A
A
Mn
Mw
0
0 0
2
4
6
8
0
2
Time (hrs )
4
6
B
Tim e (hrs )
X1Q5 5
1.250
M.
0 0
2
4
6
8
0
2
4
Time (hrs)
6
8
Time (hrs)
2000 0
~
-
~
50
8
§ 0
0
-
w.M
f\. II.
0
re
0
2
4
6
8
0
2
Time (hrs}
4
6
8
Time (hrs)
30
50
-
l• ·-
/:J,.A 25
~
Yc
A
........
20
A
A
0
0
2
4
Tim e(hrs )
6
8
0
2
4
6
8
Time (hrs)
Figu re 30.27. Comparison of the dyna mic reactor mod el predictions with plan t startup data for production rate and polymer composition.
CHAP 30 CON TROL SYST EM CASE STUD IES
1127
4. On-l ine Implementation: By runn ing the reactor mod el on a real- time proc ess cont rol com pute r in para llel with the plan t, on-li ne plan t inpu t infor mati on is used to prov ide on-line estim ates of prod uctio n rnte, poly mer composition, molecular weight distributi on (particularly Mn and Mw) as well as 1], the MVIV, every minute. Recognizing that perfe ct pred ictio n of plan t beha vior is an unat taina ble idea l, prov ision is mad e for upda ting mod el estimates on the basis of actual process meas urements when ever these beco me avai lable . However, once again, an otherwise stand ard problem is complicated by the pecu liar characteristics of indu stria l poly mer reactors: as a resul t of a varying labo rator y analysis delay of betw een 30 and 45 minutes, t5 {the time at whic h the prod uct samp le was taken), and t 1 (the time at whic h the process data actu ally beco me available) are not only diffe rent, but their diffe renc e, 1: = tk- t., is varia ble. Thus the inno vatio n process in our state estim ation scheme mus t be modified appropriately in orde r to accommodate this situation. As a resul t of these and other such considera tions (cf. also, for example, Ref. [23]), the mod el equations implemented on-li ne take the form: (30.7a)
9=
0
20
h(x)
40
(30.7b)
60
80
100
120
Time, Hours
Figure 30.28.
Off-line comparison of on-line estimates and actual laboratory measurements: complete !Hiay campaign data on MVIV.
1128
SPECIAL CONTROL TOPICS
where K,.(t) is a matrix of correction gains defined such that the innovation portion of Eq. (30.7a) is active only when t = tb i.e., when process data become available; the vector y represents estimates of the product properties (and production rate); ~is an estimate of tk- t 5 • The ~ estimates are particularly susceptible to modeling errors since they are estimates of nonfundam ental properties based on empirical correlations· polymer compositio n estimates, on the other hand, are more accurate, being estimates of fundamenta l properties obtained solely from the kinetic model. 2.00
.:0......
1.50
~
I
1.25
LOO
0.75 23:15
[
_,......_
1.75
I 0:30
•..
...."
...<:"'\. ""'
I
(a)
~~/
----
L 1:45
3:00
4:15
5:30
Model prediction Lab results
6:45
-
8:00
9:15
Clock time 2.00
1.75
./
1.50
1.25
1.00
0.75 22:30
0:00
I I
.......... ......... _,. ~
(
~
I
1:30
{b)
R ... .
--· 3:00
4:30
6:00
~
·"' ~ ::: ~
r-Model prediction Lab results
f-
7:30
9:00
10:30
Clock time
Figure 30.29. (a) Comparison of estimates and actual laboratory measurements: "live" on-line snapshot of MVIV record at about 09:00 hrs.; (b) comparison of estimates and actual laboratory measurements: "live" on-line snapshot of MVIV record just before 10:30 hrs.
CHAP 30 CONTROL SYSTEM CASE STUDIES
1129
Figures 30.28 and 30.29 are indicative of typical on-line performance of the state estimator. It should be noted that with process trends captured on-line (as in Figures 30.29(a, b)) the estimates always lead the laboratory analysis results. Figure 30.28 demonstrates the close agreement between MVIV estimates (solid line) and actual laboratory data (represented by triangles connected by the dotted line). To illustrate another aspect of the model, Figure 30.29(a) shows an on-line process trend "snapshot" of the MVIV estimates and actual laboratory data, taken sometime after 09:00 hrs as seen on a typical operator console; Figure 30.29(b) shows the same trend 1 hr 15 min later. Apart from the general agreement between the actual laboratory results (the hatched line) and the estimates (the solid line), observe that what was estimated as the current MVIV value (in Figure 30.29(a) before the laboratory measuremen t was available) was confirmed as a very accurate estimate 1 hr 15 min later in Figure 30.29(b).
30.4.4 Control Systems Design In implementing the reactor control system shown in Figure 30.25, Tier 2 depends on Tier 1 which in turn depends on a lower level of field controllers (Level 0); thus control system design must proceed logically from Level 0 to Tier 1 and finally to Tier 2
Level 0: Activity at this level is primarily concerned with the tuning of local field controllers responsible for maintaining the various reactor feed flowrates. PI controllers were employed at this level, and the direct synthesis tuning technique discussed in Chapter 15 was employed in selecting the controller parameters (d. Table 15.5). The Tier 1 control scheme actually sets the setpoint for these local controllers. Tuning the reactor level and temperature controllers is also done at this level. Tier 1: The main characteristics of this first tier are: 1. Multiple inputs (monomers, chain transfer, solvent, and catalyst
flowrates) and multiple outputs (mole fraction of reactants in the reactor: XA, X 8 , Xc for the monomers, Xr for the chain transfer agent, and X011 for the catalyst). 2. The time delays introduced by chromatographic analysis. A model predictive control scheme (cf. Chapter 27) with the following features was therefore designed for this tier:
1. A discrete control-action -implementat ion/output-sa mpling interval of 5 minutes (dictated both by the natural "process response time" and by the frequency of the chromatographic measurements). 2. Explicit prediction of reactor content response over a 1-hr time horizon, as well as corrective control action sequence calculation based on a discrete, linear, parametric model of the form: 1\
y{k + I)
A A
= Ay{k)
A
+ B u{k- m)
(30.8)
---
-------- --··-· . .... ~ ... """'" if we assume, for simplicity, that the time delays associated with each output are identical (a reasonable assumptio n since the time delay is primarily due to chromatographic analysis). 3. Control structure based on standard MPC (model predictive control) principles with some slight modifications: because reactor dynamic characteristics differ - often significantly - at each of the different operating conditions for manufacturing the various grades, different sets of MPC tuning parameters were used for each grade. 4. Provision for on-line reestimat ion of approxim ate linear model paramete rs according to the strategy outlined in Ref. [13] to accommodate changes in process characteristics during each campaign. (However , these paramete rs are never updated automatic ally; the process engineer still retains the responsib ility of using his/her discretion in deciding at which point during the campaign to swap models.) The linear multivariable model in Eq. {30.8) was identified from several pulse test experime nts. Pulses were implemen ted in the multiple inputs (monomers, chain transfer, solvent, and catalyst flowrates) and the responses of the mole fraction of the reactor contents were recorded. The techniques in Section 23.6 of Chapter 23 were used to identify the model parameter s. A catalog of these approxim ate linear models was obtained by repeating this procedure for each different product grade. Tier 2: This tier has four outputs - production rate, %A, o/oB in polymer ('YoC, of course, is determine d once these two are fixed), and 1J, the MVIV- to be regulated by the Tier 1 set-points. The proposed model predictive control scheme at this level is somewha t unusual in that two distinct - and fundamen tally differen t- models are involved: the full-scale, nonlinear first 0.15 - - Control Action, FA
---
0.13
n
[,.,.""'
0.11
·-' .!..~ 1-
""' 1-
Mole fraction, XA Set-point
\_....__ ~ ....~
~
14:45
17:45
20:45
23:45
-
14500
8500
I_ 11:45
16500
12500 FA Monomer A Flowrate 10500
/_ ~ ~
0.07
0.05 8:45
--
-
2:45
5:45
6500 8:45
Clock time
Figure 30.30.
Performance of Tier 1 control system: 24-hr trend of XA response.
I
Ll'll'1r .:>U L.Vl\'li<.LIL
.:ll~lC.lVl.l..J1,:::>J::::.
;:JJUUJJ:..:l'
ll.jl
principles model (Modell), used solely as a surrogate for the reactor to provide estimates of plant output in between the 2-hr samples; the linear parametric model (Model 2) of the type in Eq. (30.8), used in MPC fashion to calculate control action using the Model 1 output in lieu of actual measureme nt. The proposed control action implementation frequency is once every 15 min, so that the Tier 1 control system operates at three times the rate of the Tier 2 control system.
30.4.5 Some Further Results and Discussio n The typical performanc e obtained at the Tier 1 level is indicated in Figure 30.30. The hatched line represents the mole fraction XA; the correspond ing control action is represented by the solid line. This plot shows an initial 9-hr period of manual control followed by 15 hr of computer control, using the control scheme in Figure 30.25. The side-by-sid e compariso n provides a clear indication of the effectiveness of the computer control scheme. The typical performance obtained at the Tier 2 level is illustrated by the transient response shown in Figure 30.31. This 24-hr trend of a product campaign startup demonstrates two things simultaneo usly: (1) how well the kinetic model represents actual plant behavior, and (2) the effectiveness of the overall control strategy. The trend in Figure 30.31 shows the MVIV measureme nts, normalized so that the desired value is 1.0; the solid line represents the 1-minute estimates of 71, the MVIV, generated by the state estimator; the other line is the actual measured value (connected by straight lines). First, recalling that the estimates lead the actual measurements, we note that this plot indicates very good agreement between the state estimator and the plant. Furthermor e the product MVIV attains the desired value in very reasonable time and is maintained within specifications for the rest of the 24-hr period. Without the 1.50
...
1.25
....
·~ .....
1.00
r
0.75
0.50
0.25 15:00
21:00
3:00
l~
~
/'\ ................
.....
1'\r
~ ~\l.-
I-- - Model estimates - - Lab results
I--
9:00
15:00
21:00
3:00
9:00
15:00
Clock time
Figure 30.31. Performance of Tier 2 control system: 24-hr campaign startup trend of MVIV transient response.
1132
SPECIAL CONTROL TOPICS application of the control system, such startups take almost three times as long to complete, and the MVN is usually still difficult to maintai n at the desired target value thereaft er. Similar perform ance is obtaine d for the polyme r composition as well as for production rate.
30.4.6 Concl uding Remar ks The strategy we have present ed in this section for achieving good control of a multiva riable, nonline ar terpoly merizat ion reactor whose critical output variables are not available for measure ment on-line hinges on two points: 1. Being able to separat e the reactor control problem into. two parts, thereby taking advanta ge of the availability of some interme diate variable measur ements on-line, and controlling these at a faster rate than is possible with the main process output variables which are unavailable for on-line measurements.
2. Utilizing a mathem atical model (in a state estimator) as a surroga te for the physica l process , to provide on-line estimat es of the infrequently available process measurements, and using these estimate s to carry out control action at a rate which is slower than that of the first tier control system, but still much faster than if control were to be based only on the laboratory analysis.
;
I '
By holding the reactan t compos ition in the reactor reasonably constan t with the Tier 1 control system, the immediate consequence is a significant reduction in the polyme r produc t propert y variability; the task of driving these product propert ies to within specification with the second tier control system is thereby simplified considerably. The result was a significant increase in the amount of "first-q uality pounds " of polyme r produc t made at the facility, and this translat ed into a commensurate increase in the profitability of the business . Even though the process is decided ly nonline ar, and the same reactor is used to manufacture several different grades of the same product, linear model predicti ve control proved effective in this case. The addition al provisio n for cautiou s ori-line linear model parame ter reestimation, of course, provide d some enhanc ement to the control system perform ance in the most difficul t cases. Nevertheless, the plant process engineers attribut e the effectiveness of linear MPC to the fact that the most severe nonline ar effects are associat ed with temper ature variatio ns; these were all but elimina ted by the standar d operati ng procedu re of fixing the reactor tempera ture and not using it as a control variable. It should be noted, finally, that a full-scale nonlinE!ar model predictive control scheme could have been employed; the most significant limitatio n was the comput ational facilities availab le at the plant site. This limitati on therefore ultimately turned out to be a blessing in disguise since the full-scale nonline ar MPC scheme may be somewh at more difficult to maintai n than the linear scheme.
CHAP 30 CONTROL SYSTEM CASE STUDIES
30.5
1133
GUIDELINES FOR CHARACTERIZING PROCESS CONTROL PROBLEMS
The four case studies we have just presented in this chapter illustrate the fact that the various control problems encountered in various chemical processes can indeed be solved by the many different controller design techniques now available, most of which were discussed in this book. These case studies also attest to the fact that some control strategies are more appropriate than others for certain problems. As a result, it is important for the practicing engineer, charged with the responsibility of designing and implementing industrial control systems, to have a means of matching controller design strategies to the specific problem at hand in a rational manner. In this section we wish to present some concepts to assist in this task.
30.5.1 The Process Characterization Cube As diverse as chemical processes and processing units are, it is well known that they possess certain characteristics by which they may be grouped into a number of recognizable classes exhibiting similar behavior. (For example, the level of a reboiler in a distillation column, and the exit temperature of certain exothermic tubular reactors, can both exhibit inverse response.) This, in fact, was the main premise of the study of process dynamics in Part n, using ideal process models. Such classifications are particularly useful for control system design since: The characteristics that distinguish one class of processes from another also provide information which, if properly interpreted, indicate how the control problems common to each class ought to be tackled appropriately.
The appropriate controller design technique may then be selected in a rational fashion. Following the discussion in Ref. [15], as a possible starting point in the selection of a controller design technique, the process in question may be classified as shown in Figure 30.32, using the following three characteristics defined in the following manner: 1. Degree of Nonlinearity: the extent to which the process behavior is not linear - from essentially linear systems on one extreme, to those that exhibit very strong and acute nonlinear behavior on the other extreme. 2. Dynamic Character: the extent of complexity associated with the dynamic response - from simple systems exhibiting first-order, or other such low-order dynamic behavior, on the one extreme, to systems exhibiting such difficult dynamics as inverse response and time delays, on the other extreme. 3. Degree of Interaction: the extent to which all the process variables interact with one another - from those systems whose variables are totally uncoupled, or only weakly coupled, on the one extreme, to those systems whose variables are strongly coupled on the other extreme.
,.;;~
1134
SPECIAL CONTROL TOPICS
i
By assessing chemical processes in terms of these three attributes, it is possible to "locate" each process in one of the eight "pigeon holes" in Figure 30.32: four on the "front face," and four on the "back face." For example, essentially linear processes (with low to mild degree of nonlinearity), having simple to moderate dynamic character, and whose variables do not interact significantly with one another, will be located the bottom left half "pigeon hole" (or subcube) on the "front face." With a knowledge of the characteristic problems typically associated with each "pigeon hole," and the controller design technique capable of handling each problem, it is possible to use this "characterization cube" as a guide in selecting candidate controller design techniques. We recognize of course that these three attributes may not capture all the possible features of importance in all the possible classes of chemical processes; nevertheless, they represent the most significant aspects of most processes, especially as regards the design of effective controllers.
30.5.2 Characteristics of Process Control Problems and Control Scheme Selection It is well established that effective control of the single-input, single-output
(SISO) linear, fll'St-order system requires no more than classical PID feedback control (even though more complicated controller design strategies may also be employed). Thus the need for more sophisticated controllers may be considered as arising primarily to compensate for (or at least to take into consideration) deviations from this "base case" SISO, linear, first-order characteristics; also, the "directi~n"- as well as the "'magnitude "- of such deviation may now be considered as suggestive of the specific type, and extent, of sophistication which might be appropriate. The following is therefore a catalog of the eight "generic" categories of chemical processes (based on the characterization cube of Figure 30.32), their main problems, and what control schemes are suggested by these characteristics as potential candidates.
Dynamic Character
Figure 30.32.
The process characterization cube.
I
CHAP 30 CONTROL SYSTEM CASE STUDIES
1135
"Esse1ttially Li1tear" Processes (These processes are all located on the "front face" of the main cube.) 1. CATEGORY I PROCESSES (Bottom, Left half, Front face cube) Primary Attributes:
Essentially linear processes, with no difficult dynamics, and with little or no interactions among the process variables. Main Problems: None. Suggested Techniques: Single-loop PID control, with appropriate loop pairing if process is multivariable (cf. Chapters 15 and 21). Typical Examples: • Most base case flow, level, and temperature loops. • Single-point temperature (or composition) control of medium-purity columns with no significant process time delays. • Single-temperature (or composition) control of mildly nonlinear chemical reactors. 2. CATEGORY II PROCESSES (Bottom, Right half, Front face cube) Primary Attributes:
Essentially linear processes, with difficult dynamics, but with little or no interactions among the process variables.
Main Problems:
Difficult dynamics (e.g., the presence of inverse response, or time delay, etc.). Suggested Techniques: • Single-loop PID control with compensation for the difficult dynamics, e.g., the Smith Predictor for time-delay systems (cf. Chapter 17). • Other model-based control techniques such as IMC, Direct Synthesis Control (d. Chapter 19), or even MPC (d. Chapter 27). Typical Examples: • Loops with significantly delayed measurements or other delays. • Exit temperature control of an exothermic tubular reactor having inverse response, or any other such loops with inverse response. 3. CATEGORY III PROCESSES (Top, Left.half, Front face cube) Primary Attributes:
Essentially linear processes, with no difficult dynamics, but with significant interactions among the process variables. Main Problems: Significant Process Interactions. Suggested Techniques: • Single-loop PID control with compensation for the loop interactions, e.g., Decoupling, or SVD control (d. Chapter 22).
1136
SPECIAL CONTROL TOPICS
Typic al Examp les:
• Full-scale multiv ariable model -based contro l techni ques such as MPC (cf. Chapt er 27). • Two-p oint tempe rature (or composition) contro l of single, or couple d mediu m-pur ity colum ns with no signifi cant time delays. • Simultaneous conversion and composition control of mildly nonlin ear chemical reactors.
4. CATEGORY IV PROCESSES (Top, Right half, Front face
cube)
Prima ry Attrib utes:
Essen tially linear proce sses, with difficu lt dynam ics, in additi on to significant interactions among the pmcess variables. Main Problems: Combi nation of: • Difficult Dynam ics and • Significant Process Interactions. Sugge sted Techniques: • Single-loop PID control with compe nsatio n for the loop interactions (e.g., Decoupling, or SVD contro l (cf. Chapt er 22)) as well as for difficult dynam ics. • Full-scale multiv ariable model -based contro l techni ques such as MPC, with capabilities for handli ng difficult dynam ics (cf. Chapt er 27). Typic al Examp les: • Two-p oint composition control of single, or couple d, mediu m-pur ity colum ns with delaye d measu remen ts or other time delays. • Simultaneous conversion and composition control of mildly nonlin ear chemical reactors with delaye d compo sition measurements. • Most mildly nonlin ear polym er reactors with multip le control objectives.
"Significantly Nonlinear "Processes ;.
:
•
I
:11i
:l!i•.ll
w·i] .•~.· . ' f,. ':.:.!·I Ill·
lI f
'j;! Ii .·! :t if
if "
~:
(These processes are all located on the "back face" of the main cube.) 5.
CATEGORY V PROCESSES (Bottom, Left half, Back face Prima ry Attrib utes:
cube)
Significantly nonlinear processes, with no difficult dynam ics, and with little or no interac tions among the proces s variables. Main Problems: Signif icant Nonlin earity. Sugge sted Techniques: • Single-loop nonlinear model -based techniques, such as Generic Model Contro l {d. Chapt er 19). • Custom -desig ned single-loop PID controllers with process knowl edge incorporated, such as gain schedu ling (cf. Chapt er 18). Typic al Examp les: • Single-point tempe rature (or compo sition) control of very high-p urity colum ns withou t significant time delays . • Single -tempe rature (or composition) contro l of most exothermic chemical reactors.
(I, ..... · '·:.
CHAP 30 CONTROL SYSTEM CASE STUDIES
1137
6. CATEGORY VI PROCESSES (Bottom, Right half, Back face cube) Primary Attributes:
Significantly nonlinear processes, with difficult dynamics, but with little or no interactions among the process variables. Main Problems: Combination of: • Significant Nonlinearity, and • Difficult dynamics. Suggested Techniques: • Single-loop nonlinear model-based techniques, such as Generic Model Control (cf. Chapter 17) or nonlinear MPC (d. Chapter 27). • Custom-designed single-loop PID controllers with process knowledge incorporated (d. Chapter 18), and compensation for the difficult dynamics (e.g., time-delay compensation (cf. Chapter 17)). Typical Examples: • Any Category V process with significantly delayed measurements or other delays. • Exit temperature control of a highly exothermic reactors having inverse response. 7. CATEGORY VII PROCESSES (Top, Left half, Back face cube) Primary Attributes:
Significantly nonlinear processes, with no difficult dynamics, but with significant interactions among the process variables. Main Problems: Combination of: • Significant Nonlinearity, and • Significant Process Interactions. Suggested Techniques: • Full-scale multivariable nonlinear model-based control techniques such as Generic Model Control (cf. Chapter 19); or nonlinear MPC (cf. Chapter 27). Typical Examples: • Two-point temperature (or composition) control of single, or coupled, very high-purity columns without significant time delays. • Simultaneous conversion and composition control of very nonlinear chemical reactors. 8. CATEGORY VIII PROCESSES (Top, Right half, Back face cube) Primary Attributes:
Significantly nonlinear processes, with difficult dynamics, in addition to significant interactions among the process variables. Main Problems: Combination of: • Significant Nonlinearity, and • Difficult Dynamics, and • Significant Process Interactions. Suggested Techniques: • Full-scale multivariable, nonlinear, model-based control techniques with capabilities for handling difficult dynamics, such as Generic Model Control, and nonlinear MPC (d. Chapter 27).
1138
SPECIAL CONTROL TOPICS
Typical Examples:
• Two-point composition control of single, or coupled, very high-purity columns with delayed measurements or other delays. • Simultaneous conversion and composition control of very nonlinear chemical reactors with delayed composition measurements. • Some nonlinear polymer reactors with multiple control objectives.
Additional Considerations There are many situations of practical importance for which it might be necessary to take other factors into consideration in addition to the three attributes employed above. Some of these factors include: 1. Constraints: requiring controller design techniques such as MPC with explicit and intelligent constraints handling capabilities (cf. Chapter 27). 2. Frequent Disturbances: requiring special controller design techniques specifically for disturbance rejection, such as cascade or feedforward control (d. Chapter 16). 3. Ill-Conditioning: requiring specialized robust multivariable controller design techniques (d. Chapter 29), since ill-conditioning makes standard multivariable model-based techniques particularly sensitive to the effect of plant/model mismatch, thereby placing limitations on the achievable performance of such schemes. 4. Significant Inherent Variability in Process Outputs: requiring controller design techniques specifically for dealing explicitly with the stochastic nature of the measurements, such as the statistical process control schemes discussed in Chapter 28.
30.5.3 Illustrative Example To illustrate the issues raised in this section consider the following example. The process is a CSTR used to manufacture Cyclopentanol (which we shall represent by B) from Cyclopentadiene (represented by A). The kinetic scheme for this reaction is as follows:
A 2A
where C represents Cyclopentanediol, and D represents Dicyclopentadiene. The objective is to make the desired product, Cydopentanol (B), from pure feed of A, maintaining constant reactor temperature, and a constant concentration c8 of the desired product in the reactor. The feedrate and the reactor jacket temperature are available as manipulated variables. The modeling equations for this process obtained by material and energy balances are given as follows:
CHAP 30 CONTROL SYSTEM CASE STUDIES
1139
along with the outputs given by:
Here, x 10 is the feed concentration of A, x 1 is the concentration of A in the reactor, x2 is the concentration of B, x 3 is the reactor temperature, V R is the reactor volume, u 1 is the dimensionless feedrate, and u 2 is the reactor jacket temperature. Using the process parameters reported in Ref. [7] the steady-state behavior of the reactor may be investigated as a function of the feedrate u1• The reactor jacket temperature u 2 is fixed at 130"C, and the feed concentration of A, x10, is fixed at 5.1 mole/liter. Figure 30.33 shows the steady-state behavior of x2, the concentration of B, as a .function of the feedrate. The RGA parameter for this 2 x 2 system, computed as a function of the feedrate, is shown in Figure 30.34. The corresponding steady behavior of x1, the reactor concentration of A, and x31 the reactor temperature, are shown in Figures 30.35 and 30.36. Ll5 . 11 .
.
~vm :
:I
.
.
:
···········-r·············:···· ·····r·········· .·············r·············r··········-,············
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.
.
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oooooooooooo}o
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.
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.
. • 0 •
.
. • 0 •
ooooooooon1oooooooouoooo!oooooo . . ooouo?ooooooooouoo~uoooooooooooo{•••nooooooo
1 1 1 l l ·········· r············T···········r··········T············r············r···········-~·-········ · :IV
··r············r············r··········T············l·············r···········-~·-·········· 0.8'---"----"-------''------'-----J.-----J.-----J.--_J 0 20 40 60 80 100 120 140 160
Feedrate [llh]
Figure 30.33. Steady-state concentration of Cyclopentanol as a function of reactor feedrate.
1140
SPECIAL CONTROL TOPICS
Characterizing Various Operating Regimes By exam ining Figu res 30.33 and 30.34 (and analy zing the linea r trans fer funct ions obtai ned by linea rizin g the dyna mic mode l aroun d the indic ated stead y-sta te oper ating regim e) we see that this simp le proce ss show s six distin ct oper ating regim es, listed below , each exhib iting radic ally diffe rent dyna mic beha vior in terms of the three attrib utes of Nonl inear ity, Dyna mic Char acter , and Degree of Interaction. Thus depe ndin g on the oper ating cond ition s, this react or may be place d in six of the possi ble eight categ ories discu ssed above.
Operating Regime A: (u1 > 80 hr -I; y (or x 1 2) Prim ary Attri butes :
Char acter izati on: Impl icatio n:
Fairly const ant gain; Figure 30.33 indicates a fairly straig ht line in this regio n ( - Linear Beha vior); Low-order, mini mum phas e (Simple Dynamics) ; RGA const ant at - 1.1 (Virtually noninterac ting). Category I Process. 2 singl e-loo p PI contr oller s shou ld perfo rm reaso nably well in this opera ting regime.
Operating Regime B: (u 1 - 45 hr -l; y (or x 1 2) Prim ary Attri butes :
1.1 mole s/lite r)
-
1.1 mole s/lite r)
-
Mild gain varia tions ; Figu re 30.33 show s only a sligh t curve in this regio n ( - Mildly nonlinear) ; Nonm inim um phas e (Difficult Dynamics); RGA - 0.9 (Virtually noninteracting).
2r-----------------~----
--------------------~
1.5 ......... ... : ......... ....~·-···········;·· ········7········· ···~--
.
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: ·r ............!".......... t . . . . . ,. . . . . . r. . . . . .r:. . . . . . ,:. . . . . . +. . . . . . l...........+. . . . . .; . . . . . . 7............ ~.............;............ ~
o.5
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.
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........ ..., ......... ... , ......... ...
~
t·· .........t. . . . . . t. ······"··t······""""j············ ~
~
.
,,,l'' """'"' 'l'"""'"' '"' :•••••••OO••••;•••••OoooOO••:•••••••••"• 1.............,............ -r- .........,............ r............,............. r........ .
-1 .. l,,,,,,,,,,,,,,,,,,,,,.,,,.,,... ,.. -1.5 ......... ...
Feedrate [lJh]
Figur e 30.34.
Relative gain values for the process as a functi
on of reactor feedrate.
~
I
'
CHAP 30 CONTROL SYSTEM CASE STUDIES
1141
3.5.- ----- ----- ----- ----- ----. 3
~
.g "'a "..., :a
2.5
"'a
".,. -§
~
2
>.
0
1.5
20
J
40
60
80 100 Feedrate [1/h)
120
140
160
Figure 30.35. Steady-state concentratio n of Cyclopentad iene as a function of reactor feedrate.
140
135
§
130
~
.a .,f! s"".,
125
.
E-<
.su ~
120
115
110
I
0
20
40
60
80
100
120
I
140
Feedrate [1/h) Figure 30.36.
Steady-state reactor temperature as a function of reactor feedrate.
160
1142 Characteri zation: Implication :
SPECIAL CONTROL TOPICS
,,. :;~,
Category II Process. Achie~a~le controller perf~rm~nce limited by
Nonmmrm um phase behavtor; mverse response compensati on required; nonlineariti es may further complicate things.
Operating Regime C: (u 1 - 5 hr -l; y1 (or x2 ) - 0.9 moles/liter) Primary Attributes:
Characteri zation: Implication :
Fair~y co~sta~t g~in; Fi~re 30.~3 indicates a fairly stratght line m this regton ( - Lmear Behavior); Low-order, minimum phase (Simple Dynamics); RGA- -1 (Medium-to -High degree of interaction). Category III Process. Multivariab le Control will be helpful.
Operating Regime D: (u1 - 20 hr -I; y1 (or x2) - 0.9 moles/liter ) Primary Attributes:
Characteri zation: Implication :
Very mild gain variations; Figure 30.33 shows a very slight curve in this region (- Linear); Nonminim um phase (Difficult Dynamics); RGA- 0.5 (Severe interactions). Category IV Process. Multivaria ble controller with capabilitie s for handling nonminimu m phase behavior essential.
Operating Regime E: (u 1 - 9 hr - 1; y 1 (or x2 ) Primary Attributes:
Characteri zation: Implication :
-
0.82 moles/liter)
Gain undergoes sign change (Severely nonlinear); Both Minimum and Nonminim um phase (Difficult Dynamics); RGA- 0 (or 1) (Noninteracting). Category VI Process. Nonlinear controller required to handle sign change in gain as well as the changes in the minimum phase characterist ics. (No linear controller with integral action is able to stabilize such a system); Two single-loop controllers are acceptable, as long as they are nonlinear.
Operating Regime F: (u 1 - 60 hr - 1; y1 (or x 2 ) - 1.12 moles/liter) Primary Attributes:
Characteri zation: Implication :
Gain undergoes sign change (Severely nonlinear); Both Minimum and Nonminim um phase (Difficult Dynamics); RGA - ±co (Severe Interactions + Ill conditioning). Category VIII Process. Nothing short of carefully designed multivariab le nonlinear controllers will work well.
'j
l
]
1
l
i
l
l l
1
l
CHAP 30 CONTROL SYSTEM CASE STUDIES
1143
Time (h)
g
0.8
f!
0.4
...,::I
t
""E! E!: 0.2
0.6
0.4
0.8
Time (h)
Figure 30.37. Process response to 1• step change in reactor set-point (Regime A, two single-loop PI controllers).
Controller Performance Assessment To confirm these analyses, the following is an assessment of several controllers designed for the process for operating regimes A, B, and F. Figure 30.37 shows the response of the control system to a step change of 1° in reactor temperature set-point while operating in the regime A (u 1 > 80 hr-1; y1 (or x2 ) - 1.1 moles/liter) with two single-loop PI controllers. Note that the behavior is essentially linear, and that the interaction effects are not significant. (The dynamic variations in the reactor concentration of Cyclopentanol are -0.3% of the steady-state value.) This confirms that in this regime of operation, the reactor behaves essentially as a Category I process for which single-loop PI controllers are adequate. Figure 30.38 shows the system response to a step change of 1° in reactor temperature set-point while operating in the regime B (u 1 - 45 hr1; y1 (or x2 ) -1.1 moles/liter). The dotted line shows the response under two single-loop PI controllers, while the dashed line shows the response using two single-loop IMC controllers. Note the inverse response exhibited by the Cyclopentanol concentration, while the reactor temperature exhibits no such behavior. Because the reactor temperature has no inverse response, the performance of the PI temperature controller is indistinguishable from its IMC counterpart. However, the performance of the IMC concentration controller is somewhat better.
1144
SPECIAL CONTROL TOPICS 0.002
]
o"\
-a
-{).002
...(),004
.s
..
.!a
,..,
.. -----
/
-...
---·-·---
...... -
/
/ ~ ~--
....
,.,.
/
~
0
...(),006 0
0.2
0.4
0.6
0.8
Time (h)
1.5
g
..
.....
.B c.
a
t!.
,:~ 0o
0.2
j_
I
I
0.4
0.6
0.8
1
Time(h)
Figure 30.38. Process response to 1• step change in reactor set~point (Regime B);- two single-loop PI oontrollers; --- two single-loop IMC controllers.
The very problematic behavior of the process when operating in the regime F is indicated in Figures 30.39 and 30.40. Figure 30.39 shows the response of the process to a step change of -0.01 mol/1 in the Cyclopentanol concentration setpoint under two single-loop PI controllers. Observe that the process is unable to attain this new steady-stat e value; in fact, the reactor proceeds to "washout," 0.5
~ E.
~
0
0
s
...().5
c.
-1.0
Q)
0
~
Complete Washout
-1.5
I
0
0.2
0.4
0.6
0.8
0.6
0.8
1
Time (h)
4
g ... .a Q)
..
:!
S'
i!.
-4
-6
0
0.2
0.4 Time(h)
Figure 30.39. Process response to a step change of -0.01 mole/liter in Cyclopentanol concentration (Regime F, two single~loop PI controllers).
CHAP 30 CONTROL SYSTEM CASE STUDIES 2oooo, ..----,- -----.-- ---r---- ,-----.. .,
-50000
0.2
0.4
0.6
0.8
0.6
0.8
1145
Time(h)
g f
E fl
8 6
.
4
~
2
s"
~
0
8
-2
0
0
0.2
0.4 Time (h)
Figure 30.40.
Control action corresponding to process response of Figure 30.39.
and the actual (absolute) Cyclopentanol concentration goes to zero (the initial concentration was 1.1 mol/1). The corresponding control actions taken by each of the two single-loop controllers are shown in Figure 30.40. Note that the behavior of the first controller is essentially unstable. The reason for this behavior is that the process gain is close to zero at this particular steady state, becoming slightly positive for negative deviations from the steady-state flowrate, and changing signs to become slightly negative for positive flowrate deviations. Thus if the linear PI controller is designed for a positive process gain, the closed-loop system will become unstable when the actual process gain changes signs.
30.6
SUMMARY
In this final chapter we have provided four different case studies of control
system design applied to processes of industrial importance:
1. For distillation column control, we discussed how the control system goals and the inherent dynamics of the column strongly influence the choice of the control system to be employed. An experiment al example provided one illustration of advanced control system performance.
2. The control of catalytic packed bed reactors introduced us to the task of controlling temperature and composition profiles in a process - one of the most common examples of distributed parameter systems control. The control system design tasks were illustrated by the application of state estimation, cascade control, and optimizing control to an experimental reactor.
,.
.''l"ftl
1146
SPECIAL CONTROL TOPICS
3. The application of multivariable feedback/feedforward control to a solution polymerization process showed that model-based analysis of the multivariable process can often lead to simple multiloop control strategies that perform well in practice. In this case, feedforward control of recycle stream disturbances coupled to multiloop ratio controllers adequately compensated for disturbances and loop interactions and provided good control system performance. 4.
A more complex terpolymerization process was the next control system design challenge. On-line model-based state estimation and inferential control were successfully applied to a situation where the key product quality variables could not be measured except offline with a significant delay. The process control scheme showed excellent results when implemented in the plant.
Taken together these four case studies illustrate the "art and science," that is, the combination of engineering creativity and process control theory, that can be applied to provide high-performance control systems in practice. This chapter concluded with a guide for classifying the types of difficulties and specific challenges posed by a specific control problem and some recommendations for remedies to be employed. This guide can be used to provide a starting point for control system design. REFERENCES AND SUGGESTED FURTHER READING 1. 2. 3. 4. 5.
i
6.
r ,.
7.
!'· .. I
I
''
Ii
8. 9. 10.
11. 12. 13.
Ardell, G. G. and B. Gwnowski, "Model Prediction for Reactor Control," Chem. Eng. Prog., June (1983) Buckley, P. S., W. L. Luyben, and J. P. Shunta, Design of Distillation Column Control Systems,Instr. Soc. Amer., Research Triangle Park (1985) Chien, D. C. H. and A. Penlidis, "On-line Sensors for Polymerization Reactors," Rev. Macromol. Chern. Phys., C30, (1), 1-42 (1990) Congalidis, J.P., J. R. Richards, and W. H. Ray, "Feedforward and Feedback Control of a Solution Copolymerization Reactor," AIChEJ, 35, 891 (1989) Cozewith, C., "Transient Response of Continuous-flow Stirred-tank Polymerization Reactors," AIChE/,34, (2), 272 (1988) Deshpande, P. B., Distillation Dynamics and Control, Instr. Soc• .Amer., Research Triangle Park (1985) Engell, 5. and K.-U. Klatt, "Nonlinear Control of a Nonminimum Phase CSTR," Proceedings of the American Control Conference, 2941, San Francisco, June 1993 Jerome, N. F. and W. H. Ray, "High-performance Multivariable Control Strategies for Systems Having Time Delays," AIChEJ, 32, 914 (1986) Kaspar, M. H. and W. H. Ray, "Chemometric Methods for Process Monitoring and High Performance Controller Design," AIChEJ, 38, 1593 (1992) McAuley, K. B. and J. F. MacGregor, "Optimal Grade Transitions in a Gas Phase Polyethylene Reactor," AIChEJ, 38 (10), 1564 (1992) McAvoy, T. J., Interaction Analysis,Instr. Soc. Amer., Research Triangle Park (1983) Nisenfeld, A. E. and R. C. Seemann, Distillation Columns, Instr. Soc. Am.er., Research Triangle Park (1981) Ogunnaike, B.A., "On-line Modeling and Control of an Industrial Terpolymerization Reactor," Int. Journal of Control (in press) (1994)
..
r
I.
CHAP 30 CONTROL SYSTEM CASE STUDIES
1147
14. Ogunnaike, B. A., J. P. Lemaire, M. Morari, and W. H. Ray, "Advanced Multivariable Control of a Pilot-plant Distillation Column," AIChEJ, 32, 914 (1986) 15. Ogunnaike, B. A., R. K. Pearson, and F. J. Doyle, "Chemical Process Characterization: With Applications in the Rational Selection of Control Strategies," Proceedings of the 2nd European Control Conference, pp. 1067-1071, Groningen, Neth~rlands, June 1993 16. Rademacher, 0., J. E. Rijnsdorp, and A. Maarleveld, Dynamics and Control of Continuous Distillation Units, Elsevier, New York (1975) 17. Ray, W. H., "On the Mathematical Modeling of Polymerization Reactors," J. Macromol. Sci.- Rev. Macromol. Chern., CB, (1), 1-56 (1972) 18. Ray, W. H., "Modeling of Polymerization Phenomena," Ber. Bunsengesellshaft Phys. Chern., 90, 947 (1986) 19. Ray, W. H., "Polymerization Reactor Control," IEEE Control Systems, 6 (4), 3{1986) 20. Ray, W. H., "Computer-aided Design, Monitoring, and Control of Polymerization Processes," in Polymer Reaction Eng. (H. Geisler and K. H. Reichert, Ed.), VCH Pub!., 105 (1989) 21. Ray, W. H., "Modeling and Control of Polymerization Reactors," in DYCORD '92 (f. J. McAvoy, Ed.), Pergammon Press, Oxford (1992) 22. Shinskey, F. G., Distillation Control (2nd ed.), McGraw-Hill, New York (1984) 23. Schuler, H. and 5. Zhang, "Real-time Estimation of the Chain Length Distribution in a Polymerization Reactor," Chern. Eng. Sci., 40 (10), 1891-1904 (1985) 24. Schwedock, M. J., L. C. Windes, and W. H. Ray, "Steady-state and Dynamic Modeling of a Packed Bed Reactor for the Partial Oxidation of Methanol to Formaldehyde. I. Model Development," Chern. Eng. Cornrn., 78, 1 (1989) 25. Schwedock, M. J., L. C. Windes, and W. H. Ray, "Steady-state and Dynamic Modeling of a Packed Bed Reactor for the Partial Oxidation of Methanol to Formaldehyde. II. Experimental Results Compared with Model Predictions," Chern. Eng. Cornrn., 78, 45 (1989) 26. Skogestad, S., "Dynamics and Control of Distillation Columns -A Critical Survey," Proceedings DYCORD 92+, College Park, Maryland (1992) 27. Windes, L. C., A. Cinar, and W. H. Ray, "Dynamic Estimation of Temperature and Concentration Profiles in a Packed Bed Reactor," Chern. Eng. Sci., 44, 2087 (1989) 28. Windes, L. C. and W. H. Ray, "A Control Scheme for Packed Bed Reactors Having a . Changing Catalyst Activity Profile. I. On-line Parameter Estimation and Feedback Control," J. Proc. Cont., 2, 23 (1992) 29. Windes, L. C. and W. H. Ray, "A Control Scheme for Packed Bed Reactors Having a Changing Catalyst Activity Profile. II. On-line Optimizing Control," J. Proc. Cont., 2, 43 (1992)
1
~. · ~.1 'ji
I·
,j
''• :.:_,,':.;>
part V I APPENDKCJES APPENDIX A.
Co ntr ol Sy ste m Sy mb ols Us ed in Process and Ins tru me nta tio n Dia gra ms
APPENDIX B.
Co mp lex Va ria ble s, Dif fer ent ial Equations, and Dif fer enc e Eq uat ion s
APPENDIX C.
Laplace and z-T ran sfo rm s
APPENDIX D.
Re vie w of Matrix Alg ebr a
APPENDIX E.
Co mp ute r-A ide d Co ntr ol Sy
ste m De sig n
'Jr. man sfiouU ~ep liis Cittk 6ra in attic s wit fi a£( tfie furniture tfiat fie is ~(g to am£ tfie rest fie can put a in tfie (um6er room of liis ({6 wfiere fie can get it if lie wants.
'i!
:) I
1148
AJPJPENDKX
A CON TRO L SYST EM SYM BOL S USED IN PRO CESS AND INST RUM ENT ATIO N DIAG RAM S In reading Process and Instrume ntation (P&I) Diagram s, the process sensors, controllers, and actuators are indicated by special symbols. It is importan t to be able to recogniz e these symbols in order to work with design engineer s, operators, et al. Some of the most commonly employed symbols are indicated in the tables below. In many P&I diagram s, only abbrevia ted treatmen t of the control loop is given so that only the measure ment, the controller, and the actuator are shown. The standard s of the Instrume nt Society of America (ISA) are followed in this section. Ref. [1] presents a much more compreh ensive descripti on of the ISA standard s.
[1] InstruJrt entation Symbols and Identific ation, ISA-SS-1 (ANSI/I SA- 1975, R1981) Instrumentation Soc. of America, in Standard s and Practices for Instrume ntation. 7th Edition (1983).
1149
f ·.!I' ji
1150
APPENDIX A
Table A.l. Some Line Symbols
Line
-----------------------------------------------------------
#
#
#
Meaning Connection to process or mechanical link or instrument supply Electrical signal
Pneumatic signal or undefined signal
Table A.2. Some Identification Letters
lJA \.'·
nrL I
Svmbol A
c D E F I
L M p T
v
First Letter Analvsis Conductivity Density
Succeeding Letter Alarm Control
Volta~te
Flowrate Current Level Moisture lhumiditv) Pressure or Vacuum Temperature Viscosity
Indicate
Transmit Valve
1151
CONTROL SYSTEM SYMBOLS USED IN P & I DIAGRAMS
Table A.3. Some Actuator Symbols
Actuator
Svmbol
--
t*l
Manual Control Valve
~
Automatic Control Valve
-~
Motor
--~
Solenoid
~
Pressure control valve, self-contained
~
Pressure control valve, external pressure measurement
~
Pressure relief or safety valve, angular pattern
~ ~
Pressure relief or safety valve, straight through
...
Level control valve with mechanical linkage
w
!I
1152
APPENDIX A Table A.4. Some Sensor Symbol s
Svmbol
Sensor
t~
-
--
Flow sensor I transmitter using orifice meter
Flow sensorI transmitter using turbine meter
Flow sensorI transmitter, undefined type
~ L_
--
~---
Level sensor/t ransmit ter, undefined type
f
---
Pressure sensor I transmitter, undefined type
t
---
Temperature sensor/t ransmit ter, undefined type
t
---
Viscosity sensor I transmitter, undefined type
~
cr
Pressure indicator, undefin ed type
Temperature indicator, undefin ed type
J
~
l
CONTROL SYSTEM SYMBOLS USED IN P & I DIAGRAMS
1153
Table A.S. Some Example Control Loops
S
bol
Meanin
Level measurement/ transmitter, signal sent electronically to controller and actuator signal sent to valve
Cascade controller: Temperature measurement/ transmitter signal sent electronically as set-point to coolant flow controller, flow measurement/ transmitter sent electronically to flow controller, actuator signal sent to valve
Pressure measurement/ transmitter with pressure indicator, signal sent electronically to pressure controller, actuator signal sent to inlet gas control valve
·.·~.!~i'r ' '
l
I
B CO MP LE X VARIABLES, DIFFER ENTIAL EQUATIONS, AN D DIFFEREN CE EQ UA TI ON S Classical process control is kno wn to rest on such trad ition al fund ame ntal elements as linear ordinary different ial equations, the Laplace transform, and the closely related topic of complex vari ables. The corr espo ndin g fund ame ntal elements for computer control are linear difference equations, z-transfo rms, and, aga in, complex variables. Since Laplace and z-tr ansf orm s are disc usse d elsewhere in this book (see Chapter s 3 and 24 for the respective introdu ctions and Appendix C for a more complet e review) this appendix is therefore devoted to reviewing first the algebra of com plex linear ordinary dtfJerential and difference variables, then some basic elements of equations that are most relevant to proc ess dynamics and control studies. Brie f summaries of pert inen t issues rega rdin g nonlinear ordinary differential equa tions are also included.
B.l
COMPLEX VARIABLES
B.l .l Def init ion of a Complex Nu mber A complex num ber z is defined in term s of an ordered pair of real numbers (x,y) and the imaginary number j = {:1 as follows: z=(x ,y)
= x+ jy
(B. I)
The real numbers x and y are calle d, respectively, the real and the ima ginary parts of z; and it is customary to expr ess this as: Rez =x; lmz == y
1155
(B.2)
'II !
1156
APPENDIXB
iJ
p : (x,y)
•
Imag inary Axis
r
'• ''•
~
',y •
I
•
. ' ''
.•• Real Axis
Figure 8.1.
~
X
" ~
The complex number.
B.1.2 Representations of Comple x Numbers Since a complex num ber is defi ned in term s of an orde red pair of real num bers (x, y), it is natu ral to associate each complex num ber with a poin t Pin a plan e who se Car tesi an coo rdin ates are x and y (see Figu re B.l) . Wit h such repr esen tatio n, each complex num ber corr espo nds to just one poin t in the plane, and con vers ely, each poin t in the plan e is associated with just one com plex num ber. In this context, the Cart esia n x-y plan e is referred to as the complex plane; the Car tesi an x-axis beco mes kno wn as the "rea l axis " and the y-ax is as the "im agin ary axis." It is cust oma ry to then refer to diag ram s such as in Figure B.l as Arga nd diagrams. Obs erve now that the same poin t P show n in Figu re B.l can be loca ted in the complex plan e as the end poin t of a vect or of leng th r unit s disp lace d at an ang le 6 (rad ians ) from the posi tive real axis. Thu s we may equ ally well identify the complex num ber z by the ordered pair (r, 9). In gen eral it is possible to repr esen t a complex num ber in any of thes e two enti rely equ ival ent form s (kno wn resp ecti vely as the Olrtesian and the polar forms) and , as will be seen below, one representation is usually mor e convenient than the othe r for perf orm ing cert ain algebraic operations.
Cartesian (or Rectangular) Represe ntation The Cart esia n repr esen tatio n of a com
plex num ber is as given in Eq. (B.l ), i.e.:
z = x+ jy
(B.l)
Abs olut e Val ue (or Mod ulus ) The absolute value (or modulus) of the com plex num ber in Eq. (B.l ) is the non nega tive real num ber den oted I z I and defined by: lzl;::
..Jx2 +l
(B.3)
From Figure B.l it is obvious that this represents the distance from the poin t P to the origin. From Eq. (B.2} we now note that: lzl 2 = (Re d+ (Im z/
(B.4)
I
COMPLEX ALGEBRA, DIFFERENTIA L AND DIFFERENCE EQNS Com plex Con juga te
1157
Associated with ever y complex num ber z with Cartesian representation given in Eq. (B.l) is the num ber its complex conjugate defined as:
z,
z = x-jy
(B.5)
Tha t is, z is a num ber repr esen ted by the poin t (x, -y), a mirr or ima ge of the num ber z reflected in the real axis. The following are imp orta nt relation s to note abo ut complex num bers and their conj ugates. 1.
Their moduli:
IZl = lzl 2.
z
z+Rez = 3.
(B.6)
Their sum and their difference:
2
Imz =
zz =
ld
z- z Zj
(B.7)
Their pro duc t
(B.8)
Relation Eq. (B.8) is particularly usef ul; it indicates that mul tiply ing a complex num ber by its conjugate produces a (nonnegative) real number.
Pol ar Rep rese nta tion The poin t (x, y) may be represented instead by its pola r coordinates ( r, e); in this case, the corr espo ndin g complex num ber may be represented as: z
= rL9
(B.9)
whe re the symbol L is used to indi cate implicitly that 9 is an angle. The explicit pola r representation correspondin g to Eq. (B.l) is obtained by noti ng that x=r cos 9;
and
y= r sin 9
so that z may now be written as:
z=
r(cos 9+ jsin 9)
(B.lO)
The Mod ulus and the Arg ume nt Not e that the mod ulus of the complex
num ber in this form is given by: (B.l l)
~·.··~
l'
APPENDIXB
j
The angle 6 is called the argument of z, and we may write: e = arg z. If the complex num ber z is interpreted as a direc ted line segm ent in the complex plane connecting the poin t (x, y) and the origin, then, as stated earlier, r is the length (or magnitude) of this line and 6 the angle (in radians) that this line makes with the positive real axis. Observe, howe ver, that 6 is not uniq ue beca use for any positive integer k, the angles given by (9 + 2k1r) equally qualify as arguments of the same complex number. Thus we defin e the principal value of arg z (sometimes denoted by Arg z ) as that unique value of (} for which: (B.l2 )
The Exponential Pola r Form It is possible to emp loy Euler's formula: ej8
= cos 6+ jsin B
(B.l3 )
in Eq. (B.10) to obtain straightforwardly: (B.14)
nus is sometimes referred to as the exponentia
l pola r form for obvious reasons.
Transformations The following is a sum mary of the relat ionships used for trans form ing one complex num ber representation to the other . L
From Cart esian to Pola r
Given: z =x + jy, the required r and 0 are obtained from:
r=.VXl+l
(B.l5a)
mn-{;)
(B.15b)
and
o=
In using Eq. (B.15b) care mus t be taken to ensure that the quad rant in which the poin t (x, y) falls is taken into consideration. The pote ntial pitfall lies in the fact that the indiv idua l signs associated with x and with y - the mos t critical infor mati on need ed to deter mine e accu rately - are lost in the process of evalu ating the ratio y/x. The informati on abou t the quad rant in which z is located is not "automatically" contained in Eq. {B.l5b); it mus t be "man ually " supp lied. Observe therefore that as it stand s, Eq. (B.15b) will alwa ys give 0 values in the range [-n"/2, n/2]; this will be valid as long as x is positive. When x is negative, the appropriate value of 9 is obtai ned by addi ng 1r.
';,,i~'li~
.: j.
COMPLEX ALGEBRA, DIFFERENTIAL AND DIFFERENCE EQNS 2. From Pola r to Cart esian
=
Given: z r L 6 eithe r in the trigonometric form in Eq. (8.10}, or in the expo nent ial form in Eq. (B.14), the required Cart esian x and y num bers are obtained from:
x= rcos 6
(B.16a)
= rsin 6
(B.l6b)
and
y
B.1.3 Algebraic Operations The sam e basi c alge braic oper ation s of addi tion , subt racti on, divis ion, and mult iplic ation poss ible with real num bers can also be carri ed out with com plex num bers . Whi le it is true, in princ iple, that all the alge braic oper ation s can be perf orm ed usin g both the Cart esian and· the pola r forms, it is also true that for each algebraic oper ation , there is a pref erred com plex num ber repr esen tatio n whic h cons idera bly simplifies the requ ired man ipula tion. In wha t follo ws, it is with out loss of gene ralit y that we illus trate alge braic operations usin g two complex num bers Zt and Zz given in the Cart esian form by:
=XI +jyl
(B.l7 a)
t2=1 tz+i Y2
(B.l7b)
Zt
and by: Zt
= '• elfl,
(B.l8 a)
z2
= r2ei~
(B.18b)
in (exponential) pola r form; the exte nsio n to three or mor e com plex num bers is strai ghtfo rwar d. L
Add ition and Subt racti on: (Cartesian Form Preferred) Zt
±~
= (XI + jyl) ± ( Xz + jy2) = (x• ±Xz) +i(Yt ±y2)
2.
(B.19)
Mul tipli catio n: (Exponential Polar Form Preferred)
(B.20)
Usin g the alter nativ e Cart esian form, we
obtain:
~~~!!
1160
APPENDIXB
which, upon expanding and rearranging becomes: (B.2I)
3.
Division: (Expone ntial Polar Form Preferred)
(rl eiB•) (rz ei82) ~ e j(0,-11,) (B.22)
r2
It is instructive to examine how division is perform ed using the Cartesia
~ Zz
=
(x• + iYt) (.xz +iYz)
n form:
(B.23)
We must now eliminate the complex number in the denomi nator and replace it with a real number ; this is achieve d by multipl ying both numera tor and denomi nator in Eq. (B.23) by the complex conjugate of .;, a procedure kno·wn as rationalization, i.e.:
(XI + jyl) (Xz - h'2) (.xz+jy2) (.xz-.b'l) with the result that
(xtXz +Y1Y2) +i( -x1Y2 +YtXz) Xz 2 + Yl The following importa nt relations regardi ng the moduli and argume nts of the produc t and quotien t of two complex number s follow directly from the results given above. L
Products:
Ifz =Z 1Zz then:
lzl = lztllz21
(B.24)
and
arg (z) = arg (z1) + arg (z,z) 1'
L ,,,
2
zt Quotien ts: Ifz =-then : Zz
lzl
'j; i:
.,:'I
li
lz.l lz2l
r.:
(B.25)
(B.26)
and
arg (z)
arg (z1) - arg (z2 )
(B.27)
COMPLEX ALGEBRA, DIFFERENTIAL AND DIFFERENCE EQNS
1161
B.1.4 Powe rs and Roots of Complex Num bers The expon ential polar form is usefu l for repres enting integr al powe rs of a complex numb er. H the complex numb er represented by Eq. (8.14): (B.l4)
is multip lied by itself n times, we obtain the result that: (B.28)
Similarly, we have: (B.29)
ln particular, if r = 1 in Eq. (B.28), we obtain:
(B.30)
and upon introd ucing Euler's formula Eq. (8.13) for both sides of Eq. (B.30), we have: (cos 8+ jsin 0)"
= cos nO+ jsin nO
(B.31)
This result is know n as de Moivre's theorem; it is partic ularly usefu l in finding the roots of equat ions involv ing the complex numb er z. To illustrate, we consid er the classic proble m of finding the n complex roots of the equation: z"-1 = 0
(B.32)
where n is a positive integer. This is first rearranged as: z"=l =te.i O
(B.33)
where we have writte n 1 in the exponential polar form. Observe now that in this form, the modu lus and argum ent are given by: r= l and
8 = 0+211k
havin g recalled the fact that e, along with any other angle equal to 8 plus integral multiples of 27r, are equally valid argum ents of the same complex number. Thus, in the trigonometric form Eq. (B.33) becomes:
z"
= 1 = cos 211k +jsin 211k; (k=O, I, 2, ... , n-1)
(B.34)
so that:
z
= 111" = (cos21Zk+jsin2nfc) 11"; (k=O ,l,2, ... ,n-l)
We may now apply de Moivre's theorem to the RHS
z
= cos
e: } e: ) jsin
and obtain finally:
(k = 0, l, 2, ... , n - 1)
(B.35)
1162
APPENDIXB
as the expression for the n roots of the Eq. (B.32). The references provided at the end of the Appendix (particularly Ref. [6]) are recommended to the reader interested in further information on complex variables.
B.2
LINEAR DIFFERENTIAL EQUATIONS
In general, any equation of the following type:
~
~ + ... + an-1
1Jo(t) dt" + a1 (t) dt•-1
t!1.
(t) dt + a.(t)y
:;
= q(t)
(B.36)
involving functions of t (the independent variable), along with y and its derivatives (with respect to t) up to the nth derivative, is known as a linear, differential equation of order n. It is said to be linear because so long as the coefficients a;(t), i = 0, 1, 2, ... , n, and q(t) are functions oft alone (or are constant), the equation is in fact linear in the dependent variable y and its n derivatives; it is of order n because the nth derivative dny/dt" is the highest differential involved. H in particular q(t) = 0, the equation is further classified as homogeneous; otherwise it is nonhomogeneous. The following is a summary of some key methods for solving the most important classes of these linear differential equations.
B.2.1 First-Order Equations Consider the linear first-order homogeneous differential equation:
~+ t.zy
= 0
(B.37)
where a is a constant; it is easily solved by rearranging and separating the variables to give: y(t) = e-at y(O)
(B.38)
Of course not all first-order equations are this simple; but the concepts here illustrated are useful in solving the more general equations. The general nonhomogeneous linear first-order equation is given by:
~+ a(t)y
= q(t)
(B.39)
It is usually solved by the method of integrating factors and has the more general solution:
'
I ~
COMPLEX ALGEBRA, DIFFERENTIAL AND DIFFERENCE EQNS
1163
In the special case when the coefficient a is a constant, the first-order differential Eq. (B. 39) becomes: f!1ffi dt
+ qy(t) = q(t)
(B.41)
and the solution will then be obtained immediately from Eq. (8.40) as: y(t) = e-m y(O) + e-at rea" q(d)da 0
or y(t) = e-m y(O) +
J'
e-a{t-u) q(d)da
(B.42)
0
Note that to avoid the potential confusion arising from using the same variable t in the limit of the integral and as the integration variable, it is customary to introduce a dummy time argument (say, a) under the integral sign, and retain t for current time (and hence in the upper limit). It is straightforward to show (and the reader is encouraged to do so as an exercise) that if we wish to solve the standard state-space model (Eq. (4.28) from Chapter 4) which includes both control action u(t) and disturbance d(t), ie.:
~/) = ax(t) + y
bu(t) + ')d(t)
(B.43)
= cx(t)
then the solution is: y(t) = e 01 y(o)+ c r ea(!-u) bu(d) da+c r ea(!-a)')d(d) da 0
(B.44)
0
B.2.2 Higher Order Equations The nth-order linear equation with constant coefficients: ~
llodtn
~
dn-1y
+ a1dtn-1 + ... + an-1 dt + any
= q(t)
(B.45)
will have a solution of the form: y(t) =
Ao +
n
LA f!m;l r=1
(B.46)
where the m; are the n roots of the characteristic equation: (B.47)
1164
APPENDIXB The specific form of the solu tion is mos t easily foun d from the meth od of Lapl ace trans form s (see App endi x C); it is also possible to solve these equations by matr ix meth ods as show n below.
Ma trix Methods Con side r the situa tion in whic h a new set of variables, z 1 (t), z 2 (t), ... , zn(t) are intro duce d to repr esen t the variable y and its first n-1 derivatives as follows: z1(t)
y
~(t)
4l dt
= ~ dP
z3(t)
(B.48)
z._, (t)
=
z.(t)
=
dn-2 y dt"- 2 dn-1 y dtn-1
From here we easily obtain: dz (t)
-dt1- = z2 (t)
(B.49)
dz 11 _ 1 (t)
dt
= z.(t)
and
whe re the RHS expr essio n has been obta ined by solv ing Eq. (B.45) for dny/d tn and intro duci ng Eq. (B.48) appr opri ately . This set of n linea r first -ord er equa tions now cons titut e an alter nativ e repr esen tatio n of the linea r nth- orde r equa tion. Writ ten in the mor e com pact vector-matrix form (see App endi x D) Eq. (B.49) becomes:
dz}/) = Az(t) + f(t)
(B.50)
whe re then -dim ensi onal vectors z(t), f(t), and then x n matrix A are give n by:
I
COMPLEX ALGEBRA, DIFFERENTIAL AND DIFFERENCE EQNS
=
z(t)
['~] z2(t)
1165
0
0
;
f(t)
= gill_
zn(t)
Go (B.51)
A=
0 0
0
0
0
0
--an
--an-1
--an- 2
--a!
Go
Go
Go
Go
0
0 0
It is impo rtant to note the similarity between Eqs. (B.SO) and (B.41); instead of the scala r functions and coefficients we now have vector functions and matr ix coefficients. The mor e com pact matrix Eq. (B.50) may now be solv ed by the meth ods discussed in App endi x 0; the solution is:
(B.52)
where Zo is the value of the vector z at the poin t t = fo. The matr ix exponentials, using the relation Eq. (0.87 ) in Appendi x D. Note that the general state-space representa tion, first pres ente d in Chapter 4 (Eq. (4.30)), is a special form of Eq. (B.50 ): ~~- 1ol,eA(t-a>, may be evaluated
~~)
= Ax(t )+ Bu(t )+ rd(t)
(B.53)
y = Cx(t)
This has the general solution (from Eq.
(B.52)):
x(t) = eACt -to)"o + ( t eA
= Cx(t)
Jro
(B.54)
whe re the matr ix expo nent ials may be com pute d usin g Eq. (0.87 ) of App endi xO. In the special case whe re the coefficie nt matrices A, B, r, C in Eq. (B.53) are functions of t, the solution takes the form show n in Eqs. (0.91) and (0.92) in Appendix D.
1166
APPENDIXB
B.2.3 Delay-D ifferent ial Equatio ns In modelin g the dynamic behavior of certain processes, the resulting equation s indicate relations between the depende nt variable (say, y) and its derivativ es evaluated at different time arguments, for example: (B.55)
which involves not only y(t) and its first derivative, but also the function with the delay-time argument. Equations of this type are known as delay-differential (or differential-difference) equation s. Even though they are closely related to differen tial equation s, solving them requires specializ ed techniqu es. A particularly readable discussion of such equations is contained in Driver (1977) [11]. Of all equation s involving delay-time arguments, the types most commonly encounte red in process control are usually of the form:
d~/) =
ay(t) + bu(t- a)
(B.56)
(and minor variations thereof) where the delay-time argumen t is not associate d with the unknow n function y(t) hut with the "forcing function." The solutions to such equations are most straightforwardly obtained using the method of Laplace transforms (see Appendi x C).
B.3
LINEAR DIFFERENCE EQUATIONS
Conside r the situation in which, instead of dealing with a continuo us function,
y(t), as in the previous section, we now have a sequence y(O), y(l), y(2), y(3), ... , y(k), ... , y( n), where k, the index of the sequence, takes on only discrete,
integer values. Such sequences generate d by difference equations are used to represen t discrete-time processes introduc ed in Chapter 4 and develope d in great detail in Chapters 23--26.
B.3.1 First-O rder Differe nce Equatio ns By analogy with the continuo us first-ord er differen tial Eq. (B.41), the nonhom ogeneou s first-ord er difference equation with constant coefficients is given by: y(k)
+ ay(k-1) = q(k)
(B.57)
where q(k) is a known sequence. To build up a solution from the initial value y(O), we obtain: y(l) = -y(O)
a + q(I)
and subseque nt substitution into Eq. (B.57) for consecutive values of k gives:
'
COMPLEX ALGEBRA, DIFFERENTIAL AND DIFFERE.."'CE EQNS y(2)
= y(O) (-a) 2 -
y{3)
=
y{O) (-a'f
1167
aq(l) + q(2)
+
(-afq(t )- aq(2)
+ q(3)
from which we see that, in general: k
y(k)
= y(OX-a l + I, (-af'-i q(i) t=l
(B.58)
is the solution to Eq. (B.57). Note the analogy between Eqs. (B.58) and (B.42), the solution to li-te continuous differential Eq. (8.41). From Chapte r 4 we recall that the standar d discrete-time model with control u(k), disturbance d(k), and output y(k) has the form: x(k + 1) y(k)
= ax(k) + bu(k) + 'Jd(k) = a(k)
(B.59)
Applying the result in Eq. (B.58) we obtain the solution: k
y(k) = y(O)a" + c
I, ak-i [bu(i -1) + '}ti(i -1)]
r=l
(B.60)
Ji we now compare Eq. (B.59) with Eq. (B.43) and then compare their respecti ve solutions, Eqs. (B.60) and (B.44), we observe that the two solutions are completely analogous, with e•1 in Eq. (B.44) replaced by a", and the integral replaced by the fmitesum.
B.3.2 General nth-Order Difference Equations As was the case with ordinary differential equations, nonhomogeneou s, constant coefficient, linear difference equations arise from process models {cf. Chapters
23-26):
Clo)(k)
+ a 1y{k-1) +
~y(k-2)
+ ... + a,y(k-n )
= q(k)
(B.61)
This nth-order difference equation will have a solution of the form: II
y(k)
= Ao + r=l l:,A1(m;)"
(B.62)
where the m 1, i =1, 2 ... n, are then roots of the characteristic equation: 17om"+ a 1m"- 1 + ~m"- 2 + ... +a,.
=0
(B.63)
Just as we use Laplace transforms with ordinar y differential equatio ns, it is possible to use z-transforms (the "discrete counterpart'' of Laplace transfor ms) to solve linear difference equations having constant coefficients. The technique involved is discussed in Appendix C. It is also possible to convert the nth-order difference equatio n into a system of n first-order difference equatio ns and employ matrix methods.
:pi !~;
1168
n:.. n •:
Ma trix Methods By introducing n new variables zt (k), z 2 (k), ..., zn(k) defi ned as follo ws: z1(k)
=
y(k -n + 1)
z2(k)
=
y(k -n +2)
Z3(k)
=
y(k -n +3)
Zn-2 (k) =
y(k -2)
Zn-1 (k) =
y(k -1)
=
Zn(k)
·..
1
z1(k)
!.i
}I
y(k)
it is possible to convert Eq. (B.61) into a system of n linear first-ord er difference equations. Prom Eq. (B.64) we easi ly obtain:
I
~
(B.64)
~(/c)
= z2(k- 1)
= z3(k- 1)
(B.65)
=
(k) Zn-l (k-1 ) Zn-l (k) = z4 (k-1 ) Zn-2
and finally, from Eq. (B.61), we obtain, upo n solving for y(k), md Using the appropriate new -1) variables for each y(k - t) term :
znc
This syst em of n equations may now be wri tten in the mor e com pact vectormatrix form as: ~k)
= ~~k -1) + f(k)
(B.66)
whe re we see that the n-dimension al vectors z(k), f{k), md the n x n mat rix ~are given by:
(k)]
~k)
=
z1 z [ 2(k) Z4 (k)
;
•
COMPLEX ALGEBRA, DIFFERENTIAL AND
0 0
1
0
0
1
0
0
0
-a.
-an- I
-an- 2
-a]
Go
Do
Go
Go
ell=
I
DIFFERENCE EQNS
1169
0 0
This is now the matr ix representatio n of the nth-order linear difference equa tion. Aga in, it is imp orta nt to note the similarity betw een Eqs. (B.66) and (B.57); inste ad of the scalar functions and coef ficients we now have vector functions and mat rix coefficients. By following prec isely the sam e argu men ts that led to the derivation of the solu tion in Eq. (B.58 ) -pa yin g due respect to the peculiar laws of matr ix algebra (see App endi x D) -w e may obta in the solution to Eq. (B.66) just as straightforwardly; the resu lt is:
~k) == cll"z(O) +
k
"£ cll/t.-i f(t) t=l
(B.67)
where z(O) represents the vector of initi al conditions on z( k). The line ar discrete-time mod el for mul tivariable syst ems was pres ente d in Cha pter 4 (and disc usse d in deta il in Cha pter s 24-26). This is a special case of Eq. (B.66) and takes the form: x(k +I) = cllx(k) + Bu(k ) + rd(k )
(B.68)
y(k) = Cx(k )
By extension of the results above, the solution to Eq. (B.68) may be writ ten: x(k) = cllkx(O) +
•
t=l
y(k) = Cx(k )
B.4
k
L cl>k-t [Bu(i -1) + rd (i- 1)]
NONLINEAR DIFFERENTIAL EQUA
(B.69)
TIONS
As state d earlier, any equa tion that expresses a relation betw een a function y(t) and its deri vati ves is a diffe rent ial equa tion ; in part icul ar, if the indi cate d relationship is nonlinear, we have a nonl inear differential equation. For exam ple, the equation:
~
= f(t,y )
(B.70)
is a first-order nonl inea r differential equation if f{t,y) is a nonlinear function of y. The general nonl inea r nth-order diffe rential equation may be represented as:
!f2 - 1 Y . . f!r .. )! ( dt" .d" ' dtn- l ' ... ' dt 'Y' t - O where f(·) is som e nonlinear function of the indicated arguments.
(B.7l)
APPENDIXB
1170
For linear equations, there are well-defined, systematic procedures for finding solutions in all cases, some of which were reviewed in Section 8.2. Unfortunately there are no corresponding general procedures for generating solutions to all nonlinear equations. In fact, the determination of analytical solutions for nonlinear equations of any order is not always possible in general; only in a few very special cases are there some specialized methods for obtaining analytical solutions. In the vast majority of cases, one must resort to numerical techniques for constructing the approximate solutions. Thus, this section will be devoted to describing the basic approaches to numerical solution of nonlinear differential equations.
Numerical Methods The basic premise of numerical methods may be summarized as follows: 1.
The differential equation in question has an unknown solution which may be represented as: y
=
Tj(t}
(B.72)
2
This continuous function J}(t) cannot always be obtained in its "true" functional form (explicitly) by analytical techniques so an attempt is made at generating instead the discrete sequence '1(t0 ), 17(~), 17(~), ... , 17(tk), •.. , representing the numerical values it takes at specific discrete points t 0 < t1 < t2 < ... < t" < . .. separated by an interval of size M.
3.
The continuous variables in the differential equation are therefore replaced by discrete variables and the derivatives by appropriate finite difference quotients. The differential equation is thereby converted to a difference equation (in the form of a recurrence relation) which is easily solved especially when programmed on a high-speed digital computer.
4.
Since this process involves some approximation, the discrete sequence generated from the "surrogate" difference equation, which we shall refer to as y(O), y(l), y(2), ... , y(k), ..., will not match the true but unknown values 17(t 0), 17(t1), 17(t2), ••• , 17(t"), •••,precisely; however, approximation errors associated with a good numerical method are usually small.
5.
What differentiates one numerical method from another is the technique adopted for deriving the "surrogate" difference equation from the original differential equation.
Before reviewing specific numerical techniques, we note the following important issues and questions raised by numerical methods: 1.
The numerical solution y(O), y(l), y(2), ... , y(k), ... constitutes only an approximation to the exact but unknown solution because of unavoidable errors introduced in the course of its computation. These errors arise from two separate sources: (a) from the numerical methods formula itseU (which must be obtained by introducing some approximations), and (b) from the fact that in any computation, only a finite number of significant
COMPLEX ALGEBRA, DIFFERENTIAL AND DIFFERENCE EQNS
1171
digits can be retained. The former is referred to as discretization (or
formula) error; the latter as round-off error. 2
Is it always possible to estimate the magnitude of these errors? This question is important from the point of view of evaluating the integrity of the solutions generated by various numerical methods.
3.
As Llt the interval between the discrete points ~~ t1 , t 2, ••. , t1 , ••• tends to zero, will the values taken by the numerical approximation also tend to the values of the exact, but unknown, solution? This question addresses the issue of convergence.
These and other related issues not mentioned here are critical to the successful generation of numerical solutions and are therefore discussed in great detail in texts devoted exclusively to numerical methods. The supplied references [15,16] are recommended to the reader interested in pursuing these aspects further. For now we will review a few of the key techniques used to obtain numerical solutions to differential equations.
The Euler Method In solving the nonlinear first-order equation:
~ given the initial condition y( t0 )
= f(t,y)
(B.73)
=y(O): = t k and therefore replace the
1.
If we let y(k) represent y( t) at the point t continuous J(t,y) withj{t1 , y(k)), and
2.
If we replace the derivative with the finite difference approximation:
(B.74)
then the differential equation becomes:
(B.75)
which is easily rearranged to give: (B.76)
or, simply: (B.77)
W! !/
,j'
1172
APPENDIXB Observe now that starting with the initial value y(O), Eq. (8.77) can be used recursively to generate the sequence y(l), y(2), y(3), . .. as the required approximate solution to Eq. (8.73). The formula in Eq. (8.75) is known as Euler's method; it represents one of the simplest schemes available for solving initial-valu e problems. It has the advantage that it is very straightforward to use, and very easy to program on the computer; its main disadvantag e is that it is not very accurate. It can be shown that the local formula error for Euler's method is proportiona l to (M)2 and to the second derivative of 71(t ), the true, but unknown solution. While it is true, in general, that the accuracy of Euler's method may be improved by reducing the interval size At, unfortunate ly there is a limit beyond which any further reduction in interval size actually worsens the accuracy. Observe that as At is reduced, many more steps are required in going from to to the final point tN; but round-off error is introduced at each step of the calculation so that the accumulate d round-off error actually increases as the interval size At is reduced. Clearly it is possible to cross a point where the increased accuracy achieved by the interval size reduction is offset by the increase in the accumulated round-off error.
The Improved Euler Method The simple Euler method may be improved upon as follows: Let us once again consider the equation: y'(t) =
~ = fl.t,y)
(8.73)
with its initial condition y( fo) = y(O) whose unknown solution is given by tk+I we obtain:
y = 7J(f). By integrating from the point tk to
(8.78)
Observe therefore that in relation to Eq. (8.78) the Euler formula: (8.77)
is equivalent to replacingj[t,7](t)J over the entire interval [t k• tk+ 1] by f(tk,y(k)), the approximat e value taken at the left-hand boundary of the interval. A better approximat ion may be obtained if Jtt, 71( t)) in Eq. (8.78) is replaced by an average of its value at the two boundaries of the interval, i.e:
and upon replacing 1](tk) and 17(tk+l) with their respective approximate values y(k) and y(k + 1) we obtain the improved formula:
COMPLEX ALGEBRA, DIFFERENTIAL AND DIFFERENCE EQNS y(k + 1)
= y(k)
+ t.t {
f(tk ,y(k)) + f(tk+!•y(k + ~
1))}
L,
1173 (B.79)
The only complication now is the appearance of the unknown y(k + 1) in the RHS of Eq. (B.79)i this is resolved by introducing the simpler Euler formula Eq. (B.77) in its place. Simplifying the notation further by using y'(k) to represent f(t k, y(k)) we obtain the final result y(k + 1) = y(k) +
t.t {
y'(k) + f(tk+! ,y(k)+ llty'(k) )} 2
(B.80)
It can be shown that the local formula error for the improved Euler method is proportiona l to (M and since the only reasonable values for M are usually such that IM I << 1, it follows that the improved formula is indeed more accurate. It should be noted that the improved accuracy has been achieved at the expense of increased computation.
r I
The Runge-Kutta Method The formula: (B.81)
where cl
=
fih • y(k))
c2 = t(rk
+!
M ;y(k)+
c3 = t{tk+!M;y (k)+ c4
(B.82a)
~ &c1)
(B.82b)
~&c2 )
(B.82c)
= f(tk+ &;y(k)+llt c3 )
(B.82d)
is similar to the improved Euler formula except that f(t,7j(t)) is now replaced by a weighted average of the values it takes at various points in the interval [t k' t k + ]. 1 This is the formula for the (fourth-order) Runge-Kutta method; it is a very
accurate and very popular method for obtaining numerical solutions to initialvalue problems (despite the fact that it is more complicated than any of the Euler methods). It can be shown that the local formula error for this method is proportiona l to (llt)S. It should be mentioned that there are many other categories of numerical methods (e.g., variable step-size, multistep, etc.) which are discussed at length in standard texts on numerical methods. However, the reader should also note that
computer software packages abound which offer a wide variety of these
numerical teclmiques so that it is no longer necessary for one to write one's own program for carrying out the required computations. It is, however, important for one to understand the implication s of using one method as opposed to another.
1174
APPEND!XB
Higher Order Equations It can be easily shown that any higher order differential equation can be reduced to a system of several first-order equations of t..l-te type in Eq. (B.73). Numericnl techniques applicable to first-order equations extend quite straightforwardly to systems of first-order equations. Thus problems involving higher order equations, or those involving systems of first-order equations, do not raise any additional issues of consequence. See, for example, Refs. [14, 16].
REFERENCES AND SUGGESTED FURTHER READING General references that cover several aspects of applied mathematical methods (particularly complex variables and ordinary differential equations) abound; the following, arranged roughly in order of increasing depth, is a small, somewhat representative selection.
1. 2
3. 4.
5.
Stephenson, G., Mathematical Methods for Science Students, Longmans, London (1971) Greenberg, M. D., Foundations of Applied Mathematics, Prentice-Hall, Englewood Cliffs, NJ (1978) Kreyszig, E., Advanced Engineering Mathematics, (3rd ed.),J. Wiley, New York (1972) Wylie, C. R., Adwmced Engineering Mathematics, (4th ed.), McGraw-Hill, New York (1975) Sokolnikoff, I. and R. Redheffer, Mathematics of Physics and Modern Engineering, McGraw-Hill, New York (1966)
The following are two specific references on the subject of Complex Variables: the first is more modem and discusses applications; the second is considered a classic treatise on the theory with very little by way of applications. 6.
7.
Churchill, R. V., J. W. Brown, and R. F. Verhey, Complex Variables and Applications, (3rd ed.), McGraw-Hill, New York (1976) Copson, E. T., Theory of Functions of a Complex Variable, Clarendon Press, Oxford (1935)
The following are references on the general topic of Ordinary Differential Equations: Ref. [8) is very pleasant to read, Ref. [9] is a venerable classic, Ref. [10] gets very theoretical at times, and Ref. [11] contains a systematic treatment of Delay-differential equations. Boyce, W. E. and R. C. DiPrima, Elementary Differential Equations and Boundary Value Problems, (3rd ed.), J. Wiley, New York (1977) 9. lnce, E. L., Ordinary Differential Equations, Dover, New York (1956) 10. Coddington, E. and N. Levinson, Theory of Ordinary Differential Equations, McGrawHill, New York (1955) 11. Driver, R. D., Ordinary and Delay-differential Equations, Springer-Verlag, New York (1977) 8.
Two important references providing detailed and thorough treatments of the topic of Difference Equations are: 12. Goldberg, S., Introduction to Difference Equations, J. Wiley, New York (1958) 13. Milne-Thompson, L. M., The Calculus of Finite Differences, Macmillan, London (1933)
COMPLEX ALGEBRA, DIFFERENTIAL AND DIFFERENCE EQNS
1175
There are numerous useful references on the general subject of Numerical Methods; the following is somewhat of a representative sample in terms of breadth and depth of coverage. 14. Hornbeck, R. W., Numerical Methods, Quantum Publishers, New York (1975) 15. Conte, 5. D. and C. de Boor, Elementary Numerical Methods, (2nd ed.), McGraw-Hill, New York (1972) 16. Carnahan, B., H. Luther, and J. Wilkes, Applied Numerical Methods, J. Wiley, New York (1969) 17. Henrici, P., Elements of Numerical Analysis, J. Wiley, New York (1964) The following are references that focus attention on the more computational aspects of Numerical Methods: Ref. [18] is a good introductory text, while the more recent Ref. (19] is a comprehensive and immensely useful (almost indispensable) reference book. 18. Kuo, 5. 5., Computer Applications of Numerical Methods, Addison-Wesley, Reading, MA (1972) 19. Flannery, B. P., S. A. Teukolsky, and W. T. Vettering, Numerical Recipes (inC or in Fortran): The Art of Scientific Computing, W. H. Press, Cambridge University Press (1988) Two of the more specialized references concerned with the numerical solution of Ordinary Differential equations are: Ref. [20], authored by a well-respected practitioner, and Ref. [21], a more advanced treatment of the same subject. 20. Gear, C. W., Numerical Initial-value Problems in Ordinary Differential Equations, Prentice-
Hall, Englewood Cliffs, NJ (1971)
21. Henrici, P., Discrete Variable Methods in Ordinary Differential Equations", J. Wiley, New
York (1962)
Ill
AIPJPJENDKX
c LAPLACE AND z-TRANSFORMS Integra l transforms have had a most endurin g impact on the analysis and design of linear control systems and are key components of the enginee r's toolbox. The most popula r of these have been the Laplace transfor m for continuous systems, and the z-transform for discrete systems. E:ven though certain aspects of the Laplace and z-transforms have been introdu ced in Chapte rs 3 and 24, the material present ed here is intende d to be a moi:e complete summary. A brief introduction, first to the general family of integral transforms, and then to the Fourier transform in particUlar, precedes the main subject matter; it is designed to emphasize the close ties between the Laplace transform and the Fourier transform. The unifying theme is extended finally to the z-transf orm by present ing it as a natural consequence of applyin g the Laplace transform to sampled functions.
C.l
INTRODUCTION: THE GENERAL INTEGRAL TRANSFORM
The process of multiplying a function of a single variable t, say, f(t), by K(s,t), a function of two variables s and t, and integrating the resulting produc t with respect to t between limits a and b, gives rise to a function of the single survivin g variabl es, say, /(s); the original function,f(t), is thus "transformed" to /(s) by the indicated process that may be represented mathematically as:
T {f(t)} =
r
K(s, t)f(t)dt
= j(s)
(C.l)
a
• This is an expression for the general integral transform; K(s, t), the function of two variables that serves as the multiplier in the transform formula is called the kernel of the transform. By specifying various kernels and limits of integrat ion, several useful integral transforms can be obtained from Eq. (C.l). For example, when a =0, b = -, and K(s, t) =e-st, we have the Laplace transform defined in Eq. (3.1). Some other examples are: 1177
APPENDIX
1178
1. FOURIER TRANSFORM: a= -oo, b =oo, K{e», t)
c
=e-Jt»t
2. HANKEL TRANSFORM: a= 0, b = oo, K{l, t) = t Jv{lt), where J (lt) is v Bessel's function {of the first kind) of order V> -1/2 3. MELLIN TRANSFORM:
a = 0, b = oo, K(s, t) = t' -1
4. LAGUERRE TRANSFORM: a= 0, b = ...., K(n, t) = e-tL..(t), where L..(t) is the Laguere polynomial of order n
Such integral transform formulas are usually accompanied by the "inverse" expression of the kind:
1 1{)(s)}
=
r·
K*(s,t)j(s)ds
=J(t)
(C.2)
a•
by which the original function, f(t), may be recovered from its transformed version, f(s), using K"{s, t), the kernel of the inverse transform formula, and integrating out the s variable between the limits a• and b"". For example, the corresponding inverse Laplace transform expression has:
a• = a + je», b"" = a- je» and K•(s, t) = e'121tj and, for the inverse Hankel transform:
a• = 0, b• = oo, and K•(A.,t) = llv{lt) The integral transform of Eq. (C.l) and its inverse relation in Eq. (C.2) constitute a "transform pair." Integral transform pairs in general have found significant application in science and engineering; and some transforms are more natural than others for certain applications. For example, in certain aspects of the theory of elasticity, the Mellin transform is the more natural choice. For process control applications, however, the Laplace and Fourier transforms are the most natural and most useful; and it will be shown later that for the analysis and design of discrete-time control systems, it is in fact just a clever adaptation of the Laplace transform that leads to the more natural z-transform.
C.2
THE FOURIER TRANSFORM
The Fourier series expansion for a function f(t) over the interval [-L, L ] is given by: (C.3)
where the coefficients are given by:
1179
LAPLACE AND z-TRANSFORMS a. =
t fL fit)co{ nt Jt
(C.4a)
and (C.4b)
By substituting Eq. (C.4) into Eq. (C.3) and taking limits as L -> co, after carefully carrying out the required manipulations, and using the exponential representation for the sin and cos functions, we obtain: (C.5)
This is the Fourier integral formula; it provides the origin of the Fourier transform and its inverse. For, if we were to define:
J
;a
f_~ fit)e-iOJt d t
(C.6)
then Eq. {C.S} immediately becomes: (C.7)
We may now observe that, in the spirit of the general integral transform pair given in Eqs. (C.l} and (C.2}, Eq. (C.6) expresses the transform of the function f(t}, and Eq. (C.7) the corresponding inverse. Thus,J(m) defined as in Eq. (C.6) is called the "Fourier transform" of f(t), and Eq. (C.7) is the corresponding inverse "Fourier transform" formula by whichf(t) is recovered fromJ(m). Note that the domain of f(t) is infinite.
C.3
THE LAPLACE TRANSFORM
Not all functions are Fourier transformable. In particular, some important functions employed in process dynamics and control - for example, the step function, and the ramp function - are not Fourier transformable because they are functions that do not decay to zero fast enough as t ~ co. Also, the domain of the functions encountered in process dynamics and control is usually the semiinfinite region 0 :5 t < co and not the infinite region of the Fourier transform. Thus the Fourier transform may not be the most natural for process dynamics and control problems in general. The Laplace transform is the result of modifying the Fourier transform to better suit such problems.
1180
APPENDIX
c
C.3.1 Definition and Inverse Formula Consider a function f(t) that satisfies the following conditions: 1. :~i
It is "piecewise regular"; (i.e., it is bounded in every interval of the form 0 S t 1 S t S t 2, and has at most a finite number of maxima and
minima, and a finite number of finite discontinuities).
i
'.f
2.
!r. , .
It is of "exponential order" (i.e., there exist constants a, M, and T such that e-
Note that if e-<'1 1f(t) I < M then it is also true that e-<'llf(t) I < M for all a1 >a; therefore, the a required by Condition 2 is not unique. Now, let a be the greatest lower bound (infimum) of the set of a values for which Condition 2 is satisfied: then a is called the "abscissa of convergence" of the function f(t). Now, by virtue of Condition 2 and this definition of the abscissa of convergence, for any function satisfying these two conditions, the following composite function: 0;
t
emf(t);
t>
¢(t) = {
o
(C.8)
is guaranteed to be Fourier transformable regardless of whether J(t) is or not Introducing Eq. (C.8) into Eq. (C.5) gives: c"' f(t) =
2~f..
(e-a~f( 7:))e-illtC d1: dw
ei(J)' [ 0
-oo
so that: f(t)
=
_!_f
e
21r _..
j(J))~ d1: dro
(C.9)
0
and by introducing the new variable:
s
= a +jro
(C.lO)
Eq. (C.9) becomes: 1 j(t) = lim ~ tJJ ..... 1CJ
fa+jtJJ e" iooj("()e""'T d'l:ds a-}t» 0
(C.ll)
and now, by defining:
Jcs>
= [
f(t)e-" dt 0
Eq. (C.ll) immediately becomes:
(C.l2)
1181
LAPLACE AND z-TRAN SFORM S
fi.t) = lim
w-+-
~ 1r}
f
a+j(J)
(C.13)
f(s) e'' ds
a-j(J)
giving the Laplace transform and its inversion formula. variable sis From Eq. (C.lO) we may observ e that the Laplace transfo rm a is the formul on inversi the in ed indicat complex. Also, the path of integra tion as known is it oo; w-+ as jw a+ to jw afrom plane x comple the straigh t line in 3. r Chapte in ion express the in "C" the Bromwich path, and simply denote d by 3: r Chapte in Thus, as initiall y stated r and of The Laplace transform of a Junction f(t) that is piecew ise regula inverse onding corresp the (C.12); Eq. by given is order ential expon transform is given by Eq. (C.13). r integra tion in the In princip le, therefo re, accord ing to Eq. (C.13), contou
Laplac e transfo rm; comple x plane must be carried out in order to invert a e transfo rms, an Laplac of tables use to ary custom is it e, practic in howev er, . section this of exampl e of which is presen ted at the end
C.3.2 Prope rties and Usefu l Theor ems of Laplace Trans forms Basic Properties 1. Linear ity (C.l4)
d. Extension to linear combination of n functions is straigh tforwar 2. Transf orm of Deriva tives
L
{%} =
L{
~:{} =
(C. IS)
sf(s) - fi.t)l,=o s2f(s) -
sfi.t)j, =0
-
1:) I
(C.16)
t=O
and by conven tion, or, in genera l, if f"l(t) represe nts the nth derivat ive of f(t), j\O)(t) = f(t): (C.17)
When all the initial conditi ons are zero, then: L {/"\t)} = s" f(s)
(C.18)
is very useful in and an nth derivat ive is turned to an nth power of s. This result it provid es the ; models n equatio tial differen from ns obtaini ng transfe r functio
1182
APPENDIXc
motivation for working with deviation variables, since, by definition, these have zero initial conditions. 3. Transform of Integrals
~'.!''· f'
(C.l9)
n.
Additional Properties Useful In Engineering Applications
J(s), then:
H L{f(t)} =
4. Time Change of Scale
L{j{at)}
Conversely, if L-1
=
!J(: )
(C.20a)
{J(s)} =/(t), then: (C.20b)
5. Complex Shift (i.e., shift ins) (C.21)
Typical application: Since C 1(1/s) = 1, then by Eq. (C.21): L-l
{-1}= s+a
e-o'
(C.22)
= e-o• J(s)
(C.23a)
6. Time Shift
L{ft:t- a)} Conversely:
(C.23b)
This is very useful in obtaining time-domain behavior of time-delay systems. 7. Complex Differentiation (or transform of time product) L{tj{t)}
Conversely:
= - ~J(s)
(C.24a)
.
1183
LAPLACE AND z-TRANSFORMS
f(t)
" } d f(s) = t-1 L- 1 { d;
Typical application: since L{e-• 1}
L{ te-a'}
(C.24b)
= 1/(s +a), then by Eq. (C.24a): 1
(C.25)
= (s + a)2
but Eq. (C.24b) is helpful when the inverse of a transfor m is not easy to find
the
inverse of the derivati ve is known. For example, if:
')
J(s)
= In
[{Lill] (s _ 1)
because 1 dJ(s) = ;+I d.;
~
_l (e- 1 -
e1) =
l
then by Eq. (C.24b): j(t) =
t
l2 sinht t
The general form of Eq. (C.24a) is: L{f f(t)} = (-1)" ~"nJ(s)
(C.26)
which may be used to deduce, for example, that since L[1] = 1/s, then:
L{t"} 8.
n! = li+l s
Comple x Integrat ion (or transform of time quotient) (C.27)
9. Transfo rm of Periodic Functions the behavio r For an arbitrar y function f(t) that is periodic with period T (i.e., ... , [(n -1)T, 2T], [T, T], [0, s of the function is identical over the time interval nT]), let: (C.28)
then
1184
APPENDIX c L{f{t)} = ~ 1 - e-Ts
(C.29)
For exam ple, if j(t) is a train of spike s of unit heigh t, preci sely t:.t time units apart , then becau se
J(s) = 1 l -slit -e
(C.30)
(Com pare with the z-tran sform of the samp led unit step funct ion given in Chap ter 24.) 10. Final -Valu e Theo rem lim f(t)
t-+-
= s-+0 lim
[s J(s)]
(C.31)
J
provi ded s (f) does not becom e infini te for any value of s with a positi ve real part; i.e., s J(s) has no positi ve poles . (The theor em is appli cable only to funct ions for which the limit as t ~ oo exists .) This resul t is very usefu l for obtai ning the stead y-stat e gain of a (stable) proce ss from its transf er function. 11. Initia l-Val ue Theo rem lim f(t) = lim [s J(s)]
1"""'*0
(C.32)
s-too
appli cable only to funct ions for which the limit as t was used in Chap ter 7 to analy ze the behav ior of inver
~ oo exists. This result se-response system s.
12. The Conv olutio n Theo rem If L{f(t)} = J(s), and L{g(t)} =g(s), then:
L{ f~ f(t- ..l.)g(A.) dA.} =
i{
f(A.)g (t- A.) dA.}
= j(s) 8
(C.33)
appli cable in obtai ning impu lse-re spons e mode ls from trans form- doma in transf er funct ion mode ls. To take full advan tage of this theor em, it is helpf ul also to know the following about the convolution operation. The convo lution of two funct ions j(t) and g(t) of a real variab le t, writte n symb olical ly as: ~(t)
= j(t) * g(t)
is defin ed as:
~(t) =
r
f(t _ A.)g(it) d..l.
0
. ~··
(C.34a)
(C.34b)
"
LAPLACE AND z-TRANSFORMS
1185
It has the following properties :
• Commutativity:
f{t)
* g(t)
= g(t) * f{t)
* g(t)] * h(t)
= f{t)
* [g(t) * h(t)]
* h(t)
= f{t)
* h(t) + g(t) * h(t)
• Associativity:
[f(t)
• Distributivity: (with respect to addition)
[f(t) + g(t)]
The commutat ivity property is employed , for example, in the first equality in Eq. (C.33).
C.3.3 Solution of Linear Differen tial Equatio ns One of the most important applications of Laplace transform s is in the solution of linear differenti al equations . Consider the general nth-order linear differenti al equation: (C.35)
and for simplicity, let us assume that all the initial condition s are zero. Taking Laplace transform s of both sides (and for convenience, simplifyin g the notation by dropping the " used to distinguis h the Laplace transform ed function), we have, from Eq. (C.l8), that (C.36)
which is eqsily solved for y(s) to give: (C.37)
For any specific forcing function, j(t), with a Laplace transform , j(s), in principle, the solution of the differential equation, y(t), is now that particular function whose Laplace transform appears on the right-hand side of Eq. (C.37). It is impractic al to construct a Laplace transform table general enough to contain all possible functions, y(t), and their correspon ding transform s, y(s); thus in its present general form, Eq. (C.37) cannot be inverted to obtain the required y(t). However , it is possible to express the right-han d side of Eq. (C.37) as a sum of simpler functions whose inverse transform s are easily found. For example, if for a given j(s), the n roots of the denomina tor polynomi al in Eq. (C.37) are real and distinct, and given as rp r , ••• , rn, then it 2 is possible to express Eq. (C.37) as: y(s)
AI
A2 r2
A. s- r.
= - - + - - + ... + - s- r s1
By the linearity property of Laplace transform s, and by the fact that:
(C.38)
APPENDIX C
1186
r' {l/(s -a)} = eat we now obtai n the requi red y(t) as: (C.39)
an expan sion of the original Obse rve that the expre ssion in Eq. (C.38) is fractions"; the proce dure for ial comp licate d function in terms of simpl er "part there fore know n as partial is (C.38) Eq. in conve rting Eq. (C.37) to the form Laplace transf orms to solve fraction expansion. This is the key step in using linear differ ential equat ions.
C.3.4 Parti al Fraction Expa nsio n the ration al funct ion, R(s), This series of proce dures invol ves expre ssing repre sente d by:
M
R(s) = Q(s)
(C.40)
P(s), a polyn omia l of order p, as a sum of partia l fractions. It is assum ed that omia l of order q; that all the has no comm on facto rs with Q(s), a polyn is strictly proper~ (We will R(s) that i.e., coefficients are real; and that p < q; p = q, i.e., when R(s) is which in ion situat the for later prese nt a proce dure mere ly prope r.) r r , ••• , rq, are known. The The proce dures assum e that the q roots of Q(s), 11 2 to three distin ct cases: possi ble characteristics of these roots give rise 1. All q roots are real and distin ct 2. A subse t of the roots are repea ted 3. Some of the roots occur as complex conjugates CASE 1: Real and distin ct roots. In this case: (C.41)
g by (s- r 1) gives: and we want to find Ai, i = 1, 2, ... , q. Multiplyin (s- r 1)P(s)
(C.42)
Q(s)
and by settin gs= r11 we obtain the result: (C.43)
I
I
1187
LAPLACE AND z-TR ANSF ORM S
In general: (C.44)
ins of R(s) after the factor (s - ri) has Thu s, if we let tPi(s) repr esen t wha t rema ial Q(s), i.e.: nom been removed from the denominator poly (C.45)
then Eq. (C.44) translates to: (C.46)
Exam ple C.l
DIST INCT ROOTS. PARTIAL FRACTION EXPANSION:
the function: Obta in a partial fraction expansion for R
(s + 5) (s) = (s + 2)(s + 3)
Solu tion: (s + 5) (s + 2)(s + 3)
AI
A2
s+2
s+3
--+--
=
larly, -2 we obtai n immediately A1 3. Simi Mult iplyi ng by (s + 2) and setting s gives A 2 = -2. multiplying by (s + 3) and setting s = -3 N EXPANSION: DIST INCT ROOTS. Exam ple C.2 PARTIAL FRACTIO
=
Obta in a partial fraction expansion for R
the function: (s 2
+ 5s + I)
(s) = s(s 2 + 5s
+
6)
Solu tion: : Factoring the denominator quadratic gives R(s)
(s 2 + Ss + 1) + 3)
= s(s + 2)(s
so that: (s 2 + Ss + 1) s(s + 2)(s + 3)
Clearly:
(s2 + 5s + 1)/(s + 2)(s + 3)
+ 5s + 1)/s(s + 3) (? + 5s + 1)/s(s + 2)
(s 2
'
j
r
f
l'' (
1188
APPENDIXC
Thus:
I
are the requ ired coefficients. This is the parti al fraction expa nsio n resul t used in Example 3.3 of Chap ter 3.
CASE 2: Rep eate d roots. In this case, we cons ider that Q(s) has q- k disti nct root s and one root , rw is repe ated k time s, thus: R(s) =
ew_ = (-AI - + ... + Q(s) s-r 1
Aq-k
)
s-rq -k
+
P*(s ) k (s-r m)
(C.47a)
or
= RO(s)
R(s)
+
R*(s )
(C.47b)
whe re R0(s) em resp onds to the sum of unre peat ed factors in wing ed brac kets. Obs erve that the coefficients Ai, i = 1, 2, ... , q- k can be foun d as in Case 1. Now expa nd the rem aini ng term as follows:
Mul tiply ing by (s- r,i in Eq. (C.47a),
Bk
usin g Eq. (C.48), and setti ngs = r give s: 711
= }~n;. 0
[
(
s-
rm
)k ..fl& Q(s) .J
(C.49)
To simp lify the nota tion , if we defin e:
= (s- r m)" P(s) = Q(s)
(s- rm)k R(s)
(C.50)
i.e., wha t is left of R(s} after (s- r )k has been rem oved , th~n we have: 711 (C.5 l)
The othe r Bi coef ficie nts are obta ined by diffe rent iatio n. Eqs. (C.47) and (C.48) that: (s-rm )kR( s) = (s-rm )kR 0(s) +Bk
+
Obs erve from
(s-r m)B k-!+ (s-r m) 2Bk_ 2
(s- r711 )k- 2B2 + (s-r m)k -lB 1
+ ... + (C.52)
I
LAPLACE AND z-TRANSFORMS
1189
And now, by differentiating with respect to s and settin gs =rm' we obtain: (C.53)
or (C.54)
The others are determ ined similarly by repea ted differentiation in Eq. (C.52). The result is:
__1_[
4i*(s)J
tfk-j)
Bj- (k-j) !
J.s(k-J)
s=rm
(C.55)
It is straig htforw ard to generalize these result s to the case with several sets of repea ted
roots.
Examp le C.3
PART IAL FRAC TION EXPANSION: REPEATED ROOT S.
Obtain a partial fraction expans ion for the function: Rs
-
( ) -
s(s 2
I
+ 6s +
9)
Soluti on: Factoring the denom inator quadra tic gives: I R(s) = ~(s + 3)2
which we wish to expan d as:
s(s + 3) 2
In this case, the repeat ed root is at s = 3, and: P(s) = Q(s)
= s(s + 3)2
Also: I
Thus, we obtain, in the usual manne r (multiplying by
sand setting s= 0):
1190
APPENDIX C
Next, we obtain:
"l
I
and finally, since:
l
then we have:
l
9
The complete partial fraction expansion is therefore given by: s(s
1
1/9
+ 3) 2
-.;-
-113
II
-119
+ (s + 3 ) 2 + (s + 3)
CASE 3: Complex conjugate roots. In this case: R(s)
M
cl
Cz
= Q()s = -(s-r -) +s-r -( *) + R+(s)
(C.56)
where r
= a±bj
(C.57)
and R+(s) is the remaining portion of R(s). H we let
=
(C.58a) (C.58b)
then C1 and C2 are obtained in the usual manner, by multiplying in tum first by (s- r), and settings =r, and then by (s- ,.) and settings =,.; the result is:
cI -[~] (r-1'*)
(C.59)
-[~] (I'*- r)
(C.60)
Cz -
It is easy to show that C2 will always be the complex conjugate of C1 , so that in actual fact, only one of them need be evaluated. Example C.4
PARTIAL FRACI"ION EXPANSION: COMPLEX ROOTS.
Obtain a partial fraction expansion for the function: R (s) -- s(s 2 + 42s + 2)
1191
LAPLACE AND z-TRANSFORMS
Solution: Factoring the denominator quadratic gives: 4
R( s ) --
s(s - r)(s - r*)
with r
= - (1 + ;);
r*
= - (1 -f)
and we wish to expand this as: C2 Cl AI -; + (s + I + f) + (s + i - j)
4 s(s - r)(s - r*)
In this case: 4
s
and since r- r" =-2j, we obtain from Eq. (C.59) that:
and from here that
c2
= -1
+j
We obtain A1 in the usual manner (multiply by s, sets= 0) to be 2. The complete partial fraction expansion is therefore given by: 2
4 s(s - r)(s - r*)
= -; +
(-1-i)
(-l+j)
(s + I + j) + (s + I - j)
Note from Eqs. (C.59) and (C.60), and also from the example, that C1 and C2 will naturally occur as complex numbers. This is awkward if the end result is not merely partial fraction expansion, but the Laplace inversion to obtain R(t). For this reason, Eq. (C.56) is often consolidated to: (C.61)
where we have made use of the fact that C2 = C1*, the complex conjugate of C1• It is now easy to show that Eq. (C.61) simplifies to: R( )
s
(s - a)
= 2 a (s- a)2 + b2
-
2{3
b
(s- a)z + bz +
R+( )
s
(C.62)
where
a
[~]
Re(C 1) -- Re (r- r*)
(C.63a)
1192
APPENDIX C
f3 -
Im(C 1)
--
[~]
Im (r _ r*)
(C.63b)
The Laplace inversion of Eq. (C.62) will therefore be:
f3
R(t) = 1e'l1 (a cos bt -
sin bt) + R+(t)
Thus, for the function in Example C.4, a= -1, b =-1, a= -1, inverse transform is:
(C.64)
f3 = -1,
and the
2 + 2 e-t [sin (-t)- cos (-t)]
R(t)
or R(t)
=2-
2 e-t (sin t + cos t)
CASE 4: R(s) not strictly proper.
When p = q (i.e., the numerator and denominator polynomials of R(s) are of equal order), R(s) is now merely proper. The procedure for handling this case calls for expressing R(s) as: R(s) = A 0
+ R 1(s)
(C.64)
where R1(s) is now strictly proper and can therefore be expanded as before. It is easy to show that A 0 is given by: A0
=
lim R(s)
(C.65)
s->~
Example C.5
Obtain a
pa~tial
PARTIAL FRACTION EXPANSION: R(s) NOT STRICTLY PROPER. fraction expansion for the function: (s 2 +4s+3)
R (s)
= (s 2 + 9s +
20)
Solution: Factoring both the numerator and the denominator quadratics we obtain: R(s)
=
(s (s
+ 3)(s +I) + 4)(s + 5)
which is not strictly proper. First we obtain A 0 by dividing numerator and denominator by s2, before taking the limit as s ~ oo; giving the resultA0 = 1. Thus, we may expand R(s) as follows: (s
(s
+ 3)(s + I) + 4)(s + 5)
!+ _AI _ _ + _A2 __ (s + 4) (s + 5)
obtaining in the usual manner that A 1 =3, and A2 =-8. The complete partial fraction expansion is now given by:
LAPLACE AND z-TRANSFORMS
1193 R() s
=
1 +_3_ _ _8_ (s + 4) (s + 5)
The transfer function of the lead/lag system is an example of a rational function which is not strictly proper. Reference [1] should be consulted for more information about the Laplace . transform and its application in engineering, A table of Laplace transforms of some common functions is provided below in Table C.1. References [2,3] contain more extensive tables of Laplace transforms.
Table C. I. Table of Laplace Transforms of Some Common Functions
J(s)
J(t)
1
1.
-
2.
-
3.
-
1
5
1
t
52
1 s"
t" -1 (n- 1)!
2{f
4.
5 -3/2
5.
r~) (k~ O)
f-1
6.
~(k~O)
tk -1e-at
7a.
-s+a
e....,,
--
1 +1 1 s(ts + 1) 1 (s + a) 2 1 (ts + 1)2 1 s(-rs + 1?
-1 e -1/r
'tS
'r
s
(s + a)k 1
7b. 8.
9a. 9b.
10. lla.
llb. 12.
1 - 11
(s +a)
(n = 1,2, ... )
1 )" (n = 1, 2, ... ) (-rs + 1 1 (s + a)(s + b)
1-e-ttr te-• 1 t -e-tlr
r-
1 - (1 + t/-r)e -tlr
1 - t" -1 e-at -(n- 1)! 1
tn-1
e -1/r
-r"(n- 1)!
_l_(e-at- e-bt) (b- a)
1194
APPENDIXC
Table<:L Continued
13.
14. 15.
J(s)
f(t)
s (s + a)(s +b)
ae-•') ~be_,,) (
1 s(s + a)(s + b)
1 - {be_., - ae-b') _!_ [ 1 + -(a-b) ab
b b s2-b2
17.
52+ b2
18.
s2-b2 b2 s (5 2 + b2)
19.
sin bt
s2+~
16.
J
sinh bt
s
cosbt
s
cosh bt (1-cos bt)
20.
b (s + a) 2 + b2
e-~~ 1
21.
s +a (s + a) 2 + b 2
e"""' cos bt
22.
J(s +a)
e_,.'J(t)
23.
e-li•J(s)
f(t- b); withf(t) =0 fort< 0
C.4
sinbt
THE z-TRANSFORM
Just as the Laplace transform arises from specializing the Fourier transform for a one-sided (semi-infinite) independent variable, we will now show that the z-transform derives from specializing the Laplace transform for sampled functions that take nonzero values only at discrete points in time. Such a preamble is necessary if the apparent nonsymmetry between the z-transform and its inversion formula is to be understood properly.
C.4.1 Definition and Inverse Formula Consider the situation in which the continuous function f{t) in the Laplace transform expression Eq. (C.12) is sampled so that it takes on finite values f(tk} at discrete points, t()l t 1, •••, f;, ••• in time, at regular intervals of size !J.t. Let this sampled version of f(t) be .f(t). Then .f(t) =f(tk) only at the sample point tk = kilt, for k =0, 1, 2, ... ; it is zero elsewhere. It therefore appears as a "train"
l
1195
LAPLACE AND z-TRANSF ORMS
of spikes at the discrete sample points t0, t1, represen ted mathema tically as:
t
••• , 1, ••• ,
and may therefore be
(C.66)
where 0( t - tk) is the delta function. We now wish to find the Laplace transform of this function by introducing Eq. (C.66) into Eq. (C.l2): L{f'(t)) =
f~ e_., [k~~(tk) o(t- tk) Jdt
(C.67)
0
Now, by the linearity property of Laplace transforms, we know that the transform of a sum is the sum of the individu al transforms; thus Eq. (C.67) becomes: (C.68)
The integral is easily evaluate d by invoking the property of the delta function, and Eq. (C.68) becomes:
or, by replacing tk with k fl.t, we obtain finally: (C.69)
us This should now be compare d with the Laplace transform of the continuo j(t): function, (C.12)
where we observe that Eq. (C.69) is a discretized version of Eq. (C.l2). we If now for convenience (to simplify the expressi on in Eq. (C.69)), introduce the notation: (C.70)
and refer to the resulting L[f"(t)] as the "z-transform" of f(t), then Eq. (C.69) becomes: (C.71)
1196
APPENDIXc
which is the "formal" definition of the z-transform of the sampled signal f'(t}. Because Eq. (C.69} is a valid Laplace transform, its inverse transform is given by Eq. (C.13); and upon introducing the transformation in Eq. (C.70), we obtain:
J(t1,)
= f*(t)
.
where
f"J
1 = -2 . 19 ,,
''2I = =
1
!
l
· dz (C.72)
j
e-{a-jm)/>1
l
e-{a+jt»)/>1
Thus unlike the other integral transforms for which the transform and its inverse appear symmetric, the z-transform and its inverse appear to be nonsymmetri c. However, this is merely an artifact of the notational convenience employed: in its "fundamental " (if not entirely practical} form, the transform is actually as shown in Eq. (C.67), and it is as symmetrical with the inverse in Eq. (C.72), as Eqs. (C.12) and (C.13) are. As with Laplace transforms, it should be noted that the inverse transform formula is hardly ever used for inverting a z-transform. It is customary to use Tables of z-transforms, an example of which is presented at the end of this section.
C.4.2 Properties and Useful Theorems of z -Transforms
r
I f
The following are some properties and theorems of the z-transform that are particularly useful in engineering applications. Some of them have precise parallels with the Laplace transform, and some do not Because of the peculiar nature of discrete signals, some of these properties have no equivalent for the Laplace transform; by the same token some of the properties of the Laplace transform also have no precise z-transform equivalent. 1. Linearity
Extension to linear combination of n functions is straightforward. 2. Time Shift to the Left H Z{f(k)J = J(z}, then: Z{J(k+ 1)} = if
and if f{O)
(C.74)
= 0, then: Z{j(k + 1)}
= if
(C.75)
l
1
LAPLACE AND z-TRANSFORMS
1197
Also: Z(J(k + 2)} = i-J(z)- z2fl0) - z.f\1)
(C.76)
and in general: Z(J(k+m)) = znfJ(z)-zm.f\0)-zm-l.f\1)- ... -l/(m-1)
(C.77)
or
(C.78)
3. Time Shift to the Right (C.79)
Z(j(k-m)) = z-mJ(z)
4. Transform of (Forward and Backward) Differences
Define the forward difference operator, h., as: IJ.fl.k) = .1\k + 1)- .1\k)
(C.80)
then we may make use of Eq. (C.74) to obtain: Z{IJ.fl.k)) = (z- l'ff(z)- 1/{0)
(C.81)
Similarly, since from Eq. (C.80): 11~k)
= 11(11j{k)) = j{k + 2)- 2.1\k + 1) + j{k)
(C.82)
then
(C.83) In general:
m-1
Z{t1"'.1\k)} = (z-1)mJ(z)-z L,(z-1)m-i-It1:t\:O)
(C.84)
i= 0
Define the backward difference operator, V, as: V.f{k) =
.1\k)-.f{k- 1)
(C.85)
Then we may make use of Eq. (C.79) to obtain: (C.86) Similarly, since from Eq. (C.85): "'12.1\k)
= V(V.f{k))
= .1\k)- 2.1\k- 1) + .1\k- 2)
(C.86)
APPENDIX C
1198 then
(C.87)
and in general: (C.88)
5. Compl ex Shift
j(k), then the If the functio n j(t) is sample d with sample time ~t to obtain where: ri'j(k) is e-<~l_f(t) n sample d version of the functio
We now have the result: (C.89)
and the converse:
z-1{J(rz)} Typical application: since
= r~k)
(C.90)
z-1{1/(1- z-1)} = 1, then by Eq. (C.90):
z-1 {1-1pz
} = (p-Jrk = k P
1
(C.91)
(d. Examp le 24.3)
6.
Transform of Sums (C.92)
7. Compl ex Differe ntiatio n
Z{ k ftk)} = -z
£J\.z)
(C.93)
and in general: (C.94)
n f(k) = 1{k) is Typical application: since the z-transform of the unit step functio unit ramp the of form z-trans the 1 (C.93), Eq. by known to be 1/(1 - z- ), then as: d obtaine is k = function j(k)
1199
LAPLACE AND z-TRANSFORMS
Z{k} = Z{k l(k)} =
-z£(t ~ z-I)
z-1
=
-~....,--..,.
(1-z;~l)-2
8. Complex Integration (C.95)
9. Fina l-Va lue Theo rem lim lim j*(t) = lim f(k) = z-+1
t-+•
((1 - z- 1:J(z)]
(C.96)
k-+..
ide of the unit disk. (The theo rem is prov ided (1- z-1)}(z) has no poles outs the h the limit as k ~ co exists.) As with applicable only to functions for whic the g inin obta for ul usef very resu lt is Lapl ace tran sfor m equi vale nt, this func tion sfer tran e puls its from ess proc stea dy-s tate gain of a (stable) (incorporating the ZOH element). 10. Initi al-V alue Theo rem
lim j*(t)
t-+0
=
rf(z;)] lim f(k) == lim .....
k-+0
(C.97)
,
the limit as z ~ oo exists. applicable only to functions for which 11. The Discrete Convolution Theorem
: If Z{t( k)} = }(z), and Z{g(k)} = g(z), then
~if
=
~if
(C.98)
of the conv oluti on theo rem of Laplace This is a precise discrete equi vale nt le previous section. The result is applicab transforms give n as Property 12 in the from pulse transfer functions. in obtaining impulse-response models
ations C.4.3 Sol utio n of Linear Difference Equ z-tra nsfo rm find s appl icati on in the As with the Laplace tran sfor m, the Consider the linear difference equation: solu tion of linear difference equations. b u(k- 1) + ... + bmu (k- m) y(k) + a 1y(k- 1) + ... + a,Y( k- n) = 1
(C.99)
drop ping the" for convenience), we By takin g z-transforms of both side s {and obta in:
1200
APPENDIX c
which is solved for y(z) to yield:
y(z) (C.IOO)
Thus the solution to Eq. (C.99) for any given (z-transformable) sequence u(k) is given by that function y(k) whose z-transform is given in Eq. (C.lOO). Thus, as with the Laplace transform, the main challenge in finding such solutions lies in inverti ng the indicated z-transform. The technique of z-trans form inversion by long divisio n (or, equivalently expansion as an infinite series) was discussed in Chapte r 24. It is not as popular as the technique of partial fraction expansion.
C.4.4 Partia l Fracti on Expan sion The proced ure for obtaining partial fraction expansions is valid for all rational polyno mials R( •) regardless of the argume nt. Thus, what was presen ted in Section C.3.4 applies directl y once we replace s by z (or by z-1 ). We will therefore merely illustrate with some specific examples. Exampl e C.6
SOLUT ION OF A FIRST-ORDER DIFFERENCE EQUATION BY z-TRANSFORMS, AND PARTIAL FRACT ION EXPANSION.
Use z-transfoxms to solve the first-order difference equation: y(k)
= 0.7y(k- 1)
+ 1.5u(k- 1)
(C.101)
given that u(k) = 1 for all k. (That is, find the unit step respons e of the first-order system whose model is as in Eq. (C.lOl).) Solutio n: By taking z-transforms of both sides and rearranging, we obtain: y(z)
I.sz- 1 = 1 - 0.7z-1 u(z)
or, introducing the z-transform of the unit step function for u(z): 1.5z- 1
(C.102)
We now wish to expand the rational function of z-1 as:
(I
1.5z-1 z- 1)(1- 0.7z- 1)
AI
A2
= (1- z- 1) +(I- 0.7z- 1)
(C.103)
Since the roots of the denomi nator polynomial are real and distinct (they are located at z = 1 and z = 0.7), we proceed as in Section C.3.4: multiplying in Eq. (C.l03) by (1-z-1)
LAPLACE AND z-TRANSFORMS
1201
and setting z = 1 we obtain immediately A 1 = 5. Similarly, multiplying by (1- 0.7z-l) and settings = 0.7 gives A2 = -5. Thus, by partial fraction expansion Eq. (C.102) becomes: (C.l04)
from where the required solution is obtained from the inverse z-transform of Eq. (C.104) as: y(k)
=
5[1 - (0. 7)k]
(C.l05)
The next example illustrates how to handle repeated roots. Example C.7
PARTIAL FRACTION EXPANSION: REPEATED ROOTS IN z-TRANSFORM S.
Obtain a partial fraction expansion of the function: 0.8- 0.3z- 1
(C.l06)
Solution: Because of the repeated pole at z = 1, we wish to expand the RHS of Eq. (C.106) as: 0.8- 0.3z-l (I - z-IJ2(1 - o.sz-1)
AI
= 0- o.sz-I)
81 B2 +(I - z-1)2 + (1 - z-1)
We obtain A 1 = 0.2 in the usual manner: multiply by (1 - O.Sz-1) and set z = 0.5. And now: *() _ 0.8- 0.3z- 1 z - (I- o.sz-I)
and from it we obtain B2 immediately as 1.0 by setting z =1. Next, by differentiation, we obtain: d
dz
*
(z)
=
-0.1
(z - 0.5 )2
from where we now obtain B1 as..:. 0.4 by setting z =1. The required complete partial fraction expansion is therefore: 0.8- 0.3z- 1
0.2
1
-0.4
(1- z-1)2(1- o.sz-1) = (1- o.sz-1) + (1- z-1)2 +(I- z-1)
(C.l07)
which the reader may verify by longhand calculation.
The references given below should be consulted for more information about the theory of the z-transform, and its various applications. A table of z-transforms of some common functions is provided below in Table C.2; Table C.3 contains some common s transfer functions and the correspondin g pulse transfer functions incorporating the zero-order hold element.
1202
APPENDIX c Table c.2 Table of z -Transforms of Some Common Functions (Sample Time = M)
J(s)
f(t)
f(k)
1.
-1 s
1(t)
1(k)
1 1- z-1
2.
;2
t
kM
.M.z--1 (I- z-1)2
(n -1)!
sn
t"- 1
(kl:J.t)" -1
1 s+a
e-at
e-akt>t
1 1- e-a~>tz-1
-
pk
1 1- pz-1
3.
4a.
4b.
1
-
J
lim
1
a-+0 ( - )
~~ z)
n-1
5.
1 (s + a) 2
te-at
kMe-akAt
6.
s (s + a) 2
(1- at)e-at
(1 - akllt)e-ak4t
1 - (1 + aM)e-a~>tz- 1 {1 _ e-at>tz-1)2
7a.
a s(s +a)
1-e-<''
1-e-akl>t
{1 - e-a~>~~z- 1 (1- z-1)(1- e-aMz- 1)
-
1-pc
(1 -E)z-1 (1- z- 1)(1-pz-1)
e-<1'- e-bt
,..w_ e--bkl>t
-
(pl)k - (p2)k
(Pt- P2)z-l (1- Ptz-1)(1- p2z-l)
7b.
Sa.
Sb.
-
b-a (s + a)(s +b) -
Llte-•~>~z- 1
(1 _ e-al>tz-1 )2
(e-al>t_ e-bl>t~z-1 (1 - e-al>tz-1)(1- e-bl>tz-l)
9.
b (s2 + b2)
sin bt
sin bkM
z-1 sinbM (1 - 2r1cosMt + z-2)
10.
s (s2 + b2)
cos bt
cos bkllt
1- z-1cosbM (1 - 2z-1cosMt + z-2)
l
~
Table C.3. Some Common Continuous Transfer Functions and Equivalent Pulse Transfer Functions with Zero-Order Hold Sampling. (Sample Time = M)
g(z) =
g(s)
Q
~
~
b z-1 + b z-2
2 1 1 + a1 z-1 + a2 z-2
~
g(k)
'T1
1.
1 s
2.
1 s2
b1 a1
flt 2
a1 1 s"
3.
4.
1 'tS
+1
flt2
=
<1 - z-1)
bl
= (1
a1 =
kflt2
(k -1) flt 2
2
2
-+
·b b1---2 -2 , 2-2; a2
~
fltlk-1
= flt; b2 =0 = -1; az = 0
=1
~
I
(-1)" CJ"
--;:;! Cla"
- e-Af/'9; b2
-e-Ath; a2 = 0
=0
(
z z -
e-
(kflt)" --n!
[(k - 1) flt]" n!
bl pk-1 bl = (1 - p); p
= e-Af/t
or: (pk- 1 - pk)
....
N 0
w
-.. . . . . .
r~..........-~·--
.a
~Q:.,~~-I\IIi-14
$
($W.
I
..
I
•
0
u
?:::
Table C.3. Continued
@
~ ()
gz
g(s)
5.
1 s ('tS + 1)
b1 = 't
f'
=
":t -
b2
= 't
a1
= -(1
~
= e-Atl-c
b1 z-1 + b2 z-2 1 + a1 z-1 + a2 z-2
~
1 + e-At/-r ;
1 - e-At/-r -
~t e-At/~
+ e-At/-c)
g(k)
b1 b2 - - (1 - pk) + - - (1 -.pk-1) 1-p 1-p
-:c e· ~ b2='t(1-p-~t bl = 't
p
1 + p
or: lit - 't {pk- 1 -
6.
ab (s + a)(s + b)
b1 =
(a *-b)
bz al
a2
""
0
[b {1 -
e-<~At)
p
= e-Atl-c pk)
- a(1 - e-bAt)]
b1 ( b2 - - P1k- Pl) + (b- a) P1 - Pz P1 - Pz 1 [tze"dl' (1 - e-b<\1) - IJe-bAt (1 - e-<141)] b _ [b (1 - p1) - a (1 - p2)) = 1 (b -a) (b- a) b _ [apt (1 - P2) - bpz {1 - Pt~ = -(e--
--(_p k-1- p2k-?
N ,....,
R
o
~
0
........
-·-·
R
•
-
-
-
-
-
•
rr••
U444W*.....-:T
A
~~-c-.~
~
Table C.3. Continu ed
g(s)
g(z) =
~
7.
bt
(s + a'f
1 -r;2s2
+
2~u
(1 + a.dt) e-
+1
b2
at a2 ----
-
pi] I
'C
b1
b2 = p (p + at:..t - 1) p = e-<~At
or: [(1 - aM) pk- 1
~ ;~<1
I
btlql'-t + b2(k- 1)pk- 2 b1 = 1 - (1 + at:..t) p
= (e-aM)2
Ql=
~
g(k)
1 + at z-t + a2 z-2
b2 = e-<~"" (e-a"" + a.dt - 1) a1 = -'2.e-«41 a2
8.
=1 -
~
bt z-1 + b2 z-2
= 1 - e-f.IJI~ [cos (mM)
pk-1 [cos m (k - 1) t:..t + ysin m (k - 1) t:..t]i
t
+ CO't sin (coot)]
= (e-f.IJI~'f + ~~~ [~ sin (coot) = -2e-/:4tl~ cos (coot) = (~1~2
- pk [cos cokM + ysin cokM]
cos (coot~
0):::
~ ;~<1 'C
~ 'Y = -
p =
CO't e-{41/'t
---~~
-----
----
-
--------
.... "'
Q
tro
-
----
----- --
----
--~
-
,......
@$.
•W,.,
w;:;R+M !'.4l·_4W.. Pl.~~~-:.~.--.
.,....,... .• ,~-~~..,...
.........Jii+<
u
Table C.3. Continued
>< iS
i1i
§: ~
g(s)
bt z-t + bz z-2
g(z) =
s
bl = e--<'41 (s + a)Z b2 = -e-ttAI at = -2e-ttAt az = (e"'""At)2 [ab (e"'""At - e-!>At) + be (1 - e-<~At) - ac (1 - e-bAt)] (s + c) 10. (s + a) (s + b) b1 = (b -a) c) e-bAt] [c (b - a) e-aAt e-bAt + a (c - b) e""AI + b (a (a* b) bz = ab (b -a)
9.
g(k)
1 + at z-1 + az z-2
al = -(e_,At _ e-I>AI)
kpk - (k - 1) pk- 1 p =
e-aAt
l_pk -2) _b_ t_ (pk- pk) + _b_z _ (pk2 1 2 1 Pt - Pz Pt - Pz [ ab (p1 - pz) + be (1 - p1) - ac (1 - p2) ] bl = (b - a) [ c (b - a) p1 p2 + a (c - b) p1 + b (a - c) p2 J bz = ab (b - a) Pt =
a2 = (e"'""AI) (e-I'AI)
e-
Pz = e-bAt -
I.C
<::>
,.... "'
-
--
·-
-
--
·-
--
LAPLACE AND z-TRANSFORMS
1207
REFERENCES AND SUGGEST ED FURTHER READING A general reference that covers several aspects of Laplace transforms theory and applications is: 1.
Churchill, R. V., Modern Operational Mathematics in Engineering, McGraw-Hill, New York (1958)
More extensive tables of Laplace transforms may be found, for example, in: 2. 3.
CRC Standard Mathematical Tables, Chemical Rubber Co., Cleveland (1978) Abramowi tz, M. and I. A. Stegun, Handbook of Mathematical Functions, National Bureau of Standards, Washington, D. C. (1964)
A detailed treatment of the theory and application of z-transforms may be found in Ref. [4); a more abbreviated but useful discussion may be found in Ref. [5]. Each of these references contains more extensive tables of z-transforms Ref. [6] contains many worked examples of partial fraction expansions for rational polynomials in the z variable. 4. 5. 6.
Jury, E. I., Theory and Application of the z-transform Method, J. Wiley, New York (1964) Kuo, B. C., Analysis and Synthesis of Sampled-Data Control Systems, Prentice-H all, Englewood Cliffs, NJ (1963) Ogata, K., Discrete-Time Control Systems, Prentice-Hall, Englewood Cliffs, NJ (1987)
i ~
j
APJPJENDJIX
D REV IEW OF MAT RIX ALGEBRA The convenience of representing systems of several equations in compac t, vectormatrix form- and how such represe ntations facilitate further analys iscombin e to make a workin g knowle dge of matrix method s virtuall y indispensable to a proper study of multivariable control systems. Althoug h most readers will have encoun tered matrix method s before, it is perhaps useful to briefly review the essential concepts here. Those readers who feel confide nt of their skills in this area may prefer to skip over this materia l and move on to another topic.
D.l
DEFINITION, ADDI TION AND SUBTRACTION
A matrix is an array of number s arranged in rows and columns, written with the following notation:
(D.l)
Here because A contains 2 rows and 3 columns, it is called a 2 x 3 matrix. The elements lltt' a12, •••, etc., have the notation that a is the elemen t of the ith row 11 and jth column of A. In general, a matrix with m rows and n columns is said to have dimens ion m x n. In the special case when n = m (i.e., the number of rows and column s are identica l) the matrix, for obvious reasons, is said to be square; otherwi se the matrix is said to be rectangular or nonsquare. As in the case of scalar quantities, matrices can also be added, subtrac ted, multiplied, etc., but special rules of algebra must be followed. Only matrices having the same dimensions (i.e., same number of rows and columns) can be added or subtracted. For example, given the matrices A, B, C:
1209
APPENDIXD
1210
B only A and C can be added or subtracted; because its dimensions are different, can D = c + A of swn The C. or A either from, d cannot be added to, or subtracte be written:
(D.3)
(or Thus addition (or subtracti on) of two matrices is accomplished by adding s operation These matrices. subtracti ng) the correspo nding elements of the two In order. same the of matrices of number any to may, of course, be extended particula r observe that adding k identica l matrices A (equival ent to scalar the multiplic ation of A by k) results in a matrix in which each element is merely to is matrix a when Thus, k. scalar the by d multiplie A of correspo nding element each be multipli ed by a scalar, the required operatio n is done by multiply ing element of the matrix by the scalar; for example, for A given in Eq. (0.2): (D.4)
Example D.l
MATRIX ADDmO N, SUBTRACTION, AND SCALAR MULTIPLICATION.
n, The following are some simple numerical examples of matrix addition, subtractio and scalar multiplication:
[ :
: ] + [ :
: ] = [
;5 :4 ]
4[ 6
: ] - 3[ :
: ] = [
~: :I ]
1211
REVIEW OF MATRIX ALGEBRA
MULTIPLICATION
D.2
Matrix multiplication can be performed on two matrices A and B to form the product AB only if the number of columns of A is equal to the number of rows in B. H this condition is satisfied, the matrices A and B are said to be conformable in the order AB. Let us consider that A is an m x n matrix (m rows and n columns); then to form the product P= AB, B must bean nxr matrix (n rows and rcolumns). The resulting product Pis then an m x r matrix (m rows and r columns) whose elements Pij are determine d from the elements of A and B according to the following nile: n
Py··
L a 1bk.~ i =1, 2, ... , m; j =1, 2, ... , r = k=l
(D.5)
I
For example, if A and B are defined by Eq. (D.2}, then A is a 2 x 3 matrix, B a 3 x 3 matrix, and the product P = AB a 2 x 3 matrix is obtained as:
= [ ( auhu + al2b2l + al3b3l) (aubl2 + al~22 + al3b32) (aubl3 + al~23 + al3b33) ]
( ~. bll + anb2l + a23b3l) ( ~lb12 + ~22 + auh32) ( ~lbl3 + Onbn + ~3b33) (D.6)
ExampleD.2
MATRIX MULTIPU CATION.
The following are some simple examples to illustrate how matrix multiplication is carried out. 1
(3Xl+4X2 )
(3X2+4X 5}] [ 11
[ =
(-2xl-lx 2) (-2x2-lx 5)
=
-4
26
-9
J
APPEN DIXD
1212 2
,
3.
that BA exists. Unlike in scalar algebra, the fact that AB exists does not imply m x r, but order of is and exists AB then r, For example, if A is m x n and B is n x n. x m with able conform not is r x n ion dimens the since BA does not exist Thus, exist. BA and AB But if instead B had been an n x m matrix, then both the equals case) this in (n A of s column of only in cases where the numbe r the equals case) this (min A of rows of r numbe the and 8, of numbe r of rows Note, BA. and AB ts produc numbe r of column s of B, can we form both the BA will be of however, that in this case, the order of AB will be m x m while : general in that, so n, order n x (D.7)
cation In matrix algebra, therefore, unlike in scalar algebra, the order of multipli nt. importa is very or to be permutable. Those special matrices for which AB = BA are said to commute Exampl eD.3
NON COMM UTATIV ITY OF MATRI X MULTI PLICAT ION.
Let us illustrat e Eq. (D.7) with the following two matrices:
s one may comput e both Since A and 8 have the same number of rows and column AB:
=[ and BA:
19 43
22 50
J
II
1213
REVIEW OF MATRIX ALGEBRA
BA
= [ s7
2 ] = [ (5 + 18)
6 ] [ 1 8
4
3
(10 + 24}
J
(7 + 24) (14 + 32)
=[23 34] 31
from where we see that, indeed, AB
D.3
46
* BA.
TRANSPO SE OF A MATRIX
The transpose of the matrix A, denoted Ar, is the matrix formed by interchanging the rows with the columns. For example, if:
: :l then a 11 a21 AT = [
all
an
al3
a23
]
(D.8)
Thus if A is an m x n matrix, then Jll is an n x m matrix. Observe therefore that both products ATA and AA T can be formed, and that each will be a square matrix. However, we note again, that in general: (D.9)
The transpose of a matrix made up of the product of other matrices may be expressed by the relation: (D.lO)
which is valid for any number of matrices A, B, C, D, ...
ExampleD.4
TRANSPOSE OF A MATRIX PRODUCT.
To illustrate relation Eq. (0.10), let us define:
and from Example 0.3 we recall that:
APPENDIX.D
1214 [ 19 43
AD
22] 50
so that (AB)T
=[
19 43 22
J
50
Now:
so that
and Eq. (0.10) may be seen to hold.
D.4
SOME SCALAR PROPERTIES OF MATRICES
Associate d with each matrix are several sCillar quantities that are quite useful for characteri zing matrices in general; the following are some of the most importan t
0.4.1 Trace of a Matrix If A is a square, n x n matrix, the trace of A, sometime s denoted Tr(A), is defined as the sum of the elements on the main diagonal, i.e.: n
Tr(A)
= .'Ea6 •••
For example, given:
we have that: Tr(A) = (1 +4) =5
and
Tr(C) = (0+2+1) =3
(D.ll)
REVIEW OF MATRIX ALGEBRA
1215
0.4.2 Determinants and Cofactors Of all the scalar properties of a matrix, none is perhaps more important than the determinant. By way of definition, the "abs"olute value" of a square matrix A. denoted I A I , is called its determinant. For a simple 2 x 2 matrix:
(0.12)
the determinant is defined by: (0.13)
For higher order matrices, the determinant is more conveniently defined in terms of cofactors.
Cofactors The cofactor of the element aij is defined as the determinant of the matrix left when the ith row and the jfh column are removed, multiplied by the factor (-l)i+i. Forexample,letusconsiderthe3 x3matrix:
(0.14)
The cofactor, c12' of element a12 is:
(0.15)
Similarly, the cofactor C23 is:
(0.16)
The General n x n Detenninant For the general n x n matrix A whose elements a;i have corresponding cofactors cii' the determinant I A I is defined as: n
L a;Fij
IAI = i
~t
(for any column j)
(0.17)
1216
APPENDIXD or n
IAI =
ft,a;F;i
(for any row i)
(D.l8)
Eqs. (D.l7) and (D. IS) are known as the Laplace expansion formulas; they imply that to obtain I A I :
·
1. 2
Choose any row or column of A Evaluate the n cofactors corresponding to the elements in the chosen row or column. 3. The sum of the n produ cts of eleme nts and cofact ors will give the requir ed determ inant. (It is impor tant to note that the same answer is obtained regardless of the row or column chosen.) To illustr ate, let us evalua te the determ inant of the 3 x 3 matrix given by Eq. (D.14) by expan ding in the first row. In this case, we have that:
That is: a,,
al2
al3
~I
0 22
~3
a31
a32
0 33
~
£ln
~I
a23
-a,z
all 0 32
a33
~I
~2
a3t
a32
+ al3 ~I
a33
(D.I9)
It is easily shown that the expansion by any other row or column yields the same result. Examp leD.S
DETER MINAN T OF A 3 x 3 MATRIX.
The determ inant of the 3 x 3 matrix:
may be evaluat ed as indicat ed above: by expand ing in
IAI =
1
I : : I -21 : : I
+
row 1, for exampl e, we have:
31 : : I
1 (45 -48)- 2 (36 -42) + (32- 35) -3+12 -9 = 0
Thus for this matrix,
IA I
= 0. We
will have cause to refer to this matrix later on.
REVIEW OF MATRIX ALGEBRA
1217
Properties of Determinants The following are some important properties of determinants frequently used to simplify determinant evaluation.
1.
Interchanging the rows with the columns leaves the value of a determinant unchanged. The main imrlications of this property are twofold: (a) I A I = AT (b) Since rows and columns of a determinant are interchangeab le, any
I;
statement tluzt holds true for rows is also true for columns, and vice versa.
2.
If any two rows (columns) are interchanged, the sign of the determinant is reversed.
3. If any two rows (columns) are identical, the determinant is zero. 4.
Multiplying the elements of any one row (column) by the same constant results in the value of the determinant being multiplied by this constant factor; ie., if, for example:
Dl
au
all
al3
~I
~
~
~I
~2
0 33
=
and
Dl
=
kau
all
al3
~I
~
~
~I
all
"l3
thenD2 =kD1 5.
If, for any i and j ( i "# j) the elements of row (column) i are related to the
elements of row (column) j by a constant multiplicativ e factor, the determinant is zero; i.e., if, for example:
where we observe that column 1 is k times column 2, then D 1 = 0. 6.
Adding a constant multiple of the elements of one row (column) to correspondin g elements of another row (column) leaves the value of the determinant unchanged; ie., if, for example:
Dl
=
thenD2 =Dl'
au
a12
al3
~I
a22
~
a31
~2
a33
and
Dl
=
(au+ kal~
0 1l
all
(~~+~
a22
a23
("JI +~)
a32
a33
..
1218
APPENDIXD
7.
The value of a determinant that contains a whole row (column) of zeros is zero.
8.
The determinant of a diagonal matrix (a matrix with nonzero elements only on the main diagonal; see Section D.5 below) is the product of the elements on the main diagonal. The determinant of a triangular matrix (a matrix for which all elements below the main diagonal, or above the main diagonal are zero; see Section D.S below) is also equal to the product of the elements on the main diagonal.
Alien Cofactors As indicated in Eqs. (D.17) and (D.18), any expansion in which the elements of any row (colurrm) in a matrix are combined with their corresponding cofactors (i.e., a Laplace expansion) gives rise to the determinant of the matrix in question. Any other expansion in which the elements of one row (column) are combined with co factors of elements of another row (colurrm) is called an expansion by alien cofactors, and its value is always zero. Thus, for example, while the Laplace expansion using row 1 of Eq. (D.14) gives:
the expansion combining the elements of row 1 with the cofactors of row 2 gives:
and similarly:
In general, therefore, for any column j: j=k (D.20)
i*k and for any row i: n
I,a..c1.
J= 1 ' 1
~
__
{IAI;
i=k
0;
i*k
(D.21)
Thus Laplace expansion by corresponding cofactors gives I A I ; expansion by alien cofactors always gives zero. A very important implication of these facts is that if we form a matrix C from the cofactors of A, then:
0 0 IAI 0
(D.22)
l
I
REVIEW OF MATRIX ALGEBRA
1219
a diagonal matrix with the determinant of A on the main diagonal. We shall refer to this result later.
D.4.3 Minors and Rank of a Matrix LetA be a general m x n matrix with m < n. Many m xm determinants may be formed from the m rows and any m of the n columns of A. These m x m determinants are called minors (of order m) of the matrix A. We may similarly obtain several (m- 1) x (m - 1) determinants from the various combinations of (m -1) rows and (m -1) columns c-hosen from them rows and n columns of A. These determinants are also minors, but of order ( m- 1). Minors may also be categorized as 1st minor, 2nd minor, etc. The minor of the highest order is referred to the 1st minor, the next highest minor is the 2nd rninor, etc., until we get to the lowest order minor, the one containing a single element. In the special case of a square n x n matrix, there is, of course, one and only one minor of order n, and there is no minor of higher order than this. Observe, therefore, that the 1st minor of a square matrix is what we have referred to as the determinant of the matrix. The second minor will be of order (n - 1). Note, therefore, that the cofactors of the elements of a square matrix are intimately related to the 2nd minors of the matrix.
Rank of a Matrix The rank of a matrix is defined a5 the order of the highest nonvanishing minor of that matrix (or, equivalently, the order of the highest square submatrix having a nonzero determinant). In Example D5, for instance, the 1st minor (of order 3) vanished, but none of the 2nd minors (of order 2) vanished; the single elements of the matrix- nine in all- are themselves minors (of order 1), and all are nonzero. Of the non vanishing minors, therefore, the highest order is 2. Thus, A in Example D.5 is of rank 2. A square n x n matrix is said to be of full rank if its rank= n; the matrix is said to be rank deficient if its rank is less than n. In several practical applications of matrix methods, the rank of the matrix involved provides valuable information about the nature of the problem at hand. For example, in the solution of a system of linear algebraic equations by matrix methods (see Section D.7 below), the number of independent solutions that can be found is directly related to the rank of the matrix involved.
D.S
SOME SPECIAL MATRICES
1. The Diagonal Matrix H all the elements of a square matrix are zero except those on the main diagonal from the top left-hand comer to the bottom right-hand comer, the matrix is said to be diagonal. Some examples are:
1220
APPENDIXD
2.
The Tria ngul ar Matrix A squa re matrix in which all the elem ents below the main diagonal are zero is called an upper triangular matrix. By the sam e token, a lower triangular matrix is one for which all the elements above the main diagonal are zero. Thus:
and
are, respectively, examples of uppe r and
lower triangular matrices.
3. The Iden tity Matrix A diagonal matrix in whic h the nonzero elements on the main diagonal are all unity is called the identity matrix; it is frequ ently denoted by I, i.e.: 0 1 0
0 0
0
0
The significance of the identity matrix will be obvious later, but for now , we note that it has the unique property that IQ= Q= QI
(D.23)
for any general matrix Q of conforma ble orde r with the mult iplyi ng iden tity matrix. 4.
Orth ogon al Matrices
HATA = I, the identity matrix, then A is an orthogonal (or orthonormal, or unitary) matrix. For example, as the reader may easily verify:
is an orthogonal matrix. 5. Sym metr ic and Skew -Sym metr ic Matr ices Whe n every pair of (real) elements that are symmetrically placed in a matrix with respect to the main diagonal are equal, the matrix is said to be a (real) symmetric matrix. That is~ for a (real) symmetric matr ix: (D.24a)
Some examples of symmetric matrices are:
I
REVIEW OF MATRIX ALGEBRA
1221
B=r ~ ~ ~2 J ... 5
Thu s a sym met ric mat rix and its
-2
4
transpose are identical, i.e.: (D.24b)
A skew-symmetric mat rix is one for
which: (D.25a)
The following are som e examples
of such matrices:
For skew -sym met ric matrices: (D.25b)
By noti ng that aij can be exp ress
ed as:
(D.26a)
it is easily esta blis hed that every squ are mat rix A can be reso lved into the sum of a symmetric mat rix A 0 and a skew -symmetric mat rix A', i.e.: (D.26b)
6. Her mit ian Mat rice s Wh en sym met rica lly situ ated elem ents in a mat rix of com plex num bers are complex conjugates, i.e.: (D.27)
the mat rix is said to be Hermitian.
For example: [
3
(2-3 j)
J
(2+ 3j) 5 is a Her miti an matrix. Not e that the (real) symmetric mat rix is a spec ial form of a Her miti an mat rix in whi ch the coef ficients of j are absent.
7. Sin gula r Mat rice s A mat rix who se dete rmi nan t is zero is said to be singular. Thu s, for exa mpl e, the mat rix enc oun tere d in Exa mpl e D.S is a sing ular mat rix. A mat rix who se dete rmi nan t is not zero is said to be nonsingular.
1222
APPENDIXD
8. Idempotent Matrices A matrix A is said to be idempotent if: AA =A
(D.28)
It is easily verified, for example, that the matrix:
is idempotent. Note that the identity matrix is a special type of an idempotent matrix. It is easy to establish that the only nonsingular idempotent matrix is the identity matrix; all other idempotent matrices are singular.
0.6
INVERSE OF A MATRIX
The matrix counterpart of division is the inverse operation. Thus, corresponding to the reciprocal of a number in scalar algebra is the inverse of the matrix A, denoted by K 1, (read as" A inverse"): a matrix for which both AK1 and A -IA give I, the identity matrix, i.e.: (D.29)
The inverse matrix A -I does not exist for all matrices; it exists only if: 1. 2.
A is square, t and Its determinant is not zero (i.e., the matrix is non-singular).
The inverse of A is defined by: A-t =
C _ adj (A) IAI-
IAI
(D.30)
where C is the matrix of cofactors, i.e.:
C=
c" c,z [ Cz, . c22
and, as defined previously,
c, c,.] 3
•••
Cn
...
... en, cn2 cn3
C;j
Cz,.
... c,..
is the cofactor of the element aij of the matrix A.
cT, the transpose of this matrix of cofactors, is termed the adjomt of A and often abbreviated adj (A). This expression for the matrix inverse may be seen to follow directly from Eq. (0.22) and the definition of the inverse in Eq. (0.29). +Generalizing the concept of an inverse to include nonsquare matrices will be discussed shortly.
ij •
REVIEW OF MATRIX ALGEBRA
1223
Clearly because I A I = 0 for singular matrices, the matrix inverse as expressed in Eq. (D.30) does not exist for such matrices. It should be noted that 1.
The inverse of a matrix composed of a product of other matrices may be written in the form:
2
For the simple 2 x 2 matrix, the general definition in Eq. (0.30) simplifies to a form easy to remember. Thus given:
we have that IAI = ai 1a22 A-I =
1 [
IAI
ExampleD .6
a 1 ~21 ,
and it is easily shown that:
lin
(0.31)
~I
OBTAININ G MATRIX INVERSES.
Let us illustrate the foregoing discussion by obtaining the inverses of the following three matrices:
The first is a 2 x 2 matrix whose determinan t is easily obtained as according to Eq. (0.31) therefore, we easily have that
I A I =3- 2 =1; 1
from where the reader may want to verify by direct multiplica tion that AI (Airl = (AirlAI = l Next we observe that determinan t of the 3 x 3 matrix A was obtained in Example 0.5 as zero; thus it is a singular matrix, and therefore (~)3t does not exist. The determinan t of~ may be obtained by expanding in the cofactors of the first row, i.e.:
~~~
=
2
1: : 1-2 1: : I + 3 1: : I
2 (45-48)-2 (36-42) + 3 (32-35)= -3
Thus the matrix is nonsingula r, and we may proceed to compute the inverse. We recall from the definition of cofactors that the nine cofactors of A are obtained as:
1224 Cn=
APPENDIX D
I: : I I: : I
I: : I I: : I
=-3; c12=(-l)
~I =(-1)
=6; C22=
=6; C13=
I: : I I: : I
=-3; C23=(-l)
=-3
=-2
Thus the matrix of cofactors is:
so that the adjoint of ~ is:
~ (~) ~. [ "
The inverse ( ~r1 is then:
::]
To check, we see by matrix multiplication that
r
and the reader may in similar fashion verify that (A 3 1As is also equal to I.
D.7
LINEAR ALGEBRAIC EQUATIONS
Much of the motivation behind developing matrix operations is due to their particular usefulness in handling sets of linear algebraic equations. For example, the three linear equations: auxl + aiM + aiM
= bl
"21x1
+ "22l2 + "23X3
= b2
D:liXI
+ "n1i + a33'%3 = b3
(D.32)
I
REVIEW OF MATRIX ALGEBRA
1225
containing the unknowns .,, '2, .13 can be represented by the single matrix equation: Ax= b
(D.33)
where
The solution to these equations can be obtained very simply by premultiplyin g
Eq. (0.33) by A-1 to yield:
which becomes: (D.35)
upon recalling the property of a matrix inverse, that K 1A =I, and recalling
Eq. (0.23) for the property of the identity matrix.
There are several standard, computer-ori ented numerical procedures for performing the operation A - 1 to produce the solution given in Eq. (0.35). Indeed, the availability of these computer subroutines makes the use of matrix techniques very attractive from a practical viewpoint It should be noted that the solution Eq. (0.35) exists only if A is nonsingular, as only then will A- 1 exist When A is singular, K 1 ceases to exist and Eq. (0.35) will be meaningless. The singularity of A of course implies that I A I =0, and from property 5 given for determinants in Section 0.4, this indicates that some of the rows and columns of A are linearly dependent. Thus the singularity of A means that only a subset of the equations we are trying to solve are truly linearly independent; as such, linearly independent solutions can be found only for this subset It can be shown that the actual number of such linearly independent solutions is equal to the rank of A. Example0.7
SOLUTION OF UNEARALGE BRAIC EQUATIONS.
To illustrate the use of matrices in the solution of linear algebraic equations, let us consider the set of equations:
2xt
+ 2x2 + :h3
=
4x1 + 5x2 + 6x3
3
7x,_ + &:2 + 9x 3
5
which in matrix notation is given by: Ax
=
b
APPENDIX D
1226 where A, b, x are:
Notice that A is simply the third matrix whose inverse was computed in Example D.6, i.e.:
Thus, from Eq. (0.35), the solution to this set of algebraic equations is obtained as:
Ii
I
Thusx 1 =0, x 2 =1, x 3 =-1/3 is the required solution. Let us now alter the coefficient of xt in the first equation from 2 to 1 so that we now have the following set of equations to solve for the three unknowns: x 1 + 2x 2 + 3x 3 4x1 + 5x 2 + 6x 3 7x1 + Sx2 + 9x 3
1 3 5
Observe in this case that
a matrix whose determinant had previously been obtained as 0 and whose rank was later identified as 2. The immediate implication is that since A is singular, we cannot solve this new set of equations for all the three unknowns. Observe now that by adding the first and third equations we obtain an equation that is exactly twice the second equation; thus, the three equations are in fact not completely independent . It is easily shown that we can solve these equations independent ly only for two of the unknowns; the third unknown can only be obtained as a linear combination of these two. Thus there are only two linearly independent solutions to this new set of equations, exactly the same as the rank of A.
l
1227
REVIEW OF MATRIX ALGEBRA
D.S
GENERALIZED INVERSES
Consider the general problem of solving m linear algebraic equations:
(D.36)
containing the n unknowns J1, x 2 , x 3 , ••• , x,.. Observe that this system of equations, as in Eq. (D.32) can also be represented by the single matrix equation: Ax= b
(D.33)
except that in this case, A is an m x n matrix, xis ann-dimensional vector, and b is an m-dimensional vector: a,2
a,.
0 21
On
~
a3l
a32
~
am!
am2
amn
au
A=
..
.
·-[i} ·=[i]
(D.37)
1hree distinct cases of this general problem can be identified: CASEl: m=n • Equal number of equations and unknowns (well-defined system). • if A is nonsingular then n independent solutions exist. 1his is the case discussed in Section D.7.
CASE2: m >n • More equations than unknowns (overdefined system). • No "regular" solutions exist (in the sense that no set of values for the unknowns will exactly satisfy all the equations simultaneously). CASE3: m < n • Fewer equations than unknowns ( underdefined system). • An infinite set of solutions exist (in the sense that the excess n - m unknowns can be assigned any arbitrary set of values and the remaining m unknowns solved for in terms of these arbitrary values).
1228
APPENDIXD
For the Case 1 prob lem, as disc usse d in Section D.7, whe neve r I A I"# O, the requ ired solu tion is obtained as given in Eq. (D.35): X
= A- 1b
(D.35)
(It is easy to establish that whe neve r the n x n matrix A is singular, the prob lem redu ces to a Case 3 prob lem with m -no w less than n- being equal to the rank of the rank-deficient A.) In each of the othe r two cases, solutions of the form given in Eq. (D.35) can be obta ined but only after impo sing addi tiona l conditions as we now show.
Overdefined Systems The prob lem here is that there is no vector x for whic h Ax exactly equa ls b. How ever , it is possible to obta in a solu tion in whic h Ax is "closest" tob in the "leas t squa re" sense by finding a vector Q that minimizes: ¢J
= (Ax -bl( Ax -b)
(D.38)
By appl ying the usua l tech niqu es of calculus, it is easy to show that provi ded (ATA) is nonsingular, this "least squa res solution" vector is given by: (D.39a)
or (D.39b)
whic h is of the form in Eq. (D.35) with AL
AL
defined by:
= (ATAriAT
(0.40 )
now play ing the role of A-1. . Note the following abou t AL defined by Eq. (D.40): 1.
ALi sann xmm atrix whil e Ais mxn
2.
ALA = In, the n x n identity matrix, but AA L "#I
3.
AA L = ~ an m x m idempotent matr ix for which I,_ I,_ = I,_
4.
Premultiplying in (2) above by A gives : AALA =A
(D.41)
while post mult iplyi ng by A L gives: (0.42 )
Because only whe n A is multiplied on the ieft by If do we get an identity matr ix, A L is called a left inverse.
REVIEW OF MATRIX ALGEBRA
1229
Underdefined Syst ems The prob lem here is that there is an infinite set of vectors x for whic h Ax exactly equa ls b. How ever, it is possible to obtain a solut ion vector x of minl lnum norm by posin g the following constrained optimizatio n problem:
Min
cp =
t
(XI"x)
subject to: Ax = b
By the usua l meth ods of solvi ng such probl ems (for exam ple, using Lagrange multi plier s) we find that provided (AAT) is nonsingular the requi red "min imum norm solut ion" is: (D.43a) or X
= Ai1>
whic h, once again , is of the form in E"q. (0.35
(D.43b)
) with A R defin ed by:
AR = AT(A A!tl
(D.44)
now playi ng the role of A-1. Again, we note the following abou t AR defin ed by Eq. (0.44): 1.
A R is ann x m matri x while A is m x n
2
AA R =In, them x m identity matrix, but A RA ;i;l
3.
AR A = L:z anoth er n x n idempotent matr ix for whic h, as usual ,
4.
Post multi plyin g the expression in item 2 abov e
Lz Lz =Lz
by A gives: (D.45)
while pre multi plyin g by AR gives: (D.46)
In this case, we obtai n an ident ity matri x only when A is mult iplie d on the right by K; therefore AR is called a right inverse. Noti ng the simil aritie s betw een Eqs. (0.41 ) and (D.45), and also the simil aritie s betw een Eqs. (D.42) and (D.46 ), we can now state the following results: The gene ral syste m of linear algebraic equat ions in Eq. (0.33): Ax= b
(0.33 )
with A as a gene ral m x n matri x (for whic h m is not necessarily equa l to n) has the solution:
1230
APPENDIXD (0.47)
Here A+ is referred to as a generalized (or pseudo) inverse of A, and it satisfies the following conditions:
3.
J
(for the left inverse) (for the right inverse)
Either: A+A= I AA+=I or:
Observe that A-t, the regular inverse of a square, nonsingular matrix satisfies all these conditions. Thus A-t is actually a special case of A+, and t."l)e above is therefore the most general description of the inverse of any matrix. Note, finally, that only A"" 1 is both a left and a right inverse; if Eq. (D.33) is a..1. overdefined system of equations, then a least squares solution can be found only via a left inverse; for an underdefined system of equations, a minimum norm solution can be found only via a right inverse.
ExampleD.S
SOLVING AN OVERDEFINED SYSTEM OF EQUATIONS BY GENERALIZED INVERSES.
To illustrate the use of generalized inverses in the solution of a system of linear algebraic equations, let us consider the set of equations: x 1 + 2x 2
24 - x 2 -2x 1 - x 2
25 -25 -25
a set of three equations in two unknowns. Observe right away that the system is overdefined by one equation, and there is no single set of values for xt and x 2 that will simultaneously satisfy all three equations. These equations may be written in the form Eq. (0.33): Ax = b
(D.33)
In this case:
(D.48)
and from Eq. (0.47), the "least squares" solution is obtained from: (D.47)
where, recalling Eq. (0.40):
*t t '
1231
REVIEW OF MATRIX ALGEBRA
Now, ATA is obtained by direct multiplication as:
a nonsingular matrix whose determinant is 50; thus:
I [ 6 50 -2
=
(ATArl
~2 ]
so that A+ is given by: 2 A+
14
;0 [ I6 -I3
-10
-5
]
(0.49)
and
14
2 I [ + x=Ab= 50
16 -13
-10 -5
J[:J
which, upon evaluation, gives:
=
X
[:J = [~!]
(050)
We now note that the solution in Eq. (0.50) "satisfies" the system of equations only in the least squares sense; i.e., of all possible x choices, this particular x given in Eq. (0.50) provides an Ax that comes closest to b in the least squares sense. We may also observe that, as asserted earlier:
+
1 [
A A = 50
2
14
16 -13
a 2 x 2 identity matrix; also:
-10 ]
-5
1232
[
rI
APPENDIXD
0~ ~.N ~4]
--0.24
0.82
--0.3
--0.4
--0.3
0.5
(D.5I)
It will be a particularly worthwhile exercise for the reader to carefully multiply this matrix given in Eq. (0.51) by itself and therefore confirm that it is indeed an idempotent matrix.
Example D.9
SOLVIN G AN UNDERDEFINED SYSTEM OF EQUAT IONS BY GENERALIZED INVERSES.
Let us now consider the problem of solving the following set of equation
s:
2
a set of two equations in four unknowns, clearly underdefined. Observe right away that we can arbitrarily assign any values to, say, x , and ll• and solve 1 the resulting equations for Xg and x4 • There is thus an infinite number of solutions. H these equations are written in the form Eq. (033):
Ax
=
b
¥
ti
(D.33)
we would have: 2 A= [
II
3
;J
·=[]
b= [ 1: J
(D.52)
i'
and from Eq. (0.47), the "minimu m norm" solution is obtained from: (D.47)
By direct multiplication, we obtain AAr as:
and hence:
1 [ 4 20 -10
I f
where we now recall from Eq. (0.44) that:
(M1)-1
'[i
-10 ] 30
REVIEW OF MATRIX ALGEBRA
1233
Thus, we have that A+ is given by:
-10 ] 30
or -{),3
A+ =
[
-{).1
0.1
(D.53)
0.3
and therefore:
X= A+b = [
~:~ 0.1
0.3
00.5 ]
[ 120
J
-{).5
which, upon evaluation, gives:
(0.54)
The reader may now wish to verify that Eq. (0.54) does in fact satisfy the system of equations exactly, and that for the A given in Eq. (0.52) and A+ given in Eq. (0.53), AA + results in the 2 x 2 identity matrix, while A+ A results in the 4 X 4 idemp otent matrix:
[~:: ~:~ ~:~ :: ] 0.1
-{),2
D.9
0.2 0.3 0.1 0.4
0.4 0.7
EIGENVALUES, EIGENVECTORS, AND MATRIX DIAGONALIZATION
The eigen value / eigenvector problem arises in the determ inatio n of the values of a const ant A. for which the following set of n linear algebraic equat ions has nontri vial solutions:
APPENDI XD
1234
1 '
(0.55)
'This can be reexpressed as:
or
=0
(A-AI)x
(0.56)
Being a system of linear homogene ous equations, the solution to Eq. (0.55) or equivalently Eq. (0.56) will be nontrivial (i.e., x 0) if and only if:
"*
=o
IA-A.II
(0.57)
Expandin g this determina nt results in a polynomial of order n in A.:
Do"'111 +a 1....111-1
111-2
+~"'
1 ... +a11 _ 1 .... +a, =
0
(0.58)
This equation (or its determina nt form in Eq. (0.57)) is called the characteristic equation of then x n matrix A; its n roots, A. 11 A. 2, A. 3, •••,A.,.- which maybe real or imaginary, and may or may not be distinct- are the eigenvalues of the matrix. EIGENVALUES OF A 2 x 2 MATRIX.
Example 0.10
Let us illustrate the computatio n of eigenvalues by considering the matrix:
In this case, the matrix (A- AI) is obtained as: (A-A.I)
=[
1 2 3 -4
J_[ A
]. 2 0 ] = [ (1-l) (-4- A) 3 0 A
from which the characteristic equation is obtained as:
lA-AII= -(l-A)(4+ A)-6 = A2 + 3A -10=0 a second-ord er polynomia l (quadratic) with the solution: At.~
= -5,2
1235
REVIEW OF MATRIX ALGEBRA
Thus in this case the eigenvalues are both real. Note that A- 1 + A. 2 = -3, and that ~~ = -10; also note that Tr(A) = 1 - 4 = -3 and I A I = -10. Thus, we see that ~ + ~ = Tr(A) and A- 1 ~ =I AI. If we change A slightly to:
then the characteristic equation becomes:
lA-AII =
I
I- It
2
-3
4 -.?..
=A? - 5A. + 10
0
whose roots are:
which are complex conjugates. Note again that Tr(A) = 5 = A,. + lt 2 and I A I = 10
=
~~·
Finally if we make another small change in A, i.e.:
then the characteristic equation is: .?..2 -
I +6
=0
which has solutions:
so that the eigenvalues are purely imaginary in this case. Once again Tr(A) ~and IAI =5= ~~·
=0 =.:1. 1 +
Returning now to the original problem in Eqs. (D.55) and (D.56), we note that every distinct eigenvalue It when substituted into Eq. (D.56) gives rise to a corresponding nontrivial solution x; for which: (D.59)
These nontrivial solution vectors are called the eigenvectors of A. Thus every distinct eigenvalue ~._of A has associated with it a corresponding eigenvector x;, j = 1, 2, ... , n. When some eigenvalues are repeated, some specialized considerations - which we will not discuss here - are required. (See the bibliography at the end of the appendix for more details.) We shall restrict ourselves here to the case of distinct eigenvalues. The following are some useful properties of eigenvectors:
1236 1.
2
APPENDIXD Eigenvectors associated with separate, distinct eigenvalues are linearly independent.
The eigenvectors xi are solutio ns of a set of homog eneous linear equatio ns Eq. (0.59) and are thus determ ined only up to a scalar multiplier; i.e., xi and kx.. will both be a solution to Eq. (0.59), if k is a scalar constant. We obtain a normalized eigenv ector X; when the eigenvector xi is scaled by the vector norm xi i.e.:
II II,
_2._
xi= llx.;ll 3.
The normal ized eigenvector
~
is a valid eigenvector since it is a scalar
m~ltiple of ~i; it ~jo~s the sometimes desirab le proper ty that it has
II II- 1.
uruty norm, 1.e., xi
4..
The eigenvectors xi may be calculated by resorti ng to method s of solution of homogeneous linear equations.
It can be shown that the eigenvector xi associated with the eigenvalue A.j is given by any nonzero column of adj(A- A.jl); it can also be shown that there will always
be one and only one independent, nonzero column of adj (AExample D.ll
..:til).
EIGENVECTORS OF A 2 x 2 MATRIX.
Let us illustrate the computation of eigenvectOrs by considering
the 2 x 2 matrix:
for which eigenvalues, A.1 =-5, A.2 =2 were comput ed in Exampl
e 0.10.
For~:
and the adjoint is: adj(A-A - 11)=[ I
-3
-
2
6
]
We may now choose either column of the adjoint as the eigenve ctor 'f, since one is a scalar multipl e of the other; let us choose:
as the eigenvector for ~ =-5. Since the norm of this vector is --J 12 + (-3) 2 = normalized eigenvector corresponding to ~ =-5 will be:
,fTif, the
l I
REVIEW OF MATRIX ALGEBRA
1237
XI
[~] {10
Similarly for A. 2
= 2:
(A-A. 21)
[~I
2
]
--{j
and
adj (A -..:1.21) =
[~
-2 -1
]
Thus: x2
=[; J
can be chosen as the eigenvect or for eigenvalue this case is:
~
= 2. The normalized eigenvector in
Let us return again to the original eigenval ue/ eigenvector problem , and choose the calculated n linearly indepen dent eigenvectors xi, j = 1, 2, ... , n to be the columns of a matrix M, ;.e.: (0.60)
M is called a modal matrix. Obviously, if the eigenvalues lti ~re distinct, then the eigenvectors xi are all independ ent, and the modal matrix M will be nonsingu lar, and M""1 will a.tways exist. This modal matrix is very useful in converting a matrix A to diagonal form. Recall the eigenval ue/ eigenvector problem: to determin e the values of It i for which nontrivial solutions vectors xi can be found for: j = 1, 2, ... , n
(D.61)
For each j, the complete set of equations may be written more compactly as: (D.62)
If we define the diagonal matrix A as:
APPENDIXD
1238 0
0 0
i]
(D.63)
a matrix whose diagonal elements are the n eigenvalu es of A, and observe that the square bracket on the left-hand side in Eq. (D.62) is just the modal matrix M, then we see immediate ly that the square bracket on the right-han d side is just MA. Thus Eq. (D.62) may be written as: AM= MA
(D.64)
and premultip lying both sides by M-1 thus yields: M-1AM =A
(D.65)
Then x n matrix A is thus reduced to what is known as the diagonal canonical fonn by using the transform ation Eq. (D.65). By pre- and postrnulti plying both sides of Eq. (D.65) by M and M-1 respectively, one obtains the companion relation: (D.66)
These two relations are very useful in the solution of linear algebraic and differenti al equations as shall be seen later. Note that the latter relation in Eq. (D.66) indicates that a square matrix A can be decompo sed into three matrices involving only its eigenvalu es and eigenvecto rs. Example 0.12
MATRIX DIAGONALIZATION.
To illustrate matrix diagonaliz ation,let us consider the 2 x 2 matrix:
discussed in Examples D.lO and D.ll. Recall that the eigenvalue s and eigenvecto rs were determined to be:
Thus the modal matrix M is:
1239
REVIEW OF MATRIX ALGEBRA
while
[ ]
M""l
2
1 7
--::;
3 7
1 7
and the diagonal eigenvalue matrix is:
Evaluation of the LHS of Eq. (0.65) yields:
M"IAM
[; ;][: [ t -~] [ ~
1
7
7
2 -4 ] [
~3
2
] 0
4 -5 15
2
] =[ :
2
]
which verifies Eq. (0.65). Similarly, evaluation of the RHS of Eq. (0.66) gives:
verifying the equation.
The following are some general properties of eigenvalues worth noting: 1.
The sum of the eigenvalues of a matrix is equal to the trace of that matrix, i.e.: II
Tr(A)
= •L )...J J=l
2.
The product of the eigenvalues of a matrix is equal to the determinant of that matrix, i.e.: n
IAI =
I1 A..
j=l J
1240
APPENDIX D
3.
A singular matrix has at least one zero eigenvalue.
4.
If the eigenvalues of A are~, .:lz, \, ... , A.n, then the eigenv alues of A -1 are 1/ Av 1/ A.2 , 1/ A.3 , •••, 1/ An.
5.
The eigenvalues of a diagonal or a triangular matrix are identical to the elements on the main diagonal.
6.
Given any nonsi ngula r matrix T, the matrices A, and A =T AT-1 have identical eigenvalues. In this case, such matrices A and A are called similar matrices.
D.lO SINGULAR VALUE DECOMPOSITION The concept of matrix diagonalization indicated in Eq. (0.65) and the comp anion relation in Eq. (0.66) can be exten ded to all matrices, squar e and nonsq uare, by singul ar value decomposition (SVD). The main SVD result may be summ arized as follows: For any real m x n matrix A, it is always possible to find orthog onal (i.e., unitary) matrices Wand V such that: (D.67)
Here,
r is the m X n matrix: r
= [ : :J:wi iliS
·[:
0
0
a2
0
0
0
_:
]
(D.68)
o;.
where, for p = min(m,n), the diagonal elements of S,
whose m columns, W;, i = 1, 2, ..., m, are called the left singular vectors of A; these are the norma lized (orthonormal) eigenvectors of AA '· Vis the n x n matrix: (0.70)
whose n columns vi, i = 1, 2, ... ,n, are called the right singular vectors of A; these are the normalized (orthonormal) eigenvectors of AT A. By virtue of their being comp osed of orthon ormal vectors, the matrices W and V are orthogonal (or unitary) matrices, i.e.:
REVIEW OF MATRIX ALGEBRA
1241
so that
w-1
=
wr
Also:
yry = 1 = yyr
so that: y-I = yr
By applying these properties of unitary matrices, we easily obtain from Eq. (D.67) the companion relation: A= wr,y r
(0.71)
It can be show n that analogously to the eigen value / eigenvector expression for squar e matrices in Eq. (D.61), we have the more general pair of expressions: Av; o;w; Arw; = o;v;
(D.72a) (D.72b)
The ratio of the large st to the smallest singu lar value is desig nated the
condition number of A, i.e.:
(0.73)
and it provides the most reliable indication of how close A is to being singular. Note that for a singular matrix, JC(A) =co; thus nearn ess to singularity is indicated by excessively larg e- but finit e- values for IC'(A~ There are several impo rtant applications of SVD, particularly iri numerical linear algebra. Its applications in process contro l (discussed in Chapters 20 and 22) typically involves square, invertible matrices. It shoul d be noted however, that the full benefit of SVD is realized in dealin g with problems requiring the analysis of nonsquare, possibly rank-deficient matri ces. The following example illustrates SVD appli ed to a nonsq uare matrix; keep in mind , however, that efficient comp uter programs are available for SVD calculations. Example 0.13
SINGULAR VALUE DECO MPOS ITION OF A
3 x 2 MATRIX
To illustrate SVD, let us consider the 3 x 2 matrix :
(D.74)
a slightly modified version of which was studie
d in Example 0.8. For this matrix:
APPENDIX D
1242
whose eigenvalues are obtained as 10, and 5; thus the singular values of A are:
ordered such that q > "i as required by SVD analysis. Thus, the 3 x 2 matrix :E in this case is given by:
(0.75)
Right Singular Vectors The first eigenvector of ATA corresponding to .t1 is obtained as usual from adj (ArA- ~1), and since: adj (ATA-l 11)
=[
2 ] 2 -1
-4
a possible choice for the eigenvector is the second column. Normalizing this with
.V 22 + 12 =--15, the norm of the vector, we obtain the first right singular vector v 1 corresponding to a 1 =i l las:
In similar fashion, the second normalized eigenvector corresponding to .t 2 = 5 is obtained as:
., -
[;,]
Thus:
V=[
2
1
-{5
{5
-\
2
{5
{5
] *-
REVIEW OF MATRIX ALGEBRA
1243
and therefore:
[ ] 2
vr
=
15 _J_
15
.::L
15
.1... {5
(D.76)
The reader may want to verify that this Vis truly a unitary matrix by evaluatin g vTv as well as vvT and confirming that each matrix product gives the 2 x 2 identity matrix.
Left Singular Vectors For the given matrix A;
The eigenvalues of this 3 x 3 matrix are obtained from the characte ristic equation which in this case is:
i.e.: ~.Az.A.J
= 10,5,0
Note that the nonzero eigenvalues of AATare identical to the eigenvalues of ATA. For A, =10:
To find the adjoint of this matrix, we first find the cofactors and take the transpose of the matrix of cofactors. In this case, this is easily obtained as:
and by normalizing any of the nonzero columns, we obtain the first left singular vector of A as:
APPENDIXD
1244
By a similar proeedunt the seconcl and third left singular vectors ft!llpectively corresponding 1o the etsenvalues A, • 5, ond .t3 ~ 0 are oblainecl ao:
with the II!SIIlt that: 0I
W• [
...fi
I O
0I
]
...fi
(0.77)
.=!.o....L
...fi
...fi
Once again. the ...ter may wish 10 verify that this Is aloo a unitary matrix. The matrices given in Ecp. (0.75), (0.76), and (0.77) constltuie the singular !lfllue ~liml of the matrix AinEq.(D.71). Wenowoboervelhat
as m Eq. (0.74). As an exercise, the reader may also wish lo verify Eq. (0.67) for this
example.
D.ll SOLUTION OF UNEAR DIFFERENTIAL EQUATIONS AND 1HE MATRIX EXPONENTIAL It is possible to use the results of matrix algebra to provide general solutions to sets of linear onlinary diffen!ntial equations. Let us recall a dynamic system with control and disturbances neglected:
~
• Ax ;
X(O)•"'
(D.78)
Here A is a constant n x n matrix with distinct eigenvalues, and x(t) is a limevarying solution vector. Let us defme a new set of n variables. z(t), as: ll(t) ~ l.lr1ll(t)
so that
(D.79)
REVIEW OF MATRIX ALGEBRA
1245 1(1) • M&(f)
(0.80)
Here M is the modal matrix described above. Substituting Eq. (D.80) into
Eq. (0.78) yields: M ~ = AMll(t) ;
z(O) = M" 1liQ
(0.81)
Premultiplying both sides by M"1 gives:
M"1M
~
= M"1AM.r(t)
or
4!!!l dt =
z(O)- .... -v -
1\z(f).•
M"'""' "V
(0.82)
Because A is diagonal, these equalioas may now be written as:
dt • .t,z1(1)
z1(0) •
;
: 10
Thus the transformation Bq. (0.80) has converted the original Eqs. (0.78) intn n completely decoupled equations, each of which has a solution of the form:
zj<.t> • e.IJ ~ ; j
= I, 2, ... , n
This may be expressed in matrix notation as: l(t)
where
/" = [
=
e"'ro
(0.83)
~· ~ ~ .~. 0
0
0
]
(0.84)
""
is the ttllltrix trponmtilll for the diagonal matrix, A. The solution Eq. (D.83) may be put back in terms of the original variables, 1(1), by using Eq. (0.79):
M" 1x(l)
•
e"'M"'JO
1246
APPENDIXD
or l(tl
= W'M"'"o
ll(t)
=
(D.SS)
This is often written:
l'"o
(D.86)
where the matrix e"', defined as: (D.87)
is called the mtltrix exponential of AI. It is very important to note that Eqs. (0.86) and (0.87) provide the general solution to any set of homogeneous equations Eq. (0.78) provided A has distinct eigenvalues. Example 0.14
SOLUTION OF UNEAR MATRIX DIFFERENTIAL EQUATIONS.
To illustrate the solution of linear, constant coeffiaent, homogeneous differential equations, let us consider the system: (0.88)
where
Observe that A is the same matrix we have analyzed in Examples 0.10, 0.11, and D.12sowealready know llse~genvalues, At•.!:!• and modal matrix, M. Thus, we have
that
Using Eq. (D.87) we have that
-'1#-$t/2e2'] 6<_, .;• 7
Thus the solution given by Eq. (D.86) is:
REVIEW OF MATRIX ALGEBRA
1247
The extensiml of these ideas to provide solutions for the case of nonlumrogtneous 1/nesr dijfomttiAL tqUIIIUms:
!!!jf •
All(t) + BaCt>+ rcl(t):
ll(to>
="o
(0.89)
is straightforward. Here u (t), d(t) represent control variables and distutbances respectively. When the mab'kes A, B, rare constlmt mab'ices, a derivation rompletely similar to the one just given leads to the solution: ll(t)
s
.,.W-•ol:ro+
J,ACI-~[Ba(1)+rd(1)]dr
(0.90)
'o
when! the matrix exponentials, eA(t-~l, ~·~,may be evaluated using the relation
Eq. (0.87).
l!umple 0.15
SOLtmON OF LINEAR NONHOMOGENEOUS MATRIX OIFFEREN11AL EQUATIONS.
To illustrate the solution of nonhomogeneous equations using Eq. (0.90), let us
suppose we have a syolem Eq. (0.89) wilh A lite aame as lite last """"'f'le:
and
lnaddltlonaaaume "t • t1z • O,d 1 •l (aaJNtantdlstwbanee)an d lhat t0 = 0. In this case Eq. (0.90) talcea lite lonn: x(l)
= ,.V"o +
J. .,AU-~rc!(l)dr 0
Substituting for ,AI, and ,.V"o calculated in lite Example 0.14, we obtain the solution:
1248
APPENDIXD
x(t)
=
or
For the situation where the matrices A, B, r may themselves be functions of time, the solution requires a bit more computation. In this case: x(t)
= •ll(:r,to) "o +
r
~(t, to) ~('l;toT1 [Bu("' + rd("'1d-r
(D.91)
'o
~(t, ~) is an n x n time-varying matrix known as the fundamental matrix solution which may be found from:
Here
dCP(t,t0 )
---;It =
A(t)~(t, t 0 ); ~(t0 ,fo) =I
(D.92)
Because A(t), B(t), r(t) may have arbitrary time dependence, the fundamental matrix solution is usually obtained by numerical methods. Nevertheless, once ~(t,fo) is determined, the solution x(t), may be readily calculated for a variety of control and disturbance inputs, u(t ), d(t), using Eq. (D.91).
D.12
SUMMARY
· In this appendix, the techniques of matrix algebra have been reviewed. These methods find particularly useful application in providing very general solutions to sets of linear algebraic and linear ordinary differential equations. The importance of matrices as a tool for analyzing the dynamics of physical processes should not be undervalued by the reader. As an aid to further study, a bibliography is provided below. REFERENCES AND SUGGESTED FURTHER READINGt
J. Wiley, New York (1967),
1.
Kreysig, E., Advanced Engineering Mathematics (2nd ed.), Chap.7
2
Amundson, N. R., Mathematical Methods in Chemical Engineering, Prentice-Hall,
3. 4. 5. 6.
Englewood Oiffs, NJ (1966) Wylie, C. R., Advanced Engineering Mathematics, J. Wiley, New York (1966) Duncan, W. J., A. R. Collar, and R.Q. Frazer, Elementary Matrices, Cambridge University Press (1963) Bellman, R., Introduction to Matrix Analysis, McGraw-Hill, New York (1.960) Gantmacher, F. R., 1'he Theory of Matrices, (Vols. 1 and 2), Chelsea Publishing Company, New York (1960)
+Listed in increasing order of depth.
;i
~
AJPJPENDKX
E COM PUT ER-A IDED CON TRO L SYSTEM. DES IGN The calculations required for the analysis of process dynamic s, the fitting of models to experime ntal data, and the creation of control system designs can be quite tedious and challeng ing. Fortunat ely, there are a host of interacti ve Comput er-Aided Design (CAD) package s which will carry out these calculations with no program ming effort required by the user. These packages are available for reasonab le fee, and thus should be used by students and others studying the material in this book. Some of the more widely used packages are listed in Table E.l below. Reviews of the field of compute r-aided design and a discussio n of these and other CAD program s can be found in Refs. [1-3].
a
1249
APPENDIX E
1250
Table E.L Some Computer-Aided Analysis and Control System Design Packages
ACSL
Scope Primarily Simulation
cc
Comprehensive
CONSYD
Comprehensive
Ctrl-C Model-C
Comprehensive
EASY5
Comprehensive
Program
. MATLAB with Control System, Robust Control, and System Identification Toolboxes MATRIX-X
Comprehensive
Comprehensive
TUTSIM
Primarily Simulation
UC-SIGNAL UC-ONLINE
Primarily Simulation
Source Mitchell and Gauthier Assoc. 200 Baker Avenue Concord MA 01742 Systems Teclmology, Inc. 13766 S. Hawthorne Blvd. Hawthorne CA 90250 Prof. W. Harmon Ray Dept. of Chemical Eng. University of Wisconsin 1415 Johnson Drive Madison. WI 53706 Systems Control Teclmology 1801 Page Mill Road P. 0. Box 10180 Palo Alto, CA 94303 Boeing Computer Services P.O. Box24346 Seattle WA 98124 Mathworks, Inc• 24 Prime Park Way Natick, MA 01760
Integrated Systems, Inc. 3260 Jay Street Santa Clara CA 95054 Tutsim Products 200 Calif. Ave., #212 Palo Alto CA 94306 University of California Office of Tech. Licensing Berkelev, CA
REFERENCES . 1.
2. 3.
Chen, Z.-Y. (Ed.)., Computer-Aided Design in Control Sytems, Proceedings 4th IPAC Symposium, Pergamon Press, New York (1988) Holt, B. R., et al., "CONSYD- Integrated Software for Computer-Aided Control System Design and Analysis," Comput. Chern. Eng., 11, 187 (1987) Linkens, D. A (Ed.), CAD fur Control Systems, Marcel Dekker, New York (1993)
author in de x A Abramowit z, 1207 Aitolahti, 1029 Albert, 62 Altpeter, 620 Alvarez, 807 Amundson, 1248 Ardell, 1146 Aris, 401 Arkun,328 , 1029,1030 Arnold, K. ].,401 Arnold, V.I., 328 Arulalan, 1028 Ash, 980 AstrOm, 558, 586, 639, 877, 943, 980 Ayral, 1029
B Baker, 1094 Bard, 401 Beck, 401 Bellman, 1248 Beudat, 450 Berry, 717 Bhat, 1095 Biegler, 1028, 1094 Simonet, 1030 Bird, 135, 212 Bischoff, 401 Bode, 167, 620 Bodson, 639 Bongiorno, 1031 Box, 843, 1028, 1059 Boyce, 1174 Bracewell, 135, 450 Bristol, 764, 807 Brogan, 10 Brosilow, 1028
Brown, D. W., 1060 Brown,]. W., 1174 Bruns, 808 Bryson, 1094 Buckley, 31, 1146
c Cadzow, 943 Caldwell, 1028, 1029 Camp, 1031 Caracotsios, 401 Carbonell, 1095 Carnahan, 1175 Ceaglske, 31 Champetier, 639 Chang,102 8 Chen, 1250 Chien, 1146 Churchill, 1174, 1207 Cinar, 1147 Clarke, 1028 Coddington, 1174 Coggan,62 Cohen,557 Collar, 1248 Congalidis, 1146 Conle, 1178 Considine, 557 Coon,557 Copson, 1174 Corripio, 240, 557 Coughanow r, 31, 268, 355 Cozewith, 1146 Crosier, 1059 Cutler, 808, 1028
D de Boor, 1175 DelToro, 31 1251
Deshpand~980, 1028,1146 DiPrima, 1174 Doss, 1059 Downs, 807, 1059 Doyle, F.J., 1147 Doyle,]. c., 8C8, 1094 Driver, 1174 Duncan, 1248
E Eckman,31 Economou, 1028 Edgar, 980 . Engell, 1146 English, 1059 Erickson, 1028 Eykhoff, 450
F Flannery, 1175 Francis, 808 Frank, 676, 1028 Franks, 401 Franklin, 877, 943, 980 Frazer, 1248 Friedly, 327, 401
G Gagnepain, 764 Gantmacher, 1248 Garcia, 676, 807, 1028, 1030, 1094 Gay, 1094 Gear, 1175 Georgiou, 1029 Georgakis, 1029 Gerstle, 1029 Gillette, 1030
1252 Goldberg, 1174 Golubitzky, 327 Gould, 1030 Greenberg, 1174 Grosdidier, 764, 1029 Grossmann, 1094 Guckenheimer, 327, 355 Gumowski, 1146
H Hagglund, 558 Halm,355 Hanus,586 Harris, 1059, 1060 Harrison, 62 Hashinloto, 1030, 1031 Hawkins, 1028 Henrici, 1175 Henrotte, 586 Hernandez, 1029, 1030 Hillier, 1094 Hirnrnelblau, 401 Ho, 1094 Hofhnan, 1060 Hokanson, 1029 Holmes, 327, 355 Holt, 764, 1250 Hoo, 639 Hopf,315 Hopfield, 1095 Hornbeck, 1175 Horowitz, 1029 Hubele, 1059 Hulburt, 807 Hummel, 1030 Hunt, 328, 639 Hunter, 1059, 1060 I Iinoya, 620 Ince, 1174 Iooss, 327, 355 Isermann, 980 Isidori, 328
J Jabr, 1031 Jazwinski, 1094 Jenkins, 843, 1028, 1059 Jensen, 807 Jeron1e, 808, 1146 Joseph, 327, 355
INDEX K Kaiser, 1030 Kantor, 639 Kaspar, 1146 Keats, 1059 Kinnaert, 586 Klatt, 1146 Koppel, 31, 268, 355, 764 Kramer, 1094 Kravaris, 328 Kresta, 1059 Kreyszig, 1174, 1248 Krishnan1urthi, 1059 Kuo, 980, 1175, 1207
L Landau, 639 Lapidus, 401, 450 Lasdon, 1094 Lau, 807 Lecamus, 1030 Lectique, 1029 Lee, J. H., 1029, 1030 Lee, P. L., 676, 1029 Lee, w.,31 Lemaire, 764, 808, 1147 LeRoux, 1030 Levinson, 1174 Lieberman, 1094 Lightfoot, 135, 212 Linkens, 1250 Littnaun, 1030 Longwell, 327 Lopez, 557 Lucas, 1059 Luther, 1175 Luyben,31,240 ,327,401, 717, 1029, 1146 Lyung, 450 M Maarleveld, 1147 Maciejowski, 808 Marlin, 1059 Martens, 943 Martin, 1028, 1029 MacGregor, 1029, 1059, 1060, 1146 Mahrnood,808,1029 Marchetti, 1029 Marquardt, 1094 Mason, 1029
McAuley, 1146 McAvoy, 764, 807, 1029, 1095, 1146 Matsko, 1029 Maurath, 1029 Meadows, 1029 Mehra, 808, 1029, 1030 MellichaD1p,62,980, 1029 Meyer, 328, 639 Michalski, 1095 Mitchell, 1095 Milne-Thon1pson, 1174 Mohtadi, 1028 Monopoli, 639 Montague, 1095 Moore, 807, 1094 Morari, 557, 620, 676, 717, 764, 808, 980, 1028, 1029, 1030, 1094, 1147 Moreau, 1030 Morris, 1095 Morshadi, 1029 Murrill, 557 Muske, 1029, 1030
N Narenda, 639 Newell, 676, 1029 Newton, 1030 Nichols, 557 Niederlinski, 764 Niida, 1094 Nisenfeld, 1146 Nygardas, 620
0 Ogata, 877, 943, 980, 1207 Ogunnaike, 450, 639, 764, 808, 1030, 1146, 1147 Olmo, 1030 Ohshlrna, 1030 Otto, 1028, 1030 Owen, 1095 p Page, 1060 Palsson, 1028 Papon,1030 Parher, 31 Pearson, 1147 Penlidis, 1146 Piovoso, 1095
I
INDEX 1253 Pouliq uen, 1030 Powell , 877, 943 Prett, 807, 1029, 1030, 1094 Propoi , 1030
Q Qin, 1095
R Radem acher, 1147 Ragaz zi, 980 Ramake~808,1028,
1030 '
Ranz, 401 Rao, 1028 Rault, 1029, 1030 Rawlin gs, 1028, 1029, 1030 Ray, 31, 62, 401, 557, 676, 717, 764, 808, 1028, 1094, 1095, 1146, 1147 Rebou let, 639 Redhe ffer, 1174 Richalet, 1030 Richar ds, 1146 Ricker , 1030 Rijnsd orp, 1147 Rivera , 557, 1030 Robert s, 1060 Roffe!, 1060 Rosenbrock, 808 Ross, 1059 Rouha ni, 1030 Routh, 504 Rovira , 557
s Sastri, 1059 Sastry , 639 Schaeffer, 327 Schork , 1030 Schule r, 1147 Scott, 1095 Schwe dock, 1147 Seborg , 764, 980, 1028, 1029, 1031 Seema nn,114 6 Seinfeld, 401, 450 Semin o,558 Shewa rt, 1060 Shinskey,240,586,8~/,
1147 Shunta , 1146 Sim, 1030
Simminger, 1030 Skoges tad, 557, 1030, 1147 Smith, C. A., 240, 557 Smith, C. L., 557 Smith, c. R., 808 Smith, 0. J. M., 620, 1030, 1031 Smith, R. E., 557, 1095 Sokolnikoff, 1174 Stein, 1094 Stepha nopou los, 212, 1095 Stephe nson, 1174 Stewar t, 135, 212, 401 Stone, 1095 Su, 328,63 9 Subrarnarrian, 1030 Sulliva n, 676, 1029
T Takam atsu, 1030 Tanne nbaum , 808 Taylor , 1094 Tessie r, 1029 Testud , 1029, 1030, 1031 Teukb lsky, 1175 Tham, 1095 Truxal , 31 Tsing, 1031 Tu, 1031 Tuffs, 1028 Tyreus , 764
u Umeda ,1094
v Vanhamliki, 1029 Vellering, 1175 Venka tsubra manian , 1095 Verhey , 1174 Vinant e, 717 Vogel, 980
w Waller , 620 Wassick, 1031 Weber ,31 Weekman,31 Wethe rill, 1060 Whale n, 1031 Wilkes, 1175
Williams, 31, 1031 Winde s, 1147 Witten mark,5 86,639 ,877, 943, 980 Wood, 717 Woodb urn, 807 Wylie, 1174, 1248
y Yamamoto, 1031 Yeo, 1031
Yocum, 1028 Youla, 1031 Yuan, 1031
z Zadeh , 1031 Zafirio u, 558, 620, 676, 717, 808, 980, 1029, 1031, 1094 Zames , 1031 Zhang , 1147 Zhao, 1028 Ziegler, 557
subject index A abnormality detection, 1088 ACSL, 1250 actuators, 49 adaptive control, 628 AID converter, 43 alarm interpretatio n, 1088 aliasing, 826 amplitude ratio, see also magnitude ratio, 152, 281 analog ruters, 51 analog input/ output, 44 analog-to-digital converter, 43 antiresetlYin dup,585 ARIMA model, 1051 ARMAX model, 999 artificial intelligence, 1091 auctioneerin g control, 582 autoregressive moving average (ARMA) model, 999 autotuning, 555
B biological systems: anaerobic digester, 310, 405 anaesthesia control, 814 bioreactor, 357 cardiovascul ar regulator, 563, 770 hemodynamics model, 222 human pupil servomechanism, 509 immunology, 243 respiratory process, 220
"black box" models, 410 block diagrams, 463, 824, 927 Bode diagram, 153, 281 asymptotic consideration s, 306 classical controllers, 305 for feedback controller design,549 first-order system, 285 inverse-respo nse system,302 lead/lag system, 294, 300 pure capacity system, 291 second-order system,298 time-delay system, 303 Bode plot, see Bode diagram Bode stability criterion, 549 boiler, 229, 562, 811 bounded-input, boundedoutput stability, 337 Bristol array, see relative gain array (RGA),
c capillary, 154 cascade control, 12, 567 catalytic reactors, 231, 1105 cc, 1250 chemical process, defini lion, 5 objectives of operation, 6 variables of, 13 chemical reactors, 101, 138, 141, 171, 217, 252, 271, 313, 315, 331, 358, 365, 381, 395, 407, 456, 583, 591, 641, 681, 816, 984, 1067, 1138
1255
closed loop, block diagram, 463, 824, 926 characteristic equation, 486 performance criteria, 520 stability, 486 transfer functions, 468 multiloop systems, 724 Ctrl-C, 1250 Cohen and Coon tuning rules, 537 comparator, 465, 927 complex variables, 1155 complex s- plane, Nyquist map of, 286 complex z- plane, 902 computer control system, 36-61 computer-aid ed control system design, 1249 computer control, see digital computer control, condition number, 803, 1241 CONSYD, 1250 control limits (in SPC), 1037 control system synthesis, case studies of, 1097 controllabilit y, 686 controller, 16, 465, 518, 927 controller design, 21 commercial, 518 choosing controller parameters, 524 controller type, 523 conventional feedback, 461 model-based, 645 performance criteria, 520 principles, 519 via optimization , 522
1256 con troller tuning, auto tuning, 555 Cohen and Coon rules, 536 direct synthesis, 526, 538 internal model control, 529, 539 pole placement, 529 stability margins, 530, 552 with approximate models,532 with frequency response models,541 without a model, 555 time-integral rules, 525, Ziegler-Nichols approximate model rules, 536 Ziegler-Nichols stability margin rules, 553 control valve, 514 control variables, 13 comer frequency, 289 crisis management, 1088 critical gain, see also ultimate gain, 531 critically damped response, 191 crossover frequency, 550 crude oil, boiling point curve,8 CUSUM charts, 1040 cyclopentanol, 1138
D D I A converter, see digitalto-analog converter Dahlin controller, 973 damping coefficient, 184 data acquisition, 43, 47 deadbeat control, 971 dead time, see time delay, decay ratio, 520 decoupling, 773 design,776 dynamic, 777 feasibility of, 792 generalized, 781 limitations of, 785 partial, 788 simplified, 778 steady-sta te (static), 790 time scale, 755
INDEX delta function, Dirac, 82 Kroneker, 887 derivativ eaction,4 68 derivative time constant, 468 desired reference trajectory, see reference trajectory, deviation variable(s), 23 difference equations, 1166 differential equations, 1162, 1169 difficult dynamics, controller designs fur, 599 digital compulel', architecture, 38 capabilities, 38 peripherals, 38 digital computer control, 37, 821, 951 digital controller, 951 advanced, 966 poles and zeros of, 954 PID,960 digital filters, 829 digital input/output, 44 Dirac delta function, 82 direct digital control (DOC), 52 Direct Synthesis Control, 526, 538, 970, 978 discrete-time models, 107, 832, 873 backward shift form, 893 forward shift form, 894 poles and zeros, 898, 906 discrete-time systems analysis, 835, 847 block diagram. 918 discretization, 835 dynamics, 883 identification, 838 relation to continuous systems, 901, 918 stability, 933, 937 distillation columns, 7, 32, 138, 172, 230, 369, 420, 442,507,5 62,565,59 0, 711, 719, 733, 749, 760, 766, 783, 791, 798, 810, 845, 982, 1097 distributed control system {DCS),54
distributed paramete r controllers, 1083 distributed paramete r systems, 106, 376, 1083 disturban ce variables, 13 DMC, see Dynamic Matrix Control, drug ingestion, 137, 215 Dynamic Matrix Control, 1000, 1012 ·Dynamic Matrix Identification, 1013 dynamic flowsheet simulation, 1089 E EASY 5,1250 economic forecasting, 220 electronic controllers, 37 empirical process models, see also process identification, 409-450 equal-percentage valve, 514 E~,seeexponentiaily
weighted moving average, expert systems, 1091 exponentially weighted moving average, (EWMA), 1043
F fault detection, see also abnormality detection, feedback control, 12, 17 adaptive, 628 basic loop elements, 463, 514, 927 PID,467 tuning rules, 525 feedforward control, 12, 18, 571, 968 filter(s), analog, 51 digital, 829 final control element, 16, 465, 927 first order hold, 831 first order system, 139-154, 884, 912
~;
INDEX first order plus time delay model,253 approximation of higher order dynamics, 256 characte rization of process reaction curve, 533 use in controller design, 536 flow controller, 12 Fourier transform, 1178 frequency: comer,2 89 crossover, 550 Nyquist , 828 resonan t, 298 sampling, 827 frequency response analysis , 275-307 applicat ion in controller design,541 Bode/N yquist plots, 286305 identifica lion, 436 models, 110 pulse testing, 437 furnace, 8, 33, 269, 505, 581
G gain margin, 552 gasoline blending, 219,743 gain scheduling, 628 gas storage tank, 56 general ized inverses, 1227 Generic Model Control, (GMC), 671 grade transitions, 1089 grindin g circuit, 789, 810
H heatexc hanger, l07,257 , 273, 310, 377, 506, 560, 588, 596, 681, 986 heating tank, 14, 85, 95, 462 Heaviside function, 80 higher order systems, 205211 holds,8 30 Honeyw ell Multiva riable Predictive Control, (HMPC ),l016 Horizon Predictive Control, (HPC), 1016
1257
I IDCOM, 1008, 1011 ideal forcing functions, impulse,82 ramp,83 realization of, 85 rectangular pulse, 81 sinusoidal, 85 step, 80 ill-conditioning, condition number, 803 degeneracy,798 SVD, tool for detecting, 806 impulse,B2 impulse response function, in model predictive control, 1008 moments from data, 427 impulse response identification, 422 impulse response model, 111, 833 ingot, 388, 1084 input variable(s), 13 input/ output interfaces, 42 input/o utput pairing, 735 instrumentation, 47 interaction, 735 integral action, 467 interaction compensators, see decouplers, Internal Model Control, (IMC), 529, 539, 665 inverse response cornpensation,613 inverse response systems, 225-240, 608 controller designs for, 608 main characteristics, 226 physical examples, 229231
J Jury array, 938 Jury stability test, 938
K Kalman filter, 1064
L
Laplace transfon n, application to the solution of differential equations, 77, 1185 defmiti on,71,1 180 inversion, 73, 1180 tables, 1193 lead/lag systems, 161-166 lime kiln, 818 lineariz ation, approximate, 626 exact, by variable transformation, 632 liquid/l iquid extraction, 405 loop pairing, 683, 727, 735-758 lumped parameter systems, 368
M magnih lderatio ,288 manipu lated variables, 13 manometer, 185 manual control, 10 MATLAB, 1250 matrices, 1209-1248 MATRIX-X, 1250 measuring device, 465, 927 methanol oxidation, 1107 MIMO systems, see multiinput-multi-output systems, minimum variance control, 1052 Model Algorithmic Control (MAC), see also IDCOM, 1008, 1011 model-based control, 645 MODEL-C, 1250 model identification, (see process identification), model predictive control, (MPC), 991 applications of, 995 commercial software packages for, 1011 model forms for, 997 nonline ar, 1020 model reference adaptive control, 629
1258
MPC, see model predictive control, multi-input, multi-output (MIMO) systems, 683-807 multidelay compensator, 1103 multiloop control systems, controller designs for, 723 ·controller tuning, 759 multiple input, single-output systems, 582 multivariable block diagrams, '775 multivariable control, block diagram, 712, 775 controller design, 759,
773 decoupling, 716 input/output pairing, 683, 727, 735 interactions, 686, 724 process models, 688 multivariable dynamics, 694, 890 multivariable identification, 447 multivariable system poles, 703 multivariable system zeros, 704 N NARMA(X), models, see nonlinear ARMA
models, neural networks, 1091 Niederlinski index, 738 nonlinear ARMA (NARMA) models, 1026 nonlinear control, 625 nonlinear MPC, 106, 1020, 1026 nonlinear systems, 311-327 controller design philosophies, 625 dynamic response, 326 methods of dynamic analysis, 314 stability, 343 nonminirnum phase systems, 601
INDEX
Nyquist diagram. 286, 543 Nyquist frequency, 828 Nyquist plot, see Nyquist diagram, Nyquist stability criterion, 543
0 observability, 686 observers, 1064 offset, 25, 485 oil refinery, 1086 on-line optimization, 1086 open loop, control strategy, 18 stability, 333 open loop unstable systems, 617 optimal control, 674 optimization, 1086 Optimum Predictive Control, (OPC), 1014 output variable(s), 13 overdamped response, 191 overdefined systems, 1227 override control, 581 overshoot, 520
p P controller, see proportional controller, P &: I diagram, 59, 1149 packed bed reactors, 406, 1105 Pade approximations, for time delays, 261 paper machine, 982 parallel computing, 1093 parameter estimation, basic principles of, 381 differential equation models,384 partial decoupling, 788 PO controller, see proportional-plusderivative controller, pendulum, 335 performance criteria, 520 phase angle, 'Zl7 phase lag, 277 phase lead, 292 phase margin, 552
PI controller, see proportional-plusintegral controller, PID controller, see proportional-plusintegral-plusderivative controller, pipe, 246, 561 plant/model mismatch, 1070 pneumatic transmission, 37 pole placement, for continuous controller design,529 for discrete controller design,978 poles, closed loop, 496, 935 transfer function, 132, 933 pollution control, 216, 217, 331 polymerization, p~,58,270,332,
357, 456, 589, 640, 766, 844, 949, 987, 1039, 1113, 1122 predictive control, see model predictive control, Predictive Control, (PC), (commercial software package), 1015 pressing iron, 172 process and instrumentation diagrams, seeP&: I diagrams, process characterization cube, 1133 process dynamics, main objectives, 65 definition, 67 process identification, 409-450 frequency response, 4..~ impulse response, 422 multivariable, 447 pulse testing, 437 step response, 417 process model, formulation of, 92, · 363-401 interrelationships between various forms, 115, 128 various forms of: state-space, 104
INDEX
frequency response, 99 impulse response, 100 transfer function, 128, 131 transform domain, 98, 108 process reaction curve, 533 process variability, 1070 product quality, specifications, 6 product ion rate, 6 proport ional band, 467, 518 proport ional controller, 467, 474 proport ional-pl usderivative controller, 468 proportional-plus-integral controller, 467, 478 proportional-plus-integralplus-derivative controller, 468, 518 pulse testing, 437 comparison with direct sine wave testing, 436 input characteristics, 441 multivariable, 447 pulse transfer function model,867 pure capacity system, 157-161 pure gain system, 153-157 pure time delay process, limit of infinite number of first order systems in series, 262 physical example of, 245, 252, 257 transfer function of, 249 pyrolysis fractionator, 169, 589
Q quality control, see statistical process control, quality control charting, 1037 quarter- decay ratio, 531 quick-opening valve, 514
R ramp function, 83
1259 ratio control, 579 realization, 117 rectangular pulse, 81 reference trajectory, in controller design by direct synthesis, 648 for model predictive control, 996 regulatory control, 19 relative gain array (RGA), 728 relay controller, 555 reset rate, 468 reset windup , see also antireset windup , 585 resonance, 298 reverse action, in controller hardwa re, 517 ringing, 972 rise time, 520 robust controller design, 1069 robust performance, 1070 robust stability, 1070 root locus, 496 Routh stability test, 489
s safety, 6 sample-and-hold, see also zero-order hold, 824 effective time delay contributed by, 832 sampled data system, 821 block diagram analysis for, 917 closed loop block diagrams, 927 stability of, 933, 937 sampler, 823 scrubber, 454, 559 second order system, 183205, 913 selective control schemes, 581 self-tuning regulator, 630 sensors, 16 serial correlation, 1046 serial transmission, 43 servo control, 19 set-point, 19 set-point tracking, see servo problem,
set-poin t trajectory, see reference trajectory, settling time, 520 Shewar t (quality control) chart, 1037 signals, analog voltage, 51 analog current, 51 digital, 52 signal conditioning, 49, 829 amplification, 50 multiplexing, 50 filtering, 51 single-i nput multiple-output systems, 581 singula r value decomposition (SVD), 806 singula r values, 803 sinusoid al inputs, 84 SISO systems, see singleinput-single-output systems Smith predictor,605 SPC, see statistical process control, split-range control, 583 spring-s hock absorber, 185, 193 stability , 333-355 definiti ons,335 discrete time, 933 linear, 337 multivariable syst!!rns, 710 nonline ar, 343 open loop, 349 closedl oop,353 ,486 stability criteria, bilinear, 937 Bode,54 9 direct substitu tion, 494 Jury,93 7 Nyquist, 543 root locus, 496 Routh,4 89 stagewise processes, 369 state estimation, 1063 state-space model, 104 state variables, 13 statistical process control, 1033 steady state decoupler designs, 790
1260
step response , idealize d input, 80 identific ation, 433, 533, 1013 first order system, 143 higher order systems , 204 inverse respons e system, 226 lead/lag system, 164 nonline ar systems , 312 pure capacity system, 159 pure gain system. 155 second order system. 188 system with multiple right half plane zeros, 237 stochast ic process control, 1050 storage tank, 136, 171 structur al instabil ity (of multiloo p systems ), 738 supervi sory control, 52 SVD, see singula r value decomposition,
T
INDEX time series, 997, 1051 transfer function , in generali zed view of modelin g, 128 properti es, 132, 893 traditio nal, 132 transform domain model form, 108, 893 poles of, 132, 898 zeros of, 132, 898 transmit ters, 16 TUTSIM, 1250
u UC-ONUNE, 1250 UC-SIGNAL, 1250 ultimate gain. 531 ultimate period, 531 underda mped response, 191 underde fined systems , 1227 unstable system, 617
v
valve, see control valve, Tank, 21, 33, 140, 146, 158, Vogel-E dgar controll er, 975 163, 176, 313, 318, 323, Volterra series models, 330, 348, 353, 358, 404, 1026 452, 521, 571, 579, 584, 588, 592, 627, 636, 642, w 684,746 ,800,84 0,880 tempera ture controll er, 12 water heater, 136, 168, 403 tempera ture measurement, Western Electric rules, 1039 16 theoreti cal process models, 363-401 thermom eter, 403 z-transf orms, 848 time delay compen sation, applicat ion in discrete 604 time control, 859 time delay systems , 245-268, applicat ion to the 603 solution of difference approxi mations for, 261 equatio ns,873, 1199 controll er designs for, defirriti on,849, 1194 603 effect of samplin g on, 857 dynami c response s, 250, inversio n, 854, 860, 1194 254 relation to Laplace models for, 246, 265 transfor m, 859 physica l example , 246, tables, 861, 1202 252 zeros, time domain models, 832 effect of samplin g on, 906, time-int egral criteria (IAE, 909 ISE, ITAE, ITSE), 525, effect on step response , 537 206-211, 231-239 time scale decoupl ing, 755 right half plane, 231
z
zero-ord er hold (ZOH), 830, 869 Ziegler- Nichols tuning rules, 536, 553