Process control systems

Abstract: A process control technique includes a closed loop parameter estimation algorithm for process gain, time constant and deadtime. The estimation algorithm uses time integrals of system variables responding to a step input. Proper selection of the integrals (control areas) results in a set of equations which are solvable for desired process parameters.

Description: This invention relates to process control systems. More particularly, but not exclusively, the invention relates to closed loop process control systems that utilise parameter estimation. Industrial processes with large, unknown and/or time varying process delays are difficult to control. Self-tuning, in its present form, is typically inapplicable to processes of this class due to their reliance on recursive least squares parameter estimation and a proportional-integral-differential (PID) control algorithm. Recursive least squares parameter estimation techniques typically fail because of a requirement for explicit knowledge of the process deadtime. Similarly, control systems using a PID controller are unable directly to compensate for process deadtime. To maintain loop stability, these control systems must be detuned, thus degrading overall controller performance. One approach for extending self-tuning control to the foregoing class of processes is to join a recursive least squares parameter estimation algorithm with a deadtime estimator and augment the control function with deadtime compensation. Two particular methods, one employing a bank of estimators with different assumed values for the deadtime, and the second employing a single estimator to identify a set of parameters extended over a time period so as to include an assumed deadtime, have received significant attention. Unfortunately, these techniques have proven impractical for general purpose application in an industrial setting. By way of background, an example of a self-tuning process control system involving parameter estimation is described in Advances in Instrumentation, Volume 40, 1985, pages 643 to 654, and a method for determining the parameters of a model in a process control system is described in Regelungstechnik und Prozess-Datenverarbeitung, Volume 7, July 1972, pages 301 to 304. According to one aspect of the invention there is provided a process control system comprising: a controller for producing a control output for the process; means for providing a first response, resulting from a comparison of a process variable and a setpoint, to a summation unit; a model, connected to said controller and located in a feedback loop, for receiving said control output and providing an output to said summation unit; and means, connected to said summation unit, for providing a second response to said controller; wherein said controller and said model include algorithm means for updating said model based on estimated process parameters of observed process gain, lag time constant, and deadtime in response to changes in the setpoint, said algorithm means being operative numerically to calculate the values of the following control area integrals I₁ and I₂, for use in determining the estimated process parameters, as the control output approaches a new setpoint in accordance with the relationships: where: m ss = Final Value, Control Output m(t) = Control Output at time t ΔSP = Change in setpoint α = Weighting Parameter = (τ m + T m )⁻¹ τ m = Observed lag time constant T m = Observed deadtime According to another aspect of the invention there is provided a method for controlling a process, which has unknown or time varying deadtime, using a control system comprising a model of the process by measuring the response to a step setpoint change, the method comprising: providing a first setpoint to the control system; providing a process variable to the control system; providing a first new setpoint to the control system to create a step setpoint change thereto and to start an estimation procedure which estimates process parameters based on an observed process output response to said change; calculating numerically the values of the following control area integrals I₁ and I₂ as the process output approaches the first new setpoint in accordance with the relationships: where: m ss = Final Value, Control Output m(t) = Control Output at time t ΔSP = Change in setpoint α = Weighting Parameter = (τ m + T m )⁻¹ τ m = Observed lag time constant T m = Observed deadtime; using said control area integrals to determine estimated process parameters of observed process gain, lag time constant and deadtime representative of the process; and updating the process model using the estimated process parameters. In the light of the foregoing disadvantages of the prior art, a preferred embodiment of the invention described below provides a self-tuning control technique and system that incorporates both a parameter estimation algorithm and an algorithm for deadtime estimation. The preferred embodiment can solve or at least alleviate the problems associated with the prior art by providing a control technique that can include both a recursive least squares parameter estimation algorithm and a deadtime estimation algorithm. The deadtime estimation algorithm uses time integrals of system variables responding to a step or impulse input. Proper selection of the integrals (control areas) results in a set of equations which are solvable for process parameters. The utilisation of control areas for parameter estimation permits identification of process deadtime. The smoothing effects of integration attenuates the effects of process noise on the parameter estimates. The invention will now be further described, by way of illustrative and non-limiting example, with reference to the accompanying drawing, in which: Figure 1 is a schematic diagram of a model-based controller; and Figure 2 illustrates calculation of a time integral shown in Equation (2) below. Figure 1 of the drawing is a schematic diagram of a model-based controller having the following transfer function: where k m , τ m , T m , τ f = controller parameters (defined below); U(s) = a control output; and e(s) = the error between an input process variable and a setpoint. This particular transfer function assumes that the controlled process can be approximated by a first order lag with deadtime. The controller is tuned in terms of the observed process gain k m , lag time constant τ m , and deadtime T m . A fourth tuning parameter, a filter time constant τ f , specifies the desired time response of the process variable to a change in setpoint or to a disturbance. The self-tuning control system couples a variable version of recursive least squares parameter estimation with the model-based controller. The derivation of the recursive least squares algorithm is well known in the art and is incorporated herein by reference. The use of this self-tuning control system is constrained to processes with a known and fixed process delay or to processes where the delay can be measured or inferred on-line. In order to extend the application of this system to processes with unknown or time varying deadtime, a parameter estimation technique is required. The technique described herein has the advantage of estimating all process parameters, including deadtime, in a closed loop system. The basic premise relative to this technique is that certain quantitative measurements of the system response to a step setpoint change can be directly related to the process parameters. Using various control areas involving the process output, a set of non-linear algebraic equations utilising the process parameters can be developed and solved. The following steps describe the procedure used for estimating the deadtime and process parameters of a first order linear system using the controller shown in Figure 1: a) The setpoint to the controller is increased or decreased by a prescribed amount to start the estimation procedure. b) The integrals in Equations (2) and (3) shown below are calculated numerically as the response to the setpoint change. The values of both of these integrals converge as the process output approaches the new setpoint. Therefore, these integrals can be calculated over the finite time horizon from t = 0 to t = t ss , as shown in Figure 2. where: I₁, I₂ = control area integrals; m ss = final (steady state) value, control output; m(t) = control output at time t; ΔSP = change in setpoint; and α = weighting parameter = (τ m + T m )⁻¹ . c) After observing the process response to a step setpoint change, Equations (4) to (6) shown below are used to estimate the process parameters. T est = Z - τ est (6) where: k est , τ est , T est = estimated parameters; m init = initial value, control output; and b = - a α From the foregoing, it is apparent that, by using time integrals of system variables reacting to a step or impulse change, a set of equations, solvable for process parameters, results. Furthermore, the use of control areas for parameter estimation permits identification of process deadtime. In addition, the smoothing effects of integration attenuate the effects of process noise on the resulting parameter estimates. The foregoing deadtime/parameter estimator is designed to detect naturally occurring step setpoint changes and to estimate process parameters when they occur. The estimator continually calculates the average of the process variable over a fixed time horizon using a first order filter. When a setpoint change is detected, the estimator compares the average with the old setpoint to determine if the process was at steady state conditions. If so, the estimation algorithm is run. Should a second setpoint change occur before the estimation is completed, the estimation is aborted. The user may also select to have the algorithm run on demand or on the occurrence of an event or be time dependent. With respect to these additional modes of operation, the user specifies the direction and magnitude of the setpoint change to be used for the test. Triggering the estimation algorithm results in the following sequence of events: a) The estimator waits until it determines that the process is at steady state conditions. b) The setpoint is changed to a specified amount by the user. c) Parameters are estimated to characterise the process from observation of the closed loop response. d) The setpoint is returned to its pre-test value. e) A second set of parameters is estimated to characterise the response of the process moving in the opposite direction of the first test. The second test helps to identify overall process response so as to diminish effects caused by non-linearities. f) The deadtime/parameter estimator outputs the average of the estimate obtained during the two tests. The parameter estimates obtained in response to both natural and induced setpoint changes can be used to automatically update the model-based controller or can be presented to the operator for review and manual updating.

Claims: A process control system comprising: a controller for producing a control output for the process; means for providing a first response, resulting from a comparison of a process variable and a setpoint, to a summation unit; a model, connected to said controller and located in a feedback loop, for receiving said control output and providing an output to said summation unit; and means, connected to said summation unit, for providing a second response to said controller; wherein said controller and said model include algorithm means for updating said model based on estimated process parameters of observed process gain, lag time constant, and deadtime in response to changes in the setpoint, said algorithm means being operative numerically to calculate the values of the following control area integrals I₁ and I₂, for use in determining the estimated process parameters, as the control output approaches a new setpoint in accordance with the relationships: where: m ss = Final Value, Control Output m(t) = Control Output at time t ΔSP = Change in setpoint α = Weighting Parameter = (τ m + T m )⁻¹ τ m = Observed lag time constant T m = Observed deadtime A method for controlling a process, which has unknown or time varying deadtime, using a control system comprising a model of the process by measuring the response to a step setpoint change, the method comprising: providing a first setpoint to the control system; providing a process variable to the control system; providing a first new setpoint to the control system to create a step setpoint change thereto and to start an estimation procedure which estimates process parameters based on an observed process output response to said change; calculating numerically the values of the following control area integrals I₁ and I₂ as the process output approaches the first new setpoint in accordance with the relationships: where: m ss = Final Value, Control Output m(t) = Control Output at time t ΔSP = Change in setpoint α = Weighting Parameter = (τ m + T m )⁻¹ τ m = Observed lag time constant T m = Observed deadtime; using said control area integrals to determine estimated process parameters of observed process gain, lag time constant and deadtime representative of the process; and updating the process model using the estimated process parameters. A method as claimed in claim 2, including solving a set of three non-linear algebraic equations which relate to the process gain, lag time constant and deadtime respectively as follows T est = Z - τ est where: k est , τ est , T est = Estimated parameters m init = Initial value, Control Output and: b = - a α where: k m = Observed process gain τ f = Filter time constant to determine the estimated process deadtime, process gain and lag time for updating the process model. A method as claimed in claim 3, including the steps of continually calculating an average of the process variable over a fixed time horizon using a first order filter, and starting the estimating procedure only if a comparison of the average with the first setpoint determines that the process was at steady state conditions. A method as claimed in claim 4, including the step of aborting the estimation procedure if another setpoint change occurs before the estimation procedure is completed. A method as claimed in claim 3, including the step of provided a second new setpoint to the controller to create a setpoint change thereto in an opposite direction with respect to the change created by said first new setpoint, thereby to characterize the overall response of the process and diminish effects caused by non-linearities.

Inventors: BUCHNER MARC, LANE JOHN DAVID, LOPARO KEN, SCHEIB THOMAS JOSEPH, BUCHNER, MARC, LANE, JOHN DAVID, LOPARO, KEN, SCHEIB, THOMAS JOSEPH
Applicants: INT CONTROL AUTOMATION FINANCE, INTERNATIONAL CONTROL AUTOMATION FINANCE S.A.
Application year: 1989
Main classification: G05B13
IPC codes: G05B13, G05B23