Hybrid linear-neural network process control
First Claim
1. An apparatus for modeling a process, said process having one or more disturbance variables as process input conditions, one or more corresponding manipulated variables as process control conditions, and one or more corresponding controlled variables as process output conditions, said apparatus comprising:
- a data derived primary analyzer adapted to sample an input vector spanning one or more of said disturbance variables and manipulated variables, said data derived primary analyzer generating an output based on said input vector;
an error correction analyzer adapted to sample said input vector, said error correction analyzer estimating a residual between said data derived primary analyzer output and said controlled variables; and
an adder coupled to the output of said data derived primary analyzer and said error correction analyzer, said adder summing the output of said primary and error correction analyzers to estimate said controlled variables.
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Abstract
A hybrid analyzer having a data derived primary analyzer and an error correction analyzer connected in parallel is disclosed. The primary analyzer, preferably a data derived linear model such as a partial least squares model, is trained using training data to generate major predictions of defined output variables. The error correction analyzer, preferably a neural network model is trained to capture the residuals between the primary analyzer outputs and the target process variables. The residuals generated by the error correction analyzer is summed with the output of the primary analyzer to compensate for the error residuals of the primary analyzer to arrive at a more accurate overall model of the target process. Additionally, an adaptive filter can be applied to the output of the primary analyzer to further capture the process dynamics. The data derived hybrid analyzer provides a readily adaptable framework to build the process model without requiring up-front knowledge. Additionally, the primary analyzer, which incorporates the PLS model, is well accepted by process control engineers. Further, the hybrid analyzer also addresses the reliability of the process model output over the operating range since the primary analyzer can extrapolate data in a predictable way beyond the data used to train the model. Together, the primary and the error correction analyzers provide a more accurate hybrid process analyzer which mitigates the disadvantages, and enhances the advantages, of each modeling methodology when used alone.
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Citations
39 Claims
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1. An apparatus for modeling a process, said process having one or more disturbance variables as process input conditions, one or more corresponding manipulated variables as process control conditions, and one or more corresponding controlled variables as process output conditions, said apparatus comprising:
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a data derived primary analyzer adapted to sample an input vector spanning one or more of said disturbance variables and manipulated variables, said data derived primary analyzer generating an output based on said input vector;
an error correction analyzer adapted to sample said input vector, said error correction analyzer estimating a residual between said data derived primary analyzer output and said controlled variables; and
an adder coupled to the output of said data derived primary analyzer and said error correction analyzer, said adder summing the output of said primary and error correction analyzers to estimate said controlled variables. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20)
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21. A method for modeling a process having one or more disturbance variables as process input conditions, one or more corresponding manipulated variables as process control conditions, and one or more corresponding controlled variables as process output conditions, said method comprising the steps of:
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(a) picking one or more selected variables from said disturbance variables and said manipulated variables;
(b) providing said selected variables to a data derived primary analyzer and an error correction analyzer;
(c) generating a primary output from said selected variables using said data derived primary analyzer;
(d) generating a predicted error output from said selected variables using said error correction analyzer; and
(e) summing the output of said primary and error correction analyzers. - View Dependent Claims (22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32)
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33. A program storage device having a computer readable program code embodied therein for modeling a process, said process having one or more disturbance variables as process input conditions, one or more corresponding manipulated variables as process control conditions, and one or more corresponding controlled variables as process output conditions, said program storage device comprising:
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a data derived primary analyzing code adapted to sample an input vector spanning one or more of said disturbance variables and manipulated variables, said data derived primary analyzing code generating an output based on said input vector;
an error correction analyzing code adapted to sample said input vector, said error correction analyzing code estimating a residual between said data derived primary analyzing code output and said controlled variables; and
an adder code coupled to the output of said data derived primary analyzing code and said error correction analyzing code, said adder code summing the output of said primary and error correction analyzing code to estimate said controlled variables. - View Dependent Claims (34, 35, 36, 37, 38, 39)
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Specification