Adaptive-predictive control and optimization system

• US 5,841,652 A
• Filed: 04/03/1996
• Issued: 11/24/1998
• Est. Priority Date: 04/03/1996
• Status: Expired due to Fees

• Current Assignee: SCAP Europa SA
• Original Assignee: SCAP Europa SA
• Inventors: Sanchez, Juan Martin
• Primary Examiner(s): Elmore, Reba I.
• Assistant Examiner(s): Garland, Steven R.
• Application Number:
  US08/627,055
• Time in Patent Office: 965 Days
• Field of Search: 364/146, 364/147, 364/148-157, 364/160-165, 364/172, 364/191, 364/188, 364/148.01-148.1, 395/903, 395/904, 395/906, 395/914, 706/903, 706/904, 706/906, 706/914
• US Class Current: 700/44
• CPC Class Codes: G05B 13/026 using a predictor

Abstract

An Adaptive-Predictive Control and Optimization System enables a designer to construct a control and optimization scheme using graphical operators to represent adaptive-predictive controllers and to represent complementary operating logic operations. The control and optimization scheme controls an actual or simulated process in accordance with at least one predefined process performance criteria and is constructed by integrating the adaptive-predictive controllers with the complementary operating logic by selecting and interconnecting their corresponding graphical representations. The adaptive-predictive controller predicts the value of an adaptive-predictive driven vector during at least one future sampling instant, and generates, at each of the sampling instants, a control vector that drives the value of the predicted driven vector to satisfy a predefined controller performance criterion at the at least one future sampling instant. The complementary operating logic drives the process toward predefined process performance criteria such as optimizing the process performance, being responsive to at least one process operating condition and interacting with the process instrumentation.

Claims

1. A method of designing a control and optimization scheme for generating a process control vector during each of a plurality of sampling instants, said process control vector comprising at least one process control variable and being applied to an apparatus which carries out a process having at least one process input variable and at least one process output variable, said at least one process input variable defining a process input vector and said at least one process output variable defining a process output vector, said apparatus varying said process input vector as a function of said process control vector, said method comprising the steps of:

(A) defining at least one controller for predicting a value of a driven vector during at least one future sampling instant, said driven vector being comprised of said at least one driven variable, said at least one controller generating, at each of said sampling instants, an outputted control vector that drives said value of said predicted driven vector to satisfy a predefined controller performance criterion at said at least one future sampling instant;

(B) selecting at least one complementary operating logic operation; and

(C) combining said at least one controller with said at least one complementary operating logic operation to control said process in accordance with at least one predefined process performance criterion;

said at least one complementary operating logic operation being selected such that when said at least one complementary operating logic operation is combined with said controller, said controller operates in such a manner that said process is optimized in accordance with said at least one predefined process performance criterion.

2. The method of claim 1, wherein said step of defining at least one controller includes selecting, using a computer aided design tool, one from a first group of graphical input/output operators each representing a respective type of controller operation.

3. The method of claim 2, wherein said step of selecting, using said computer aided design tool, at least one complementary operating logic operation includes selecting one from a second group of graphical input/output operators each representing a respective complementary operating logic operation.

4. The method of claim 3, wherein each of said first and second groups of graphical input/output operators includes at least one input and at least one output, and said step of combining said at least one controller with said at least one complementary operating logic operation includes defining at least one interconnection between a respective one of said at least one input or said at least one output of the selected one of said first group of graphical input/output operators with a respective one of said at least one input or said at least one output of the selected one of said second group of graphical input/output operators.

5. The method of claim 4, further comprising the step of generating, from the selected ones of said first and second groups of graphical input/output operators and said at least one interconnection, an intermediate code suitable for execution in at least one computing environment.

6. The method of claim 5, further comprising the step of compiling said intermediate code to generate an object code suitable for execution in a respective computing environment.

7. The method of claim 1, wherein said selecting step includes selecting said at least one complementary operating logic operation such that when said at least one complementary operating logic operation is combined with said controller, said controller generates said outputted control vector that optimizes said process in accordance with said at least one predefined process performance criterion.

8. The method of claim 1, wherein said selecting step includes selecting said at least one complementary operating logic operation that is responsive to at least one process operating condition.

9. The method of claim 8, wherein said at least one predefined process performance criterion is an optimum value of said at least one process operating condition, and said combining step combines said at least one controller with said at least one complementary operating logic operation such that said controller generates said outputted control vector that enables said at least one process operating condition to approach said optimum value.

10. The method of claim 8, wherein said at least one predefined process performance criterion is a change in said at least one process operating condition, and said combining step combines said at least one controller with said at least one complementary operating logic operation such that said controller generates said outputted control vector as a function of said change in said at least one process operating condition.

11. The method of claim 1, wherein said at least one predefined process performance criterion is the control of at least one process instrumentation, and said selecting step selects said at least one complementary operating logic operation that controls said at least one process instrumentation.

12. The method of claim 1, wherein said selecting step includes selecting said at least one complementary operating logic operation that varies the value of a set point for said at least one controller.

13. The method of claim 1, wherein said selecting step includes selecting said at least one complementary operating logic operation that varies the value of a control period for said at least one controller.

14. The method of claim 1, wherein said selecting step includes selecting said at least one complementary operating logic operation that controls an actuator.

15. The method of claim 1, wherein said selecting step includes selecting said at least one complementary operating logic operation that operates as a function of at least one measured value.

16. The method of claim 1, wherein said selecting step includes selecting said at least one complementary operating logic operation that transforms said process output vector into said driven vector.

17. The method of claim 1, wherein said selecting step includes selecting said at least one complementary operating logic operation that transforms said outputted control vector into said process control vector.

18. The method of claim 17, wherein said apparatus carries out a simulated process and generates, using said simulated process, said process output vector in response to said process control vector that is generated by said at least one complementary operating logic operation.

19. The method of claim 1, wherein said selecting step includes selecting said at least one complementary operating logic operation that includes a logic operator.

20. The method of claim 1, wherein said selecting step includes selecting at least one complementary operating logic operation that includes an arithmetic operator.

21. The method of claim 1, wherein said selecting step includes selecting at least one complementary operating logic operation that includes a filtering operator.

22. The method of claim 1, wherein said selecting step includes selecting at least one complementary operating logic operation that includes a range restricting operator.

23. The method of claim 1, wherein said selecting step includes selecting at least one complementary operating logic operation that includes a multiplexing operator.

24. The method of claim 1, wherein said selecting step includes selecting at least one complementary operating logic operation that includes a pulse forming operator.

25. The method of claim 1, wherein said controller generates, at each of said sampling instants, a desired driven vector that represents a desired value of said driven vector at said future sampling instant, and generates, at each of said sampling instants, said outputted control vector that drives said value of said predicted driven vector to equal said desired driven vector at said future sampling instant.

26. The method of claim 1, wherein said controller uses an advanced control methodology to satisfy said predefined controller performance criterion.

27. A system for facilitating the design of a control and optimization scheme for generating a process control vector during each of a plurality of sampling instants, said process control vector comprising at least one process control variable and being applied to an apparatus which carries out a process having at least one process input variable and at least one process output variable, said at least one process input variable defining a process input vector and said at least one process output variable defining a process output vector, said apparatus varying said process input vector as a function of said process control vector, said system comprising:

(A) a controller design tool for facilitating the definition of at least one controller, said at least one controller for predicting a value of a driven vector during at least one future sampling instant, said driven vector being comprised of said at least one driven variable, said at least one controller generating, at each of said sampling instants, an outputted control vector that drives said value of said predicted driven vector to satisfy a predefined controller performance criterion at said at least one future sampling instant;

(B) a complementary operating logic design tool for facilitating the selecting of at least one complementary operating logic operation; and

(C) an integration design tool for facilitating the combining of said at least one controller with said at least one complementary operating logic operation to control said process in accordance with at least one predefined process performance criterion;

said complementary operating logic design tool facilitating selecting said at least one complementary operating logic operation such that when said at least one complementary operating logic operation is combined with said controller, said controller operates in such a manner that said process is optimized in accordance with said at least one predefined process performance criterion.

28. The system of claim 27, wherein said controller design tool is operable for selecting one from a first group of graphical input/output operators each representing a respective type of controller operation.

29. The system of claim 28, wherein said complementary operating logic design tool is operable for selecting one from a second group of graphical input/output operators each representing a respective complementary operating logic operation.

30. The system of claim 29, wherein each of said first and second groups of graphical input/output operators includes at least one input and at least one output, and said integration design tool is operable for defining at least one interconnection between a respective one of said at least one input or said at least one output of the selected one of said first group of graphical input/output operators with a respective one of said at least one input or said at least one output of the selected one of said second group of graphical input/output operators.

31. The system of claim 30, further comprising a first compiler for generating, from the selected ones of said first and second groups of graphical input/output operators and said at least one interconnection, an intermediate code suitable for execution in at least one computing environment.

32. The system of claim 31, further comprising a second compiler for compiling said intermediate code to generate an object code suitable for execution in a respective computing environment.

33. The system of claim 27, wherein said complementary operating logic design tool facilitates selecting said at least one complementary operating logic operation such that when said at least one complementary operating logic operation is combined with said controller, said controller generates said outputted control vector that optimizes said process in accordance with said at least one predefined process performance criterion.

34. The system of claim 27, wherein said complementary operating logic design tool facilitates selecting said at least one complementary operating logic operation that is responsive to at least one process operating condition.

35. The system of claim 34, wherein said at least one predefined process performance criterion is an optimum value of said at least one process operating condition, and said complementary operating logic design tool facilitates combining said at least one controller with said at least one complementary operating logic operation such that said controller generates said outputted control vector that enables said process operating condition to approach said optimum value.

36. The system of claim 34, wherein said at least one predefined process performance criterion is a change in said at least one process operating condition, and said complementary operating logic design tool facilitates combining said at least one controller with said at least one complementary operating logic operation such that said controller generates said outputted control vector as a function of said change in said at least one process operating condition.

37. The system of claim 27, wherein said at least one predefined process performance criterion is the control of at least one process instrumentation, and said complementary operating logic design tool facilitates selecting said at least one complementary operating logic operation that controls said at least one process instrumentation.

38. The system of claim 27, wherein said complementary operating logic design tool facilitates selecting said at least one complementary operating logic operation that varies the value of a set point for said at least one controller.

39. The system of claim 27, wherein said complementary operating logic design tool facilitates selecting said at least one complementary operating logic operation that varies the value of a control period for said at least one controller.

40. The system of claim 27, wherein said complementary operating logic design tool facilitates selecting said at least one complementary operating logic operation that controls an actuator.

41. The system of claim 27, wherein said complementary operating logic design tool facilitates selecting said at least one complementary operating logic operation that operates as a function of at least one measured value.

42. The method of claim 27, wherein said complementary operating logic design tool facilitates selecting said at least one complementary operating logic operation that transforms said process output vector into said driven vector.

43. The method of claim 27, wherein said complementary operating logic design tool facilitates selecting said at least one complementary operating logic operation that transforms said outputted control vector into said process control vector.

44. The system of claim 43, wherein said apparatus carries out a simulated process and generates, using said simulated process, said process output vector in response to said process control vector that is generated by said at least one complementary operating logic operation.

45. The system of claim 27, wherein said complementary operating logic design tool includes selecting at least one complementary operating logic operation that includes a logic operator.

46. The system of claim 27, wherein said complementary operating logic design tool facilitates selecting at least one complementary operating logic operation that includes a non-linear function operator.

47. The system of claim 27, wherein said complementary operating logic design tool facilitates selecting at least one complementary operating logic operation that includes an arithmetic operator.

48. The system of claim 27, wherein said complementary operating logic design tool facilitates selecting at least one complementary operating logic operation that includes a filtering operator.

49. The system of claim 27, wherein said complementary operating logic design tool facilitates selecting at least one complementary operating logic operation that includes a range restricting operator.

50. The system of claim 27, wherein said complementary operating logic design tool facilitates selecting at least one complementary operating logic operation that includes a multiplexing operator.

51. The system of claim 27, wherein said complementary operating logic design tool facilitates selecting at least one complementary operating logic operation that includes a pulse forming operator.

52. The system of claim 27, wherein said controller generates, at each of said sampling instants, a desired driven vector that represents a desired value of said driven vector at said future sampling instant, and generates, at each of said sampling instants, said outputted control vector that drives said value of said predicted driven vector to equal said desired driven vector at said future sampling instant.

53. The system of claim 27, wherein said controller uses an advanced control methodology to satisfy said predefined controller performance criterion.

54. A method of generating a process control vector during each of a plurality of sampling instants, said process control vector comprising at least one process control variable and being applied to an apparatus which carries out a process having at least one process input variable and at least one process output variable, said at least one process input variable defining a process input vector and said at least one process output variable defining a process output vector, said apparatus varying said process input vector as a function of said process control vector, said method comprising the steps of:

(A) predicting a value of a driven vector during at least one future sampling instant, said driven vector being comprised of said at least one driven variable;

(B) generating, at each of said sampling instants, an outputted control vector that drives said value of said predicted driven vector to satisfy a predefined controller performance criterion at said at least one future sampling instant; and

(C) performing at least one complementary operating logic operation to control said predicting and generating steps such that said process is optimized in accordance with at least one predefined process performance criterion.

55. The method of claim 54, wherein said performing step includes performing said at least one complementary operating logic operation such that said outputted control vector is generated that optimizes said process in accordance with said at least one predefined process performance criterion.

56. The method of claim 54, wherein said performing step includes performing said at least one complementary operating logic operation that is responsive to at least one process operating condition.

57. The method of claim 56, wherein said at least one predefined process performance criterion is an optimum value of said at least one process operating condition, and said performing step performs said at least one complementary operating logic operation such that said outputted control vector that enables said process operating condition to approach said optimum value is generated.

58. The method of claim 56, wherein said at least one predefined process performance criterion is a change in said at least one process operating condition, and said performing step performs said at least one complementary operating logic operation such that said outputted control vector is generated as a function of said change in said at least one process operating condition.

59. The method of claim 54, wherein said at least one predefined process performance criterion is the control of at least one process instrumentation, and said performing step performs said at least one complementary operating logic operation that controls said at least one process instrumentation.

60. The method of claim 54, wherein said performing step includes at least one complementary operating logic operation that varies the value of a set point.

61. The method of claim 54, wherein said performing step includes at least one complementary operating logic operation that varies the value of a control period.

62. The method of claim 54, wherein said performing step includes at least one complementary operating logic operation that controls an actuator.

63. The method of claim 54, wherein said performing step includes at least one complementary operating logic operation that is performed as a function of at least one measured value.

64. The method of claim 54, wherein said performing step includes performing said at least one complementary operating logic operation that transforms said process output vector into said driven vector.

65. The method of claim 54, wherein said performing step includes performing said at least one complementary operating logic operation that transforms said outputted control vector into said process control vector.

66. The method of claim 65, wherein said apparatus carries out a simulated process and generates, using said simulated process, said process output vector in response to said process control vector that is generated by said at least one complementary operating logic operation.

67. The method of claim 54, wherein said at least one complementary operating logic operation includes a logic operator.

68. The method of claim 54, wherein said at least one complementary operating logic operation includes an arithmetic operator.

69. The method of claim 54, wherein said at least one complementary operating logic operation includes a filtering operator.

70. The method of claim 54, wherein said at least one complementary operating logic operation includes a range restricting operator.

71. The method of claim 54, wherein said at least one complementary operating logic operation includes a multiplexing operator.

72. The method of claim 54, wherein said at least one complementary operating logic operation includes a pulse forming operator.

73. The method of claim 54, wherein said generating step generates, at each of said sampling instants, a desired driven vector that represents a desired value of said driven vector at said future sampling instant, and generates, at each of said sampling instants, said outputted control vector that drives said value of said predicted driven vector to equal said desired driven vector at said future sampling instant.

74. The method of claim 54, wherein said generating step uses an advanced control methodology to satisfy said predefined controller performance criterion.

75. A system for generating a process control vector during each of a plurality of sampling instants, said process control vector comprising at least one process control variable and being applied to an apparatus which carries out a process having at least one process input variable and at least one process output variable, said at least one process input variable defining a process input vector and said at least one process output variable defining a process output vector, said apparatus varying said process input vector as a function of said process control vector, said system comprising:

(A) at least one controller for predicting a value of a driven vector during at least one future sampling instant, said driven vector being comprised of at least one driven variable, said at least one controller for generating, at each of said sampling instants, an outputted control vector that drives said value of said predicted driven vector to satisfy a predefined controller performance criterion at said at least one future sampling instant;

(B) complementary operating logic for performing at least one complementary operating logic operation; and

(C) at least one interconnection between said at least one controller and said complementary operating logic such that said controller operates in a manner that said process is controlled in accordance with at least one predefined process performance criterion.

76. The system of claim 75, wherein said at least one complementary operating logic is operable such that said controller generates said outputted control vector that optimizes said process in accordance with said at least one predefined process performance criterion.

77. The system of claim 75, wherein said at least one complementary operating logic is responsive to at least one process operating condition.

78. The system of claim 77, wherein said at least one predefined process performance criterion is an optimum value of said at least one process operating condition, and said at least one complementary operating logic is operable such that said controller generates said outputted control vector that enables said process operating condition to approach said optimum value.

79. The system of claim 77, wherein said at least one predefined process performance criterion is a change in said at least one process operating condition, and said at least one complementary operating logic is operable such that said controller generates said outputted control vector as a function of said change in said at least one process operating condition.

80. The system of claim 75, wherein said at least one predefined process performance criterion is the control of at least one process instrumentation, and said at least one complementary operating logic is operable such that said at least one complementary operating logic controls said at least one process instrumentation.

81. The system of claim 75, wherein said complementary operating logic varies the value of a set point for said at least one controller.

82. The system of claim 75, wherein said complementary operating logic varies the value of a control period for said at least one controller.

83. The system of claim 75, wherein said complementary operating logic controls an actuator.

84. The system of claim 75, wherein said complementary operating logic is a function of at least one measured value.

85. The system of claim 75, wherein said complementary operating logic transforms said process output vector into said driven vector.

86. The system of claim 75, wherein said complementary operating logic transforms said outputted control vector into said process control vector.

87. The system of claim 86, wherein said apparatus carries out a simulated process and generates, using said simulated process, said process output vector in response to said process control vector that is generated by said complementary operating logic.

88. The system of claim 75, wherein said at least one complementary operating logic operation includes a logic operator.

89. The system of claim 75, wherein said at least one complementary operating logic operation includes an arithmetic operator.

90. The system of claim 75, wherein said at least one complementary operating logic operation includes a filtering operator.

91. The system of claim 75, wherein said at least one complementary operating logic operation includes a range restricting operator.

92. The system of claim 75, wherein said at least one complementary operating logic operation includes a multiplexing operator.

93. The system of claim 75, wherein said at least one complementary operating logic operation includes a pulse forming operator.

94. The system of claim 75, wherein said controller generates, at each of said sampling instants, a desired driven vector that represents a desired value of said driven vector at said future sampling instant, and generates, at each of said sampling instants, said outputted control vector that drives said value of said predicted driven vector to equal said desired driven vector at said future sampling instant.

95. The system of claim 75, wherein said controller uses an advanced control methodology to satisfy said predefined controller performance criterion.