Computer method and apparatus for optimized controller in a non-linear process
First Claim
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1. Computer apparatus for controlling a non-linear manufacturing process comprising:
- a controller for determining and adjusting manipulated variable values for controlling a subject non-linear manufacturing process, the controller employing a linear model for modeling effect that would result in the subject manufacturing process with a step change in manipulated variable values; and
an optimizer coupled to the controller for updating the linear model of the controller, as the subject non-linear manufacturing process transitions from one operating point to another, in a high degree of non-linearity between manipulated variables and controlled variables of the subject process, the controlled variables being indicative of physical properties of the subject process, the optimizer utilizing a non-linear model of the subject process for updating the linear model and determining target values of the controlled variables.
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Abstract
A first principles, steady state model of a desired polymer process is applied with a non-linear optimizer to a linear controller. Model process gains and optimal target values for controller variables result. These results are utilized by a multivariable linear controller to achieve nonlinear control of the subject process. Preferably the nonlinear optimizer is DMO/SQP. The steady state model is produced by Polymers Plus and the linear controller is DMCplus, all of Aspen Technology, Inc. in Cambridge Mass.
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Citations
14 Claims
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1. Computer apparatus for controlling a non-linear manufacturing process comprising:
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a controller for determining and adjusting manipulated variable values for controlling a subject non-linear manufacturing process, the controller employing a linear model for modeling effect that would result in the subject manufacturing process with a step change in manipulated variable values; and
an optimizer coupled to the controller for updating the linear model of the controller, as the subject non-linear manufacturing process transitions from one operating point to another, in a high degree of non-linearity between manipulated variables and controlled variables of the subject process, the controlled variables being indicative of physical properties of the subject process, the optimizer utilizing a non-linear model of the subject process for updating the linear model and determining target values of the controlled variables. - View Dependent Claims (2, 3, 4, 5, 6, 7)
the optimizer gain adapts the linear model of the controller with the determined gains. -
5. Computer apparatus as claimed in claim 1 wherein the optimizer is executed as frequently as the controller.
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6. Computer apparatus as claimed in claim 1 wherein the non-linear model of the optimizer is a rigorous, first principles, non-linear model.
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7. Computer apparatus as claimed in claim 1 wherein the subject non-linear manufacturing process is a polymer process.
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8. A method for controlling a non-linear manufacturing process comprising the computer implemented steps of:
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utilizing a linear model, modeling effect that would result in a subject manufacturing process with a step change in manipulated variable values used for controlling said process;
using a non-linear model of the subject process, (i) updating the linear model as the subject process transitions from one operating point to another, in a high degree of non-linearity between the manipulated variables and controlled variables indicative of physical properties of the subject process, and (ii) determining target values of the controlled variables. - View Dependent Claims (9, 10, 11, 12, 13, 14)
the step of updating the linear model includes gain adapting the linear model with the determined gains.
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12. A method as claimed in claim 8 wherein the step of updating is executed as frequently as the subject process transitions from one operating point to another.
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13. A method as claimed in claim 8 wherein the step of using a non-linear model includes using a rigorous, first principles, non-linear model.
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14. A method as claimed in claim 8 wherein the subject process is a polymer process.
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