Optimization of manufacturing process automation in the presence of time-varying operating conditions

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Automatic control systems are critical to manufacturing today because they allow for steady process operations, consistent product quality, less waste, and control of emissions. However, most current systems are not designed to optimally handle time-varying operating conditions introduced by time-varying factors such as feedstock changes, product grade changes, demand changes, multi-modes due to process nonlinearities and even operator shift changes. The inability to finely control processes can lead to lower product quality, additional waste, and increased emissions of environmentally undesirable substances. As a result, it is difficult to meet both increased product quality specifications and more stringent environmental regulations - facts of life for industry today - with conventional automation control. We propose to develop a set of tools for improved process control of systems with time-varying characteristics. The approach we will take is based on system identification and optimization of a set of control laws including time invariant as well as time variant control laws for a class of time-varying processes. Our objective is to develop strategies to ensure product quality specifications while minimizing control input energy. Time-varying system identification and process control, particularly for the hybrid or switching systems, are areas of active research. Our solution will be designed to leverage automation system infrastructure from the existing to a foreseeable 10-year horizon so that it can be implemented in the industrial distributed control systems (DCS) without additional capital cost. This will make it possible to quickly apply the technology to industry. Improved control reduces variability, allowing processes to be operated closer to their setpoints without violating constraints. This will lead to better product quality and a reduced environmental footprint. Optimizing the control of time-varying operations will make industry more efficient and more competitive in the global marketplace.