Advanced Process Control

Technologies and Experience

in Metal Processing Industry

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Predictive Control in Metal Processing Industry

Advanced Process Control

Sherpa Engineering overview

The Model Based Predictive Control
technology

Our Direct Experience

Typical Advanced Control Project
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Predictive Control in Metal Processing Industry

Key features

Locations
Set up in 1997
Certified in 2002
Turn over 2008 : 11,5 M
Two subsidiaries :

Kintesys
Ariamis

120 employees
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Predictive Control in Metal Processing Industry

Customers

5%
10%
AERONAUTICS

65%

SPACE
ESA, CNES, EPAS

AUTOMOTIVE
PSA, RENAULT, SVE, Delphi,
UTAC, Peugeot Sport, Honeywell
(Garrett), JTEKT, Valo, General
Motors, HPI, Magneti Marelli,
Paulstra,

SNECMA moteurs, Hispano Suiza,

Hurel Hispano, Latcore, Messier
Bugatti, Messier Dowty, Goodrich,
Dassault Aviation, NFM

10%

8%

INDUSTRY & ENERGY

Veolia, Total, Scneider
, Alcan/Pechiney, JGC, IIPG, Soteica,
NTE, Sollac, St Gobain, Exxon Mobil,
Melox, Sagem
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2%
DEFENCE

TRANSPORTATION
VOLVO TRUCKS, ALSTOM,
INRETS

Turbomca, Thals, Giat Industries

Predictive Control in Metal Processing Industry

M
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ns tor
or s
s
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tw ric
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F
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er

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ac ng
hi i n
ne es
Co A s
nd ir
i
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Pl
an
Fl
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ds

A skilled company with strong assets

System Analysis
& Specification
Modelling
Scientific Calculation
Synthesis and tests analysis
& identfication

Sherpa commitment :
Supporting
our customer from initial concept to industrial
Sizing
Structure study
solution
Diagnostic
Simulation
End user tools

Reliability Analysis
Automatics, Signal
processing, Control
Real time prototyping
Quality,Methodology
Organization,Strategy

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Predictive Control in Metal Processing Industry

MBPC: Model Based Predictive Control

Principles
Set point

Process
output

Reference
output

Reference

Control
variable

Error

Predicted
output
Model

Find the Control variable which minimises the Error

between the reference output and the predicted output

Model  predicted output

Reference (specification)  reference output
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Predictive Control in Metal Processing Industry

Model Based Predictive Control

Technologies

MBPC products:

Developed by Adersa, France

Currently owned by Sherpa Engineering

HIECON: Hierarchical Control.

Applicability:

Multivariable control systems

Individual units (e.g., distillation columns, furnaces, etc.)

Plant wide (e.g., Topping, Vacuum, Hydrotreating, Reforming, etc.)

PFC: Predictive Functional Control

PCR: Predictive Control of Reactors (subset of PFC)

Applicability:

Individual control loops with one input/one output and feed forward
compensation
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Predictive Control in Metal Processing Industry

MBPC - Advantages

Useful where PIDS are not sufficient enough:

difficult dynamic behaviour (long dead-time, under damped, inverse
response, integrative, instable)

compensation of measured disturbances

use of a disturbance model

use of the difference measure/model

multivariable systems

Wide-open methodology

follow-up of set point profile with no lag error

handles constraints on input & output variables

Easy tuning

design parameters are specification parameters rather than tuning
parameters (trade-off between robustness and dynamics is clearly
negotiable)

attractive to the technical person who has a limited control background

Online model

makes start-up easier

opens the way to monitoring and diagnosis

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Predictive Control in Metal Processing Industry

Sherpa Experience Table

Have been performing a lot of MBPC projects worldwide for more than 20 years

Technology transfer: JGC (Japan), INFOTROL (Korea), Setpoint (USA), SOTEICA (Argentina),
SUPCON (China)
Metallurgical, glass & plastic
Car & mechanical systems

Oil industry

Chemical & Food

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Predictive Control in Metal Processing Industry

Experience in Metal Processing

Industry

Continuous Casting: Typical Control Structure
CV = Controlled Variable
Steel Laddle

MV = Manipulated Variable
DV = Disturbance Variable
Stopper Servo
Controller

Gate Servo
Controller

Position
feedback

MV1
position
set point

MV3
position set
point

CV3
Tundish
Weight

Tundish
Mould Level
Predictive
Control
CV1=Level 1

DV1
DV2

CV2=Level 2

Line 1
Mould
DV1 = Casting
speed of line 1

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Tundish
Weight
Predictive
Control

Predictive Control in Metal Processing Industry

Line 2
Mould

DV2 = Casting
speed
of line 2
10

Experience in Metal Processing

Industry

Continuous Casting ARCELOR Fos-sur-mer (France)

Mould Level Control:

1995: Model Based Predictive Control: plant tests, model
identification, simulation, PFC control design, integration validation.
Requirement: standard deviation of the level reduced by factor 2.

2007: Redesign in progress following installation of a new level sensor
and upgrade of calculator (from PC to Schneider Electric PLC with
PCR Library).

Tundish Weight Control:

2003: Design of a Model Based Predictive Control: plant tests, model
identification, simulation, PCR control design, integration validation.

Requirement : number of gate motions < 15/hour.
weight variations within range 3 T.

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Predictive Control in Metal Processing Industry

11

Experience in Metal Processing

Industry

Cold Rolling Mill: Typical Control Structure for single stand

Entry
tension

Eccentricity
compensation
Feedback

Frequency
identification

Periodic input
thickness
compensation

Input
thickness
Output
thickness

Input
thickness

Output
thickness

Feed
forward

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Predictive Control in Metal Processing Industry

12

Experience in Metal Processing

Industry

Cold Rolling Mill PECHINEY NH /PECHINEY RU (France)

1989-2003: Advanced Thickness Control for single/multi stands rolling
mills Use of system models (mix of physical models [client knowledge,
mechanical thermal equations ] and black box models derived from
plant tests):

Feedback control (PFC)

Feedforward control (DV1 = input thickness, DV2 = speed variation)
Roll Eccentricity Compensation
Chatter identification and compensation

1993-1994: Advanced Bending Control for single stand rolling mills. PFC
using black box models.

Hot Rolling Mill PECHINEY IS /PECHINEY RH (France)

1997-2000: Advanced Control (PFC) using system models:

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Output thickness control

Inter-stand tensions control
Flatness control (through a measured criteria)
Coil temperature control

Predictive Control in Metal Processing Industry

13

Experience in Metal Processing

Industry

Strip Accumulator PECHINEY NH (France)

Accumulator for Heat Treatment Furnace:

1993: Strip Tension Control: plant tests, model identification,
simulation, PFC control design, integration validation.

Accumulator for Coating Line:

1995: Strip Tension Control.

Particularity: under-damped systems.

Cuttings PECHINEY NH (France)

1999: Strip Tension Control: plant tests, model identification,
simulation, PI control design, integration validation.

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Predictive Control in Metal Processing Industry

14

Advanced Control Project Phases

1. Audit, Pre-study.
2. Audit of the levels 0.
3. Modelling Identification Simulator.
4. Control design and Tests in simulation.
5. Integration into the control system.
6. Commissioning and Economic Benefits
Evaluation (Post Audit).
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Predictive Control in Metal Processing Industry

15


Audit, pre-study:

Phase 1 in an Advanced Control

Project

What ?

Getting in touch with the process

Functional analysis following a system approach (MV, CV, DV, )

Analysis of the existing performances

Definition of the requirements and specifications

Selection of appropriate targets, corresponding prerequisite

Pre-evaluation of workload

How ?

Training and collaborative analysis (1 week)

Data acquisition for performance analysis:

Review of existing models:
T
T

Flam = Larc . largeur . KF . QF T . am + (1 T ) av

ee
es

v 3nom

F3nom M 3
F3mes

Review of existing control structure:

Cdage

max

y
x
z

BM

h3

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Predictive Control in Metal Processing Industry

16

min

v 3


Audit of the levels 0:

What ?

Phase 2 in an Advanced Control

Project

Analysis of sensors & actuators (accuracy, dynamic response ).

Modelling of levels 0.
Data acquisition

How ?

Stand 2 Screw pulses

Design of plant pre-tests

Stand 2 Screw position (north side)

Analysis of responses

Re-tuning of level 0
control loops if necessary

Translation into a control

engineering language
-85
1
Pulse

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Delay

Predictive Control in Metal Processing Industry

0.2s+1

1
s

T ransfer Fcn

Integrator

Position
(m ic)

17

Backlash

Phase 3 in an Advanced Control

Project

Modelling Identification Simulator :

What ?

Dynamic simulation tool for control evaluation purpose.

How ?

Plant tests design

Data processing & Identification

Simulator building

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Predictive Control in Metal Processing Industry

18


Control Design :

What ?

Phase 4 in an Advanced Control

Project

Design of a control responding to requirements.

How ?

Definition of control structure

Tuning of predictive controllers

Tests in Simulation

Screw
position

Rolling
force set
point

Level
2

Constraints

Tensions
set point

Motors
speed

Level
1

Thickness
set point

Tensions
Forces

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Predictive Control in Metal Processing Industry

Currents

19

Hydraulic
position

Thickness

Phase 5 in an Advanced Control

Project

Integration into the Control System :

Depending on the site control system and the users skill or
availability, the integration is performed by:

Sherpa

The user himself

An external company at client convenience

An any case, the integration is validated by Sherpa.

Simulation

PLC

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Predictive Control in Metal Processing Industry

20

Phase 6 in an Advanced Control

Project

Commissioning and
Economic Benefits Evaluation
(Post Audit).

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Predictive Control in Metal Processing Industry

21

Example of difficult dynamic system : Control of

the tension of a strip accumulator
Open Loop Control
CV

C
+

D
+

MV

motor

The main difficulty is to stabilize

the process due to the particular
form of the speed/friction torque
characteristic of the motor

DV

Predictive Control

CV

in a certain area the system can

be considered as locally unstable

MV

Predictive control is well suited for

under damped systems control
DV
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Predictive Control in Metal Processing Industry

22

Disturbances compensation
The prediction of the
disturbance effect is
calculated with the
identified model

Measured
Disturbance
Variable
(DV)

MODEL

Controlled
Variable
(CV)

Total
Output

Manipulated
Variable (MV)
The controller can
calculate the action in
such a way to
counteract the
disturbance

Application in metal industry : compensation of speed effect

(decreasing of thickness at speed-up)
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Predictive Control in Metal Processing Industry

23

Speed effect compensation

8011: he=600 hs=320m gc=-0.4m/s KGCsim=8.1+-86.8/vc

8011: he=600 hs=320m gc=-0.4m/s KGCsim=8.1+-86.8/vc

Rolling force

Rolling force
140

130

130
T

140

120

120

110

110

Measured output thickness

80
60
40
20
0
-20
600
400

mic
T

Roll speed set point

600
400
200

Uncoiler motor current set point

300

200

200

80
60
40
20
0
-20

300

100
0
-20
-40
0

10

15

20
25
30
Time (secondes)

Entry tension

Roll gap correction

Roll speed set point

Uncoiler motor current set point

100

Roll acceleration set point

m/mn/s

m/mn/s

1.4

Roll gap correction

200

1.5

Advanced MBPC control

m/mn

mic

1.4

1.6

mic

1.5

0
-1

Entry tension

m/mn

1.6

Classical PI control

mic

5
0

Measured output thickness

10

35

40

45

50

Roll acceleration set point

0
-20
-40
0

10

15

20
25
30
Time (secondes)

35

40

45

50

Thickness control PFC: ACP=On(trep:vfixe=15,vvar=5s),TNDV=On(KGC=8.1+-86.8/vc)

Thickness control PI: Kp=0.5,Ki=3.0,TNDV=Off(KGC=0.0+0.0/vc)
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Predictive
Control
in Metal Processing
Industry
24
Entry
tension control: Reg=Off,G_comp_inert=1.0
Entry tension control: Reg=Off,G_comp_inert=1.0

Example of multivariable system:

Use of 2 actuators to control 1 output

Target : reproduction of
acceleration during gear
shift

2 actuators are available :

longitudinal jack: high
dynamic (10 Hz) but limited
range (7 cm)

pitch: slow dynamic
(0.14 Hz) but with a large
range (23 )

A specific procedure
enables to mix both
actuators in an optimal
way
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A physical simulator is used to

evaluate different power trains

Predictive Control in Metal Processing Industry

25

Example of multivariable system: Use

of 2 actuators to control 1 output

The strategy allows to follow the
set point even during stiff gear
shift :

the slow actuator is used to reach
the steady state value

the fast one is used in transient
mode to improve the dynamic of
the response

the procedure assures a zero
steady state value for the
longitudinal jacket

Application in metal processing :

Rolling force control

Fast actuator = upstream tension
set point

Slow actuator = screw setting of
upstream stand

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Predictive Control in Metal Processing Industry

26

Example of polynomial set point:

Control of a fast and accurate robot
1
0
0

MBPC

speed
set point

position

PI

current

speed

The robot is used for the manipulation of plastic parts coming out of
extrusion machines and going through a well defined path to a piling
up stack

Requirements :








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Accuracy is to be less than 1 mm over a 1500 mm dynamic path

The docking accuracy should be less than 0.2 mm.
Acceleration is limited to 20 m/s2 and speed reaches 15 m/s.
Robustness: load may vary from 0 kg to 20 kg.
Predictive Control in Metal Processing Industry

27

Example of polynomial set point:

Control of a fast and accurate robot
Classical PID control

Predictive control
follow-up of polynomial set points
robustness regarding the oscillatory mode
which is badly characterized (depends on the
robot load, and on the position of the other axes)

Results with PID

Results with PFC

1

1
Position

Position

0.5
0
0

0.5

0.2

0.4

0.6

0.8

1.2

1.4

1.6

1.8

0.2 mm

0
-0.001
0

0.2

0.4

0.6

0.8

1.2

1.4

1.6

1.8

0.2

0.4

0.6

0.001
0.5
0

0.001
Error

0
0

-0.001
0

0.8

1.2

1.4

0.2

0.4

0.6

0.8

1.2

1.4

Ramp docking of the strip thickness (coil head)

Temperature control in batch heater furnaces.
Predictive Control in Metal Processing Industry

1.8

0.2 mm

Error

Application in metal processing:

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1.6

28

1.6

1.8