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industrial process control, except for the system identification purpose. This is partly reasoned by the fact that the
computational capacity and data storage of the industrial
computerized systems are limited [28].
The use of process models appeared early in Coales and
Notons pioneering approach of on-line identifications in
1956 [29], and in an internal model controller introduced
by Smith in 1957 [30]. But Richalet is actually the first
to introduce MPC to industry with the receding (predictive)
horizon idea in 1972 [31]. The technique has evolved a long
way since. Almost all process control vendors nowadays
offer MPC to their customers, either as a functional block
for unit operation in a distributed control system (DCS), or
as a separate software package for plant-wide control. It is
notably that DCS is a specific name designated to the proprietary computer systems tailored made for large industrial
plants, similarly to PLC (programmable logic controller) for
discrete logic control applications.
Predictive control, as a matter of fact, assimilates basic
human activities [32]. A particular human action is usually
undertaken based on assumptions and expectations about
the future outcome. Model predictive control uses the past
information of states and the process model to predict future
control actions. The applications of MPC techniques are
apparently more popular in refineries and petrochemical
plants than in other industries, because the linearised system
models are adequate for processes in those industries. The
typical installations of MPC in industry are hierarchical.
The MPCs provide set points to the local controllers with
traditional PI/PID controllers finely tuned. If a predictive
controller starts to mislead the system behavior, the operator
simply isolates it and lets the local loops hold the plant using
the last received set points [2]. The process plant should be
stable in this condition, so in the worst case it is safe to run
the plant as it is without predictive control layer.
It is interesting to refer back to the debate for optimal
control and optimisation necessary to engineers in the 1960s
[33]. While it was found to be very successful in the
aerospace industry (there were more than 300 references
in a survey about theory and practice of optimal control at
that time, as quoted in [33]), the optimal control techniques
initially failed to provide a convincing solution to industrial process industries due to inherent constraints, model
uncertainty, unmeasured disturbance, as well as computer
capability at that time [34], [32]. There had been a resurgence
of the method that widespread in industry due to strategic
changes. The revitalized strategy was as follows: ... for large
complex problems, it may be better to encode optimality
criteria in more vague but more realistic terms, than to force
unwilling problems into an ill-fitting straitjacket to allow
rigorous optimisation [32]. MPC is among successful stories
using this strategy.
There are many good references of industrial MPCs.
The original work on DMC (Dynamic Matrix Control) is
referenced to in [35], [36]. The original IDCOM (Identification and Command) is referenced to in [31]. Other well
known commercialized packages such as QDMC (Quadratic
Dynamic Matrix Control) [37], QDMPC Plus from Aspentech, RMPCT (Robust Model Predictive Control Technology)
inside the Profit Controller from Honeywell, PFC (Predictive
Functional Control), HIECON (Hierarchical Constraint Control), ExaSMOC from Shell and Yokogawa, ConnoisseurTM
from Invensys, and some others predominant the industrial
MPC market.
For NMPC (MPC for severely nonlinear processes using nonlinear models and programming), the Sequential
Quadratic Programming (SQP) [38] is the well-known numerical method, wherein the objective function is quadratically approximated and the nonlinear constraints are linearized before solving at each iteration step. They are the
extension of Newton-type methods for converging to the
solution of the Karush-Kuhn-Tucker (KKT) conditions of
the constrained optimization. The solutions do not, however,
guarantee the system stability. In this field, the stability of
the closed-loop system is usually achievable by adding a
suitable equality or inequality terminal constraints to the
setup, or enforced stability constraints. The nominal stability
of infinite horizon problems is described in [39]. The formal
proof for the closed-loop stability for the receding-horizon
control (finite horizon) of Lipschitz continuous nonlinear
systems using the equality terminal constraints was provided
in [40].
Adding the terminal constraints may, nonetheless, cause
extra computation cost or even infeasibility to the optimisation algorithm. Moreover, if the chosen predictive horizon is
short, the problem may not have any solutions. The region
of attraction corresponding to such terminal constraints is
normally conservative [18]. The approach of dual-mode
control which defines a neighborhood around the desired
steady state, within which the system can be steered to, by
a linear state feedback controller, is presented in [41], [42],
[43], [44]. Several research papers have proposed methods on
how to enlarge the region of attraction for NMPC algorithms
since then. The other approaches for guaranteeing stability
are the contractive state MPC [45], the Control Lyapunov
Function (CLF) MPC [46], [47] and the converse Lyapunovbased MPC [48]. The perturbed state-feedback [49] with
the control invariant set approach [50], [51] has proved to
be effective for robust NMPCs [52], [53], [54], [55], [56],
[57]. The tube-based approach is becoming more and more
widespread used within the MPC research community lately
[23]. For output feedbacks, the most common approach is to
estimate states using an observer. The closed-loop stability is
not guaranteed, nonetheless, even when both the state based
NMPC and the nonlinear observer are stable. Findeisen et al.
[16] shown that an additional condition must be considered
to guarantee the stability for the augmented system.
The early NMPC software packages available to the industrial users consist of NOVA-NLC of Pavilion Technologies (using first principles models), Process Perfecter (using
input-output Hammerstein models) and some other partial
solutions for nonlinear systems such as Aspen Target using
artificial intelligent techniques [17]. There are two types of
state constraints, hard and soft, in these industrial MPCs.
minimize
x
F x = f,
(1)
(2)
(3)
(4)
x,z
s.t. Ax + Bz = c,
(5)
n
(6)
zk+1
(7)
yk+1
yk + (Axk+1 + Bzk+1 c) .
(8)
x
z
minimize
x
(9)
(10)
minimize
x
(20)
(21)
uk+1 : =
uk + xk+1 zk+1 ,
(22)
=
=
Axk + Buk
Cxk
(24)
(25)
(Q + F T F )1 [q + F T (zk + uk f )],
zk+1
uk+1
=
=
max{0, F xk uk + f },
uk + F xk+1 + zk+1 f.
minimize
N
1
X
k=0
xTk Qx xk + uTk Ruk + xTN QN xN (26)
1
T
1
T
=
1 (F Q F )n (F Q F )
.
(13)
Another approach for solving (9) is presented in [71],
wherein the inequality constraints is created for the copying
variable of the following:
1 T
x Qx + q T x
2
s.t. y = w
(15)
F w f.
(16)
(14)
(12)
xk+1
xk+1 : =
zk+1 : =
(11)
minimize
(28)
minimize
x
(29)
(30)
(31)
R 0
T
0
I
0 Qx
Q = Nd
, f = Ax0 0 . . . 0 ,
0
QN
B
I
0
0
0
0
0
0
A B
I
0
0
0
0
0
0
A
B
I
0
F =
.
..
..
..
..
..
..
..
.
.
.
.
.
.
.
0
0
0
0
A B I
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