Industrial Control Systems Design Michael J Grimble Industrial Control Centre, University of Stra thclyde, Glasgow, UK JOHN WILEY & SONS, LTD Chichester New York Weinheim • Brisbane Singapore • Toronto Copyright© 2001 by John Wiley & Sons Ltd, Baffins Lane, Chichester, West Sussex POl9 IUD, UK National 01243 779777 International (+44) 1243 779777 e-mail (for orders and customer service enquiries): cs-books@wiley.co.uk Visit our Home Page on http://www.wiley.co.uk or http://www.wiley.com All Rights Reserved No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, scanning or otherwise, except under the terms of the Copyright Designs and Patents Act 1988 or under the terms of a licence issued by the Copyright Licensing Agency, 90 Tottenham Court Road, London WIP 9HE, UK, without the permission in writing of the Publisher, with the exception of any material supplied specifically for the purpose of being entered and executed on a computer system, for exclusive use by the purchaser of the publication Neither the author nor John Wiley & Sons Ltd accept any responsibility or liability for loss or damage occasioned to any person or property through using the material, instruction, methods or ideas contained herein, or acting or refraining from acting as a result of such use The authors and Publisher expressly disclaim all implied warranties, including merchantability of fitness for any particular purpose There will be no duty on the authors of Publisher to correct any errors or defects in the software Designations used by companies to distinguish their products are often claimed as trademarks In all instances where John Wiley & Sons is aware of a claim, the product names appear in initial capital or capital letters Readers, however, should contact the appropriate companies for more complete information regarding trademarks and registration Other Wiley Editorial Offices John Wiley & Sons, Inc., 605 Third Avenue, New York, NY 10158-0012, USA Wiley-VCH Verlag GmbH, Pappelallee 3, 0-69469 Weinheim, Germany Jacaranda Wiley Ltd, 33 Park Road, Milton, Queensland 4064, Australia John Wiley & Sons (Canada) Ltd, 22 Worcester Road, Rexdale, Ontario M9W ILl, Canada John Wiley & Sons (Asia) Pte Ltd, Clementi Loop #02-01, Jin Xing Distripark, Singapore 129809 Library of Congress Cataloguing-in-Publication Data Grimble, Michael Industrial control systems design / Michael Grimble p cm Includes bibliographical references and index ISBN 0-471-49225-6 I Production control Automatic control Title TSI55.8.G75 2000 670.42'75 - dc21 00-059433 British Library Cataloguing in Publication Data A catalogue record for this book is available from the British Library ISBN 47149225 Produced from camera-ready copy supplied by the author Printed and bound in Great Britain by Bookcraft (Bath) Ltd, Midsomer Norton This book is printed on acid-free paper responsibly manufactured from sustainable forestry, in which at least two trees are planted for each one used for paper production I am pleased to dedicate this text to my wife Wendy and children Claire and Andrew It has been a privilege to live in Scotland for almost the last two decades and to work with my colleagues at the University of Strathclyde Contents xv Preface Introduction to Advanced Industrial Control I 1.1 Introduction 1.1.1 Hierarchical Modelling and Control 1.1.2 Benefits of Advanced Process Control 1.1.3 Frequency Domain and State Space Methods 1.2 Robust 1.2.1 1.2.2 1.2.3 1.2.4 1.2.5 1.2.6 1.3 Fault-tolerant Control Systems 1.3.1 Summary of Terms in Fault-tolerant Control 1.3.2 Summary of Terms in Fault Monitoring 1.3.3 Fault Monitoring and Diagnosis 1.3.4 Redundancy in Fault and Failure Diagnosis Methods 1.3.5 Control Reconfiguration 1.3.6 Multiple Model Approach 1.3.7 Safety Critical Control System Design 13 14 14 16 18 20 22 25 1.4 Intelligent Control and Artificial Intelligence 1.4.1 Artificial Neural Networks 1.4.2 Fuzzy Control 1.4.3 Expert Systems and Knowledge Based Systems 1.4.4 Genetic Algorithms 25 26 27 28 28 1.5 Total Control and Systems Integration 1.5.1 Systems Integration and Fault Conditions 29 30 1.6 Concluding Remarks 31 1.7 References' 31 Control Design Models for Plant Uncertainty Uncertainties in Multivariable Systems Robust Stability and Performance Robust Controllers: Limitations and Advantages Structured Singular Values Linear Matrix Inequalities vii 7 10 11 12 12 viii I CONTENTS Polynomial System Descriptions H2 Optimal and Feedforward Control 2.1 Introduction 2.1.1 Industrial Controller Structures 2.1.2 Discrete-time Models and Terminology 2.2 Wiener 2.2.1 2.2.2 2.2.3 2.2.4 2.2.5 2.3 Polynomial FeedforwardlFeedback Solution 2.3.1 Polynomial System Description and Solution 2.3.2 Three DOF Control Law Proof 2.3.3 Cost-function Minimisation 2.3.4 Optimal Solution: Properties and Structure 2.4 Multiple DOF LQG Control Problem 2.4.1 Polynomial System Description 2.4.2 Feedback/Feedforward System Equations 2.4.3 Error and Control Signal Costing Terms 2.4.4 Cost-function and Optimal Control Solution 2.4.5 Invariance Property 2.5 Design of Feedforward Controllers 2.5.1 Feedforward in Dynamic Ship Positioning Systems 2.6 Concluding Remarks 2.7 References Feedforward/Feedback Solution System Model and Signals LQG Control Problem and Wiener-Hopf Theorem Wiener-Hopf Solution of DOF Control Problem Wiener-Hopf Cost-function Minimisation Structure of the Wiener-Hopf Optimal Solution H2 Predictive Optimal Control 3.1 Introduction 3.1.1 The LQGPC Solution Strategy 3.1.2 Applications of Predictive Control 3.1.3 Predictive Control Terminology 3.2 GPC System Description and Prediction 3.2.1 Optimal Linear Predictor 3.2.2 Derivation of the Predictor 3.3 Generalised Predictive Control Law 3.3.1 Solution for the GPC Optimal Control Law 3.3.2 Algorithm for the GPC Optimal Control Law 3.3.3 Relationship Between GMV and GPC Control 3.3.4 Predictiv