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Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.
PUBLIC INFORMATION
L10 - PlantPAx® MPC: Optimization in the Logix Controller for Easy Deployment
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.
Agenda
Course Feedback
Lab Overview – Go!
What is Model Predictive Control?
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.
Model Predictive Control (MPC) is an advanced process control (APC) technique which
Systematically handles multivariable control problems with difficult dynamics and internal
interactions between process variables in a unified way
Explicitly takes into account process constraints (safety, equipment, quality limits, …)
Handles measured disturbances (feed-forward control)
Uses process models to predict future process output
Handles process dead-time, processing and measurement lags
Calculates optimal control moves based on defined objective function subject to constraints
Design and tuning is intuitive and relatively easy compared with other APC techniques
What is Model Predictive Control
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.
MPC versus PID Control
Coordinate multiple interacting PIDs
Predictably manage external disturbances
Handle long or complex process dynamics
Maximize performance up to process limits
PID tuning is subjective and requires time and experience
We do this because it makes
processors money:
Higher production, yields, efficiency
and product quality
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.
MPC Opportunities
Coating Oven
Distillation Column
Compressor
Chemical Reactor
Boiler
Furnace
Dryer
Drilling Rig
and many more
5
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.
Making Control Scheme Smarter
MPC
SP
6
M
Arc
hit
ec
ture
wit
h M
PC
PID
PID left in the scheme or direct output control
SP
PID PID
PID
High / Low Select Logic,
Gain Scheduler
Decoupling,
Override
Control
PID
M
SP
Tra
dit
ion
al
Co
ntr
ol A
rch
ite
ctu
re
Easier to design and maintain
6
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.
now
CV
MV
MV
1 Horizon
CVSP
MVSP
0
How a Receding Horizon works
7
measured
calculated (predicted)
calculated and sent out as MV
CV
Constraints
CV MVProcess
Controller
Model
CV predictionMV prediction
MPC
Setpoints
1
0
2
1
0
2
1
2
)(
)()(
)()(
Horizon
k
MoveSupp
Horizon
k
SPCoef
Horizon
k
SPCoef
kMVMV
kMVkMVMV
kCVkCVCVJ
The Task: Minimize J by calculating MV over the Horizon
0
1 Horizon0
Horizon0 1
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.
PID vs MPC variables
8
CV
CVSP
MVSP
DVDV
MV
CV
unmeasured disturbance
MPC
Process
PV
SPCV
PV
unmeasured disturbance
PID
Process
CV – Controlled (Process) Variables: objective and/or constraints
DV – Disturbance Variables: affects CVs, but is independent of controller
MV – Manipulated Variables: PID targets or outputs that MPC adjusts to meet
objectives
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.
• Design the MPC Application:
• Controlled Variables: What are we trying to do better, what is in the way/limits this today?
• Manipulated Variables: What can we adjust to affect this result today?
• Disturbance Variables: What do you watch out for that causes / forecasts a change?
• Perform Plant Testing (set up trends/logs for above variables)
• Individually step each MV & DV (as possible) within safe limits to see changes in CV’s.
• Develop MPC models based on identification of above data
• Develop any calculations necessary to support MPC goals
• Implement/integrate and test application, train operators and turn-on!
Measure Improvement!
A MPC Project
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.
MPC in Integrated Architecture
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FactoryTalk® ProductionCentre, FactoryTalk® Historian,
Pavilion® Real-Time Optimization™ …
Pavilion8® MPC, Software CEM®, VOA®, Asset Management, …
Rockwell Software Studio 5000®, PlantPAx™ MPCBuilder,
PlantPAx™ ModelBuilder
• PlantPAx® MPC
• IMC,CC,MMC
• FuzzyLogic
• SoftSensor® (AOI)
• PID,PIDE
• Motion
• Discrete
M P C
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. 11
PlantPAx™ MPC (logix embedded): simpler, faster
Coating Oven MPC
Note available Short-Cuts
Lab Problem
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.
PlantPAx MPC Lab Setup
12
Controller 1756-MPC Module
Lab Files:
Oven.ACD
OvenDataSet.CSV
Oven_ModelReady.mpc
Oven_SimulationReady.mpc
Oven_ExportReady.mpc
0 1 2
• PlantPAx MPCBuilder
• Studio 5000
• RSLinx Classic
• FT View SE Client
192.168.1.112
192.168.1.113
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.
Dynamic Identification
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.
Combustion gas suction
MV0
DV3
CV0Oven_Temp
CV1Oven_Press
Ambient_Temp
MV1
Heating
Chamber
rpm constant
Combustion gas circulation
Atmospheric pressure (constant)
Curing Oven MPC – 2MVs, 4DVs, 2CVs
14
Metal stripDV2
Combustion gas exhaust
Metal strip
Hot air inlets Suction_Flow
Pressure
(constant)
DV2
DV1
MV0
MV1
DV0
CV1
Air_Flap_Valve
Gas_Valve
Suction_Flow
Hot_Air_Temp
Hot_Air_Press
Oven_Temp
Oven_Press
Ambient_Temp
DV3
CV0
Hot Air Supply
Gas Supply
Hot_Air_Temp
Hot_Air_Press
DV0
DV1 Air_Flap_Valve
Gas_Valve
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.
MPC Configuration & Settings
Oven
DV2
DV1
MV0
MV1
DV0
CV1
Air_Flap_Valve
Gas _Valve
Suction_Flow
Hot_Air_Press
Hot_Air_Temp
Oven_Temp
Oven_PressAmbient_Temp
DV3
CV0310C
340C
60 50 260 s
2C/s
21 65
max -1 Pa
min -20 Pa
100%
0%
100%
0%
max 600C
min 550C
max 250Pa
min 200Pa
max 40C
min 27C
max 0.3m3/s
min 0.2m3/s
keep pressure within limits
track temperature setpoint
OversampleDT – MPC frequency 0.5 seconds
SPValueReq - True
SPProg 0%
ROC 10%/s
Scale 100%
ROC 10%/s
Scale 100%
SPTrajectoryReq - True
Coef 100
Scale 100 C
ZoneReq - True
Coef 10
Scale 10 Pa
CVSPTrajectory
0 s 310 C
6 s 310 C
21 s 340 C
50 s 340 C
65 s 310 C
260 s 310 C
ZoneHiLimit -1 Pa
ZoneLoLimit -20 PaDV2
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.
Do not skip Faceplates
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.
We Want Your Feedback!
Session Surveys:Please take a couple minutes to complete a quick session survey to tell us about the session you just attended.
3
1
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On the PSUG mobile app:
1. Locate session using Schedule or Agenda Builder.
2. Click on the survey icon on the lower right corner of
the session detail
3. Complete survey
4. Click the Submit Form button
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.
We Want Your Vote!
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1
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Town Hall Voting:Everyone’s vote matters! Help guide the development of the PlantPAx system by casting yours.
On the PSUG mobile app:
1. Locate session using Schedule or Agenda Builder.
2. Click on the survey icon on the lower right corner of
the session detail
3. Complete survey
4. Click the Submit Form button
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.
PUBLIC INFORMATION
THANK YOU
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