Journal of Process Control最新文献

{"title":"Towards hybrid modeling with mechanistic and real-time data embed iterative co-optimization for industrial processes","authors":"Mingyu Liang,&nbsp;Yi Zheng,&nbsp;Shaoyuan Li","doi":"10.1016/j.jprocont.2025.103567","DOIUrl":"10.1016/j.jprocont.2025.103567","url":null,"abstract":"<div><div>This paper addresses the hybrid modeling challenges arising from incomplete mechanistic models and operational data noise interference in process industries, proposing a two-layer joint iterative optimization framework for updating parameters of hybrid models integrating mechanistic and data-driven models. The framework achieves real-time anomaly elimination through an outlier screening algorithm, while employing a bidirectional feedback algorithm to enable continuous collaboration and mutual constraints between mechanistic and data-driven models during parameter identification and iterative updates, ensuring robust hybrid model predictions. The proposed method resolves hybrid modeling and updating under conditions of mechanistic model information deficiency. Additionally, by incorporating model uncertainty and prior knowledge, it accomplishes a knowledge-incorporated hybrid modeling process, demonstrating significant practical value. Unlike conventional hybrid modeling approaches where mechanistic knowledge merely guides the modeling process, our method achieves dynamic co-evolution between mechanistic and data-driven models. This paper elaborates on three key aspects: (1) using mechanistic models to screen anomalous data; (2) incorporating mechanistic parameter uncertainty and prior knowledge through Bayesian methods to design knowledge-guided parameter updating method; (3) implementation details of the two-layer joint iterative optimization algorithm. Comparative experiments validate the method’s superior performance under multiple operating conditions and anomalies, demonstrating its scientific validity and practical value in dynamic optimization processes.</div></div>","PeriodicalId":50079,"journal":{"name":"Journal of Process Control","volume":"155 ","pages":"Article 103567"},"PeriodicalIF":3.9,"publicationDate":"2025-11-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145324807","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"计算机科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Multivariable soft sensor with a predictor of mutually dependent errors applied to an industrial fractionator","authors":"Oleg Snegirev ,&nbsp;Vladimir Klimchenko ,&nbsp;Denis Shtakin ,&nbsp;Andrei Torgashov ,&nbsp;Fan Yang","doi":"10.1016/j.jprocont.2025.103555","DOIUrl":"10.1016/j.jprocont.2025.103555","url":null,"abstract":"<div><div>This paper addresses the development of a multivariable soft sensor (SS) with a predictor designed to handle mutual dependencies within multivariate error series. Typically, the mutual influence in vector time series is characterized using cross-correlation. The proposed multivariable cross-correlated error predictor (MCCEP) framework effectively manages such dependencies and is compatible with any data-driven SS model. Forecasted error values are fed back into the SS output as corrections, refining the final predictions of quality indicators. The MCCEP model is constructed through statistical analysis to minimize the generalized variance – defined as the determinant of the covariance matrix – of multivariate forecast errors. Unlike conventional approaches such as bias update techniques, the MCCEP model is chosen from a broad class of predictors for multivariate linear processes, explicitly considering the dynamic relationships among the univariate components of the SS error process. For the <em>n</em>-dimensional case, it is analytically demonstrated that MCCEP minimizes the generalized variance of multivariate errors by leveraging the cross-correlation functions among the univariate components of the time series, thereby enhancing SS accuracy. Analytical methods for constructing MCCEP using the autocovariance generating function and the squared SS error coherence spectrum are developed. The framework’s superiority is highlighted through a case study involving an industrial fractionator, where the SS with MCCEP outperforms conventional SSs employing dynamic partial least squares and bias updates or developed sequentially without considering interdependencies among univariate components of multi-output model errors.</div></div>","PeriodicalId":50079,"journal":{"name":"Journal of Process Control","volume":"155 ","pages":"Article 103555"},"PeriodicalIF":3.9,"publicationDate":"2025-11-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145106723","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"计算机科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Output consensus for interconnected systems via the internal model principle and a model predictive control based strategy","authors":"Ye Zhang ,&nbsp;Fei Li ,&nbsp;Dongya Zhao ,&nbsp;Xing-Gang Yan ,&nbsp;Sarah K. Spurgeon","doi":"10.1016/j.jprocont.2025.103551","DOIUrl":"10.1016/j.jprocont.2025.103551","url":null,"abstract":"<div><div>Interconnected systems are commonly found in process networks. In this paper, an output consensus framework is proposed for a class of continuous interconnected linear heterogeneous systems subject to constraints. A distributed output consensus control strategy is developed by combining the internal model principle (IMP) with model predictive control (MPC). A distributed iterative algorithm is designed to solve the IMP conditions for interconnected systems. The IMP based control plays two main roles: On the one hand, it helps to deal with the interconnection effects existing between the subsystems; on the other hand, it drives the subsystems to track the reference dynamics in order to achieve output consensus. The MPC determines an optimized control gain while being able to handle constraints. Simulation examples and experimental trials are presented to validate the effectiveness and superiority of the proposed method.</div></div>","PeriodicalId":50079,"journal":{"name":"Journal of Process Control","volume":"155 ","pages":"Article 103551"},"PeriodicalIF":3.9,"publicationDate":"2025-11-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145097509","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"计算机科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"A cross-layer cooperative optimization framework for optimal scheduling of multi-grade PET fiber production","authors":"Jiale Zhang,&nbsp;Wenli Du,&nbsp;Xin Dai","doi":"10.1016/j.jprocont.2025.103540","DOIUrl":"10.1016/j.jprocont.2025.103540","url":null,"abstract":"<div><div>The fluctuations in the supply chain market of polyethylene terephthalate (PET) fibers have been intensifying in recent years. Existing research on the production scheduling of PET plants is usually based on the assumption of a stationary supply chain market. However, these works ignore supply chain fluctuations and market competition, and the schedule obtained may become sub-optimal or infeasible in the real market. This paper considers using the game to represent the competition and cooperation relationships in the market among enterprises with limited supply capacity to obtain equilibrium supplies. Meanwhile, changes in the market prices will cause changes in the equilibrium supplies of the game. In addition, price prediction and supply decisions support the production schedule to achieve high economic efficiency. Therefore, we propose a cross-layer cooperative optimization framework between the supply chain layer and production chain layer for production scheduling optimization. In the supply chain layer, price trends are predicted by synchronous spatio-temporal relationship network, and equilibrium supplies are obtained through a multi-firm multi-product game. In the production chain layer, a production scheduling optimization model that integrates predicted prices and equilibrium supplies from the supply chain layer is established. The effectiveness of the proposed method is verified on a real-world PET plant.</div></div>","PeriodicalId":50079,"journal":{"name":"Journal of Process Control","volume":"155 ","pages":"Article 103540"},"PeriodicalIF":3.9,"publicationDate":"2025-11-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145050180","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"计算机科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Excitation-free closed-loop identification based on adaptive hysteresis loop width adjustment strategy","authors":"Chonggao Hu ,&nbsp;Ridong Zhang ,&nbsp;Furong Gao","doi":"10.1016/j.jprocont.2025.103552","DOIUrl":"10.1016/j.jprocont.2025.103552","url":null,"abstract":"<div><div>Aiming at the problem that the traditional system identification methods are not adaptive enough when the system model parameters change significantly, this paper proposes an excitation-free closed-loop identification method based on an adaptive hysteresis loop width adjustment (AHLWA) strategy. Firstly, the AHLWA strategy is proposed according to the direction of change of the mean value of the power spectrum (MVPS) of the input signal, which can respond to the trend of the system's dynamic characteristics and dynamically adjust the hysteresis loop width parameters in real time. Secondly, an excitation-free closed-loop identification method based on the AHLWA strategy was developed by integrating the AHLWA strategy with the prediction error method. In addition, to accurately quantify the model error and detect model parameter variations, an improved model error detection method is proposed to quantify the model error by using the unexcited closed-loop identification technique. The numerical example simulation results indicate that the MVPS of the proposed identification method increases from 0.01 to 0.25 compared to the relay feedback identification method, which ensures the continuous excitation of the input signals and significantly improves the identification accuracy when the system model parameters change significantly. Meanwhile, the proposed identification method is further validated by applying it to the temperature control system of industrial coking furnaces. In addition, the proposed identification method can update the benchmark model on time, which makes the system model error significantly lower than 30%, providing an effective solution for model error detection in industrial closed-loop systems.</div></div>","PeriodicalId":50079,"journal":{"name":"Journal of Process Control","volume":"155 ","pages":"Article 103552"},"PeriodicalIF":3.9,"publicationDate":"2025-11-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145050181","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"计算机科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Melt viscosity control in polymer extrusion using nonlinear model predictive control with neural state space modelling and soft sensor feedback","authors":"Yasith S. Perera ,&nbsp;Jie Li ,&nbsp;Chamil Abeykoon","doi":"10.1016/j.jprocont.2025.103556","DOIUrl":"10.1016/j.jprocont.2025.103556","url":null,"abstract":"<div><div>Melt viscosity is a key quality indicator in polymer extrusion processes, as it directly influences the mechanical properties, dimensional stability, and surface finish of the final product. However, real-time melt viscosity monitoring and control remain a major challenge in industrial polymer extrusion, due to the limitations of physical viscosity monitoring techniques, such as disturbances to the melt flow, reduced throughputs, and measurement delays. To address this issue, this study proposes a nonlinear model predictive control framework that enables direct, real-time control of melt viscosity using non-invasive feedback from a deep neural network-based soft sensor. A neural state-space model is trained on real experimental data to learn the underlying process dynamics and serves as the internal model of the controller. The soft sensor provides melt viscosity estimates based on readily available process variables (i.e., screw speed and barrel temperatures). These estimates are used by an extended Kalman filter with state augmentation to correct the internal state predictions. The proposed control system was rigorously evaluated via simulation across a variety of setpoint changes and disturbance scenarios. Results show that the controller maintains the melt viscosity within <span><math><mo>±</mo></math></span>2 % of the setpoint, irrespective of the initial conditions used, with settling times below 20 s. Under step and ramp disturbances applied to the output variable, screw speed, and barrel temperatures, the controller exhibited strong disturbance rejection capabilities. Notably, under step disturbances of <span><math><mo>±</mo></math></span> 100 Pa⋅s acting on the melt viscosity output, the controller quickly restored the viscosity to the setpoint with settling times under 18 s. The real-time closed-loop melt viscosity control framework proposed in this study should be invaluable for advancing process monitoring and control of polymer extrusion processes.</div></div>","PeriodicalId":50079,"journal":{"name":"Journal of Process Control","volume":"155 ","pages":"Article 103556"},"PeriodicalIF":3.9,"publicationDate":"2025-11-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145221456","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"计算机科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Nonlinear model predictive control with an infinite horizon approximation","authors":"San Dinh,&nbsp;Yao Tong,&nbsp;Zhenyu Wei,&nbsp;Owen Gerdes,&nbsp;L.T. Biegler","doi":"10.1016/j.jprocont.2025.103565","DOIUrl":"10.1016/j.jprocont.2025.103565","url":null,"abstract":"<div><div>Current nonlinear model predictive control (NMPC) strategies are formulated as finite predictive horizon nonlinear programs (NLPs), which maintain NMPC stability and recursive feasibility through the construction of terminal cost functions and/or terminal constraints. However, computing these terminal properties may pose formidable challenges with a fixed horizon, particularly in the context of nonlinear dynamic processes. Motivated by these issues, we introduce an alternate moving horizon approach where the final element in the horizon is constructed from an infinite-horizon time transformation. The key feature of this approach lies in solving the proposed NMPC formulation as an extended boundary value problem, using orthogonal collocation on finite elements. Numerical stability is ensured through a dichotomy property for an infinite horizon optimal control problem, which pins down the unstable modes, extending beyond open-loop stable dynamic systems, and leads to both asymptotic and robust stability guarantees. The efficacy of the proposed NMPC formulation is demonstrated on three case studies, which validate the practical application and robustness of the developed approach on real-world problems.</div></div>","PeriodicalId":50079,"journal":{"name":"Journal of Process Control","volume":"155 ","pages":"Article 103565"},"PeriodicalIF":3.9,"publicationDate":"2025-11-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145324811","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"计算机科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Optimal inventory control for bottleneck isolation in general processes","authors":"Archana Kumaraswamy,&nbsp;Evren Mert Turan,&nbsp;Johannes Jäschke","doi":"10.1016/j.jprocont.2025.103557","DOIUrl":"10.1016/j.jprocont.2025.103557","url":null,"abstract":"<div><div>Optimal inventory control seeks to isolate the economic effect of bottlenecks and maximise the throughput of processes. This is challenging in complex topologies with disturbances causing shifting bottlenecks. Decentralised and model predictive control schemes have been proposed for bottleneck isolation of sequential processes. Although decentralised control schemes work well for sequential processes, they are difficult to apply to more complex topologies such as parallel arrangement of units, flow splits, mergers, and recycles that are common in the industry. In contrast, such multi-input multi-output systems can be naturally handled with model predictive control schemes. This work extends a preliminary model predictive control scheme in the literature to achieve bottleneck isolation in general process topologies. In particular, a seriatim amongst inventories and system outflows is created using weights in the objective function. Our approach is simple to implement and is shown to optimally isolate bottlenecks on a wide range of case studies and topologies.</div></div>","PeriodicalId":50079,"journal":{"name":"Journal of Process Control","volume":"155 ","pages":"Article 103557"},"PeriodicalIF":3.9,"publicationDate":"2025-11-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145267024","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"计算机科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Fault detection and isolation for a class of nonlinear systems based on a bundle of observers and zonotope analysis","authors":"Chi Xu ,&nbsp;Zhenhua Wang ,&nbsp;Nacim Meslem ,&nbsp;Tarek Raïssi ,&nbsp;Yi Shen","doi":"10.1016/j.jprocont.2025.103561","DOIUrl":"10.1016/j.jprocont.2025.103561","url":null,"abstract":"<div><div>This paper introduces a novel fault detection and isolation (FDI) approach for nonlinear systems subject to unknown but bounded disturbances. The proposed approach combines a bundle of fault detection observers (FDOs), tuned by a peak-to-peak performance technique, with an offline reachability method to generate reliable actuator fault detection and isolation thresholds. Moreover, a sliding-window algorithm, based on zonotopic computation, is designed to be able to provide dynamical fault detection thresholds. This allows one to reduce the conservatism and, by the way, enhance the efficiency of the proposed approach. A quadruple-tank system is considered as a case study, where the theoretical findings of this work are supported by simulation results. In addition, on this example, the performance of the proposed method is compared to that of another method selected from the literature.</div></div>","PeriodicalId":50079,"journal":{"name":"Journal of Process Control","volume":"155 ","pages":"Article 103561"},"PeriodicalIF":3.9,"publicationDate":"2025-11-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145267021","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"计算机科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Canonical correlation analysis-aided design of Kalman filter-based residual generator for monitoring of industrial control systems","authors":"Long Gao ,&nbsp;Donghua Zhou ,&nbsp;Steven X. Ding","doi":"10.1016/j.jprocont.2025.103569","DOIUrl":"10.1016/j.jprocont.2025.103569","url":null,"abstract":"<div><div>Kalman filters are widely applied for residual generation thanks to the property that the generated residual is white and of minimum covariance. This enables an optimal monitoring. However, the explicit mathematical model is difficult to achieve in a real industrial automation system, and the effect of the feedback has not been explicitly considered in the existing data-driven design method, which degrades the monitoring performance of a Kalman filter-based monitoring system. To deal with such an issue, this paper proposes a purely data-driven realization of the Kalman filter-based residual generator for process monitoring of industrial control systems with a closed-loop configuration. Firstly, a least-mean-square interpretation of canonical correlation analysis (CCA) is introduced, which is helpful to explore the relationships between inputs and outputs of industrial control systems. Then, a CCA-aided Kalman filter-based residual generator is constructed, which is realized by identifying the Kalman gain matrix and the data-driven stable kernel representation. Different from the existing method, the proposed one achieves superior monitoring performance by considering closed-loop dynamics and the correlation between inputs and noises, which is caused by the feedback control structure of systems. The effectiveness of the proposed method is demonstrated and compared through an experimental three-tank system.</div></div>","PeriodicalId":50079,"journal":{"name":"Journal of Process Control","volume":"155 ","pages":"Article 103569"},"PeriodicalIF":3.9,"publicationDate":"2025-11-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145324810","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"计算机科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}