Industrial Control Loop Performance Evaluation via Full Reconstruction Simulation
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Solution Overview
Problem
Current methods for evaluating industrial control loop performance, such as those based on minimum variance control, fail to consider the influence of control modules like PID controllers, filters, and dead-bands, leading to inaccurate and incomplete performance assessments.
Innovation Solution
A method and device for evaluating industrial control loop performance through full loop reconstruction simulations, which includes reconstructing control modules, establishing a mathematical model, optimizing parameters, and performing simulation calculations to obtain an ideal control performance index, considering the impact of all control modules like PID controllers, filters, and dead-bands.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If minimum variance control method is used for performance evaluation, then the evaluation process is simple, but the evaluation accuracy is poor because it does not consider the influence of control modules
Solution Approach 1:
The control loop is segmented into multiple control modules (PID controller, filters, dead-bands, etc.) for individual reconstruction and simulation. Each module is reconstructed separately based on historical data, allowing accurate evaluation of each module's influence on overall performance while maintaining manageable complexity through modular processing
Solution Approach 2:
Virtual copies of the actual control loop and its modules are created through reconstruction simulation. These virtual models replicate the behavior of physical control modules using historical process data, enabling accurate performance evaluation without requiring physical intervention or simplification of the actual system
2Device complexity
If only PID controller is considered in performance evaluation, then the evaluation method is simple, but the evaluation completeness is poor because other control modules are ignored
Solution Approach 1:
The reconstruction simulation framework is designed to universally handle multiple types of control modules beyond just PID controllers. The system can reconstruct and simulate filters, dead-bands, and other control functions using the same methodology, making the evaluation approach versatile and complete while managing complexity through a unified multi-functional platform
3Device complexity
If variance is used as performance index, then the index calculation is simple, but the evaluation applicability is limited because it is not suitable for tracking reference value and overcoming deterministic disturbances
Solution Approach 1:
The performance index parameters are changed from simple variance-based metrics to more comprehensive metrics that can evaluate reference tracking and disturbance rejection. The system calculates performance indices such as integrated absolute error and other metrics that are suitable for evaluating deterministic disturbance compensation and reference value tracking, while maintaining computational efficiency through the reconstructed simulation framework
Data Source
AI summary
A method and device for evaluating the performance of an industrial control loop based on full loop reconstruction simulations. The method comprises: performing reconstruction simulation on control modules one by one except a controlled object in the loop, and judging the correctness of the reconstructed modules; establishing a mathematical model of the object, connecting the mathematical model to the reconstructed modules to complete reconstruction of the entire loop, and optimizing the mathematical model of the object to obtain an optimized model of the object; adjusting parameters of the modules according to a control performance index, and performing simulation calculation on the reconstructed loop using the parameters to obtain an ideal value of the reconstructed performance control index for evaluating the performance of the loop. The loop is reconstructed, the influence of the modules, a PID controller, a filter, a piece-wise linear function and a deadband, on the performance is evaluated.