控制系统性能评价与诊断研究
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摘要
当前，控制领域的研究主要集中在模型的辨识、控制器的设计、控制系统的鲁棒性等方面，而很少对运行中的控制器性能进行评价。事实上，很多控制器在实际运行时难以达到设计的性能要求。因此，如何从生产过程的日常运行数据中获得一些有关控制器的性能信息，从而能够早期识别、诊断控制器的性能问题是现场工艺和控制人员都很关心的问题。近年来，工业界对控制系统性能要求的提高极大地推动了控制器性能评价与诊断的研究。
用最小方差准则来评价控制器的性能，仅需过程变量的常规闭环操作数据和过程的时间延迟特性。本文利用最小方差准则，给出了单变量、多变量及串级控制回路的性能评价方法，并对工业中两个精馏塔控制系统的性能进行了分析。分析结果表明，最小方差准则是控制器性能评价方面的一个有效和可行的基准。
本文重点是针对PID控制器的特征，对单回路PID控制系统和串级PID控制系统给出了系统的性能评价方法和诊断方法。利用最小方差准则得到二者的设定点跟踪性能和调节性能。并通过监测反馈回路振荡和响应迟钝来分析性能降低的原因以缩小原因诊断范围。仿真和液位控制实验说明该方法有效而简单。
Now the research of control engineering domain mainly focus on model identification , design of controller and robustness of control systems, etc. Little has been done to the performance assessment of the running controllers. In fact, many running controllers can't achieve the design index. So, It is a concerned problem for local technicians and control engineers that how to obtain the performance information of the controllers from the operating data so that the performance problem can be recognized and diagnosed early. Recently, the demand of high control system performance from industry promotes the development of the research of controller performance assessment and diagnosis rapidly.
Only routine closed-loop operating data and knowledge of the process time delay are needed using minimum variance as a benchmark in controller performance assessment. Controller performance assessment algorithms based on minimum variance for single loop control system , multivariate control system and cascade control system are derived in the paper. Two industrial distillation column examples are given to illustrate the methods of control system performance assessment, and the results reveal its efficiency and feasibility.
The main results of the paper are the systemic performance assessment and diagnosis methods for single PID and cascade PID control system, in which the set point tracking and regulation performance are evaluated using minimum variance as a benchmark. The detection methods of oscillation and sluggishness in feedback control loop are given, in order to reduce the diagnosis range of poor performance causes. Simulation and level control experiments are given to illustrate the results.
用最小方差准则来评价控制器的性能，仅需过程变量的常规闭环操作数据和过程的时间延迟特性。本文利用最小方差准则，给出了单变量、多变量及串级控制回路的性能评价方法，并对工业中两个精馏塔控制系统的性能进行了分析。分析结果表明，最小方差准则是控制器性能评价方面的一个有效和可行的基准。
本文重点是针对PID控制器的特征，对单回路PID控制系统和串级PID控制系统给出了系统的性能评价方法和诊断方法。利用最小方差准则得到二者的设定点跟踪性能和调节性能。并通过监测反馈回路振荡和响应迟钝来分析性能降低的原因以缩小原因诊断范围。仿真和液位控制实验说明该方法有效而简单。
Now the research of control engineering domain mainly focus on model identification , design of controller and robustness of control systems, etc. Little has been done to the performance assessment of the running controllers. In fact, many running controllers can't achieve the design index. So, It is a concerned problem for local technicians and control engineers that how to obtain the performance information of the controllers from the operating data so that the performance problem can be recognized and diagnosed early. Recently, the demand of high control system performance from industry promotes the development of the research of controller performance assessment and diagnosis rapidly.
Only routine closed-loop operating data and knowledge of the process time delay are needed using minimum variance as a benchmark in controller performance assessment. Controller performance assessment algorithms based on minimum variance for single loop control system , multivariate control system and cascade control system are derived in the paper. Two industrial distillation column examples are given to illustrate the methods of control system performance assessment, and the results reveal its efficiency and feasibility.
The main results of the paper are the systemic performance assessment and diagnosis methods for single PID and cascade PID control system, in which the set point tracking and regulation performance are evaluated using minimum variance as a benchmark. The detection methods of oscillation and sluggishness in feedback control loop are given, in order to reduce the diagnosis range of poor performance causes. Simulation and level control experiments are given to illustrate the results.
引文
[1] 王锦标，方崇智．过程计算机控制．北京：清华大学出版社，1992．
[2] 翁维勤，孙洪程．过程控制系统及工程，第2版，北京：化学工业出版社，2002．
[3] 金以惠．过程控制．北京：清华大学出版社，1993．
[4] 严伯钧，尹俊熙，张仁忠，杨公源．过程控制系统分析与设计，北京：中国纺织出版社，1994．
[5] 王树青．先进控制技术及应用．北京：化学工业出版社，2001．
[6] strm K J, Hgglund T. PID Controllers: Theory, Design, and Tuning, second edition, Instrument Society of America, Research Triangle Park, NC, 1995.
[7] Ender D B. Process control performance: Not as good as you think. Control Engineering, 1993,40(10):180-190.
[8] Rinehart N, Jury E How control valves impact process optimization. Hydrocarbon Processing, 1997,6:53-56.
[9] 杨马英．模型预测控制的性能监视与评价——综述．第21届中国控制会议论文集．杭州：浙江大学出版社，2002，253-259．
[10] Qin S J. Control performance monitoring—A review and assessment. Computer and Chemical Engineering, 1998,23(2): 173-186.
[11] Alan J.Hugo. Performance assessment of process controllers, www.controlartsinc. com/pdf/PerformanceAssessment.PDF.
[12] Harris T J, Seppala C T, Desborough L. A review of performance monitoring and assessment techniques for univariate and multivariate control systems. Journal of Process Control, 1999,9:1-17.
[13] Astrm K J. Introduction to stochastic control theory.Academic Press,1970.
[14] Harris T J. Assessment of control loop performance. Can. J. Chem. Eng., 1989, 67(10): 856-861.
[15] Box G E E Jenkins G M. Time series analysis, forecasting and control. Holden-Day, 1970.
[16] Stanfelj N, Marlin T E, MacGregor J E Monitoring and diagnosis process control performance: the single loop case. Ind. Eng. Chem. Res., 1993, 32:856-861.
[17] Huang B, Shah S L, Kwok K Y. Good, Bad or Optimal? Performance assessment of multivariable process. Automatica, 1997, 33(6):1175-1183.
[18] Hgglund T. A control-loop performance monitor. Control Eng .Practice, 1995,3(11): 1543-1551.
[19] Miao T, Seborg D E. Automatic .detection of excessively oscillatory feedback control loops. U. S.Patent#5 , 1998,719-788.
[20] Miao T, Seborg D E. Automatic detection of excessively oscillating feedback control loop. IEEE Conference on Control Applications Proceedings, Kohala Coast-Island of Haiwai'i, USA.,1999,8:359-364.
[21] Hgglund T. Automatic detection of sluggish control loops. Control Engineering Practice, 1999, 7:1505-1511.
[22] Desborough L, Harris T J. Performance assessment measure for univariate feedback control. Can. J. Chen. Eng.,1992, 70:1186-1197.
[23] Kozub D J, Garcia C E. Monitoring and diagnosis of automated controllers in chemical process industries. AIChE Meeting, St Louis, MI, 1994.
[24] Lynch C B , Dumont G A. Closed loop performance monitoring, Proc.2nd, IEEE Conference On Control Applicatians, Vancouver, B.C., 1993, 835-840.
[25] Tyler M L , Morari M. Performance assessment for unstable and nonminium-phase system.. On-line Fault Detection and Supervision in the Chemical Process Industries IFAC Workshop, Newcastle-upon-Tyne UK, 1995, 3:187-192.
[26] Eriksson P C, Isaksson A J. Some aspects of control performance monitoring, Proc.3rd IEEE Conference on control Applications, Glasgow. Scotland, 1994,1029-1034.
[27] Rhinehart R R.A watch dog for controller performance monitoring, Proc. American Control Conference, Seattle, WA, 1995,2239-2240.
[28] Miao T, Seborg D E. A monitoring strategy for flow and pressure control loops, In 2nd Asia-Pacific Conference on control and measurement, Wuhan-Chongqing, China, 1995.
[29] Tyler M L, Morari M. Performance monitoring of control system using likehood methods,, Proc American Control Conference, Seattle. WA, 1995, 1245-1249.
[30] Ko B S, T. F. Edgar, Assessment of achievable PI control performance for Linear process with dead time. Proceeding of the American Control Conference. Philadephia PA, June 1998,1548-1552.
[31] Ko B S, Edgar T F. Performance assessment of cascade control loops. AIChE Journal, 2000, 46(2):281-291.
[32] Thornhill N F , Shah S L , B Huang. Controller performance assessment in setpoint tracking and regulatory control. ADCHEM2000, Pisa Italy June 14-16th 2000:1-6.
[33] Kozub D J. Controller performance monitoring-and diagnosis: experiences and challenges. Proc 5th lnt Conference on Chemical Process Control, Tahoe, CA, AIChE and CACHE, 1996, 83-96.
[34] Swanda A P, Seborg D E. Controller performance assessment based on setpoint reponse data . Proceeding of the American Control Conference, San Diego CA, June 1999, 3863-3867.
[35] Biao Huang, Shah S L. Practical issues in multivariable feedback control performance assessment. Journal of Process Control, 1998,8(5/6):421-430.
[36] Ju J, Chiu M S. An on-line monitoring procedure for 2×2 and 3×3 full multivariable
cotrol systems. Chemical Engineering Science, 1998, 53(6): 1277-1293.
[37] Wang B, Chiu M S. Online monitoring of controller performance from servo information. Proceeding of the 1998 IEEE ISIC/CIRA.ISAS Conference, Gaithersburg MD, Sept, 1998, 221-226.
[38] Kammer L C, Bitmead R R, Bartlett P L .Optimal controller properties from closed-loop experiments.Automatica,1998,34(1),83-91.
[39] Alexander H. A method for detection of stiction in control valves. Control Engineering Practice. 1998.7:1221-1231.
[40] 成成，黄道．IPCA 在故障检测与分离中的应用．华东理工大学学报，2000，26(5)：502-506．
[41] 马智明，阳宪惠．采用主元分析的过程故障诊断方法．自动化学报，2000(增刊B)：125-129．
[42] Kozub D J. Controller performance monitoring and diagnosis: experiences and challenges. Proc 5th Int Conference on Chemical Process Control, Tahoe, CA, AIChE and CACHE, 1996,83-96.
[43] Lynch C B, Dumont G A. Control loop performance monitoring, IEEE Transactions on Control Systems Technology, 1996,4(2),185-192.
[44] Vishnubhotla A, Shah S L, Huang B A. Feedback and feedforward performance analysis of the Shell industrial closed loop data set. IEAC Symposium Advanced Control of Chemial Processes, Banff Alberta,Canada, Pergamon Press, Oxford, 1997,313-318.
[45] Jofriet P J, Bialkowski W L. Process knowledge: the key to on-line monitoring of process variability and control loop performance. Conference Proceedings of the Control Systems Conference, TAPPI Press, Nocross GA, 1996,187-193.
[46] Harris T J, Seppala C T, Jofriet P J, Surgenor B W. Plant-Wide feedback control performance assessment using an expert-system framework. Control Engineering Practice, 1996, 4(9):1297-1303.
[47] Thornhill N F, Oettinger M, Fedenczuk P. Refinery-wide control loop performance assessment, Journal of Process Control, 1999, 9(2), 109-124.
[48] Biao Huang, Shah S L, Kwok E K, Zurcher J. Performance assessment of multivariate control loops on a paper-machine headbox. The Canadian Journal of Chemical Engineering, 1997,75(1):134-142.
[49] Harris T, Boudreau F, Macgregor J F. Performance assessment of multivariable feedback controllers. Automatica, 1996,32(11):1505-1518.
[50] Shah S L, Patwardhan R, Biao Huang. Multivariate controller performance analysis: methods, applications and challenges, 2001 CPC-6 Conference, Tuscon, AZ ,January 2001, 187-219.
[51] Rogozinski M, Paplinski A and Gibbard M. An algorithm for calculation of a nilpotent interactor matrix for linear multivatiable systems. IEEE Transactions on Automatic
Control.,1987,32(3):234-237.
[52] Biao Huang, Shah S L, Fujii H. The unitary interactor matrix and its estimation using closed-loop data, J .Proc. Control,1997, 7(3): 195-207.
[53] Thomhill N F, Shah S L, Biao Huang. Controller Performance assessment in set point tracking and regulatory control. Int. J. Adapt. Control Signal Process,2003,17:709-727.
[54] Seppala C T, Harris T J, Bacon D W. Time series methods for dynamic analysis of multiple controlled variables. Journal of Process Control,20002, 2:257-276.
[55] Box G E P, Jenkins G M, Reinsel G C. Time series analysis: Forecasting and Control,3rd Ed., Prentice-Hall, Englewood Cliffs,NJ, 1994.
[56] 组态王 Version5.1用户手册．北京：北京亚控自动化软件科技有限公司，2000．
[57] 胡寿松．自动控制原理．第3版．北京：国防工业出版社，1994．
[58] Thornhill N F, Hgglund T. Detection and diagnosis of oscillation in control loops. Control Eng. Prac., 1997,5:1343-1354.
[59] 黄文梅，熊桂林．信号分析与处理——matlab语言及应用．长沙：国防科技大学出版社，2000．
[60] MATLAB教程——基于6.x版本．北京：北京航空航天大学出版社,2001．
[61] 黄忠霖．控制系统MATLAB计算与仿真．北京：国防工业出版社，2001．
[62] 李庆扬，王能超，易大义．数值分析．武汉：华中理工大学出版社，1982．
[2] 翁维勤，孙洪程．过程控制系统及工程，第2版，北京：化学工业出版社，2002．
[3] 金以惠．过程控制．北京：清华大学出版社，1993．
[4] 严伯钧，尹俊熙，张仁忠，杨公源．过程控制系统分析与设计，北京：中国纺织出版社，1994．
[5] 王树青．先进控制技术及应用．北京：化学工业出版社，2001．
[6] strm K J, Hgglund T. PID Controllers: Theory, Design, and Tuning, second edition, Instrument Society of America, Research Triangle Park, NC, 1995.
[7] Ender D B. Process control performance: Not as good as you think. Control Engineering, 1993,40(10):180-190.
[8] Rinehart N, Jury E How control valves impact process optimization. Hydrocarbon Processing, 1997,6:53-56.
[9] 杨马英．模型预测控制的性能监视与评价——综述．第21届中国控制会议论文集．杭州：浙江大学出版社，2002，253-259．
[10] Qin S J. Control performance monitoring—A review and assessment. Computer and Chemical Engineering, 1998,23(2): 173-186.
[11] Alan J.Hugo. Performance assessment of process controllers, www.controlartsinc. com/pdf/PerformanceAssessment.PDF.
[12] Harris T J, Seppala C T, Desborough L. A review of performance monitoring and assessment techniques for univariate and multivariate control systems. Journal of Process Control, 1999,9:1-17.
[13] Astrm K J. Introduction to stochastic control theory.Academic Press,1970.
[14] Harris T J. Assessment of control loop performance. Can. J. Chem. Eng., 1989, 67(10): 856-861.
[15] Box G E E Jenkins G M. Time series analysis, forecasting and control. Holden-Day, 1970.
[16] Stanfelj N, Marlin T E, MacGregor J E Monitoring and diagnosis process control performance: the single loop case. Ind. Eng. Chem. Res., 1993, 32:856-861.
[17] Huang B, Shah S L, Kwok K Y. Good, Bad or Optimal? Performance assessment of multivariable process. Automatica, 1997, 33(6):1175-1183.
[18] Hgglund T. A control-loop performance monitor. Control Eng .Practice, 1995,3(11): 1543-1551.
[19] Miao T, Seborg D E. Automatic .detection of excessively oscillatory feedback control loops. U. S.Patent#5 , 1998,719-788.
[20] Miao T, Seborg D E. Automatic detection of excessively oscillating feedback control loop. IEEE Conference on Control Applications Proceedings, Kohala Coast-Island of Haiwai'i, USA.,1999,8:359-364.
[21] Hgglund T. Automatic detection of sluggish control loops. Control Engineering Practice, 1999, 7:1505-1511.
[22] Desborough L, Harris T J. Performance assessment measure for univariate feedback control. Can. J. Chen. Eng.,1992, 70:1186-1197.
[23] Kozub D J, Garcia C E. Monitoring and diagnosis of automated controllers in chemical process industries. AIChE Meeting, St Louis, MI, 1994.
[24] Lynch C B , Dumont G A. Closed loop performance monitoring, Proc.2nd, IEEE Conference On Control Applicatians, Vancouver, B.C., 1993, 835-840.
[25] Tyler M L , Morari M. Performance assessment for unstable and nonminium-phase system.. On-line Fault Detection and Supervision in the Chemical Process Industries IFAC Workshop, Newcastle-upon-Tyne UK, 1995, 3:187-192.
[26] Eriksson P C, Isaksson A J. Some aspects of control performance monitoring, Proc.3rd IEEE Conference on control Applications, Glasgow. Scotland, 1994,1029-1034.
[27] Rhinehart R R.A watch dog for controller performance monitoring, Proc. American Control Conference, Seattle, WA, 1995,2239-2240.
[28] Miao T, Seborg D E. A monitoring strategy for flow and pressure control loops, In 2nd Asia-Pacific Conference on control and measurement, Wuhan-Chongqing, China, 1995.
[29] Tyler M L, Morari M. Performance monitoring of control system using likehood methods,, Proc American Control Conference, Seattle. WA, 1995, 1245-1249.
[30] Ko B S, T. F. Edgar, Assessment of achievable PI control performance for Linear process with dead time. Proceeding of the American Control Conference. Philadephia PA, June 1998,1548-1552.
[31] Ko B S, Edgar T F. Performance assessment of cascade control loops. AIChE Journal, 2000, 46(2):281-291.
[32] Thornhill N F , Shah S L , B Huang. Controller performance assessment in setpoint tracking and regulatory control. ADCHEM2000, Pisa Italy June 14-16th 2000:1-6.
[33] Kozub D J. Controller performance monitoring-and diagnosis: experiences and challenges. Proc 5th lnt Conference on Chemical Process Control, Tahoe, CA, AIChE and CACHE, 1996, 83-96.
[34] Swanda A P, Seborg D E. Controller performance assessment based on setpoint reponse data . Proceeding of the American Control Conference, San Diego CA, June 1999, 3863-3867.
[35] Biao Huang, Shah S L. Practical issues in multivariable feedback control performance assessment. Journal of Process Control, 1998,8(5/6):421-430.
[36] Ju J, Chiu M S. An on-line monitoring procedure for 2×2 and 3×3 full multivariable
cotrol systems. Chemical Engineering Science, 1998, 53(6): 1277-1293.
[37] Wang B, Chiu M S. Online monitoring of controller performance from servo information. Proceeding of the 1998 IEEE ISIC/CIRA.ISAS Conference, Gaithersburg MD, Sept, 1998, 221-226.
[38] Kammer L C, Bitmead R R, Bartlett P L .Optimal controller properties from closed-loop experiments.Automatica,1998,34(1),83-91.
[39] Alexander H. A method for detection of stiction in control valves. Control Engineering Practice. 1998.7:1221-1231.
[40] 成成，黄道．IPCA 在故障检测与分离中的应用．华东理工大学学报，2000，26(5)：502-506．
[41] 马智明，阳宪惠．采用主元分析的过程故障诊断方法．自动化学报，2000(增刊B)：125-129．
[42] Kozub D J. Controller performance monitoring and diagnosis: experiences and challenges. Proc 5th Int Conference on Chemical Process Control, Tahoe, CA, AIChE and CACHE, 1996,83-96.
[43] Lynch C B, Dumont G A. Control loop performance monitoring, IEEE Transactions on Control Systems Technology, 1996,4(2),185-192.
[44] Vishnubhotla A, Shah S L, Huang B A. Feedback and feedforward performance analysis of the Shell industrial closed loop data set. IEAC Symposium Advanced Control of Chemial Processes, Banff Alberta,Canada, Pergamon Press, Oxford, 1997,313-318.
[45] Jofriet P J, Bialkowski W L. Process knowledge: the key to on-line monitoring of process variability and control loop performance. Conference Proceedings of the Control Systems Conference, TAPPI Press, Nocross GA, 1996,187-193.
[46] Harris T J, Seppala C T, Jofriet P J, Surgenor B W. Plant-Wide feedback control performance assessment using an expert-system framework. Control Engineering Practice, 1996, 4(9):1297-1303.
[47] Thornhill N F, Oettinger M, Fedenczuk P. Refinery-wide control loop performance assessment, Journal of Process Control, 1999, 9(2), 109-124.
[48] Biao Huang, Shah S L, Kwok E K, Zurcher J. Performance assessment of multivariate control loops on a paper-machine headbox. The Canadian Journal of Chemical Engineering, 1997,75(1):134-142.
[49] Harris T, Boudreau F, Macgregor J F. Performance assessment of multivariable feedback controllers. Automatica, 1996,32(11):1505-1518.
[50] Shah S L, Patwardhan R, Biao Huang. Multivariate controller performance analysis: methods, applications and challenges, 2001 CPC-6 Conference, Tuscon, AZ ,January 2001, 187-219.
[51] Rogozinski M, Paplinski A and Gibbard M. An algorithm for calculation of a nilpotent interactor matrix for linear multivatiable systems. IEEE Transactions on Automatic
Control.,1987,32(3):234-237.
[52] Biao Huang, Shah S L, Fujii H. The unitary interactor matrix and its estimation using closed-loop data, J .Proc. Control,1997, 7(3): 195-207.
[53] Thomhill N F, Shah S L, Biao Huang. Controller Performance assessment in set point tracking and regulatory control. Int. J. Adapt. Control Signal Process,2003,17:709-727.
[54] Seppala C T, Harris T J, Bacon D W. Time series methods for dynamic analysis of multiple controlled variables. Journal of Process Control,20002, 2:257-276.
[55] Box G E P, Jenkins G M, Reinsel G C. Time series analysis: Forecasting and Control,3rd Ed., Prentice-Hall, Englewood Cliffs,NJ, 1994.
[56] 组态王 Version5.1用户手册．北京：北京亚控自动化软件科技有限公司，2000．
[57] 胡寿松．自动控制原理．第3版．北京：国防工业出版社，1994．
[58] Thornhill N F, Hgglund T. Detection and diagnosis of oscillation in control loops. Control Eng. Prac., 1997,5:1343-1354.
[59] 黄文梅，熊桂林．信号分析与处理——matlab语言及应用．长沙：国防科技大学出版社，2000．
[60] MATLAB教程——基于6.x版本．北京：北京航空航天大学出版社,2001．
[61] 黄忠霖．控制系统MATLAB计算与仿真．北京：国防工业出版社，2001．
[62] 李庆扬，王能超，易大义．数值分析．武汉：华中理工大学出版社，1982．
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