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Adaptive control is helping create n Rapid and irregular setpoint trajectory 4. Manual tuning of controller parameters
faster, more accurate control for many changes is not required
applications. In this article, control n Noise, disturbances, and changing 5. Closed-loop system stability analysis
industry leader Dr. George Cheng operating conditions and criteria are available to guarantee
describes the concepts behind Model- the system stability[1]
Free Adaptive (MFA) control and shows PID controllers can be embedded in high-
its benefits compared to Proportional- speed control equipment, but cannot deal Based on the core MFA technology,
Integral-Derivative (PID) and model- effectively with all these problems. Since CyboSoft has developed a set of general-
based control. He also highlights the PID is a fixed controller with no adaptive purpose MFA controllers, each of which
elements of a real-world application in capability, its parameters have to be solves a tough control problem:
piezomotor control. retuned when process dynamics, product
types, or operating conditions change. n Single Input Single Output (SISO)
Since the beginning of time there has been MFA to replace PID and eliminate
a desire to move life along at a faster pace. A model-based adaptive control approach controller manual tuning
In our world today, speed is indeed often can be difficult and costly to implement n Nonlinear MFA to control nonlinear
the most decisive factor between winning because developing a process model processes
and losing. and keeping it accurate always pose n Time-optimal MFA to reach control
a challenge. For dynamic modeling condition in minimum time
This faster is better rule impacts our based adaptive control, there may not n Feedforward MFA controller to deal
industry in a huge way. For example, saving be enough time and data to learn a new with measurable disturbances
a second or two in a semiconductor wafer model. Control experts typically design n Antidelay MFA to control processes
process step can substantially reduce the a high-speed complex control system with large τ-T ratio
cost of ownership of a multimillion dollar with precise process models requiring n Robust MFA to protect the process
tool. For some control components such significant financial and time investments. variables from running outside their
as a gas flow or liquid flow controller, a These systems usually require special bounds
quarter or half second faster to force the hardware and software that are difficult to n Time-varying MFA controller to
flow to track its setpoint can be decisive. build and change. control time-varying processes
In high-end motion control, customers n Multiple Input Multiple Output
demand subnanometer accuracy and Fundamentally, the control speed and the (MIMO) MFA to control
submicrosecond control update rates. control algorithm complexity will always multivariable processes
be in conflict. Therefore, a simpler control
Why PID and model-based algorithm is always desirable, no matter MFA control products provide cost-
control fail how much computing power is available. effective and user-friendly solutions for
The speed bottleneck of a piece of the high-speed complex control market.
equipment is often related to its automatic Benefits of MFA control MFA controllers do not require process
control system, which has three key MFA control, as its name suggests, is an models that are difficult to develop and
elements: sensors, actuators, and adaptive control method that does not maintain. Once installed, no controller
controllers. When equipment becomes require process models. This patented tuning is required. In most cases, MFA
more complex and the flexible production technology has been developed by controllers can directly replace the legacy
capability is critical, high-speed adaptive CyboSoft. An MFA control system is controllers such as PIDs and achieve
control systems become critical and must defined to have the following properties: immediate improvements in control
deal effectively with problems including: performance resulting in significant
1. Precise quantitative knowledge of the economic benefits. Due to their general-
n Nonlinearity process is not necessary purpose nature, MFA controllers have
n Dead-zone and hysteresis 2. Process identification mechanism or been deployed in almost every sector of
n Open-loop oscillating identifier is not included in the system industrial control applications[2].
n Large τ-T ratio (where τ is delay time 3. Controller design for a specific process
and T is time constant) is not needed
E0 =1 wij
e(t)
N(.
) E1 p1
q1
∑ ϕ(.
) hi
z-
1 E2 p2
q2
∑ ϕ(. q0=1
)
z- o(t) v(t)
1 E3 p3 q3
∑ ϕ(. ∑ ϕ(. ψ(. Kc
) ) ) +
..... +
.....
z- qN
1 EN p
∑ ϕ(.
)
Figure 2
Figure 4
of the MFA controllers can be saved in range, high-accuracy motion control with control technology and Combined
a database so that such information or adaptive capability is essential. Intelligence methodology. George is a
value(s) can be preloaded the next time the senior member of ISA and IEEE, and a
equipment is to run in the same condition. For example, oil or gas well drilling member of ISA’s Automation Industry
The autocalibration feature can save a is typically done manually by drilling Advisory Council.
lot of manpower in applications where machine operators. The drilling speed and
tedious one-on-one manual calibration is efficiency can be inconsistent depending To learn more, contact George at:
required for each control loop or device. on the operator’s skill and work attitude.
If the drill bit hits a rock, the operator CyboSoft, General Cybernation
Application: would want to penetrate slowly to avoid Group, Inc.
MFA piezomotor control breaking the drilling bit. If the drilling is 2868 Prospect Park Drive, Third Floor
A general-purpose high-speed MFA going through mud, the operator would Rancho Cordova, CA 95670
control system is based on National want to penetrate as quickly as possible Tel: 916-631-6313
Instruments’ (NI’s) CompactRIO under certain safety boundaries. Fax: 916-631-6312
embedded control and data acquisition E-mail: gscheng@cybosoft.com
platform. The combination of NI’s Based on this idea, automatic drilling Website: www.cybosoft.com
LabVIEW software, related hardware equipment is developed to improve
including a PC, CompactRIO, Compact the drilling safety and efficiency by References
Fieldpoint, PXI, and third-party specialty automatically controlling the rate of [1] George Cheng, “Model-Free Adaptive
Control,” in Instrument Engineers’ Handbook
hardware and software makes it a user- penetration and weight on bit. However,
- Process Control and Optimization, ed. Bela
and developer-friendly Programmable each drilling rig can be different due to Liptak (CRC Press LLC, 2005)
Automation Controller (PAC) platform, its design and type, wear and tear of the George Cheng, “MFA in Control with
well suited for high-speed control mechanical components, and so on. In CyboCon,” CyboSoft, General Cybernation
applications. addition, the operating conditions will be Group Inc., March 2002
George Cheng, “Model-Free Adaptive Control,”
different from rig to rig, and from location in Techniques of Adaptive Control, ed. Vance
CyboSoft has embedded a variety of to location, the controllers used in drilling VanDoren (Burlington: Elsevier Science, 2003).
MFA controllers into the LabVIEW equipment often require parameter
[2] Vance VanDoren, “Model Free Adaptive
platform and can deliver a general-purpose tuning. Retuning PID controllers requires Control - This New Technique for Adaptive
high-speed and high-precision experienced engineers or technicians Control Addresses a Variety of Technical
adaptive control solution running on to travel to a remote location after each Challenges,” Control Engineering Europe,
NI’s CompactRIO PAC system with rig up-and-down. This effort can cost March 2001
George Cheng, Min He, and De-Lin Li, “Model-
performance (10 microsecond updates both time and money. MFA-based
Free Coking Furnace Adaptive Control,”
and I/O using an FPGA, 1 millisecond autodrilling equipment eliminates the Hydrocarbon Processing, December 1999
run time in the operating system) and need for controller tuning providing major George Cheng and Li-Qun Huo, “Control
precision (with 16-bit analog inputs and economical and competitive benefits to System Optimizes EOR Steam Generator
outputs) previously unattainable with off- the equipment vendors and users. Output,” Oil & Gas Journal (September 2003)
George Cheng and Li-Qun Huo “Chinese Steel
the-shelf hardware. Plant Clears Air with Software - Model-Free
Faster MFA is better Adaptive Control Puts Ling-Yuan Iron and Steel
Figure 4 shows a CyboSoft time-optimal To serve the high-speed control market, in League of Its Own,” InTech, October 2003
MFA controller in NI’s CompactRIO MFA controllers are typically embedded Michael Major, “Model-Free Adaptive Control
on an Evaporator,” Control, Sepember. 1998
controlling a piezomotor manufactured by in custom hardware. Since MFA is model-
Dave Seiver and Ovidiu Marin, “Air Separation
Physik Instrumente, which demonstrates free, the MFA control software functions Advances with MFA Control,” Control, May
consistent control performance whether have a very small footprint and can run 2001
the piezo stage has weight or no weight at high speed in a regular embedded Stephen Harris, “Model-Free Adaptive Control
on it. environment. This capability makes of an FCC Catalyst Dilute Phase Vacuum
Transport System,” Control, June 2004
the MFA control solution even more George Cheng, “Tomato Process Improvements
Benefits of high-speed compelling for customers or equipment Using Model-Free Adaptive Controllers,”
MFA control vendors using high-speed control. This Tomato News, April 2004
High-speed MFA control solutions offer revolutionary technology allows users to George Cheng, “Model-Free Adaptive (MFA)
Control,” IEEE Computing and Control
many benefits: achieve significant advantages by being
Engineering, June/July 2004
faster and more competitive. IES George Cheng and Wen-De Zhang, “Model-Free
1. Consistent control performance in all Adaptive Technology Improves Distillation
operating conditions George S. Cheng has Column Chain Control,” Hydrocarbon
2. Elimination of controller manual BS, MS, and PhD Processing, October 2004
George Cheng and Zhong-Wei Zhang, “Model-
tuning degrees in Electrical Free Adaptive Control of Turbidity in Water
3. Lower support costs Engineering and is the Coagulation Process,” Control Engineering
4. Safer high-speed operations chairman and chief Europe, October 2004.
5. Higher production throughput technical officer of
CyboSoft, General
Most importantly, MFA has become an Cybernation Group, Inc. He holds 10
enabling technology for a new generation U.S. patents and the related international
of equipment where high-speed, long- patents, and is the developer of MFA