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This presentation was presented at National Instruments NIWeek 2007 to demonstrate how to use LabVIEW to implement model predictive control (MPC) strategies to control complicated coax manufacturing processes. Both MatLAB MPC and LabVIEW MPC were implemented in these applications.
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Model Predictive Control Implementation with LabVIEW
Yurong Kimberly Wang, Ph.D.Principal Control Systems Engineer
Tyco Electronics
Wilsonville, Oregon
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Tyco Electronics / Precision Interconnect
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Precision Interconnects
• COMFORT, MODULUS3, BLUE RIBBON, BASIS, ERGOLINE, LIFELIC, AND SLIMLINE ARE TRADE MARKS
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Coax Manufacturing Processes
• Dielectric layer • Taping or Extrusion
• Shield layer• Braiding or Serving
• Jacket layer• Taping or Extrusion
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Taped or Extruded Coax
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Coax Property
)ln(96.59
d
D
kZo
• C: capacitance (pF/Foot)
• Td: time delay (ns/Foot)
• Z0: impedance (Ohm)
• k: dielectric constant
• D: outer diameter (Mil)
• d: center conductor diameter (Mil)
• Formulae
)ln(
95.16
dDk
C
kTd 016.1
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Process Control Challenge• Multiple Outputs
• Capacitance, Diameter, Time delay, Impedance, …
• Multiple Inputs• Screw speed, line speed, barrel temperatures, tape tensions, …
• Long and Variable Time Delays• Variable line speeds and sensor to actuator distances
• Input and Output Constraints• Input and output upper and lower spec limits
• Nonlinearity• Variety of operating conditions
• Disturbances• Center conductor variation, tape thickness variation, …
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Model Predictive Control (MPC) Law
• Model-based multi-variable control
• Optimal control law with I/O constraints
• Nonlinear control with model mismatch
• Long and variable time delay process
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MPC System and Optimization
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MPC Sampling Instants
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System ArchitectureProduction
QualityEngineers
Production
Plant Managers
Production
ProcessEngineers
Production
Manufacturing Engineers
Manufacturing Information Server
Business NetworkReport Program for Data Analysis
Production
RemoteUsersInternet
Control Network
Local Control Module
Local Control Module
Local Control Module
Business Network
OPC Client & Server for Data Logging
OPC Client & Server for Data Sharing
Production
LabVIEWHMI & MPC Control
Figure 1. System Architecture
Local Control Module
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LabVIEW Project Explorer
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LabVIEW – Based Application• LabVIEW Professional Development• LabVIEW Real-Time Module• Data Logging and Supervisory Control Module• Simulation Module• Control Design Toolkit• Advanced Signal Processing Toolkit• Database Connectivity Toolkit• Internet Connectivity Toolkit• Report Generation Toolkit• Compact FieldPoint Hardware and Device Drivers
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LabVIEW MPC Implementation
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LabVIEW MPC Code
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LabVIEW MPC ApplicationManual to auto control with disturbance rejection
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MatLABTM MPC – Initial Approach
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MatLAB MPC Script Node
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MatLAB MPC ApplicationManual to auto control with disturbance rejection
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Polymer Extrusion MPC HMI
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MPC Output Weighting Effect
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Manufacturing Benefit• Consistent product quality
Multi-variable auto-controlled product quality
• Productivity improvement Unmanned overnight MPC control with alarm monitoring Production speed auto ramp with feedforward compensation
• Equipment cost reduction Inner tape layer diameter gauge elimination
• Sensor fault detection Controller acting up with sensor fault readings
• Labor cost reduction Coax quality on-line prediction and off-line test reduction
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Reference Material
• LabVIEW Model Predictive Control Module User Manual by National Instruments
• MatLAB Model Predictive Control Toolbox User Manual by MathWorks
• Advanced Control Unleashed by Terrence L. Blevins, Gregory K. McMillan, Willy K. Wojsznis,
and Michael W. Brown, ISA• Models Unleashed – Virtual Plant and Model Predictive Control
Applications, A Pocket Guide by Gregory K. McMillan, Robert A. Cameron, ISA
• Dual-Target Predictive Control for Food Extrusion by Y. Wang and J. Tan, Control Engineering Practice 8 (2000)
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