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Improving Process Monitoring via Dynamic Multi-Fidelity Modeling 通过动态多保真度建模改进过程监控
Q3 Engineering Pub Date : 2025-01-01 DOI: 10.1016/j.ifacol.2025.07.145
Rastislav Fáber , Marco Vaccari , Riccardo Bacci di Capaci , Karol Ľubušký , Gabriele Pannocchia , Radoslav Paulen
We study real-time process monitoring, where employed online sensors yield inaccurate information. A multi-fidelity (MF) modeling approach is adopted that integrates dynamic information from online, low-fidelity (LF) data with infrequent, high-fidelity (HF) laboratory measurements. The proposed methodology is demonstrated on a composition monitoring problem derived from real oil refinery operations. The developed MF model exhibits a significant improvement in accuracy with respect to both LF data (online sensor) and the HF model (standard soft sensor). The results highlight the potential of MF modeling for improving process monitoring and control through the integration of diverse data sources.
我们研究实时过程监控,其中使用在线传感器产生不准确的信息。采用多保真度(MF)建模方法,将在线低保真度(LF)数据的动态信息与不频繁的高保真度(HF)实验室测量相结合。最后,以实际炼油厂的成分监测问题为例进行了验证。开发的中频模型在低频数据(在线传感器)和高频模型(标准软传感器)的精度方面都有显著提高。结果突出了MF建模的潜力,通过集成不同的数据源来改善过程监测和控制。
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引用次数: 0
Data-driven material removal rate estimation in bonnet polishing process 阀盖抛光过程中数据驱动的材料去除率估计
Q3 Engineering Pub Date : 2025-01-01 DOI: 10.1016/j.ifacol.2025.07.147
Michal Darowski , Muhammad Faisal Aftab , David Walker , Hongyu Li , Christian W. Omlin
Bonnet polishing is an ultra-precision polishing technique used for manufacturing components utilized in optics, electronics, and Scientific instrumentation, where sub-nanometer accuracy is required. However, the process is not fully deterministic and requires multiple process-metrology iterations. In modern computer numerically controlled (CNC) machines, polishing is performed by moderating the bonnet tool dwell time at each location based on the input parameters and material removal rate (MRR). While the MRR is typically treated as constant once established, it continuously evolves due to the process’s dynamic nature and changing conditions. This variability in MRR impacts the convergence of the polishing process, necessitating repeated surface processing and resulting in increased manufacturing time and cost. In this work, we present a data-driven approach to estimate the amount of material removed during the pre-polishing routine in bonnet polishing. The estimations are based on the force exerted by the bonnet tool on a polished surface along the three dimensions. Measurements were obtained using a bespoke force table with load sensors across three axes, mounted on the Zeeko IRP600 machine table. The results demonstrate the Effectiveness of this data-driven approach for estimating MRR, achieving a mean absolute error of 0.0541 µm and a mean absolute percentage error of 5.89% across the test set.
阀盖抛光是一种超精密抛光技术,用于制造光学、电子和科学仪器中需要亚纳米精度的部件。然而,该过程不是完全确定的,需要多次过程计量迭代。在现代计算机数控(CNC)机床中,抛光是通过根据输入参数和材料去除率(MRR)调节阀盖刀具在每个位置的停留时间来完成的。虽然MRR一旦建立通常被视为常数,但由于过程的动态性和不断变化的条件,它会不断演变。MRR的这种可变性影响了抛光过程的收敛性,需要重复的表面加工,从而增加了制造时间和成本。在这项工作中,我们提出了一种数据驱动的方法来估计在阀盖抛光的预抛光过程中去除的材料量。这些估计是基于阀盖工具沿三维方向对抛光表面施加的力。测量使用定制的力表,其负载传感器横跨三轴,安装在Zeeko IRP600机床上。结果证明了这种数据驱动方法用于估计MRR的有效性,整个测试集的平均绝对误差为0.0541µm,平均绝对百分比误差为5.89%。
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引用次数: 0
A hierarchical multimode dynamic process monitoring scheme and its application to the Tennessee Eastman process⁎ 一种分层多模式动态过程监控方案及其在田纳西伊士曼过程中的应用[j]
Q3 Engineering Pub Date : 2025-01-01 DOI: 10.1016/j.ifacol.2025.07.148
Jiaorao Wang , Lishuai Li , S. Joe Qin
Multimode characteristics commonly exist in modern industrial processes. Previous multi-model approaches treat steady states and transitions separately. However, identifying each mode is often tedious, generally achieved through clustering, requiring operators to tune hyperparameters extensively. As practitioners prefer a concise and easily implemented approach for multimode dynamic process monitoring, we initially propose a hierarchical scheme to simplify the modeling process while enhancing monitoring performance. Our method iteratively constructs dynamic models in a hierarchical, monitoring-oriented manner without mode partition. It offers three advantages. Firstly, modeling is directly conducted following a hierarchical structure driven by monitoring indexes, which is more concise and ensures monitoring performance. Secondly, by eliminating mode partition, only three hyperparameters, such as model order and the termination condition, need to be decided by humans. This significantly reduces human labour and facilitates the applicability of the proposed method across various processes. Lastly, by focusing on dynamic characteristics rather than steady-state and transitional modes, our method reduces the number of required models for a given process, resulting in a simpler multi-model structure that still ensures monitoring performance.
多模式特性在现代工业过程中普遍存在。以前的多模型方法分别处理稳态和过渡。然而,识别每个模式通常是繁琐的,通常通过聚类实现,需要操作员广泛地调优超参数。由于从业者更喜欢简洁且易于实现的多模式动态过程监控方法,我们初步提出了一种分层方案,以简化建模过程,同时提高监控性能。我们的方法以分层的、面向监控的方式迭代地构建动态模型,没有模式划分。它提供了三个优势。首先,直接按照监测指标驱动的分层结构进行建模,更加简洁,保证了监测性能。其次,通过消除模态划分,只需要人工决定模型阶数和终止条件三个超参数。这大大减少了人力劳动,并促进了所提出的方法在各种过程中的适用性。最后,通过关注动态特性而不是稳态和过渡模式,我们的方法减少了给定过程所需模型的数量,从而产生了更简单的多模型结构,仍然确保了监测性能。
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引用次数: 0
Symmetric Kullback Leibler divergence-based design of experiments with estimation of unspecified values 基于非指定值估计的对称Kullback Leibler散度实验设计
Q3 Engineering Pub Date : 2025-01-01 DOI: 10.1016/j.ifacol.2025.07.197
Brijesh Kumar , Mani Bhushan
In this work, we propose a Symmetric Kullback Leibler divergence (SKLD)-based approach for optimal Design of Experiments (DOE) along with estimation of unspecified values in the design of experiments data matrix. Using SKLD as optimality criteria as opposed to various existing alphabetic optimality criteria, facilitates the incorporation of end-user desired performance of estimates. For the case when experimental noise is Gaussian and uncorrelated, the proposed approach results in a Mixed Integer Non-Linear Programming (MINLP) problem. This problem is NP-hard to solve. Hence, a novel heuristic solution strategy is also proposed which solves the proposed problem iteratively and sequentially. In particular, the MINLP problem is split into two sub-problems: (i) Non-Linear Programming (NLP) problem: to estimate optimal unspecified values, and (ii) Non-Linear Integer Programming (IP) problem: to obtain optimal DOE. These two subproblems are solved sequentially and iteratively until convergence is reached. The proposed solution strategy guarantees the decreasing behaviour of SKLD value. The efficacy of the proposed solution strategy is tested on an illustrative example and a Material synthesis problem, and performance is compared with Fedorov exchange algorithm, Forward Greedy search algorithm, and some of the popular MINLP solvers available in GAMS environment. Results demonstrate that the proposed solution approach outperforms most other methods.
在这项工作中,我们提出了一种基于对称Kullback Leibler散度(SKLD)的实验优化设计(DOE)方法,以及实验数据矩阵设计中未指定值的估计。使用SKLD作为最优性标准,而不是各种现有的字母最优性标准,有助于合并最终用户期望的估计性能。在实验噪声为高斯且不相关的情况下,该方法求解的是一个混合整数非线性规划问题。这个问题是np难解的。在此基础上,提出了一种新的启发式求解策略,迭代地、顺序地求解所提出的问题。特别是,MINLP问题被分成两个子问题:(i)非线性规划(NLP)问题:估计最优未指定值;(ii)非线性整数规划(IP)问题:获得最优DOE。这两个子问题依次迭代求解,直至收敛。所提出的求解策略保证了SKLD值的递减行为。在一个实例和一个材料合成问题上验证了所提出的求解策略的有效性,并与Fedorov交换算法、前向贪婪搜索算法以及GAMS环境下一些流行的MINLP求解器进行了性能比较。结果表明,所提出的求解方法优于大多数其他方法。
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引用次数: 0
Automatic design of robust model predictive control of a bioreactor via Bayesian optimization⁎ 基于贝叶斯优化的生物反应器鲁棒模型预测控制自动设计
Q3 Engineering Pub Date : 2025-01-01 DOI: 10.1016/j.ifacol.2025.07.115
Tobias Brockhoff , Moritz Heinlein , Georg Hubmann , Stephan Lütz , Sergio Lucia
Model predictive control (MPC) is an advanced control strategy that can deal with general nonlinear systems and constraints but relies on accurate predictions given by a dynamic model. To satisfy constraints and improve performance despite imperfect models, robust MPC methods can be formulated. Multi-stage MPC is a robust MPC method based on the formulation of scenario trees. The resulting optimization problems can be large, as the number of scenarios considered in the tree results from the combinations of all possible uncertainties. For systems with many uncertainties, as it is the case in bioprocesses, the optimization problems become rapidly intractable. To solve this issue, heuristics are typically used to select the most relevant uncertain parameters and their range of uncertainty. In this paper, we propose a two-step approach to obtain a systematic design of multi-stage MPC controllers: First, the key uncertain parameters are extracted based on the parametric sensitivities. Second, Bayesian optimization is employed for tuning of the range of uncertainties. The approach is applied to a bioreactor simulation study. The proposed approach can avoid constraint violations that are otherwise obtained by standard MPC while being less conservative than a manually-tuned robust controller.
模型预测控制(MPC)是一种先进的控制策略,可以处理一般的非线性系统和约束,但依赖于动态模型给出的准确预测。为了在模型不完善的情况下满足约束条件并提高性能,可以制定鲁棒的MPC方法。多阶段MPC是一种基于情景树的鲁棒MPC方法。所产生的优化问题可能很大,因为树中考虑的场景数量来自所有可能的不确定性的组合。对于具有许多不确定性的系统,如生物过程,优化问题很快变得棘手。为了解决这个问题,通常使用启发式方法来选择最相关的不确定参数及其不确定范围。本文提出了多级MPC控制器的系统设计方法:首先,根据参数灵敏度提取关键的不确定参数;其次,采用贝叶斯优化方法对不确定性范围进行调整。该方法已应用于生物反应器模拟研究。所提出的方法可以避免标准MPC所导致的约束违反,同时比手动调谐的鲁棒控制器保守性更低。
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引用次数: 0
Surrogate modeling and control optimization of batch crystallization process of β form LGA β型LGA间歇结晶过程的代理建模与控制优化
Q3 Engineering Pub Date : 2025-01-01 DOI: 10.1016/j.ifacol.2025.07.169
Bo Song , Tao Liu , Mingyan Zhao , Yan Cui , Yuanjun Li
To describe a quantitative relationship between the operating conditions of cooling crystallization process and product crystal size distribution (CSD), a surrogate modelling method based on the Gaussian process regression (GPR) is proposed by using only experimental data of batch crystallization process of β form L-glutamic acid (LGA). A modified design of experiments (DoE) is presented to reduce the number of batch crystallization experiments. Based on the surrogate model, an objective function reflecting the concentration of product CSD and desired yield is introduced to optimize these operating conditions. Experiments on the seeded cooling crystallization process of β-LGA are conducted to verify the effectiveness and advantage of the proposed method.
为了定量描述冷却结晶过程操作条件与产物晶粒尺寸分布之间的关系,提出了一种基于高斯过程回归(GPR)的替代建模方法,该方法仅使用β型l -谷氨酸(LGA)间歇结晶过程的实验数据。为了减少间歇结晶实验的次数,提出了一种改进的实验设计(DoE)。在代理模型的基础上,引入反映产物CSD浓度和期望产率的目标函数,对这些操作条件进行优化。通过对β-LGA种子冷却结晶过程的实验,验证了该方法的有效性和优越性。
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引用次数: 0
A flow rate soft sensor for pumps with complex characteristics 一种用于复杂特性泵的流量软传感器
Q3 Engineering Pub Date : 2025-01-01 DOI: 10.1016/j.ifacol.2025.07.172
Sebastian Leonow, Qi Zhang, Martin Mönnigmann
Flow rate soft sensors have become an important alternative for costly hardware flow meters, as they can estimate the flow rate with sufficient precision from easily measurable variables by using models and state estimation algorithms. This paper addresses the fundamental challenge that arises from ambiguous estimation problems, where the measured variable corresponds to two or more possible flow rate values. We develop and implement a decision algorithm that yields correct results in an industrial setup with substantial measurement noise. The results demonstrate a reliable flow rate estimation, providing a viable solution for real-time flow monitoring in centrifugal pumps with complex characteristics.
流量软传感器可以利用模型和状态估计算法从容易测量的变量中获得足够精度的流量,已成为昂贵的硬件流量计的重要替代方案。本文解决了由模糊估计问题引起的基本挑战,其中测量变量对应于两个或多个可能的流量值。我们开发并实现了一种决策算法,该算法在具有大量测量噪声的工业设置中产生正确的结果。结果表明,该方法的流量估计是可靠的,为具有复杂特性的离心泵流量实时监测提供了可行的解决方案。
{"title":"A flow rate soft sensor for pumps with complex characteristics","authors":"Sebastian Leonow,&nbsp;Qi Zhang,&nbsp;Martin Mönnigmann","doi":"10.1016/j.ifacol.2025.07.172","DOIUrl":"10.1016/j.ifacol.2025.07.172","url":null,"abstract":"<div><div>Flow rate soft sensors have become an important alternative for costly hardware flow meters, as they can estimate the flow rate with sufficient precision from easily measurable variables by using models and state estimation algorithms. This paper addresses the fundamental challenge that arises from ambiguous estimation problems, where the measured variable corresponds to two or more possible flow rate values. We develop and implement a decision algorithm that yields correct results in an industrial setup with substantial measurement noise. The results demonstrate a reliable flow rate estimation, providing a viable solution for real-time flow monitoring in centrifugal pumps with complex characteristics.</div></div>","PeriodicalId":37894,"journal":{"name":"IFAC-PapersOnLine","volume":"59 6","pages":"Pages 361-366"},"PeriodicalIF":0.0,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144830819","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
Stochastic Model Predictive Control of Blood Glucose Levels using Probabilistic Meal Anticipation⁎ 使用概率进食预期的随机模型预测控制血糖水平
Q3 Engineering Pub Date : 2025-01-01 DOI: 10.1016/j.ifacol.2025.06.009
Mohammad Ahmadasas , Mate Siket , Mudassir M. Rashid , Ali Cinar , Mustafa Bilgic
Unannounced meals introduce substantial disturbances, causing large deviations in blood glucose concentrations from the desired range. Accurate estimation of meal timing and size is crucial for precise state estimation in a Kalman filter. Achieving accurate meal estimation remains a challenging task for fully-automated insulin delivery systems. This paper proposes incorporating a correction mechanism for the estimated states, where missed meals are detected by a neural network. Additionally, a Bayesian network is utilized to forecast timing probabilities of the next meal. Our proposed stochastic model predictive controller (SMPC) incorporates predicted meal scenarios. We evaluate the controller performance with respect to the stochasticity of the dietary patterns; the results illustrate that integrating the most likely meal scenarios into SMPC decision-making enhances both robustness and performance.
未经宣布的用餐会带来实质性的干扰,导致血糖浓度大大偏离预期范围。进餐时间和大小的准确估计是卡尔曼滤波器精确状态估计的关键。实现准确的膳食估计仍然是一个具有挑战性的任务,全自动胰岛素输送系统。本文提出了一种对估计状态的校正机制,其中缺失的膳食由神经网络检测。此外,利用贝叶斯网络预测下一餐的时间概率。我们提出的随机模型预测控制器(SMPC)包含了预测的用餐场景。我们根据饮食模式的随机性来评估控制器的性能;结果表明,将最可能的用餐场景整合到SMPC决策中可以提高鲁棒性和性能。
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引用次数: 0
In-Silico Validation of Parameter Optimization Strategies for Automated Insulin Delivery Systems using the UVA Replay Simulation Technology 使用UVA重放模拟技术的自动化胰岛素输送系统参数优化策略的硅验证
Q3 Engineering Pub Date : 2025-01-01 DOI: 10.1016/j.ifacol.2025.06.022
María F. Villa-Tamayo (Ms) , Jacopo Pavan (PhD) , Marc Breton (PhD)
Automated insulin delivery (AID) systems have shown significant potential in managing type 1 diabetes (T1D), yet personalizing therapy parameters remains challenging. This study advances the optimization of AID therapy profiles through an updated decision support system (DSS) leveraging the University of Virginia Replay Simulator (UVA-RS). The DSS employs a personalized glucose-insulin dynamics model to simulate glucose response to therapy adjustments and an optimization algorithm to determine therapy parameters that improves overall glycemic control. We evaluated the system’s performance through three in-silico scenarios, focusing on recommendation reliability, constraint impact, robustness to metabolic and behavioral variability, and performance over five-month simulated use. Results indicate improved therapy personalization and glycemic control, supporting the potential for DSS to enhance AID system efficacy.
自动化胰岛素输送(AID)系统在治疗1型糖尿病(T1D)方面显示出巨大的潜力,但个性化治疗参数仍然具有挑战性。本研究通过利用弗吉尼亚大学重播模拟器(UVA-RS)的更新决策支持系统(DSS),推进了AID治疗方案的优化。DSS采用个性化的葡萄糖-胰岛素动力学模型来模拟葡萄糖对治疗调整的反应,并采用优化算法来确定改善整体血糖控制的治疗参数。我们通过三个计算机场景评估了系统的性能,重点关注推荐可靠性、约束影响、对代谢和行为可变性的鲁棒性以及五个月模拟使用的性能。结果表明,改善治疗个性化和血糖控制,支持DSS提高AID系统疗效的潜力。
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引用次数: 0
Personalized Meal Bolus Calculator for Type-1 Diabetes Accounting for Diurnal Effects 个性化膳食丸计算器1型糖尿病会计日影响
Q3 Engineering Pub Date : 2025-01-01 DOI: 10.1016/j.ifacol.2025.06.023
Dinesh Krishnamoorthy , Francis J. Doyle (III)
Type 1 diabetes management requires compensating carbohydrate intake with bolus insulin matched to the meal size. Recent clinical studies revealed diurnal variations in insulin sensitivity (SI) in patients with type 1 diabetes, where the insulin resistance varies over the day. Diurnal variations in insulin sensitivity requires different bolus insulin dose for the same meal size depending on the time of the meal. Standard bolus calculators that use patient-specific parameters such as insulin-carb-ratio (CR) and correction factors (CF), however do not account for such diurnal variations. To address this gap, this paper proposes a fully data-driven safe and personalized bolus calculator that explicitly accounts for the diurnal variations. The proposed algorithm safely learns the optimum bolus needs tailored to each patient without the need for any patient-specific parameters such as carb-ratio, correction factor, insulin sensitivity etc., nor any historical clinical data. The proposed algorithm is tested and verified on the 10-adult cohort of the FDA-accepted UVA/Padova T1DM simulator.
1型糖尿病的管理需要补偿碳水化合物的摄入与膳食量相匹配的胰岛素。最近的临床研究揭示了1型糖尿病患者胰岛素敏感性(SI)的日变化,其中胰岛素抵抗在一天中变化。胰岛素敏感性的日变化需要根据用餐时间,在相同的饭量下给予不同的胰岛素剂量。然而,使用胰岛素-碳水化合物比(CR)和校正因子(CF)等患者特定参数的标准剂量计算器不能考虑这种日变化。为了解决这一差距,本文提出了一个完全数据驱动的安全和个性化的剂量计算器,明确地说明了日变化。该算法不需要任何患者特定的参数,如碳水化合物比例、校正因子、胰岛素敏感性等,也不需要任何历史临床数据,即可安全地学习为每位患者量身定制的最佳剂量需求。该算法在fda认可的UVA/Padova T1DM模拟器的10名成人队列上进行了测试和验证。
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引用次数: 0
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