Pub Date : 2026-02-01Epub Date: 2026-01-06DOI: 10.1016/j.jprocont.2025.103611
Yun Li , Neil Yorke-Smith , Tamas Keviczky
Constructing uncertainty sets as unions of multiple subsets has emerged as an effective approach for creating compact and flexible uncertainty representations in data-driven robust optimization (RO). This paper focuses on two separate research questions. The first concerns the computational challenge in applying these uncertainty sets in RO-based predictive control. To address this, a monolithic mixed-integer representation of the uncertainty set is proposed to uniformly describe the union of multiple subsets, enabling the computation of the worst-case uncertainty scenario across all subsets within a single mixed-integer linear programming (MILP) problem. The second research question focuses on mitigating the conservatism of conventional RO formulations by leveraging the structure of the uncertainty set. To achieve this, a novel objective function is proposed to exploit the uncertainty set structure and integrate the existing RO and distributionally robust optimization (DRO) formulations, yielding less conservative solutions than conventional RO formulations, while avoiding the high-dimensional continuous uncertainty distributions and the high computational burden typically associated with existing DRO formulations. Given the proposed formulations, numerically efficient computation methods based on column-and-constraint generation (CCG) are also developed. Extensive simulations across three case studies are performed to demonstrate the effectiveness of the proposed schemes.
{"title":"On data-driven robust optimization with multiple uncertainty subsets: Unified uncertainty set representation and mitigating conservatism","authors":"Yun Li , Neil Yorke-Smith , Tamas Keviczky","doi":"10.1016/j.jprocont.2025.103611","DOIUrl":"10.1016/j.jprocont.2025.103611","url":null,"abstract":"<div><div>Constructing uncertainty sets as unions of multiple subsets has emerged as an effective approach for creating compact and flexible uncertainty representations in data-driven robust optimization (RO). This paper focuses on two separate research questions. The first concerns the computational challenge in applying these uncertainty sets in RO-based predictive control. To address this, a monolithic mixed-integer representation of the uncertainty set is proposed to uniformly describe the union of multiple subsets, enabling the computation of the worst-case uncertainty scenario across all subsets within a single mixed-integer linear programming (MILP) problem. The second research question focuses on mitigating the conservatism of conventional RO formulations by leveraging the structure of the uncertainty set. To achieve this, a novel objective function is proposed to exploit the uncertainty set structure and integrate the existing RO and distributionally robust optimization (DRO) formulations, yielding less conservative solutions than conventional RO formulations, while avoiding the high-dimensional continuous uncertainty distributions and the high computational burden typically associated with existing DRO formulations. Given the proposed formulations, numerically efficient computation methods based on <em>column-and-constraint generation</em> (CCG) are also developed. Extensive simulations across three case studies are performed to demonstrate the effectiveness of the proposed schemes.</div></div>","PeriodicalId":50079,"journal":{"name":"Journal of Process Control","volume":"158 ","pages":"Article 103611"},"PeriodicalIF":3.9,"publicationDate":"2026-02-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145928383","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"计算机科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2026-02-01Epub Date: 2026-01-13DOI: 10.1016/j.jprocont.2026.103627
Shuai Tan , Shuxuan Zeng , Jijie Han , Qingchao Jiang , Weimin Zhong , Jiayi Wang
Multi-source domain adaptation poses more complex challenges compared to traditional single source domain adaptation. While constrained target domain labeling and limited information from a single source can be mitigated, the inherent discrepancies among multiple domains exacerbate the difficulty of fault diagnosis under varying operating conditions, particularly in real industrial systems with diverse and intricate environments. To tackle these issues, a novel Multi-source Inter-domain Feature Discrepancy (MIFD) model is proposed in this paper, which differs from existing multi-source adaptation methods by explicitly modeling inter-domain feature discrepancies instead of solely enforcing a unified shared feature space through global or marginal distribution alignment. In the proposed framework, a three-scale alignment mechanism is introduced to jointly align feature representations, class semantics, and domain distributions, thereby constraining domain shifts at multiple semantic levels while preserving domain-pair-specific characteristics. A discrepancy-aware feature matching module is developed to enable the extraction of reliable and transferable features tailored to specific source–target domain pairs. Furthermore, a class-center and domain alignment strategy is designed to constrain conditional distributions and alleviate pseudo-label bias. In addition, a dual-level weighting scheme is proposed, by which domain contributions are adaptively quantified and irrelevant classes are automatically filtered. Experimental results on two benchmark fault diagnosis scenarios under partial label space settings demonstrate that the proposed MIFD model outperforms state-of-the-art multi-source domain adaptation methods by up to 5.13% on the CWRU dataset and achieves an improvement of 2.16% on the TEP dataset, effectively reducing negative transfer and domain conflicts while enhancing diagnostic robustness under label space inconsistency.
{"title":"An inter-domain feature discrepancy method for multi-source partial domain fault diagnosis","authors":"Shuai Tan , Shuxuan Zeng , Jijie Han , Qingchao Jiang , Weimin Zhong , Jiayi Wang","doi":"10.1016/j.jprocont.2026.103627","DOIUrl":"10.1016/j.jprocont.2026.103627","url":null,"abstract":"<div><div>Multi-source domain adaptation poses more complex challenges compared to traditional single source domain adaptation. While constrained target domain labeling and limited information from a single source can be mitigated, the inherent discrepancies among multiple domains exacerbate the difficulty of fault diagnosis under varying operating conditions, particularly in real industrial systems with diverse and intricate environments. To tackle these issues, a novel Multi-source Inter-domain Feature Discrepancy (MIFD) model is proposed in this paper, which differs from existing multi-source adaptation methods by explicitly modeling inter-domain feature discrepancies instead of solely enforcing a unified shared feature space through global or marginal distribution alignment. In the proposed framework, a three-scale alignment mechanism is introduced to jointly align feature representations, class semantics, and domain distributions, thereby constraining domain shifts at multiple semantic levels while preserving domain-pair-specific characteristics. A discrepancy-aware feature matching module is developed to enable the extraction of reliable and transferable features tailored to specific source–target domain pairs. Furthermore, a class-center and domain alignment strategy is designed to constrain conditional distributions and alleviate pseudo-label bias. In addition, a dual-level weighting scheme is proposed, by which domain contributions are adaptively quantified and irrelevant classes are automatically filtered. Experimental results on two benchmark fault diagnosis scenarios under partial label space settings demonstrate that the proposed MIFD model outperforms state-of-the-art multi-source domain adaptation methods by up to 5.13% on the CWRU dataset and achieves an improvement of 2.16% on the TEP dataset, effectively reducing negative transfer and domain conflicts while enhancing diagnostic robustness under label space inconsistency.</div></div>","PeriodicalId":50079,"journal":{"name":"Journal of Process Control","volume":"158 ","pages":"Article 103627"},"PeriodicalIF":3.9,"publicationDate":"2026-02-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145979668","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"计算机科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
This paper presents a novel control framework that integrates Physics-Informed Neural Networks (PINNs) with Model Predictive Control (MPC) for nonlinear dynamical systems. Unlike traditional MPC, which requires solving optimization problems in real time, the proposed method trains a single feedforward neural network to serve as an explicit controller that directly maps the current state, set-point, and disturbance signals to optimal control actions. The network is trained using a composite loss function that enforces the governing differential equations while incorporating control-oriented objectives such as set-point tracking, control smoothness, and soft constraints on states, inputs, and outputs. The proposed controller is validated on both single-input single-output (SISO) and multi-input multi-output (MIMO) water-tank benchmark systems, demonstrating accurate set-point tracking, effective measured disturbance rejection, and strong generalization across thousands of randomized test scenarios. A runtime comparison with a nonlinear MPC performing online optimization confirms that the explicit PINN-MPC approach achieves comparable control performance while requiring several orders of magnitude less computation time. These results highlight the scalability and computational efficiency of the proposed framework, positioning it as a novel paradigm for real-time control of nonlinear systems.
{"title":"An explicit model predictive control framework based on physics-informed neural networks","authors":"Argyri Kardamaki , Teo Protoulis , Alex Alexandridis , Haralambos Sarimveis","doi":"10.1016/j.jprocont.2026.103634","DOIUrl":"10.1016/j.jprocont.2026.103634","url":null,"abstract":"<div><div>This paper presents a novel control framework that integrates Physics-Informed Neural Networks (PINNs) with Model Predictive Control (MPC) for nonlinear dynamical systems. Unlike traditional MPC, which requires solving optimization problems in real time, the proposed method trains a single feedforward neural network to serve as an explicit controller that directly maps the current state, set-point, and disturbance signals to optimal control actions. The network is trained using a composite loss function that enforces the governing differential equations while incorporating control-oriented objectives such as set-point tracking, control smoothness, and soft constraints on states, inputs, and outputs. The proposed controller is validated on both single-input single-output (SISO) and multi-input multi-output (MIMO) water-tank benchmark systems, demonstrating accurate set-point tracking, effective measured disturbance rejection, and strong generalization across thousands of randomized test scenarios. A runtime comparison with a nonlinear MPC performing online optimization confirms that the explicit PINN-MPC approach achieves comparable control performance while requiring several orders of magnitude less computation time. These results highlight the scalability and computational efficiency of the proposed framework, positioning it as a novel paradigm for real-time control of nonlinear systems.</div></div>","PeriodicalId":50079,"journal":{"name":"Journal of Process Control","volume":"158 ","pages":"Article 103634"},"PeriodicalIF":3.9,"publicationDate":"2026-02-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146038429","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"计算机科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2026-02-01Epub Date: 2026-01-16DOI: 10.1016/j.jprocont.2026.103628
Vikram Singh, Somesh Kumar Sharma
Maintaining quality in the manufacturing system has become a critical challenge in today’s rapidly evolving technological landscape. To overcome this, current research examines the role of Multi-Agent Technology (MAT) in improving the quality of manufacturing processes. For this, a conceptual framework consisting of eight factors and thirty-seven variables of MAT, identified from the literature, was analyzed using the Analytical Hierarchical Process (AHP), Sensitivity Analysis, Decision-Making Trial and Evaluation Laboratory (DEMATEL), and Technique for Order Preference by Similarity to Ideal Solution (TOPSIS). AHP findings revealed ‘Production Planning’ as the highest-priority factor, followed by ‘Process Monitoring, Control, and Data Acquisition.’ DEMATEL established the interrelationships among variables, ensuring a collaborative approach to maintaining quality. Sensitivity analysis and TOPSIS validated the AHP results for consistency and robustness. The findings also indicated that Virtual Manufacturing, Distributed Digital Manufacturing, and Adaptive Agent-Based Architecture were the globally top ranked variables in the framework that help to ensure the quality of manufacturing processes. These findings contribute to developing autonomous, high-precision manufacturing systems for long-term competitiveness and quality assurance. This study provides valuable insights for researchers and managers, demonstrating that MAT and its parameters can be customized to optimize manufacturing quality.
{"title":"Understanding the role of multi-agent technology on quality of manufacturing organizations: A hybrid MCDM analysis","authors":"Vikram Singh, Somesh Kumar Sharma","doi":"10.1016/j.jprocont.2026.103628","DOIUrl":"10.1016/j.jprocont.2026.103628","url":null,"abstract":"<div><div>Maintaining quality in the manufacturing system has become a critical challenge in today’s rapidly evolving technological landscape. To overcome this, current research examines the role of Multi-Agent Technology (MAT) in improving the quality of manufacturing processes. For this, a conceptual framework consisting of eight factors and thirty-seven variables of MAT, identified from the literature, was analyzed using the Analytical Hierarchical Process (AHP), Sensitivity Analysis, Decision-Making Trial and Evaluation Laboratory (DEMATEL), and Technique for Order Preference by Similarity to Ideal Solution (TOPSIS). AHP findings revealed ‘Production Planning’ as the highest-priority factor, followed by ‘Process Monitoring, Control, and Data Acquisition.’ DEMATEL established the interrelationships among variables, ensuring a collaborative approach to maintaining quality. Sensitivity analysis and TOPSIS validated the AHP results for consistency and robustness. The findings also indicated that <em>Virtual Manufacturing, Distributed Digital Manufacturing,</em> and <em>Adaptive Agent-Based Architecture</em> were the globally top ranked variables in the framework that help to ensure the quality of manufacturing processes. These findings contribute to developing autonomous, high-precision manufacturing systems for long-term competitiveness and quality assurance. This study provides valuable insights for researchers and managers, demonstrating that MAT and its parameters can be customized to optimize manufacturing quality.</div></div>","PeriodicalId":50079,"journal":{"name":"Journal of Process Control","volume":"158 ","pages":"Article 103628"},"PeriodicalIF":3.9,"publicationDate":"2026-02-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145979669","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"计算机科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2026-01-01Epub Date: 2025-12-24DOI: 10.1016/j.jprocont.2025.103613
Hui Zhang , Wangyan Li , Jie Bao , Fei Liu
This paper investigates distributed set-membership estimation (DSME) for Markov linear jump systems (MJLSs) with uncertain transition probabilities. To effectively leverage the information of mode probability within the framework of DSME, the MJLS is transformed into a parameter uncertainty system for each mode by using the indicator function method. An outer bounding ellipsoid method is developed to cover the union, transforming the multiplicative uncertainties from transition probability uncertainties and the state estimation set (SES) into additive ellipsoids. A novel consensus-based distributed set-membership estimator is proposed, incorporating the mode and node information. Furthermore, a sufficient condition for the existence of the SES is developed. The SES for each mode is optimized by minimizing the trace of the shape matrix, from which the overall SES is derived (as their Minkowski sum). A wastewater treatment process example is presented to illustrate the effectiveness of the proposed method.
{"title":"Distributed set-membership estimation for Markov jump linear systems with uncertain transition probabilities","authors":"Hui Zhang , Wangyan Li , Jie Bao , Fei Liu","doi":"10.1016/j.jprocont.2025.103613","DOIUrl":"10.1016/j.jprocont.2025.103613","url":null,"abstract":"<div><div>This paper investigates distributed set-membership estimation (DSME) for Markov linear jump systems (MJLSs) with uncertain transition probabilities. To effectively leverage the information of mode probability within the framework of DSME, the MJLS is transformed into a parameter uncertainty system for each mode by using the indicator function method. An outer bounding ellipsoid method is developed to cover the union, transforming the multiplicative uncertainties from transition probability uncertainties and the state estimation set (SES) into additive ellipsoids. A novel consensus-based distributed set-membership estimator is proposed, incorporating the mode and node information. Furthermore, a sufficient condition for the existence of the SES is developed. The SES for each mode is optimized by minimizing the trace of the shape matrix, from which the overall SES is derived (as their Minkowski sum). A wastewater treatment process example is presented to illustrate the effectiveness of the proposed method.</div></div>","PeriodicalId":50079,"journal":{"name":"Journal of Process Control","volume":"157 ","pages":"Article 103613"},"PeriodicalIF":3.9,"publicationDate":"2026-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145840900","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"计算机科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2026-01-01Epub Date: 2025-12-11DOI: 10.1016/j.jprocont.2025.103595
Rafael D. de Oliveira, Johannes Jäschke
Dynamic Flux Balance Analysis (dFBA) models are powerful metabolic models that have a large potential for application in bioprocess control and optimisation. However, dFBA has an embedded linear FBA optimisation problem with degenerate solutions that give rise to multiple possible state trajectories that all satisfy the model. To address this uncertainty, we propose using a robust control approach based on Multi-stage Economic Nonlinear Model Predictive Control, which allows handling the degenerate solutions of the FBA problem without being too conservative. We propose to add a regularisation term to the FBA problem, to ensure a unique solution and generate the uncertainty scenarios by varying the regularization weights. The scenarios generated in that way then correspond to different solutions of the FBA problem. Then, the KKT conditions of the regularised FBA problem are imposed as equality constraints on the optimal control problem, which is solved using a direct collocation approach. Our methodology is evaluated through a case study on the optimal control of a fed-batch bioreactor for Escherichia coli growth, subject to a constraint on acetate concentration. The results demonstrate that the proposed MS-ENMPC approach, combined with the dFBA model, effectively satisfies the constraints despite uncertainties in the system trajectories.
{"title":"Multi-stage Economic Nonlinear Model Predictive Control of bioreactors using dynamic flux balance analysis models","authors":"Rafael D. de Oliveira, Johannes Jäschke","doi":"10.1016/j.jprocont.2025.103595","DOIUrl":"10.1016/j.jprocont.2025.103595","url":null,"abstract":"<div><div>Dynamic Flux Balance Analysis (dFBA) models are powerful metabolic models that have a large potential for application in bioprocess control and optimisation. However, dFBA has an embedded linear FBA optimisation problem with degenerate solutions that give rise to multiple possible state trajectories that all satisfy the model. To address this uncertainty, we propose using a robust control approach based on Multi-stage Economic Nonlinear Model Predictive Control, which allows handling the degenerate solutions of the FBA problem without being too conservative. We propose to add a regularisation term to the FBA problem, to ensure a unique solution and generate the uncertainty scenarios by varying the regularization weights. The scenarios generated in that way then correspond to different solutions of the FBA problem. Then, the KKT conditions of the regularised FBA problem are imposed as equality constraints on the optimal control problem, which is solved using a direct collocation approach. Our methodology is evaluated through a case study on the optimal control of a fed-batch bioreactor for <em>Escherichia coli</em> growth, subject to a constraint on acetate concentration. The results demonstrate that the proposed MS-ENMPC approach, combined with the dFBA model, effectively satisfies the constraints despite uncertainties in the system trajectories.</div></div>","PeriodicalId":50079,"journal":{"name":"Journal of Process Control","volume":"157 ","pages":"Article 103595"},"PeriodicalIF":3.9,"publicationDate":"2026-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145737899","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"计算机科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2026-01-01Epub Date: 2025-12-01DOI: 10.1016/j.jprocont.2025.103592
Chonggao Hu , Ridong Zhang , Furong Gao
Traditional two-dimensional (2D) model predictive model iterative learning control strategies can only rely on feedback to passively deal with time delays, repetitive disturbances, and non-repetitive disturbances of batch processes. To address these shortcomings, this paper proposes a two-dimensional model predictive iterative learning control strategy using an improved state space model structure with new error compensation (2D-EC-MPILC). Firstly, a two-dimensional extended non-minimal state space (2D-ENMSS) model is established, which can provide more degrees of freedom for controller design. Secondly, a novel error compensation (EC) strategy is proposed to correct the tracking error value of the current batch. The novel 2D-EC-MPILC controller is designed with both additional tuning degrees and batch-wise error correction, ensuring an improved control performance. The proposed algorithm is tested on the holding pressure control system of an injection molding process and the temperature control system of a nonlinear batch reactor.
{"title":"New design of two-dimensional model predictive iterative learning control with novel error compensation for batch processes","authors":"Chonggao Hu , Ridong Zhang , Furong Gao","doi":"10.1016/j.jprocont.2025.103592","DOIUrl":"10.1016/j.jprocont.2025.103592","url":null,"abstract":"<div><div>Traditional two-dimensional (2D) model predictive model iterative learning control strategies can only rely on feedback to passively deal with time delays, repetitive disturbances, and non-repetitive disturbances of batch processes. To address these shortcomings, this paper proposes a two-dimensional model predictive iterative learning control strategy using an improved state space model structure with new error compensation (2D-EC-MPILC). Firstly, a two-dimensional extended non-minimal state space (2D-ENMSS) model is established, which can provide more degrees of freedom for controller design. Secondly, a novel error compensation (EC) strategy is proposed to correct the tracking error value of the current batch. The novel 2D-EC-MPILC controller is designed with both additional tuning degrees and batch-wise error correction, ensuring an improved control performance. The proposed algorithm is tested on the holding pressure control system of an injection molding process and the temperature control system of a nonlinear batch reactor.</div></div>","PeriodicalId":50079,"journal":{"name":"Journal of Process Control","volume":"157 ","pages":"Article 103592"},"PeriodicalIF":3.9,"publicationDate":"2026-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145646040","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"计算机科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2026-01-01Epub Date: 2025-12-13DOI: 10.1016/j.jprocont.2025.103607
Lukas Munser , Ángeles Hoyo , Felix Petzke , Jaime A. Moreno , Stefan Streif
The detection and isolation of various faults in controlled environment agriculture is a notoriously complicated task, since various biological, sensory, and mechanical phenomena may interact with each other. In the present work, a residual-based approach is presented which enables the detection, isolation and quantification of different types of faults. For this purpose, observers are designed that can approximate the residuals despite model inaccuracies and measurement noise. The approach is demonstrated through experiments in a small-scale vertical farming unit whereby it is possible to distinguish between different fault types during operation.
{"title":"Residual-based fault detection and isolation in control environment agriculture","authors":"Lukas Munser , Ángeles Hoyo , Felix Petzke , Jaime A. Moreno , Stefan Streif","doi":"10.1016/j.jprocont.2025.103607","DOIUrl":"10.1016/j.jprocont.2025.103607","url":null,"abstract":"<div><div>The detection and isolation of various faults in controlled environment agriculture is a notoriously complicated task, since various biological, sensory, and mechanical phenomena may interact with each other. In the present work, a residual-based approach is presented which enables the detection, isolation and quantification of different types of faults. For this purpose, observers are designed that can approximate the residuals despite model inaccuracies and measurement noise. The approach is demonstrated through experiments in a small-scale vertical farming unit whereby it is possible to distinguish between different fault types during operation.</div></div>","PeriodicalId":50079,"journal":{"name":"Journal of Process Control","volume":"157 ","pages":"Article 103607"},"PeriodicalIF":3.9,"publicationDate":"2026-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145749776","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"计算机科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2026-01-01Epub Date: 2025-12-19DOI: 10.1016/j.jprocont.2025.103610
Ritu Ranjan, Costas Kravaris
Sensors are ubiquitous in modern industrial systems, and are prone to faults due to harsh condition in which they are placed. Sensor faults can impact the product quality and operational safety as control loops heavily depends on the accuracy of sensor measurement feedback. In this paper, we propose active sensor-fault tolerant control (FTC) strategies that can take proactive measures during faults involving timely correction of faulty measurements, ensuring the system remains within predefined safety and quality constraints. The concept of maximal output admissible set is leveraged to determine acceptable operating set (AOS) which is the set of initial process states that meet safety and quality constraints at all times. To support decision-making, we introduce a novel critical fault function (CFF) that quantifies the fault size and time available before the system exits the AOS if no corrective action is taken. While the AOS and CFF are computed offline, the CFF is implemented online with real-time fault estimates to trigger measurement correction in time. A linear functional observer and a nonlinear state observer, combined with a predictive scheme is proposed to estimate fault size and enhance robustness during transient phase of observers. Alternatively, a bank of state observers is used for fault detection and isolation and subsequently the state observer estimator based on healthy sensors are utilized for state feedback in control loops. The proposed sensor FTC strategy is tested on an exothermic Continuous Stirred Tank Reactor (CSTR) as a case study. The results demonstrate the strategy's effectiveness in handling sensor faults, ensuring both quality and safety constraints are met. Thus, this paper contributes to the advancement of practical active sensor FTC ensuring the resilience of industrial systems.
{"title":"Observer-based diagnosis and predictive framework for sensor-fault tolerant control of process systems","authors":"Ritu Ranjan, Costas Kravaris","doi":"10.1016/j.jprocont.2025.103610","DOIUrl":"10.1016/j.jprocont.2025.103610","url":null,"abstract":"<div><div>Sensors are ubiquitous in modern industrial systems, and are prone to faults due to harsh condition in which they are placed. Sensor faults can impact the product quality and operational safety as control loops heavily depends on the accuracy of sensor measurement feedback. In this paper, we propose active sensor-fault tolerant control (FTC) strategies that can take proactive measures during faults involving timely correction of faulty measurements, ensuring the system remains within predefined safety and quality constraints. The concept of maximal output admissible set is leveraged to determine acceptable operating set (AOS) which is the set of initial process states that meet safety and quality constraints at all times. To support decision-making, we introduce a novel critical fault function (CFF) that quantifies the fault size and time available before the system exits the AOS if no corrective action is taken. While the AOS and CFF are computed offline, the CFF is implemented online with real-time fault estimates to trigger measurement correction in time. A linear functional observer and a nonlinear state observer, combined with a predictive scheme is proposed to estimate fault size and enhance robustness during transient phase of observers. Alternatively, a bank of state observers is used for fault detection and isolation and subsequently the state observer estimator based on healthy sensors are utilized for state feedback in control loops. The proposed sensor FTC strategy is tested on an exothermic Continuous Stirred Tank Reactor (CSTR) as a case study. The results demonstrate the strategy's effectiveness in handling sensor faults, ensuring both quality and safety constraints are met. Thus, this paper contributes to the advancement of practical active sensor FTC ensuring the resilience of industrial systems.</div></div>","PeriodicalId":50079,"journal":{"name":"Journal of Process Control","volume":"157 ","pages":"Article 103610"},"PeriodicalIF":3.9,"publicationDate":"2026-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145797808","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"计算机科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2026-01-01Epub Date: 2025-12-05DOI: 10.1016/j.jprocont.2025.103604
Yanxin Zhang, Shaoyuan Li
The dynamic evolution of suspended sediment plume for deep-sea mining poses significant challenges for long-term prediction, owing to its inherently nonlinear transport behavior, unknown key parameters, and changing monitoring conditions after mining. To address these issues, this study proposes a framework integrating prediction, sensing, and refinement. Specifically, an incremental Physics-Informed Neural Network (PINN) enhanced with the Learning without Forgetting (LwF) strategy is developed to enable adaptive parameter updates while preserving prior physical knowledge. Furthermore, the sensor layout is optimized to enhance local observability. Numerical results demonstrate that, compared with the traditional PINN model, the proposed method effectively reduces prediction errors by 18.6% and achieves accurate prediction of the dynamic suspended sediment plume.
{"title":"An incremental physics-informed neural network for rapid prediction of suspended sediment plume for deep-sea mining","authors":"Yanxin Zhang, Shaoyuan Li","doi":"10.1016/j.jprocont.2025.103604","DOIUrl":"10.1016/j.jprocont.2025.103604","url":null,"abstract":"<div><div>The dynamic evolution of suspended sediment plume for deep-sea mining poses significant challenges for long-term prediction, owing to its inherently nonlinear transport behavior, unknown key parameters, and changing monitoring conditions after mining. To address these issues, this study proposes a framework integrating prediction, sensing, and refinement. Specifically, an incremental Physics-Informed Neural Network (PINN) enhanced with the Learning without Forgetting (LwF) strategy is developed to enable adaptive parameter updates while preserving prior physical knowledge. Furthermore, the sensor layout is optimized to enhance local observability. Numerical results demonstrate that, compared with the traditional PINN model, the proposed method effectively reduces prediction errors by 18.6% and achieves accurate prediction of the dynamic suspended sediment plume.</div></div>","PeriodicalId":50079,"journal":{"name":"Journal of Process Control","volume":"157 ","pages":"Article 103604"},"PeriodicalIF":3.9,"publicationDate":"2026-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145694511","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"计算机科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}