Abstract: In tuning a controller for a process in a feedback control system, a method is provided for bringing the system into asymmetric self-excited oscillations for measuring the frequency of the oscillations, average over the period value of the process output signal and average over the period control signal and tuning the controller in dependence of the measurements obtained. An element having a non-linear characteristic is introduced into the system in series with the process and set point signal is applied to excite asymmetric self-excited oscillations in the system. An algorithm and formulas are given for identification of the process model having the form of first order plus dead time transfer function. PI controller settings are given as a function of the dead time/time constant ratio. An apparatus for performing the method is disclosed.

Abstract: A method and apparatus for controlling a non-linear mill. A linear controller is provided having a linear gain k that is operable to receive inputs representing measured variables of the plant and predict on an output of the linear controller predicted control values for manipulatible variables that control the plant. A non-linear model of the plant is provided for storing a representation of the plant over a trained region of the operating input space and having a steady-state gain K associated therewith. The gain k of the linear model is adjusted with the gain K of the non-linear model in accordance with a predetermined relationship as the measured variables change the operating region of the input space at which the linear controller is predicting the values for the manipulatible variables. The predicted manipulatible variables are then output after the step of adjusting the gain k.

Abstract: A method and apparatus for automatically adjusting the gains of a feedback controller while the process continues to run and the controller continues to operate and control the process is disclosed. A desired closed-loop control bandwidth and a target loop transfer function are specified by the operator, and the tuning is accomplished automatically with minimal operator intervention and without the need for developing a model of the process. The automatic tuner subjects the process to one or more disturbance and the operation of both the process and the controller are monitored.

Abstract: A facility for selecting and refining electrical parameters for processing a microelectronic workpiece in a processing chamber is described. The facility initially configures the electrical parameters in accordance with either a numerical of the processing chamber or experimental data derived from operating the actual processing chamber. After a workpiece is processed with the initial parameter configuration, the results are measured and a sensitivity matrix based upon the numerical model of the processing chamber is used to select new parameters that correct for any deficiencies measured in the processing of the first workpiece. These parameters are then used in processing a second workpiece, which may be similarly measured, and the results used to further refine the parameters.

Abstract: An apparatus, system and process is provided for communicating safety-related data, over an open system, from a sender to a receiver. Safety-related components, including function blocks, flexible function blocks, resource blocks and transducer blocks, as well as, safety-related objects are provided. Also, an extended safety-related protocol provides for authenticating communications between safety-related components over an existing black channel, such as one using a fieldbus Architecture.

Abstract: A method for developing and using real time applications for a dynamic system having a sensing subsystem, actuation subsystem, a control subsystem, and an application subsystem utilizes stochastic compute time algorithms. After optimization functions, desired state and constraints are received and detector data has been provided from a sensor subsystem, a statistical optimization error description is generated. From this statistical optimization error description a strategy is developed, including the optimization errors, within the control subsystem. An execution module within the control subsystem then sends an execution strategy to various actuators within the actuation subsystem.

Abstract: An adaptive process controller drives a process variable to be substantially equivalent to a set point and adapts the controller gain, the controller reset, and/or the controller rate, based on model free adaptation. The adaptive controller combines a controller gain computed from an oscillation index with a controller gain computed from a steady state estimate and that adapts the controller reset/rate by forcing the ratio of two of the controller proportional, integral or derivative terms to be equal to a predetermined value.

Abstract: A method for controlling process parameters to achieve constant process conditions, including studying the actual data and reference data independent of time and applying them one on top of the other so that, in the case of optimum match, a 45° straight line is achieved or, in the case of non-match, one tries to achieve a 45° straight line by modifying the process parameters.

Abstract: The present invention includes a system and method for fine tuning the control of a manufacturing process. A material adjusting device is in communication with a PID controller and PID control loop, and is used to alter a flow of material used in the manufacturing process, so as to maintain a target physical property of the material at a setpoint. A measurement device captures measurements of the flow relevant to the physical property of interest. A change is introduced to the material adjusting device while the PID controller and PID control loop are disabled, and appropriate measurements of the flow are continually captured; a process that may be repeated several times. Once sufficient physical property measurement data has been captured, the data is loaded into an optimization program that outputs optimized controlled parameters that may be used by the PID controller and control loop to better control the physical property of the material.

Abstract: A system and method for controlling a mass flow controller to have a constant control loop gain under a variety of different types of fluids and operating conditions, and for configuring the mass flow controller for operation with a fluid and/or operating conditions different from that used during a production of the mass flow controller. Further, the system and method includes providing control by reducing the effects of hysteresis in solenoid actuated devices by providing a non-operational signal to the solenoid actuated device.

Abstract: A control system that constantly and accurately controls a control variable so that it remains within an allowable range is provided. The control system in accordance with the present invention estimates a steady-state deviation d in a controlled object as a steady-state deviation estimation value d? on the basis of a control variable y and a final desired value y2. A control variable y in a controlled object based on the initial desired value y1 is estimated as the primary estimation value y1? on the basis of at least the initial desired value y1 and the steady-state deviation estimation value d?. If a primary estimation value y1? is within an allowable range, then a final desired value y2 agreeing with an initial desired value y1 is determined, while, if the primary estimation value y1? is out of the allowable range, then the final desired value y2 is determined on the basis of at least a boundary value of the allowable range.

Abstract: A method includes processing a plurality of workpieces in accordance with an operating recipe. Metrology data associated with the processing is collected. A control model including at least one tuning parameter having a default value is provided. A plurality of perturbations is introduced to shift the tuning parameter from its default value. Control actions are generated based on the metrology data and the perturbations to the tuning parameter in the control model to modify the operating recipe. An error signal associated with each of the perturbations is generated. The default value of the tuning parameter is modified based on the error signals.

Abstract: A characteristic control device which is provided with a basic control module which determines the amount of control used to control the output of a control subject based on predetermined input data and control parameters which relate output to the control subject to the input data and which controls the characteristics of the control parameters, a characteristic storage mechanism for storing the basic control parameters, and a characteristic automatic modification mechanism which determines, in accordance with predetermined conditions, and automatically modifies, the control parameters which are applied to the basic control module based on the basic control parameters stored in the characteristic storage mechanism and the input data.

Abstract: A method and apparatus for tuning a feedforward compensation parameter in a motion control system is provided. According to one such embodiment, the method includes the acts of determining an initial value of a feedforward compensation parameter and commanding an initial movement of an actuator according to a test motion routine (wherein the initial value of the parameter is used in the control of the actuator). Error associated with the initial movement is determined. A potential value of the feedforward compensation parameter is determined. A movement of the actuator is commanded according to the test motion routine (wherein the potential value of the parameter is used in the control of the actuator) and error associated with the movement is determined. The errors associated with the movements are compared and, based on the act of comparing the errors, one of the values is selected as a current best value. In a further embodiment, such acts are repeated until the current best value is an optimum value.

Abstract: A two-wire field-mounted process device with multiple isolated channels includes a channel that can be an input channel or an output channel. The given input or output channel can couple to multiple sensors or actuators, respectively. The process device is wholly powered by the two-wire process control loop. The process device includes a controller adapted to measure one or more characteristics of sensors coupled to an input channel and to control actuators coupled to an output channel. The controller can be further adapted to execute a user generated control algorithm relating process input information with process output commands. The process device also includes a loop communicator that is adapted to communicate over the two-wire loop.

Abstract: A method for controlling a controlled process in response to an input signal and a disturbance signal includes modeling the controlled process in a process model; controlling the process model by a first controller; isolating the first controller from the disturbance signal so that the first controller may be designed for an optimal response to the input signal; driving the first controller by a first drive signal proportional to the difference between the input signal and a process model output signal; isolating a second controller from the input signal so that the second controller may be designed for an optimal response to the disturbance signal; and driving the second controller by a second drive signal proportional to difference between a process output signal and the process model output signal.

Abstract: A control apparatus includes a manipulated variable output unit, calculation unit, first lower limit setting unit, first upper limit setting unit, second lower limit setting unit, second upper limit setting unit, and controlling element. The manipulated variable output unit outputs first and second manipulated variables to an object to be controlled. The calculation unit calculates a limit cycle auto-tuning control parameter. The controlling element performs feedback control calculation based on the control parameter for the deviation between a set point and a controlled variable to calculate the first manipulated variable, and outputs the calculated first manipulated variable to the object.

Abstract: The present invention is directed to generate an adaptive value in a short time. An adaptive value generating program has an adaptive procedure control program and a DOE tool. The DOE tool is a general statistical processing tool. The adaptive value procedure generating program functions as an interface between a measuring apparatus and the DOE tool. In a data obtaining process, the adaptive value procedure generating program automatically determines a method of selecting a measurement point and passes the result to the DOE tool. Selection of an approximation function and selection of an optimization method are automated. Further, evaluation of a final approximation expression and determination of confirmation data are also automated.

Abstract: A method for developing and using real time applications for a dynamic system having a sensing subsystem, actuation subsystem, a control subsystem, and an application subsystem utilizes stochastic compute time algorithms. After optimization functions, desired state and constraints are received and detector data has been provided from a sensor subsystem, a statistical optimization error description is generated. From this statistical optimization error description a strategy is developed, including the optimization errors, within the control subsystem. An execution module within the control subsystem then sends an execution strategy to various actuators within the actuation subsystem.

Abstract: A pattern recognition adaptive controller configured to dynamically adjust proportional gain and integral time control parameters based upon patterns that characterize the closed-loop response. The pattern recognition adaptive controller receives a sampled signal representative of the controlled variable, and determines a smoothed signal based on the sampled signal. The controller determines an estimated noise level of the sampled signal and determines if the control output and process output are oscillating quickly based on predefined criteria. The controller adjusts the gain used by the controller if the control output and process output are oscillating quickly. If the control output and process are not oscillating quickly, the controller determines whether there has been a significant load disturbance, whether there is an insignificant pattern, and/or whether the control output is saturated.

Abstract: A method for evaluating whether a measurable disturbance on a process controlled by a feedback controller is suitable for feed-forward control. The disturbance is measured. The controller output signal due to the disturbance is measured. A first reference signal corresponding to the controller output signal is measured when responding to disturbance entering before the process. A second reference signal corresponding to the controller output signal is generated when responding to a disturbance entering after the process. It is estimated where in the process the disturbance enters by comparing the measured controller output signal due to the disturbance with the reference signals. It is evaluated whether the disturbance is suitable for feed-forward control depending on where in the process the disturbance enters.

Abstract: A method for tuning a PID controller includes the steps of inducing equivalent relationships between PID gains of the PID controller and parameters of time delay control (TDC), selecting a natural frequency vector and a damping ratio vector so as to acquire a desired error dynamics of the closed PID control loop system, selecting a sampling time of the closed PID control loop system, determining the parameters of TDC on the basis of the natural frequency vector, the damping ratio vector and a closed loop stability condition for TDC, and selecting PID gains of the PID controller on the basis of the equivalent relationships.

Abstract: A control apparatus which controls a controlled system with a transfer function regarded as a secondary delay, comprises an outer loop which performs negative feedback of an output of the controlled system in order to obtain a deviation between the output and a desired value, an inner loop which performs negative feedback of a signal obtained by multiplying a differential value of the output of the controlled system by a first gain to the deviation, and a nonlinear inner feedback loop which uses the differential value of the output of the controlled system and a product obtained by multiplying an absolute value of the deviation e or n-th (n is an integer) power of the absolute value by the second gain to perform positive feedback to the deviation.

Abstract: In one embodiment, a method and machine are provided for tuning compensation parameters in a motion control system associated with a mechanical member. The method includes the steps of receiving an indication of a compensation parameter to be tested, based on the compensation parameter to be tested causing a signal associated with a desired motion of the mechanical member to be commanded, acquiring control data associated with the signal, acquiring measurement data associated with actual motion of the mechanical member in response to the signal, analyzing the control and measurement data; and based on the step of analyzing the control and measurement data, implementing a value of the compensation parameter.

Abstract: A method of ascertaining control parameters for a control system having a controller and a plant includes establishing a model of the plant and a model of the controller and calculating a performance index for a closed-loop system as a function of controller parameters, accounting for selected stability margins.

Abstract: In a control method, the first controlled variable is made to coincide with a predetermined controlled variable set point. A relation variable representing the relationship between second controlled variables which are designated in advance from measured second controlled variables different from the first controlled variable so as to maintain a predetermined relationship is calculated. A control actuator is so controlled as to make the calculated relation variable coincide with a predetermined relation variable set point. The difference between the calculated relation variable and a relation variable set point corresponding to the calculated relation variable is calculated. The calculated difference is added to the measured first controlled variable. A manipulated variable is calculated by performing feedback control calculation so as to make the sum coincide with the controlled variable set point. The calculated manipulated variable is output to a corresponding control actuator.

Abstract: According to a feedback control method, the response process of set point tracking control is divided into three, tracking, convergence, and stabilization phases. The phase is switched to the tracking phase at set point change start time as the tracking phase start time. The manipulated variable which causes the controlled variable to tracking the set point is continuously output in the tracking phase. The phase is switched to the convergence phase at, as the convergence phase start time, specific set point tracking control elapsed time at which the controlled variable does not exceed the set point in the tracking phase. A manipulated variable which converges the controlled variable to the vicinity of the set point is continuously output in the convergence phase. The phase is switched to the stabilization phase at, as the stabilization phase start time, time at which the controlled variable reaches a preset situation in the convergence phase.

Abstract: In one embodiment, a method and machine are provided for tuning compensation parameters in a motion control system associated with a mechanical member. The method includes the steps of receiving an indication of a compensation parameter to be tested, based on the compensation parameter to be tested causing a signal associated with a desired motion of the mechanical member to be commanded, acquiring control data associated with the signal, acquiring measurement data associated with actual motion of the mechanical member in response to the signal, analyzing the control and measurement data; and based on the step of analyzing the control and measurement data, implementing a value of the compensation parameter.

Abstract: A method for predicting transient response of a closed loop apparatus includes the steps of: (a) providing a first reference tool that relates load-free impedance response with a first design gain-phase variable; (b) providing a second reference tool that relates load-free impedance response with a second design gain-phase variable; (c) determining a combined impedance response as a function of frequency; (d) employing at least one of the first and second reference tool to establish a first design value for one of the phase variable and the design load impedance at a characteristic frequency that occurs at a peak value of the combined impedance response; (e) employing at least one of the first and second reference tool to establish a second design value for the other parameter of the phase variable and the design load impedance at the characteristic frequency; (f) establishing a transient multiplier as a function of frequency associated with the output voltage with the design load impedance for selected value

Abstract: In one embodiment, a method of and apparatus for self-calibrating a motion control system is provided. The method includes the steps of receiving a test parameter, ensuring a reasonable test can be executed based on the test parameter, generating a part program based upon the test parameter, instructing a user of the motion control system regarding set up of a device capable of acquiring data associated with the test, and executing the test, wherein the part program is executed as part of the test.

Abstract: In one embodiment, a method of and apparatus for determining calibration options in a motion control system is provided. The method includes the steps of measuring error in a commanded motion, modeling the error, identifying sources of the error; and predicting a degree to which applying compensation for one of the sources of the error might affect the error.

Abstract: The system and method disclosed herein allow a user to retrieve data from various process control loops and organize that data in dynamic manner to allow for multiple types of data analysis. A user may associate individual process control loops into groups and analyze the data and impact of select process control loops in those groups. Since the associations of process control loops into groups can be done dynamically, the user is able to easily reconfigure groups (i.e. add or remove process control loops) and redo the analysis. Another feature is the storage of both the data retrieved and the results of the analysis so that comparisons can be performed and reports can be generated.

Abstract: A method and a system for controlling a force feedback member able to interact with another member, including a local model for calculating a set point addressed to the force feedback member from a plurality of variables, and a remote model for estimating interactions and variables of the other member, with updating on receiving data from another remote system, and resynchronizer means able to send a resynchronization message to the other system.

Abstract: An apparatus is provided for controlling a system to achieve a specified response. In one embodiment, the apparatus is a proportional, integrative, and derivative (PID) controller having a proportional element, an integrative element, and a derivative element coupled together. The elements respond to a reference signal and generate a control signal that causes a plant to generate a plant output. The proportional element has a gain element where the gain is a function of the ultimate gain of the plant (Ku) and the ultimate period of the plant (Tu). The controllers may also be embodied in non-PID controllers that share common elements, such as the use of: (a) Astrom-Hagglund controller output as an input for a subsequent controller; (b) internal feedback; and (c) a subsequent controller that performs a subtraction operation to generate the difference between the output of the Astrom-Hagglund controller and the output of the subsequent controller.

Abstract: Kiln/cooler control and upset recovery using a combination of model predictive control and expert systems. A method for controlling a non-linear process includes the steps of first providing a controller that is operable to receive inputs representing measured variables of the process and predicting on an output of the controller predicted control values for manipulatible variables that control the process. An expert system is provided that models the actions of an operator of the process over an operating region of the process that represents a set of rules for actions to be taken by an operator upon the occurrence of predetermined conditions in the operation of the process. The operation of the controller is overridden with the expert system when one of the predetermined conditions exists and taking the associated action by the expert system to control the operation of the process by changing one or more of the manipulatible variables.

Abstract: Various systems and methods permit a parameter associated with a system to be dynamically tuned to an optimal value. For instance, a method of operating the system with the parameter set at a current value, determining a performance of the system with the parameter at the current value, determining a performance of the system with the parameter at a second value, and comparing the performances.

Abstract: A method for compensating for torque ripple in pulse width modulated machines including providing damping for transient disturbances utilizing a fixed feedback controller and rejecting steady disturbances utilizing an adaptive controller.

Abstract: System and method for user configuration of an autotuning algorithm for a controller in a motion control system. A desired trajectory in one or more dimensions for the motion control system is received. Values of one or more gains for a controller are initialized. A response trajectory of the controller and motion control system in response to the desired trajectory is received, and an error determined between the response trajectory and the desired trajectory. A gain space is then experimentally searched to determine final values of the one or more gains for the controller that minimize the error (e.g., Euclidean norm) between the response trajectory and the desired trajectory, e.g., via simulated annealing, or other stochastic, quasi-random, and/or deterministic approaches. After experimentally searching, the controller is operable to control the motion control system substantially in accordance with the desired trajectory using the determined values of the one or more gains.

Abstract: A system and method for controlling a controlled parameter that affects a target parameter of a target zone is disclosed. The method comprises providing a feedback control loop having a switching controller, a controlled device, and an averaging device. The controlled device comprises a time constant and a specified operational characteristic. The controlled device comprises a first operational state and a second operational state. The method further comprises calculating a time constant for the averaging device based at least on the time constant for the controlled device, and the specified operational characteristic. The specified operational characteristic may comprises a minimum amount of time that the controlled device operates before it can be switched between the first operational state and the second operational state.

Abstract: A system and method for controlling a device such that device operates in a smooth manner. The system may switch between control architectures or vary gain coefficients used in a control loop to control the device. As the architecture or gains are switched, the control signal may be smoothed so that the device does not experience an abrupt change in the control signal it receives. In one embodiment, the control signal may be smoothed by adding a decaying offset value to the control signal to create a smoothed control signal that is applied to the device.

Abstract: A method and apparatus for controlling a non-linear mill. A linear controller is provided having a linear gain k that is operable to receive inputs representing measured variables of the plant and predict on an output of the linear controller predicted control values for manipulatible variables that control the plant. A non-linear model of the plant is provided for storing a representation of the plant over a trained region of the operating input space and having a steady-state gain K associated therewith. The gain k of the linear model is adjusted with the gain K of the non-linear model in accordance with a predetermined relationship as the measured variables change the operating region of the input space at which the linear controller is predicting the values for the manipulatible variables.

Abstract: An automatic gain adjustment device and method capable of accurately adjusting a gain with a simple structure. In an automatic gain adjustment method of a feedback control system that uses a phase difference between an output signal obtained from a controlled object and an input signal while controlling the object based on the input signal, a phase shift amount is set to cause a frequency of the input signal to coincide with the crossover frequency at which the open loop gain forming the feedback control system becomes 0 dB, and a phase of the input signal is shifted based on the phase shift amount.

Abstract: A method for tuning a PID controller includes the steps of inducing equivalent relationships between PID gains of the PID controller and parameters of time delay control (TDC), selecting a natural frequency vector and a damping ratio vector so as to acquire a desired error dynamics of the closed PID control loop system, selecting a sampling time of the closed PID control loop system, determining the parameters of TDC on the basis of the natural frequency vector, the damping ratio vector and a closed loop stability condition for TDC, and selecting PID gains of the PID controller on the basis of the equivalent relationships.

Abstract: The manipulated variable is calculated as a linear form of the command of fixed periods after and such data from fixed periods before, that are controlled variable until the present period, manipulated variable until the last period, and measurable disturbance until fixed periods after. The number/order of needed values is determined by order systemisation and is limited in small number. And coefficients are calculated solving propagator equation called COFRE under FT-determining. Using the deviation of estimation gap, changing of the system and the occurrence of not measurable disturbance are judged. When changing of the system is judged control parameters are tuned fast, and when the occurrence of not measurable disturbance are judged automatic tuning is stopped in order to avoid from that parameters are broken. The control period is also automatically optimised. The invented method is applicable for from the simple system to the complex system.

Abstract: A multivariable control method and system suitable for manipulating process variables based on observed changes in controlled objectives without extensive data analysis or involved model development. The method includes operating the process at an initial set of process variables and an initial set of controlled objectives, monitoring the set of process variables and the set of controlled objectives while continuously operating the process, adjusting one or more members of the set of process variables based upon a non-linear optimization with respect to a desired set of controlled objectives, and utilizing the monitored set of process variables and the monitored set of controlled objectives in the non-linear optimization.

Abstract: A method for predicting stability of a closed loop apparatus is disclosed. The closed loop apparatus has an open loop impedance and at least one inherent internal gain. The method comprises the steps of: (a) identifying an impedance scaling factor associated with the closed loop apparatus that may be expressed in terms including the open loop impedance, the at least one inherent internal gain, a gain variable and a phase variable; (b) vectorally establishing a first scaling value for the impedance scaling factor as a function of frequency while maintaining a first variable of the gain variable and the phase variable at a first working value to record the first scaling value for a plurality of frequencies.

Abstract: A control arithmetic device includes a subtracting section, disturbance application detecting section, error correction amount calculating section, error correction amount convergence calculating section, and control arithmetic section. The subtracting section calculates the error of a controlled variable on the basis of a controlled variable and set point for a controlled system. The disturbance application detecting section detects, in control cycles, on the basis of the error output whether a disturbance is applied. The error correction amount calculating section calculates an error correction amount on the basis of the magnitude of the error when application of a disturbance is detected. The error correction amount convergence calculating section performs a convergence operation. A control arithmetic method is also presented.

Abstract: A predictive and self-tuning PI controller includes an apparatus for variably assigning gains thereto in accordance with specified time functions following a change in set-point. The control gains are computed in accordance with a plurality of input parameters and subsequently continuously adjusted to set-point errors based on a GPC approach thereby to optimize performance indices derived from simple and classical user specifications. Variation and tuning of control gains in accordance with set-point errors permits the PI controller to be useful in the general area of process control and applicable to a wider range of processes compared to traditional PI control, including time-delay processes, unstable processes and processes with time-varying dynamics.

Abstract: A method for providing independent static and dynamic models in a prediction, control and optimization environment utilizes an independent static model (20) and an independent dynamic model (22). The static model (20) is a rigorous predictive model that is trained over a wide range of data, whereas the dynamic model (22) is trained over a narrow range of data. The gain K of the static model (20) is utilized to scale the gain k of the dynamic model (22). The forced dynamic portion of the model (22) referred to as the bi variables are scaled by the ratio of the gains K and k. The bi have a direct effect on the gain of a dynamic model (22). This is facilitated by a coefficient modification block (40). Thereafter, the difference between the new value input to the static model (20) and the prior steady-state value is utilized as an input to the dynamic model (22). The predicted dynamic output is then summed with the previous steady-state value to provide a predicted value Y.

Abstract: A method and apparatus for controlling a non-linear mill. A linear controller is provided having a linear gain k that is operable to receive inputs representing measured variables of the plant and predict on an output of the linear controller predicted control values for manipulatible variables that control the plant. A non-linear model of the plant is provided for storing a representation of the plant over a trained region of the operating input space and having a steady-state gain K associated therewith. The gain k of the linear model is adjusted with the gain K of the non-linear model in accordance with a predetermined relationship as the measured variables change the operating region of the input space at which the linear controller is predicting the values for the manipulatible variables.