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Control of Unstable Bioreactor Using Fuzzy Tuned PI Controller
Control of Unstable Bioreactor Using Fuzzy Tuned PI Controller
Control of Unstable Bioreactor Using Fuzzy Tuned PI Controller
B. Satishkumar, M. Chidambaram
Department of Chemical Engineering,
Indian Institute of Technology, Chennai, India
Correspondence to: M. Chidambaram
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1
Introduction
Bioreactors have a non-linear behaviour and exhibit output multiplicity for certain parameter values [1, 2]. Some
of the steady states may also be unstable such that, even a
small perturbation in the process conditions will make the
system to move away from the steady state. Usually it is
desired to operate the bioreactor at the unstable steady
state [2] and hence a feedback controller is required to
operate it in the unstable steady state. Conventional PI
controllers do not give satisfactory response for non-linear
processes like bioreactor because of the change in process
gain and time constant with the operating conditions.
Further, there is a signicant delay in the output measurement [1] which deteriorates the performance of the
closed loop system. So, a controller tuned at one operating
condition may even destabilise the system for other operating conditions. A review of the work done on control
of bioreactors is given by Agrawal and Lim [1] and
Shimizu [3]. Chen and Chang [4] have analysed the difculties in controlling the unstable bioreactor using a proportional controller.
Controller design for open loop unstable system is more
difcult than for stable systems. Some common performance specications for stable systems may be impossible
to achieve for unstable systems. De Paor and O'Malley [5]
have proposed a Ziegler-Nichols type formulae for tuning
P/PI/PID controllers for unstable rst order plus time
delay systems. Chidambaram [6] has given a review of the
work done in control of unstable systems.
As the operating conditions change, the PI/PID controller with xed settings may not maintain a satisfactory
response. Frequent tuning of the controller settings is done
by the operator based on his experience to get a good
response. Hence, it is desirable to translate the operators
experience into an automatic scheme. The fuzzy logic
developed by Zadeh [7] can be used for this. Reported
works on fuzzy self tuning of conventional controllers
show a good improvement in process response for stable
systems [812].
In this paper, a rule based fuzzy logic tuner is developed
for tuning a conventional PI controller for controlling an
unstable bioreactor. The fuzzy tuner is implemented to
improve the response of the PI controller. The perfor-
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mance of this tuning scheme is evaluated by simulation of The performances of the closed loop system are evaluated
the non-linear model equations of the bioreactor.
by simulating the non-linear model equations with the
controller parameters given above. The system being initially in the stable steady state 3 (X 1:5301; S 0:1746)
2
is forced to move to the unstable steady state 2
PI Controller design
(X 0:9951; S 1:5122). The response shows a large
The model equations of a continuous bioreactor exhibiting
overshoot and it takes long time to settle as shown in
substrate inhibition, proposed by Agrawal and Lim [1] is
Fig. 1. The response of the system for a 30% step change in
used for simulation studies. For some operating paramethe set point of cell mass concentration X is shown in
ters the system exhibits output multiplicity. The model
Fig. 2. The PI controller response is much oscillatory.
equations are given as:
Since there are uncertainties in the kinetics of bioreactor,
dX=dt l DX ;
1 the robustness of the PI controller is studied for uncertainties in measurement delay and the cell mass yield c.
dS=dt Sf SD lX=c ;
2 For a 20% uncertainty in measurement delay L, the PI
controller with the settings as given by (8) is unable to
where:
stabilise the system for a 30% step change in set point
l lm S=km S kI S2 :
3 from X 0:9951. The system exhibits continuous oscillaIt is desirable to control the cell mass concentration X of tions as given by Jacob and Chidambaram [13] and is
shown in Fig. 3. For a 25% uncertainty in the yield factor c
the reactor by manipulating the dilution rate D. Feed
substrate concentration Sf is considered as disturbance. the system shows a highly oscillatory behaviour and it
This control structure is termed to be turbidostat [1]. The takes a long time to settle. The response for this case is
shown in Fig. 4. Simulation is carried out for a load change
system parameters are given by:
in feed substrate concentration Sf by 30% of the steady
c 0:4 g=g; Sf 4% g=l; lm 0:53 l=h;
state value and the result is shown in Fig. 5.
Solving the model Eqs. (1)(3) with these model parame- Fuzzy tuning of PI controller
ters give the following three solutions:
By tuning conventional controllers using fuzzy logic, good
improvement in the process response is shown in the litX; S1 0; 4 wash-out condition;
erature for stable systems. He et al. [8] have parameterised
X; S2 0:9951; 1:5122 unstable;
5 the Ziegler-Nichols tuning rule by a single parameter and
then tuned that parameter using fuzzy logic and have
X; S3 1:5301; 0:1746 stable :
applied it for stable transfer function models. Ramkumar
Of these steady states, in the wash-out condition, there is and Chidambaram [12] have modied the He et al. method
no conversion at all, and the bioreactor is not operated in by parameterising the Ziegler-Nichols formula by two
this steady state. In the stable steady state, the conversion parameters and then tuning them by fuzzy logic. They
rate is too high, which may lead to product inhibition on
specic growth rate. Hence, as stated earlier, it is desirable
to operate the reactor in the unstable steady state. Linearising the non-linear model equations around the operating point (0.9951, 1.5122) gives [13] the transfer function
relating deviation in cell mass concentration (from the
steady-state) and the deviation in dilution rate:
where:
Kc 0:7356; sI 5:452 :
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Fig. 6. Schematic diagram of fuzzy self-tuning PI controller
The schematic diagram of a fuzzy self-tuning PI controller is shown in Fig. 6. The velocity form of PI controller
algorithm is given by:
Du Kc en en1 Ki en :
10
wsmall x lnx=4 or
wbig x ln1 x=4
or xbig w 1 e4w ;
xsmall w e4w ;
11
12
Z
S
M
L
B
B
B
B
S
B
B
B
S
S
B
B
S
S
S
B
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Performance evaluation
The performance of the closed loop system when forced to
move from the stable steady state 3 (X 1:5301;
S 0:1746) to the unstable steady state 2 (X 0:9951;
S 1:5122) is shown in Fig. 1. The overshoot is reduced
and it settles faster. For a 30% step change in the set point,
the oscillations are reduced as shown in Fig. 2. With 20%
uncertainty in measurement delay L, for a 30% step change
in set point from X 0:9951 fuzzy tuning helps to stabilise
the closed loop response where the PI controller fails to
stabilise. The response for this case is shown in Fig. 3. For
a 25% uncertainty in c the oscillations are reduced and it
settles faster as shown in Fig. 4. For load change in feed
substrate concentration Sf by 30% the results are equally
comparable. The variation of proportional gain for the
cases shown in Figs. 1 and 3 are shown in Figs. 9 and 10.
Since, the integral gain Ki is kept constant, sI will vary
similarly but with a different scale. To sum up, we can say
that fuzzy tuning improves the robustness of the controller
under process uncertainties which is a major requirement
for non-linear processes such as bioreactors with uncertainties in process kinetics.
Tuning both the proportional gain and integral gain
individually has also been tried for this unstable bioreactor
control problem. The integral gain also has been normalised between 0 and 1 using a similar equation as (10). The
tuning rules for the normalised integral gain dKi is as
shown in Table 2. Additional 16 rules are required for this
case.
After several simulation trials, the values
Kc;maxa 0:68; Kc;mina 0:4 and Ki;maxa 0:1;
Ki;mina 0:02 are found to give better results. The simulation result for the case shown in Fig. 1 is given here in
Fig. 11. There is not much improvement in the process
response even though an additional 16 rules are used for
tuning the integral gain.
131
Fig. 10. Controller gain variation for the response shown in Fig. 3
De
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B
B
B
B
B
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Fig. 11. Comparison of responses of tuning only Kc and tuning both Kc and Ki for Fig. 1 tuning only Kc ; tuning both Kc
Fig. 9. Controller gain variation for the response shown in Fig. 1 and Ki
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5
References
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Conclusions
for continuous bioreactors, Adv. Biochem. Biotechnol. 30
A fuzzy logic based tuning method for PI controller for
(1989) 6190
unstable systems is developed. Simulation application
2. DiBiasio, D.; Lim, H.C.; Weigand, W.A. An experimental
studies on an unstable continuous bioreactor shows that
verication of stability and multiplicities of steady states in a
the overshoot for a servo problem is reduced signicantly
biological reactor, AIChE J. 27 (1981) 284292
by the fuzzy tuning method. The fuzzy tuning of PI con3. Shimizu, K.: An overview of control system design of biotroller maintains the stability of the reactor under process
reactors, Adv. Biochem. Biotechnol., 50 (1993) 6681
4. Chen, L.M.; Chang, H.C.: Global stabilisation of biological
uncertainties whereas xed setting PI controller gives
reactors by linear feedback control, Chem. Eng. Commun. 27
sustained oscillations. The present method uses only 16
(1984) 231254
rules.
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type for unstable process with time delay, Int. J. Contr. 49
(1989) 12731284
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PID controllers, IEEE Trans on SMC, 23, 5 (1993) 13921398
10. Baras, J.S.; Patel, N.S.: Derivation of fuzzy rules for parameter free PID gain tuning, Proceedings of the IFAC symposium ADCHEM`94, Kyoto, Japan (1994) 319324
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strategy, Control Engg. Practice, 2, 1 (1994) 147153
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