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Design and Implementation of Industrial Internet of Things (Iiot) Framework For Nonlinear Actuator Health Monitoring and Compensation
Design and Implementation of Industrial Internet of Things (Iiot) Framework For Nonlinear Actuator Health Monitoring and Compensation
Project Summary :
This project proposal aims to develop an intelligent Industrial Internet of Things
framework for compensating actuators nonlinearities and its health monitoring. It may be
noted that, various actuators are found in industries for driving various processes. For
example, handling of materials using robotic manipulators will require motors or
pneumatic actuators. Manufacturing industries employ pneumatic control valves to
manipulate flow rates to regulate product compositions, temperature, pressure etc. In
integrated power systems, actuators such as governor for controlling steam flow rate for
reheated turbines, actuator for manipulating turbine blade pitch in wind turbine etc. are
ubiquitous. In nutshell, actuators are essential part of industries and affect the final
throughput of the industry in a considerable manner. However, these actuators are prone
to suffer severe nonlinearities such as static-friction (stiction), deadband, deadzone etc.
which can potentially disturb the desired profitability of the plant by providing reduced
control level performance. To overcome this issue, the current practice is to manually
check the actuators in the plant at various locations by technicians and observe its health
condition. This method is quite unreliable, expensive and can cause detrimental effects on
the control performance. Also, many times information regarding actuators’ current
condition is desired at supervisory level to plan a scheduled maintenance for fixing of
actuator/s or their replacement. This can be further very tedious, since scheduled plant
maintenance is often carried out in open loop mode with minimal dependence on input
from technicians visiting the plant. If, between two successive maintenance operations,
actuator fails; it can lead to catastrophic results. In order to address these issues, this
project proposal aims to garner the capabilities of recently investigated technology of
Industrial Internet of Things (IIoT). Through IIoT, it is possible that the data from
actuators, irrespective of their quantity and geographical location in a large plant, can be
easily accessed. In this project, this input-output data of actuators will be used to monitor
the condition of actuators in the plant. This data along with unique ID of different
actuators in the plant will be transmitted to a cloud database to monitor the health of
actuator using intelligent algorithms. The condition of actuators in the plant will be
assessed with the help of its nonlinearity estimation, as the nonlinearity index associated
with any actuator can be used to predict the life of actuator and its current health. The
application of the nonlinearity index is two-fold in this project. One of the use of
nonlinearity index will be in implementation of the nonlinearity compensation algorithm
and second use will be in assessment of actuators' health and taking supervisory action at
a higher level of industrial automation hierarchy.
Objectives :
Keywords :
Actuator nonlinearity, Nonlinearity compensation, Industrial Internet of Things (IIoT),
Stiction, Fuzzy logic
Stiction compensation is a challenge in industries and attention has been paid to this area recently.
A framework for choosing the parameters of knocker pulses, in the approach proposed by Hägglund
[1], was introduced by Srinivasan and Rengaswamy [2, 3]. Further, Cuadros presented a modification
[4], to be integrated with knocker or constant reinforcement method in order to gain reduced variability
on process variable. Srinivasan and Rengaswamy (2008) presented a “two move approach” for the
stiction compensation in control valves [5]. This technique used a separate compensator, whose output
at every sampling instant was evaluated through OP, its derivative and value of stiction band (S). This
scheme was reliant on an exact measure of valve and stiction parameters However, this cannot be
guaranteed in a practical environment [6]. Cuadros et al. (2012) revisited two move approach and
presented two new methods for compensating stiction [8]. This work again used a separate
compensator and added signal to the control loop other than the controller output. It was assumed that
the dynamics of valve and the process are similar, which cannot be guaranteed [6, 7]. In year 2000,
Kayihan and Doyle [9], proposed use of a local nonlinear controller making an internal loop with
original process variable to curb stiction deteriorating effects. Mohammad and Huang [10] presented
stiction compensation scheme through controller tuning. Further, Arifin et al. (2014) provided an
improved method of stiction compensation for control valve which is claimed to require minimal
information from process or the operator [11]. Wang presented a stiction compensation method [12],
loosely based on addition of a pulse in control signal (as in knocker method or two move approach),
but with a different procedure of determining the pulse characteristics. Brasio et al. have presented an
extensive review on stiction nonlinearity in [13], and covered modelling, detection, quantification and
compensation of stiction from over one hundred fifty articles. An aspect covered in this review article
was nonlinearity compensation in control valves. It was inferred that the compensation of stiction in
control valves is a relatively lesser explored area [14], and only limited methods are reported for
stiction compensation. The most studied method is, knocker method [1] or its modified version, which
employ a separate compensator and adds some signals (knocker pulses) in the control signals.
However, it has been observed that the additional pulses are usually filtered by low pass characteristic
of pneumatic actuators and thereby reducing their effectiveness in valve having pneumatic actuators
[5]. Further, the review article which accounted for over one hundred and fifty articles, reported no
any integrated stand-alone automated framework which could identify or detect, estimate, and then
compensate the hard nonlinearity in the control loops. Some efforts at national level are also being
made Advanced Process Control Laboratory (APCL) at Netaji Subhas University of Technology, Delhi
has majority of the work on stiction compensation in control valves. Two different techniques namely
stiction combating intelligent controller (SCIC) [6, 15] and nonlinear proportional integral controller
[14] were developed to compensate the stiction nonlinearity in control loop with pneumatic control
valve. Effects of tuning in SCIC controller and related comparison are shown in [16, 17]. It may be
noted that, these works were mainly focused on compensation of stiction effects on the control loop,
and no information of detection was employed in these works. Sivagamisundari and Sivakumar have
performed few research activities in detecting and compensating stiction nonlinearity in pneumatic
control valves [18–22]. Another instance of identification of stiction in valves by a neuro-fuzzy system
can be seen which is explored at CSIR-CLRI laboratory at Chennai, India by Arumugum and Panda
[23]. It may be inferred from the survey presented that effect of hard nonlinearities such as stiction,
which has a characteristic of hysteresis and friction, is not being studied thoroughly in industrial
control aspect and not much work is being reported in this area.
It has been pointed out in literature survey that separate techniques are available to detect and
compensate the stiction effects on the control performance. The separate existence of the detection
estimation technique and compensation technique for nonlinearities in control loop may render the
industrial control practitioner for following problems,
The abovementioned points illustrate the need of an automated integrated framework which
could monitor the health of control valve, compensate nonlinearity as well as control the process
variable of interest. This development will not only cause the control performance to improve but also
the product quality and efficiency of controlled process. This improvement will further cause a
reduction in wasted manpower and energy; and can significantly decrease the maintenance issues in a
plant. The following illustration might be seen as the gap which is to be explored in this research
proposal,
Valve health
monitoring
Unified framework for valve health
monitoring and compensation
Nonlinearity
estimation and NOT Available !!!
compensation
Existing Status
3 Research Plan
This project proposal aims to develop a unified framework for the monitoring of the actuators’
health in view of various nonlinearities present in it. Primarily stiction is the root cause of deterioration
in the control performance in the industrial control loops and the most common final control element
affected is the control valves. Since, there is no unified framework for the control valves actuators
health monitoring and stiction compensation, this work is an attempt to deal with the same problem.
In order to assess the valve health, the controller output, control valve actuator response, and
final process variable will be observed and recorded simultaneously. Then with the help of Industrial
Internet of Things (IIoT) platform, a machine learning algorithm using fuzzy system will be assessing
the control valve health parameters. The valve health parameters will comprise of the measure of its
hysteresis and stiction nonlinearity parameters. A brief representation of this framework is presented
in Figure 1, where different run time data will be observed from plant at different valve locations and
with the help of associated valve identification code (Valve ID), the data will be stored in a cloud
database. Further, on the basis of acquired data, the stiction and hysteresis related parameters will be
estimated so as to assess the valve health. Further, supervisor actions will be generated to take timely
corrective actions and prevent valve failures.
Machine
Run time learning
data algorithm
IIO T
PLATFORM
LINK WITH
LOCAL CONTROLLERS Actuator
Industry
health data
Suggested
supervisory
actions
Figure 1: An Industrial Internet of Things (IIoT) framework for actuators health monitoring.
Also, the problem of stiction compensation is a big menace in industry which can considerably
reduce the plant productivity by introducing large amplitude limit cycles in different process variables,
such as controlled variable and manipulated variables. These sustained oscillations can potentially
reduce the life span of the actuators which can in urn cause large load on the financial health of the
industry. Also, if these oscillations are further ignored, these can also cause severe instability problems
with a possibility of loss of materials and even worse lives. To compensate for these problems, it is
desired that a stand-alone algorithm which can take care of control and compensation at local level of
distributed control system, will be more beneficial. A possible block diagram of the proposed stand-
alone control and stiction compensation structure is presented in Fig. 2. It may be inferred from this
block diagram that it is an adaptive control scheme which can change its gains in run time to
compensate for the stiction nonlinearity. The intelligent compensator-cum-controller depicted in Fig.
2 is an intelligent system which uses fuzzy logic for its implementation. Since the system is intelligent,
and uses a measure of nonlinearity present in the loop with the help of nonlinearity index (NI), the
controller will also be able to function in normal mode when no hard nonlinearity affects the loop.
The automatic nonlinearity detection facility through IIoT platform will be an added advantage,
since it might be possible that the control loop component is newly installed and does not suffer from
any hard nonlinearity. The measure of NI will make sure that only necessary compensation occurs in
the control loop. It needs a mention here that Fig. 2 shows the structure of the control loop with
compensator-cum-controller only, however, the complete framework will also accommodate the
detection and estimation aspect.
Error (e) Fuzzy
𝟏− 𝐳 −𝟏
system
𝐓
NI
KI
Controller
+ + output
Process + × +
−𝟏
variable 𝟏− 𝐳
𝐓 KP
Sampling period 𝑧 −1
(T)
SP Final
+- OP PV
Controller Actuator control Process
element
Sensor
++
Disturbanc
e
Fig. 2. Proposed intelligent stand-alone controller and compensator for actuator nonlinearity.
1. Puneet Mishra, Vineet Kumar and K. P. S. Rana, “A fractional order fuzzy PID controller for binary
distillation column control,” Expert Systems with Applications, vol. 42, no. 22, pp. 8533-8549, 2015.
(SCIE Indexed, I.F. – 3.92)
2. Puneet Mishra, Vineet Kumar and K. P. S. Rana, “An online tuned novel nonlinear PI controller for
stiction compensation in pneumatic control valves,” ISA Transactions, vol. 58, pp. 434-445, 2015. (SCIE
Indexed, I.F. – 3.39)
3. Puneet Mishra, Vineet Kumar and K. P. S. Rana, “A novel intelligent controller for combating stiction
in pneumatic control valves,” Control Engineering Practice, vol. 33, pp. 94-104, 2014. (SCIE Indexed,
I.F. – 2.60)
4. Puneet Mishra, Vineet Kumar and K.P.S. Rana, “Intelligent Ratio Control in Presence of Pneumatic
Control Valve Stiction,” The Arabian Journal for Science and Engineering, vol. 41, no. 2, pp. 677 – 689,
2016. (SCIE Indexed, I.F. – 0.865)
5. Vineet Kumar, K.P.S. Rana, Puneet Mishra, “Robust speed control of Hybrid Electric Vehicle using
fractional order fuzzy PD and PI controllers in cascade control loop,” Journal of the Franklin Institute,
vol. 353, no. 8, pp. 1713-1741, 2016. (SCIE Indexed, I.F. – 3.13)
6. Vineet Kumar, K. P. S. Rana, Jitendra Kumar, Puneet Mishra and Sreejith S. Nair, “A Robust
Fractional Order Fuzzy P + Fuzzy I + Fuzzy D Controller for Nonlinear and Uncertain
System,” International Journal of Automation and Computing, Springer Publication. (SCOPUS
Indexed)
7. Vineet Kumar, K.P.S. Rana, Jitendra Kumar, Puneet Mishra, “Self-tuned Robust Fractional Order
Fuzzy PD controller for Uncertain and Nonlinear Active Suspension System,” Neural Computing and
Applications, Springer, vol. 30, no. 6, pp. 1827-1843. (SCIE Indexed, I.F. – 2.505)
8. Nithilasaravanan. K, Nitisha Thakwani, Puneet Mishra, Vineet Kumar, KPS Rana, “Efficient Control
of Integrated Power System using Self Tuned Fractional Order Fuzzy PID Controller,” accepted for
publication in Neural Computing and Applications, Springer. (SCI Index, I.F. – 2.505)
9. Puneet Mishra, Vineet Kumar, K.P.S. Rana, “An Efficient Method for Parameter Estimation of a
Nonlinear System using Backtracking Search Algorithm,” Engineering Science and Technology – An
International Journal, Elsevier, vol. 21, no. 3, pp. 338 - 350 (SCOPUS Indexed).
10. Vishal Goyal, Puneet Mishra, Vinay K Deolia, “A robust fractional order parallel control structure for
flow control using a pneumatic control valve with nonlinear and uncertain dynamics,” Arabian Journal
for Science and Engineering (Springer), vol. 44, no. 3, pp. 2597-2611, 2019. (SCI index, I. F. – 1.092)
11. Aasheesh Shukla, Vishal Goyal, Puneet Mishra and V. K. Deolia, Cooperative relay beamforming in
IDMA communication networks. Journal of Electrical Engineering, 69(4), pp.300-304, 2018. (SCIE
indexed)
12. Vishal Goyal, Puneet Mishra, Aasheesh Shukla, V.K. Deolia, and Aarti Varshney, “A fractional order
parallel control structure tuned with meta-heuristic optimization algorithms for increased robustness,”
Journal of Electrical Engineering, vol. 70, no. 1, pp. 16-24, 2019. (SCIE indexed)
5 Bibliography
[1] T. Hägglund, “A friction compensator for pneumatic control valve,” Journal of process control, vol.
12, no. 8, pp. 897-904, 2002.
[2] R. Srinivasan and R. Rengaswamy, “Stiction compensation in process control loops: A framework for
integrating stiction measure and compensation,” Industrial & engineering chemistry research, vol. 44,
no. 24, pp. 9164-9174, 2005.
[3] R. Srinivasan and R. Rengaswamy, “Techniques for stiction diagnosis and compensation in process
control loops,” In American Control Conference, pp. 6-pp. IEEE, 2006.
[4] de Souza L. Cuadros, C. J. Munaro, and S. Munareto, “Novel model-free approach for stiction
compensation in control valves,” Industrial & Engineering Chemistry Research, vol. 51, no. 25, pp.
8465-8476, 2012.
[5] R. Srinivasan and R. Rengaswamy, “Approaches for efficient stiction compensation in process control
valves,” Computers and Chemical Engineering, vol. 32, pp. 218-229, 2008.
[6] P. Mishra, V. Kumar, and KPS Rana, “A novel intelligent controller for combating stiction in
pneumatic control valves,” Control Engineering Practice, vol. 33, pp. 94-104, 2014.
[7] M. Farenzena, J. O. Trierweiler, “Modified PI controller for stiction compensation,” In Proceedings
of the 9th International Symposium on Dynamics and Control of Process Systems (DYCOPS 2010).
Leuven, Belgium, July.
[8] de Souza L Cuadros, C. J. Munaro, and S. Munareto, “Improved stiction compensation in pneumatic
control valves,” Computers & Chemical Engineering, vol. 38, pp. 106-114, 2012.
[9] A. Kayihan, F. J. Doyle, “Friction compensation for a process control valve,” Control Engineering
Practice, vol. 8, pp. 799-812, 2000.
[10] M. A. Mohammad, B. Huang, “Compensation of stiction through controller tuning,” Journal of
Process control, vol. 22, pp. 1800-1819, 2012.
[11] B. M. S. Arifin, C. J. Munaro, MAAS Choudhury, and S. L. Shah, “A model free approach for online
stiction compensation,” IFAC Proceedings Volumes, vol. 47, no. 3, pp. 5957-5962, 2014.
[12] J. Wang, “Closed-loop compensation method for oscillations caused by control valve
stiction,” Industrial & Engineering Chemistry Research, vol. 52, no. 36, pp. 13006-13019, 2013.
[13] A. S. Brásio, A. Romanenko and N. C. Fernandes, “Modeling, detection and quantification, and
compensation of stiction in control loops: The state of the art,” Industrial & Engineering Chemistry
Research, vol. 53, no. 39, pp. 15020-15040, 2014.
[14] Puneet Mishra, Vineet Kumar and K. P. S. Rana, “An online tuned novel nonlinear PI controller for
stiction compensation in pneumatic control valves,” ISA Transactions, vol. 58, pp. 434-445, 2015.
[15] Puneet Mishra, Vineet Kumar and K.P.S. Rana, “Intelligent Ratio Control in Presence of Pneumatic
Control Valve Stiction,” The Arabian Journal for Science and Engineering, vol. 41, no. 2, pp. 677 –
689, 2016.
[16] Puneet Mishra, Vineet Kumar and K. P. S. Rana, “Stiction Combating Intelligent Controller Tuning:
A Comparative Study,” in Proceedings of the IEEE International Conference on Advances in
Computer Engineering and Applications (ICACEA), March 19-20, 2015, pp. 534-541, IMS
Ghaziabad, India.
[17] Puneet Mishra, Vineet Kumar, KPS Rana, “A comparative study for flow control with SCIC and NPIC
controllers,” presented at ICCCNT, IIT Delhi, 3-5 July, 2017.
[18] S.Sivagamasundari, D. Sivakumar, “A New Methodology to Compensate Stiction in Pneumatic
Control Valves,” International Journal of Soft Computing and Engineering, Volume 2, Number 6, Jan
2013, pp. 480-484, 2013.
[19] S.Sivagamasundari, D. Sivakumar, “Quantification of Nonlinear Valve Stiction Model using
Compound Evolution Algorithms,” International Journal of Engineering Research and Applications,
Volume 2, Number 1, Jan 2012, pp. 932-938. 2012.
[20] S.Sivagamasundari, D. Sivakumar, “A Practical Modelling Approach for Stiction in Control Valves,”
Procedia Engineering, Elsevier, Volume 38, Number 3, Mar 2012, pp. 3308-3317. 2012.
[21] S.Sivagamasundari, D. Sivakumar, “Estimation of Valve Stiction Using Particle Swarm
Optimization,” Sensors & Transducers, Volume 129, Number 6, Jun 2011, pp. 149-162. 2011.
[22] S.Sivagamasundari, D.Sivakumar, A Practical Modelling Approach for Stiction in Control Valves,
Indian Chemical Engineering Congress, Dec 27-28, 2010, Annamalai University, pp. 179-180,
Annamalai nagar, Indian Institute of Chemical Engineers.
[23] S. Arumugum, R. C. Panda, “Identification of Stiction Nonlinearity for Pneumatic Control Valve using
ANFIS Method,” International Journal of Engineering and Technology, vol. 6, no. 2, pp. 570-578.
6 Equipment available with the Institute/ Group/ Department/Other Institutes for the
Project
Equipment Generic name of Model, make and year Remarks including
available equipment of purchase accessories available
and current usage of
equipment
PI & his group Pilot scale pneumatic Anshuman These equipment are
control vales (4 pcs) Technologies, PCT available with PI and
100, 2018 his group and
MyRIO – 1900 National Instruments currently one PhD
(NI), 2018 students is working
Data acquisition facilities National Instruments towards his thesis on
(NI), USB – 6009, these setup
2015
Pilot scale plant to study Anshuman
flow, level and temperature Technologies, PCT -
control 100, 2018
Other institutes NA NA NA
in the region
Budget Details
Birla Institute of Technology and
Budget Head Science (BITS)-Pilani Campus Total
3. Institution
Ph.D. Thesis Title: Some Investigations on Intelligent Controllers for Nonlinear Processes
Guide’s Name: Dr. Vineet Kumar, Prof. K.P.S. Rana, and Prof. A. P. Mittal
Institute/University: Netaji Subhas Institute of Technology, New Delhi (University of Delhi,
New Delhi)
Year of Award: 2017
10. Work Experience (Chronological Order)
12. Publications (List of papers published in SCI Journals, in year wise descending order).
NIL
The principal investigator, Dr. Puneet Mishra, has a strong exposure in the fields of
process control, nonlinear control, and intelligent control. Sound knowledge of bio-
inspired global optimization algorithm can also be credited to his name. He has
developed/implemented more than five, recently proposed bio-inspired optimization
algorithm namely genetic algorithm, cuckoo search algorithm, grey-wolf optimization
algorithm, backtracking search algorithm, bat algorithm, flower pollination algorithm etc.
All these algorithms were implemented in labVIEW platform in Advanced Process Control
Laboratory, at Netaji Subhas Institute of Technology, New Delhi. Further, he has a sound
knowledge of hard nonlinearities and their behavior in process control loop. He has
developed two novel compensation techniques for the same and their behavior was justified
and validated on a hardware laboratory scale setup. This was done with help of LabVIEW
software and associated data acquisition facilities. He has a strong hands-on experience on
different data acquisition facilities like PCI based DAQ card (NI PCI – 6221), USB DAQ
card (NI USB – 6009), fieldpoint, myRIO – 1900, CompactRIO etc.
Apart from this, all the fuzzy based systems were developed from scratch without any
help of built-in fuzzy based toolkits for the implementation of intelligent control for his
PhD thesis work. This provides a real potential for designing a novel and strong control
algorithm for real time applications. For the proposed research work, a prototype of
compensation algorithm has already been developed. The results are encouraging for the
primary tests conducted for flow control process on a laboratory scale hardware setup at
Intelligent control lab, at BITS, Pilani, Pilani campus.