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Abstract: Supermarket refrigeration systems are hybrid systems due to switching of the
continuous dynamics and due to the presence of discretely switched actuators such as valves
and compressors. The main control goal for these systems is to keep temperature and pressure
levels within tight bounds while minimizing the wear of the compressors. In our previous work, a
hierarchical model-predictive control scheme was proposed for supermarket refrigeration systems
that overcomes the major drawback of traditional control schemes for these systems: excessive
switching of the compressors due to synchronization of the local controllers of the display cases.
In every NMPC iteration, low-level temperature controllers were employed, and the high-level
optimization task was reduced to the determination of optimal parameters for these controllers.
While this approach was successfully applied to systems of moderate size, it did not yield
satisfactory results for larger systems due to the combinatorial growth of the search space.
Furthermore, fast drastic changes of the external disturbances could not be handled well by this
technique. This paper presents several extensions to overcome these problems.
Keywords: Predictive control, process control, refrigeration systems, switched systems, hybrid
systems
in time of these pulses are determined which leads to minimization of the number of switches of the compressors.
an optimization problem with only continuous decision An additional advantage of this approach is that the num-
variables. As in our scheme, the cost function is evaluated ber of compressor switchings is not included in the cost
by simulation of the hybrid model. This approach was function, removing a discontinuous term in the cost func-
capable of keeping all process variables within the bounds. tion. (3) The simulation of the locally controlled system
However, in each MPC iteration a complex NLP problem is performed using a fixed-step Runge-Kutta algorithm,
with many decision variables had to be solved within a leading to a linear growth of the numerical effort with
short time horizon since the points in time at which the the number of display cases. (4) An additional low-level
display case inlet valves switch were optimized directly. controller is implemented that continuously monitors the
process and switches the compressors directly if sudden
This paper proposes an extension of the hierarchical
large changes of the external disturbances occur.
NMPC approach for supermarket refrigeration systems
that was presented in Sonntag et al. [2007]. In this ap-
proach, the switching of the input valves of the display 2. SYSTEM DESCRIPTION
cases is not optimized directly, but simple low-level con-
trollers are employed that regulate the temperatures in Edible goods that are sold in supermarkets are usually
the display cases with a high sampling frequency. The located in open refrigerated display cases to avoid de-
parameters of these controllers are adjusted by a high-level terioration and to enable easy access for the customers.
NMPC optimizer that operates on a longer time horizon, Fig. 1 shows a schematic representation of a supermarket
thus leaving more computation time for the NLP step in refrigeration system. It consists of four major parts: several
every NMPC iteration. The high-level optimization also display cases, a compressor rack, a suction manifold, and
determines the switching sequences of the compressors. a condenser. Liquid refrigerant is supplied to the display
While this approach was successfully applied to a refriger- cases through inlet valves. The refrigerant evaporates, thus
ation system with two display cases and two compressors removing heat from the air around the evaporator. The
(see Sonntag et al. [2007]), it did not yield good results for resulting vapor accumulates in the suction manifold and
larger systems for several reasons: (a) the enlargement of is fed to the condenser via the compressors which increase
the discrete input space that is caused by an increase of the pressure of the refrigerant vapor. Since the evaporation
the number of compressors could not be handled efficiently temperature of the refrigerant increases with the pressure,
by this algorithm, (b) the algorithm considered only a the thermal energy from the display cases can be removed
single compressor switch in every NMPC iteration, thus in the condenser at room temperature. Finally, the lique-
severely limiting the available degrees of freedom, and (c) fied refrigerant is fed back to the display cases. The cross-
the computational effort for the simulation of the process section of an open refrigerated display case is shown in
model increased drastically with the number of display Fig. 2. Cold air is circulated through the display case and
cases. Furthermore, sudden large changes of the external forms an air curtain in front of the edible goods. Thermal
disturbances that e.g. occur when the system is switched energy is transferred from the goods to the air curtain
from day-time to night-time operation could not be han- (Q̇goods−air ) and, since the temperature of the surrounding
dled well. The extensions that are presented in this paper air is larger than that of the air curtain, the curtain
remedy the above-mentioned problems: (1) Only a subset also absorbs heat from the surroundings (Q̇airload ). The
of the possible compressor switches is considered over absorbed thermal energy is transported to the evaporator
the immediate future, and a real value of the compressor (Q̇air−wall ) in which the refrigerant evaporates and thus
capacity is assumed in the remote future, thus decoupling takes on the thermal energy (Q̇e ).
the number of alternative switchings from the dimension
of the discrete input space. (2) The discrete search is per- The controlled variables of the system are the pressure
formed by solving a sequence of continuous optimization inside the suction manifold and the temperatures of the
problems with an increasing number of switches, and the
search is stopped as soon as a policy is found that meets
the specification. This reflects the main control goal, the
. .
.
.
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17th IFAC World Congress (IFAC'08)
Seoul, Korea, July 6-11, 2008
air inside the display cases. As the system never reaches ing inlet valve vi influence the dynamics of the mass of
a steady state, the control goal is not to track setpoints, refrigerant in a display case mref,i according to
but to maintain these variables within specified bounds.
mref,max − mref,i
This is achieved using two types of discrete control inputs:
if vi = 1, (a)
dmref,i τf ill
The expansion valves at the inlets of the display cases = (5)
dt Q̇e,i
can be opened or closed, and the compressors can be −
if vi = 0. (b)
switched on or off individually. The pressure in the suction ∆hlg
manifold and the temperatures of the air and of the Here, the maximum amount of refrigerant each display
walls in the display cases can be measured directly, and case can accommodate is represented by mref,max , Q̇e,i
an approximation of the temperature of the goods can is defined in Eq. 11, the specific enthaply of evaporation
be obtained from temperature sensors that are located of the remaining liquefied refrigerant in the evaporator is
close to the goods in the display cases. The external given by ∆hlg , and τf ill is a time constant. The display
disturbances to the system are the energy transfer from the case is filled with refrigerant as long as the inlet valve is
outside air to the display cases (Q̇airload ) and an additional open (Eq. 5.a), and after the inlet valve has been closed,
flow of refrigerant into the suction manifold (ṁref −const ) the remaining refrigerant evaporates according to Eq. 5.b.
that originates from additional cooling facilities which are The temperature dynamics within the i-th display case is
not modeled. These disturbances are measurable. given by:
3. THE HYBRID MODEL dTg,i Q̇goods−air,i
=− , (6)
dt mgoods · cpgoods
The hybrid model used in this work was proposed in dTw,i Q̇air−wall,i − Q̇e,i
Larsen et al. [2007]. It has been implemented as a hybrid = , (7)
dt mwall · cpwall
automaton with continuous and discrete inputs [Lynch
dTair,i Q̇goods−air,i + Q̇airload − Q̇air−wall,i
et al., 2003, Stursberg, 2004]. = , (8)
dt mair · cpair
The hybrid model of the supermarket refrigeration system
with
may contain an arbitrary number of display cases ndc . The
state of each display case is described by four differential Q̇goods−air,i = U Agoods−air · (Tg,i − Tair,i ) , (9)
state variables: the temperature of the goods (Tg,i ), the Q̇air−wall,i = U Aair−wall · (Tair,i − Tw,i ) , (10)
temperature of the evaporator wall (Tw,i ), the tempera-
ture of the air inside the case (Tair,i ), and the mass of Q̇e,i = U Awall−ref (mref,i ) · (Tw,i − Te (Psuc )) , (11)
liquid refrigerant within the evaporator of the display case mref,i
U Awall−ref (mref,i ) = U Awall−ref max · . (12)
(mref,i ). Thus, the vector of continuous state variables of mref,max
the i-th display case is given by Here, mgoods , mwall , mair , cpgoods , cpwall , cpair , U Agoods−
xdc,i = [Tg,i , Tw,i , Tair,i , mref,i ]T . (1) air , U Aair−wall , and U Awall−ref max are constant model
parameters, and Te is the evaporation temperature of the
The dynamics of the condenser unit is not modeled. Hence,
refrigerant which is a function of the suction pressure Psuc .
the overall continuous state vector of the model can be
The dynamics of the suction pressure is given by
written as
dPsuc ṁin−suc + ṁref −const − V̇c · ρsuc
x = [xTdc,1 , . . . , xTdc,ndc , Psuc ]T , (2) = dρsuc
, (13)
dt Vsuc · dP
where Psuc is the pressure in the suction manifold. Since suc
each display case is equipped with an inlet valve for the with
refrigerant, the discrete input vector is given by ndc
X Q̇e,i vc · ηvol · Vd
v = [v1 , . . . , vndc , vc ]T . (3) ṁin−suc = , V̇c = . (14)
i=1
∆h lg 100
Here, v1 , . . . , vndc are binary variables representing the
The total mass flow of refrigerant from all display cases
state of the inlet valves (open/closed), and vc ∈ Ξc (given
into the suction manifold is given by ṁin−suc , and
in %) determines the relative capacity 3 of the compressors
ṁref −const is an external disturbance that represents an
that are currently running within the compressor rack.
additional flow of refrigerant from other unmodeled cool-
The set Ξc contains all discrete capacity levels that can
ing facilities into the suction manifold. Using the relative
be realized by switching one or several compressors on. In
capacity of the running compressors vc (see Eq. 3), the
this paper, a system with three compressors of different
capacities is investigated. For this system, Ξc is defined volume flow V̇c from the suction manifold can be com-
as: puted. ρsuc is a nonlinear refrigerant-dependent function
modeling the density of the vapor in the suction manifold,
Ξc := {0 %, 30 %, 60 %, 100 %}. (4) and ηvol and Vd are constant model parameters.
The continuous dynamics is modeled by a lumped-
parameter ODE system 4 under the assumption that all 4. THE HIERARCHICAL CONTROL SCHEME
display cases are of equal design. The amount of refrigerant
in a display case and the current state of the correspond- A scheme of the control strategy developed in this work
is shown in Fig. 3. At every sampling instant, low-level
3 Thus, the values 0% (100%) always indicate that all compressors
controllers provide discrete control inputs to the plant
are off (on), independently of the number of compressors. while the high-level NMPC scheme sets the parameters of
4 See Larsen et al. [2007] for a more detailed description of the
the low-level controllers and determines a suitable strategy
model. for the compressor switches on a larger time horizon.
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17th IFAC World Congress (IFAC'08)
Seoul, Korea, July 6-11, 2008
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17th IFAC World Congress (IFAC'08)
Seoul, Korea, July 6-11, 2008
0 if y ≤ y ≤ y,
Compressor capacity vc vc , 4 λ (y) = y − y if y < y, (18)
y,y y − y if y > y,
vc ,3 ucc
with y, y, y ∈ R. The first term of the cost function aims
vc , 2 , vdef vcs at the minimization of the variance of the suction pressure
and, thus, at the desynchronization of the air temperatures
vc ,1 in the display cases, and the second term adds a penalty
for violations of the admissible region.
vc ,0
t
Discrete Continuous tp Based on the concepts introduced above, the execution
(a) Step 1: no compressor switch. of the sequential optimization scheme in every NMPC
iteration can be written as follows (see also Fig. 5):
vd ,1 = vc ,3 (1) Compute vcs and determine vdef,− , vdef , vdef,+ .
(2) First step (no compressor switch):
vc , 4
Compressor capacity vc
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17th IFAC World Congress (IFAC'08)
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with 5 display cases and 3 compressors with capacities system, a comparison to the simulation results of a smaller
as defined in Eq. 4. The controller and the simulation system under traditional control given in Larsen et al.
model were implemented in Matlab, and the TOMLAB - [2007] shows that the presented control scheme adheres
based NLP solver NPSOL was employed for the solution better to the constraints and significantly reduces the
of the continuous optimization problems 7 . Fig. 6 shows frequency of the controller switching.
the trajectories of the air temperatures and of the suction
pressure, and the switching behavior of the compressors. 6. CONCLUSIONS AND FUTURE WORK
Initially, the system is operated in a day-time scenario
In this paper, several extensions of the NMPC-based
(Q̇airload = 3000 W , ṁref −const = 0.2 kg s , and P = control strategy for supermarket refrigeration systems that
1.7 bar). After 1800 seconds, the system is switched into was introduced in Sonntag et al. [2007] were presented.
night-time operation, i.e. the display cases are covered The extensions enable the application of the scheme to
with blankets which leads to a reduction of Q̇airload large systems that are subject to drastic disturbances
to 1800 W , and the unmodeled cooling facilities are by (1) restricting the complexity of the optimization
switched off (ṁref −const = 0 kg s ). Furthermore, P is task, (2) introducing a sequential optimization scheme to
increased to 1.9 bar. The controller is capable of keeping increase the available degrees of freedom and to avoid
all process variables within the bounds and desynchronizes discontinuities in the cost function, (3) implementing an
the air temperatures very quickly. Furthermore, the low- efficient simulation strategy for large-scale systems, and
level compressor controller detects the drastic change in (4) introducing a low-level pressure controller. Simulation
the external disturbances and switches off all compressors. studies show that the new control scheme is capable of
Although there is no direct comparison available for this keeping the process variables within tight bounds while
7 The following parameter values were used: tp = 900 s, topt = 200 s,
reducing the switching frequency of the compressors. Our
T = 2 %, T = 5 %, and P = 1 bar. current research aims at a stronger exploitation of the
model structure to allow for a more efficient optimization.
6 REFERENCES
upper bound
5
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vc [%]
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