Real-Time Optimization of Automatic Control

This article has been accepted for publication in a future issue of this journal, but has not been
fully edited. Content may change prior to final publication. Citation information: DOI 10.1109/TIE.2016.2577623, IEEE
Transactions on Industrial Electronics
IEEE TRANSACTIONS ON INDUSTRIAL ELECTRONICS
Real-Time Optimization of Automatic Control

Systems with Application to BLDC Motor
Testrig
Hao Luo, Student Member, IEEE, Minjia Krueger, Tim Koenings, Steven. X. Ding,
Shane Dominic and Xu Yang, Member, IEEE
Abstract—Driven by the increasing demands on produc- online operation during the lifetime of the automatic control
tion quality, system performance and the reliability and systems, due to 1) the occurrence of unknown/unexpected
safety issues of process industry, this paper proposes an disturbances and the unavoidable model mismatch between the
integrated process monitoring and control design tech-
nique for industrial control systems. The proposed ap- real plant and the given model, 2) the change of operational
proach is an alternative realization of Youla parameteriza- conditions/parameters, 3) malfunctions of system components
tion which allows the performance of the controlled sys- and 4) the components replacement in a maintenance/repair
tems to be improved without modifying or replacing the pre- action. Many technological advanced control systems have
designed control systems, while the closed-loop stability been developed in academic research in order to achieve
is guaranteed. In addition, a residual signal is available
for the fault detection and isolation (FDI) purpose. The better control performance, however, many obstacles persist in
effectiveness and performance of the proposed approach industrial practice that block the realization and implementa-
are demonstrated on a brushless direct current (BLDC) tion of the designed advanced methods to complex industrial
motor test rig. applications. One of these obstacles is that, in many cases,
Index Terms—Data-driven, Fault-tolerant control, Pro- the pre-designed control systems of the complex industrial
cess monitoring, Robustness optimization, Youla parame- systems are not allowed to be modified and only few research
terization. efforts have been made to the advanced controller design with
existing pre-designed controllers.
I. I NTRODUCTION In industrial practise, PI/PID controllers are most widely
implemented and their design techniques have been well
N OWADAYS, due to the increasing demands on produc-
tion quality, system performance and economic benefits
in industrial production, the production quality, system reli-
studied. Although there already exist many online PI/PID
tuning techniques in literature, see e.g. [9]–[12], the stability
of the closed-loop is still a very important and critical issue
ability and safety issues on the modern industrial processes
while tuning PI/PID controllers online. In most of the cases, a
become the most critical aspects and have gained lots of
trade-off between the performance and the stability region has
attention from both the academical and the industrial field.
to be made. Furthermore, for a PI/PID-controlled real plant,
During the past several decades, to enhance the production
it is very hard to determine its stability region online and
quality while ensuring the safe and reliable operation of
thus the control performance is limited. Strongly motivated
the industrial processes, optimal control, robust control, fault
by these observations, the major contribution of our study in
detection and isolation (FDI) and fault-tolerant control (FTC)
this paper is, an integrated process monitoring and control
techniques [1]–[5] have received more and more attention
structure is developed, which parameterizes all stabilizing
and have been successfully applied on plenty of industrial
controllers based on the existing control loop. Associated with,
processes to keep the industries competitive. Especially, a
an iterative online optimization approach is proposed to design
trend of integrating FDI into the feedback control loops
the so-called parameterization matrix, by which the closed-
can be recently observed [3], [6]–[8]. However, the offline
loop stability is easily guaranteed. Although there are many
optimal design settings could rarely guarantee an optimal
design methods that have been proposed to design the parame-
terization matrix [3], [5], [13], [14], they mainly focused on the
Manuscript received December 18, 2015; revised March 25, 2016; control problem in observer-based state feedback framework.
accepted April 24, 2016. The first author thanks for the financial support
provided by the China Scholarship Council. For industrial applications, those methods require to replace
Hao Luo, Minjia Krueger, Tim Koenings, Steven X. Ding and the existing PI/PID controllers by observer-based state feed-
Shane Dominic are with the Institute for Automatic Control and Com- back ones during the implementation as realised in [13]. The
plex Systems (AKS), University of Duisburg-Essen, 47057, Duisburg,
Germany (emails: {hao.luo, minjia.krueger, tim.koenings, steven.ding, proposed approach leads to an alternative way and provides
shane.dominic}@uni-due.de). Corresponding author: Minjia Krueger. much easier and simpler industrial implementation procedure
Xu Yang is with the School of Automation and Electrical Engineering, to enhance system robustness without affecting the closed-loop
University of Science and Technology Beijing, 100083, Beijing, China
(emails: yangxu@ustb.edu.cn). stability and the pre-designed tracking performance. Moreover,
a residual signal is also available for further FDI purpose. The
0278-0046 (c) 2016 IEEE. Personal use is permitted, but republication/redistribution requires IEEE permission. See http://www.ieee.org/publications_standards/publications/rights/index.html for more information.
This article has been accepted for publication in a future issue of this journal, but has not been fully edited. Content may change prior to final publication. Citation information: DOI 10.1109/TIE.2016.2577623, IEEE
proposed approach has been successfully implemented in a d v

brushless direct current (BLDC) Motor Test rig. ω e u up yp y
K(z) Gg(z)
The rest of the paper is organized as follows. The prelimi-
Controller Plant
naries on Youla parameterization are addressed in Section II, -
while the proposed online optimization technique is given in
Section III. In Section IV, a case study on a BLDC motor
test rig is demonstrated and the implementation results are Fig. 1. Standard feedback control loop
discussed. At last, Section V concludes this paper.
II. P RELIMINARIES AND P ROBLEM F ORMULATION and yp,k ∈ Rm as the actual input and output of the plant,
respectively. Below, we present a lemma [15] that provides the
A. Preliminaries on Youla Parameterization
stability analysis of the standard feedback control loop.
Consider a stabilizable and detectable nominal system G(z),
which has a state-space realization of the form: Lemma 1: Let K(z) be a controller with transfer function
(2), then the following statements are equivalent:
A B • The feedback control loop consists G and K is in-
G(z) = (1)
C D ternally
for all G with transfer function G =
stable
−1
and let G(z) = N (z)M −1 (z) = M̂ −1 (z)N̂ (z) respectively M̂ + ∆M̂ N̂ + ∆N̂ where ∆M̂ , ∆N̂ ∈ RH∞
be the right-coprime factorization (RCF) and left-coprime
and ∆M̂ ∆N̂ ∞
< b.
factorization (LCF) of G(z) over RH∞ , then the set of all
X̂ − N Q

proper controllers via Youla parameterization [4], [5] achiev- • ≤ 1b .
Ŷ + M Q
ing internal stability can be parameterized by: ∞
−1 Under the assumption that the general plant Gg (z) with
K(z) = − Ŷ (z) + M (z)Q(z) X̂(z) − N (z)Q(z) model uncertainty and the faults is stabilized by the nom-
−1 inal controller (Q = 0): K0 (z) = −X −1 (z)Y (z) =
= − X(z) − Q(z)N̂ (z) Y (z) + Q(z)M̂ (z) (2) −Ŷ (z)X̂ −1 (z), our design objective is to online reconfigure
the parameterization matrix Q(z) ∈ RH∞ to enhance the
where M (z), M̂ (z), N (z), N̂ (z), X(z), X̂(z), Y (z) and Ŷ (z) closed-loop robustness (against model uncertainty, faults and
∈ RH∞ satisfy the doubly Bezout identities: disturbances) using online input and output data, while the

X(z) Y (z) M (z) −Ŷ (z) I O closed-loop stability is guaranteed. Although there are many
= (3) design methods that have been proposed to design the pa-
−N̂ (z) M̂ (z) N (z) X̂(z) O I
rameterization matrix in literature (e.g. [3], [5], [13], [14],
and Q(z) ∈ RH∞ is the so-called Youla parameterization [16], [17]), they mainly focused on the control problems in
matrix. Let the doubly coprime factorization of G(z) be observer-based state feedback framework which require to
chosen as modify the existing feedback controller. In order to achieve
 
A + BF B L easier industrial implementation, in the next section, we first
M (z) −Ŷ (z)
= F I O  study an alternative realization of Youla parameterization,
N (z) X̂(z) based on which the existing feedback controller K(z) is
C + DF D I
  treated as nominal controller. This alternative realization al-
A − LC −(B − LD) −L
X(z) Y (z) lows the performance of the controlled systems to be improved
= F I O 
−N̂ (z) M̂ (z) without modifying or replacing the pre-designed control sys-
C −D I
tems. Based on the alternative realization, an online iterative
where F and L are chosen such that A + BF and A − LC optimization method with closed-loop stability guarantee is
are both stable. proposed.
B. Problem Formulation III. O NLINE O PTIMIZATION OF AUTOMATIC C ONTROL

In order to deal with model uncertainty and the internal S YSTEMS
faults of the plant, we consider the general plant Gg (z) A. An Alternative Realization of Youla Parameterization
Gg (z) = (M̂ + ∆M̂ + M̂f )−1 (N̂ + ∆N̂ + N̂f ) (4) Based on the Youla parameterization, Theorem 2 forms the
foundation of our subsequent studies:
where ∆M̂ , ∆N̂ ∈ RH∞ represent the model uncertainty and
Theorem 2: Given a control loop with the plant model (4) un-
M̂f , N̂f ∈ RH∞ are used to denote the internal faults, and
der the assumption that ∆M̂ + M̂f ∆N̂ + N̂f ≤ ε,
the standard feedback control loop as shown in Fig. 1, where ∞
and a control signal u0 (k) provided by the existing controller
ωk ∈ Rm , uk ∈ Rl , yk ∈ Rm and ek := ωk − yk ∈ Rm re-
K(z) which internally stabilizes the control loop, then all
spectively represent the reference signal, process input, process
controllers which internally stabilize the control loop can be
output variables and tracking error. Moreover, dk ∈ Rl and
parameterized by
vk ∈ Rm respectively denote the unknown input disturbance
and measurement noise, and consequently we note up,k ∈ Rl u(z) = u0 (z) + Q(z)r(z) (5)
to unknown/unexpected disturbances or model uncertainties

- d v or some system faults etc., then the system robustness can be
ω e u0 u up yp y enhanced by designing the parameterization matrix Q(z). In
Gg(z)
K(z)
Plant order to obtain an implementable iterative online configura-
tion approach of Q(z) in Fig. 2, we first apply data-driven
ur r realizations of kernel and image representations to construct
Q(z) Observer-based
Residual Generator the observer-based residual generator according to [3], [18],
rf which generally has the following state-space representation:
Rf(z)
zk+1 = Az zk + Bz uk + Lz rk (7)
ŷk = Cz zk + Dz uk (8)
Fig. 2. Realization of the Youla parameterization for existing control
loops rk = yk − ŷk (9)
which delivers a state estimate for T x(k), i.e. z(k) = T x̂(k).
which is shown in Fig. 2, where Q(z) is a stable parameteri- T is a full order state transformation matrix, and
zation matrix that satisfies Az = T AT −1, Bz = T B, Cz = CT −1 , Dz = D. (10)

X̂ − N Q 1 To design the parameterization matrix, we restrict the dynamic
< . (6) l×m
Ŷ + M Q ∞
ε complexity of Q(z) ∈ RH∞ in controllable canonical form
[19], which gives us less design parameters and has following
Additionally, the residual vector r(z) = y(z) − ŷ(z) is state-space representation:
available for fault detection and isolation (FDI) purposes and
Rf (z) is the postfilter that can be designed to enhance FDI xr,k+1 = Ar xr,k + Br rk (11)
performance. ur,k = Cr xr,k + Dr rk (12)
The proof is straight forward based on Youla parameteri- where,
zation (see [3]) and Lemma 1, and thus omitted here. This 
0 1 ··· 0

alternative parameterization provides an integrated design of  . .
0 . . ..

process control and monitoring, i.e. on the one hand the 
 0 

residual signal is available for FDI purpose, while on the  .. .. . . 
 . . . 1 
other hand the controller design becomes much easier (to 
 ⋆ ⋆ ⋆ ⋆ ··· ⋆ ⋆ ⋆ ⋆


design Q(z) ∈ RH∞ ), which guarantees the closed-loop sta- 
 .. .. .. .. .. .. .. .. ..


bility. That is to say, given an existing stabilization controller Ar =  . . . . . . . . . ,
 
K(z) which ensures the closed-loop stability and provides 
 0 1 ··· 0 

satisfactory tracking performance, then the robustness (against  .. . 
 0 0 . .. 
disturbances, model uncertainty, faults etc.) of the closed- 
.. ..

 .. 
loop can be enhanced by designing a stable parameterization  . . . 1 
matrix Q(z) satisfying condition (6) while the closed-loop ⋆ ⋆ ⋆ ⋆ ··· ⋆ ⋆ ⋆ ⋆
stability is guaranteed. Recently, data-driven realizations of  
kernel and image representations have been proposed in [3], 0  
[18], based on which, the data-driven design of observer-based  0  c11 · · · c1q

..

 Cr =  .. .. ..  ,
fault detection and control systems is achieved using process   . . . 
 . 
input and output data. In the next subsection, based on the  
cl1 · · · clq
 1 
data-driven realizations of kernel and image representations, 
 .. .. ..


an gradient-based optimization approach is proposed for online Br =  . . . ,
   
configuration of the parameterization matrix Q(z). 
 0 
 d11 · · · d1m

 0 
 Dr =  .. .. ..  .
 ..   . . . 
B. Online Optimization of the Youla Parameterization Ma-  . 
dl1 · · · dlm
trix 1
From the parameterization of all stabilizing controllers The ⋆’s in the matrix Ar represent the possible non-zero
shown in Fig. 2, it is clear that the nominal controller elements, xr (k) ∈ Rq is the state vector and Ar ∈ Rq×q is a
K(z) ensures stability and tracking performance but may not stable matrix chosen by the designer. Typically, one would
necessarily attain satisfactory robustness performance against select the eigenvalues of the matrix Ar to be comparable
model uncertainty and internal faults. By introducing the in magnitude with the eigenvalues of the observer dynamics
parameterization matrix Q(z) ∈ RH∞ , it provides an easier Az − Lz Cz . Cr ∈ Rl×q and Dr ∈ Rl×m are the design
option to enhance the system robustness without affecting parameters of Q(z), thus we note:
the closed-loop stability and the pre-designed control perfor-
mance. More precisely, if the residual signal r(k) = 0 then θc = col (Cr ) ∈ Rl·q , θd = col (Dr ) ∈ Rl·m , (13)
T
Fig. 2 becomes the original control loop, and if r(k) 6= 0 due θ = θcT θdT (14)
where col(X) vectorizes X: To successfully generate θ to minimize the quadratic cost

  function, a normalized gradient algorithm is chosen for up-
x1
dating the design parameters θ in a steepest descent direction.

col(X) =  ..  ∈ Rn·m
.  Since the steepest descent direction of J is − ∂J
∂θ , for the above
xm chosen cost function:

for X = x1 · · · xm ∈ Rn×m , xi ∈ Rn , i = 1, · · · , m. N +k0 −1 ∂ek

∂J 1 X
To construct the closed-loop dynamics, assume the existing = eTk We,k uTk Wu,k ∂θ
∂uk
∂θj N ∂θ
stabilizing controller is stabilizable and detectable and has k=k0
following discrete-time state-space realization: 1 T
= ε φj
N j
xc,k+1 = Ac xc,k + Bc ek (15)
uc,k = Cc xc,k + Dc ek (16) which suggests the update law for θ to be:
Additionally, it is worth to notice that PI/PID controllers can ∂J −1

be reformulated into a discrete-time state-space representation θj+1 = θj − Γj m , θ0 = 0, (20)
∂θj j
using trapezoidal technique [20], and the resulting discrete-
time state-space representation is stabilizable and detectable.
where j denotes the iteration number, 0 < Γj = ΓTj <
Since most of the industrial processes are strictly proper, in
2Il·(m+q) is a gain matrix, θ0 is an initial value and mj =
order to match the industrial practice, D in Eq. (1) is here
κ + φTj φj with κ > 0 being a design parameter. The step
assumed to be zero. However, a similar result would be easily
obtained when D 6= 0. Based on the parameterization of size Γj scales the convergence speed, therefore it could be
determined by searching for the minimum of the cost function
all stabilizing controllers shown in Fig. 2, the closed-loop
along the search direction. In order to obtain the perfect step
dynamic from external signals dk , ωk , rk to ek and uk has
size, some adaptive methods are presented in [21], [22]. These
the following state-space representation:
     methods determine Γj based on the optimization theory. Also
zk+1 Az − Bz Dc Cz Bz Cc Bz Cr zk in identification approaches some techniques are presented to
xc,k+1  =  −Bc Cz Ac 0  xc,k  calculate an optimal step size. In this paper such an adaptive
xr,k+1 0 0 Ar xr,k scheme is used, which is introduced in [23],
| {z }
Acl
  α
Bz Dc Bz (Dr − Dc ) + Lz Γj = Il·(m+q) (21)
k φj k22 +βj
+  Bc −Bc  ωk , (17)
rk
0 Br
| {z } with α being a positive constant and
Bcl
 
z ∂J T ∂J
ek −Cz 0 0  k  ∂θj ∂θj−1
= xc,k βj = βj−1 − ρ (22)
uk −Dc Cz Cc Cr (k φj−1 k22 +βj−1 )
2
| {z } xr,k
Ccl

I −I ωk in which, ρ is a positive constant that indicates the step
+ . (18) size of the algorithm. The values α and β depends on the
Dc Dr − Dc rk
| {z } optimization problem. In most case, α is chosen equal to one
Dcl
and β depends on the actual and previous gradient. If the
To enhance the system robustness, we consider to minimize sign from the previous and actual gradient are the same, so
the effects, brought by the unknown/unexpected disturbances β can be increased during the iteration steps, otherwise it is
and noises, on the tracking error ek and the control signal decreased. The range is from 0 to 1. The convergence of the
uk . Therefore, the following cost function is chosen for the adaptive scheme is proofed in [23]. In Eq. (20), mj is a so-
optimization problem: called normalizing matrix which does not explicitly depend
N +k0 −1
on θ, i.e. the gradients ∂ek ∂uk
∂θ and ∂θ should be independent of
1 X θ. To ensure such a condition, the following theorem plays a
minimize J = eTk We,k ek + uTk Wu,k uk
2N key role in the iterative configuration of Q(z).
k=k0 (19)

X̂ − N Q 1 Theorem 3: Given the parameterization of all stabilizing
subject to <
Ŷ + M Q ∞
ε controllers
as shown in Fig. 2 with plant model G(z) =
A B
where k0 and N are integers represent the starting point of and the observer-based residual generator (7)-(9),
C O
the optimization and the time window respectively, We,k = denote:
T T
We,k ≥ 0 and Wu,k = Wu,k > 0 are weighting factors,

and the involving term of uk ensures a penalty on the control Az − Bz Dc Cz Bz Cc −Cz O
energy. AG = , CG =
−Bc Cz Ac −Dc Cz Cc
then the following gradient estimators deliver the gradients is also stable, which guarantees the stability of the proposed
of ek , uk w.r.t. the design parameters of Q(z), which are gradient estimators (23)-(26).
independent of θ:
 r
∂zk+1
  r
∂zk

Remark 4: It is worth to notice that, the provided gradients
 ∂x∂θ ∂θci  Bz Ici are unbiased when the input disturbance d and the measure-
c
r i  = AG  ∂x r + xrr.k (23)
c,k+1 c,k O ment noise v are both zero-mean noises. Furthermore, the
∂θci ∂θci
" ∂e #  r
 Hessian matrix of the cost function (19) w.r.t. θ is positive
∂zk
k
∂θci ∂θci  O semi-definite while the gradient estimators are not functions of
∂uk = C G  r
∂xc,k + xrr,k (24) the tuning parameters θ. Therefore, the optimization problem
∂θ
Ic i
ci ∂θci (19) w.r.t. θ is convex and its global optimum (w.r.t. the
where θci is i-th element of θc and Ici = ∂Cr
. given structure of the parameterization matrix Q(z) ∈ RH∞ )
∂θci
    is guaranteed. Comparing with other gradient-based tuning
r r
∂zk+1 ∂zk
Bz Idi
methods, the most advantage of the proposed one is that the
∂θdi ∂θdi
 ∂xrc,k+1
 = AG  ∂xrc,k
+ rk (25) proposed gradient estimators can directly provide the gradi-
O
∂θdi ∂θdi ents online without injecting any specific inputs or applying
 
" ∂ek
# ∂zkr
any offline experiments. The convergence speed of θ can be
∂θdi ∂θdi O proved to be exponential which is referred to [24].
∂uk = CG  ∂xrc,k
+ rk (26)
∂θdi
Idi
∂θdi
In summary, Algorithm 1 is given for the online configura-
∂Dr tion of the parameterization matrix Q(z).
where θdi is i-th element of θd and Idi = ∂θdi .
Proof. According to the transfer function matrices from resid- Algorithm 1. Q CONFIG
ual signal r to u and e (17)-(18), the proof is straightforward Step 1 Formulate the state-space representation of
computation and thus omitted. Here, only the stability of AG the existing controller (15)-(16). Construct
is discussed. Assume the nominal plant G(z) and the nominal the observer-based residual generator (7)-(9)
controller K(z) given in Eqs. (1) and (15)-(16) are stabilizable using data-driven realizations of kernel and
and detectable. The internal stability of the standard feedback image representations according to [3], [18].
control loop shown in Fig. 1 implies the closed-loop dynamic Step 2 Choose the system order q of Q(z) and set
from the external signals dk , ωk , rk to ek and up,k are stable, Ar to be stable, initialize Cr = O ∈ Rl×q
i.e. the following system is stable: and Dr = O ∈ Rl×m .

xk+1 xk dk Step 3 Construct the gradient estimators according to
= Ā + B̄
xc,k+1 xc,k ωk − vk (23)-(26) and set initial states equal to zero.

up,k xk dk Step 4 Evaluate the kernel representation
of the ex-
= C̄ + D̄ X̂
ek xc,k ωk − vk isting controller = εe .
Ŷ
where, ∞
−1 Step 5 Set the time window N and the starting point
O AB O I −Dc O Cc k0 .
Ā = +
Ac OO Bc D I −C O Step 6 Set the weighting factors We,k ≥ 0, Wu,k >
−1 0, choose the design parameters {α, β0 , κ,
B O I −Dc
B̄ = ρ} > 0.
O Bc D I
−1 Step 7 for j = 1 to θj+1 = θj
I −Dc O Cc 7.1 Collect ωk , yk and uk from k = k0 to
C̄ =
D I −C O k = N + k0 − 1.
−1
I −Dc 7.2 Calculate φj , mj , βj and Γj .
D̄ =
D I 7.3 Update θj according to (20).
Note that the inverse exists when the feedback loop is well- 7.4 Set k0 = N + k0 and set Cr and Dr
posed [5], for the case when D = 0, the feedback loop is according to (13)-(14).

always well-posed, i.e. the inverse always exists. Therefore, X̂ − N Q
7.5 If ≤ εe , then update Q(z).
the internal stability of the closed-loop is equivalent to the Ŷ + M Q ∞
condition that Ā is stable, i.e. end for.

A − BDc C BCc
Ā =
−Bc C Ac IV. L ABORATORY I MPLEMENTATION
is stable.
Applying
a state transformation with transfer matrix A. Description of the test rig
T O
T̄ = with the full-rank matrix T defined in (10), The test rig consists of basically two BLDC motors as
O I
then shown in Fig. 3, where both motors are mechanically coupled

Az − Bz Dc Cz Bz Cc with a torque measuring shaft. The Maxon motor is used here
Āz = as the test motor while the Nanotec motor is providing the
−Bc Cz Ac
time measurements from the Target PC and sends the tuned

parameters back to the Target PC.
B. HIL simulation result

In order to illustrate the effectiveness and the performance
ECU
ECU Torque measuring of the proposed algorithm in Section III, the HIL simulation
Shaft
has been carried out, in which the structure of Q(z) has been
defined as a constant (q = 0). During the HIL simulation,
Test Motor Load Motor
the control objective is to minimize the effects of the load
Maxon Nanotec and the fault on the tracking error where the reference signal
of the motor speed is given as 3000 rpm. Set the weighting
Fig. 3. BLDC motor test rig
factors in the cost function (19) equal to identity matrices
with appropriate dimension and the load profile applied is a
square wave. The first load period begins at 11 s, from 11
Host PC s to 16 s, the load provided by the Nanotec motor is with
constant current −0.1 A. From 16 s to 21 s there is no extra
(Q Tuning Algorithm)
load provided. This load period has been repeated during the
Tuned TCP/IP Real Time

Parameter Q Measurements Residual Signal
200
Residual without Optimization
150
Residual with Optimization
Target PC 100
50
Control Real Time -50

CAN bus Measurements
r
Signals -100
-150
-200
BLDC Motor
-250
Test Rig
-300
-350
0 1000 2000 3000 4000 5000 6000
Fig. 4. HIL simulation schematic Samples
Fig. 5. Residual signals

designed load profile on the test motor. The detailed technical
parameters can be found in the data sheets [25]–[27].
The real-time Hardware-in-the-loop (HIL) simulation has x 10
4 Detection Result
11
been realized with Simulink/xPC Target, which is demon- JRMS
10
strated in Fig. 4. After compilation of the simulation model, Jth,RMS
the speed controllers are implemented in the Target PC while 9
the current controllers are embedded in the motor electronic 8

control unit (ECU). Both the speed and the current controllers
Test Statistic
7
are PI controllers, where parameters of the current controllers 6
are tuned using the modulus optimum technique [9] while
5
the parameters of the speed controller are tuned using T-
4
Summenregel [28]. The proposed configuration algorithm is
located in the Host PC. 3
The communication between the hardware and the Target 2
PC is realized through CAN bus, where during the HIL 1

simulation, the Target PC is sending control signals to the 0
0 1000 2000 3000 4000 5000 6000
BLDC motors while the sensors are delivering real time
Samples
measurements to the Target PC. On the other hand, the
communication between the Target PC and the Host PC
is using TCP/IP protocol, where the Host PC receives real Fig. 6. JRM S test statistic and threshold Jth,RM S
Real−Time Optimization Results

3500
Fault
3000
2500
Motor Speed (rpm)
2000
3400
1500
3000
1000 2600
5000 5200 5400 5600 5800 6000

500
Motor Speed without Optimization

Motor Speed with Optimization
0
0 1000 2000 3000 4000 5000 6000 7000
Samples
Load Profile
-0.1A
11s 16s 21s 26s 31s 36s 41s 46s 51s 56s
Q0=0 Q1 Q2 Q3 Q4
Fig. 7. HIL simulation result
realized by adding a proportional gain in the control system.

x 10
6 Cost Function Fig. 7 demonstrates the effects of this fault on the measured
9.02 motor speed. The residual signals provided by the residual
generator are compared in Fig. 5, while the evaluation result
9.01
of the root mean square (RMS) value of the residual signal
J
9 according to [29] is given in Fig. 6. The post-filter Rf (z) can

be deigned to enhance the robustness of the residual signal
8.99
0 1000 2000 3000 4000 5000 6000 7000 rf (z) against unknown inputs and model uncertainties, more
−3 Updated parameterization matrix detailed design schemes are referred to [2]. Here the post-filter
x 10
0
Rf (z) is simply chosen as identity matrix.
−2
The update of the tuned parameterization matrix Q(z)
took place at 20 s, 30 s, 40 s and 50 s. Fig. 8 shows the
Q
−4
corresponding cost function J and the updated Q(z). It can be
−6
seen that the robustness of the system was gradually improved
−8
0 1000 2000 3000 4000 5000 6000 7000
after every update of Q(z).
Samples
V. C ONCLUSION
Fig. 8. Cost function and the updated Q(z) In this paper, based on the study on the Youla parame-
terization, an alternative realization is proposed which allows
the performance of the controlled systems to be improved
HIL simulation, as shown in Fig. 7. Additionally, a fault of without modifying or replacing the pre-designed control sys-
the actuator with power reduction of 20% at 30 s (3000- tems. Based on this alternative realization, an iterative online
th sample) is considered. In the HIL simulation, the fault is optimization approach with closed-loop stability guarantee for
the so-called Youla parameterization matrix is proposed. The [16] B.D.O. Anderson, “From Youla-Kucera to identification, adaptive and
proposed approach provides an easy option to enhance the nonlinear control,” Automatica, vol.34, no.12, pp.1485–1506, Dec. 1998.
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system robustness performance without affecting the closed- Birkhäuser, 1997.
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effectiveness has been demonstrated on a BLDC motor test kernel and image representations and their application to fault detection
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rig with a real-time HIL simulation. Under the designed load 2014.
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X̂
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Fault-Tolerant Control, Springer, 2003.
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[3] S.X. Ding, Data-driven Design of Fault Diagnosis and Fault-tolerant
Control Systems, Springer, 2014. Hao Luo (S’15) received his B.E. degree in elec-
[4] B.A. Francis, A Course in H-Infinity Control Theory, Springer-Verlag, trical engineering from XiAn Jiaotong University,
1987. China, in 2007, M.Sc. degree in electrical engi-
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Prentice-Hall, 1996. sity of Duisburg-Essen, Germany, in 2012.
[6] S.X. Ding, “Integrated design of feedback controllers and fault detec- He is currently working toward the Ph.D. de-
tors,” Annual Reviews in Control, vol.33, pp.124–135, Dec. 2009. gree at the Institute for Automatic Control and
[7] S.X. Ding, G. Yang, P. Zhang, E.L. Ding, T. Jeinsch, N. Weinhold and M. Complex Systems (AKS) at the University of
Schultalbers, “Feedback control structures, embedded residual signals, Duisburg-Essen. His research interests include
and feedback control schemes with an integrated residual access,” IEEE model based and data-driven fault diagnosis,
Trans. Control Syst. Technol., vol.18, no.2, pp.352–367, Mar. 2010. fault-tolerant systems and their application on
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Tuning, 2nd Ed., ISA: The Instrumentation, Systems, and Automation
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[10] J. Esch, T. Könings and S.X. Ding, “Optimal performance tuning of
a PI-controller for an integrator plant with uncertain parameters as a
convex optimisation problem,” 52nd IEEE Conference on Decision and Minjia Krueger received her B.E. degree in
Control, Firenze, pp.1977–1982, Dec. 2013. Measuring and Control from Huazhong Univer-
[11] A. O’Dwyer, Handbook of PI and PID Controller Tuning Rules, 3rd sity of Science and Technology,Wuhan, China,
Ed., Hackensack NJ: Imperial College Press, 2009. in 2008, M.Sc. degree in electrical engineering
[12] C-C. Yu, Autotuning of PID Controllers: Relay Feedback Approach, and information technology from University of
Springer Verlag London, 1999. Duisburg-Essen, Germany, in 2012.
[13] S. Yin, H. Luo and S.X. Ding, “Real-time implementation of fault- She is currently a Ph.D. student at the In-
tolerant control systems with performance optimization,” IEEE Trans. stitute for Automatic Control and Complex Sys-
Ind. Electron., vol.61, no.5, pp.2402–2411, May. 2014. tems (AKS) at the University of Duisburg-Essen.
[14] Y. Zhang, Y. Yang, S.X. Ding and L. Li, “Data-driven design and Her research interests include model based and
optimization of feedback control systems for industrial applications,” data-driven fault diagnosis, and their applica-
IEEE Trans. Ind. Electron., vol.61, no.11, pp.6409–6417, Nov. 2014. tions on industrial processes and renewable energy systems.
[15] T.T. Georgiou and M.C. Smith, “Optimal robustness in the gap metric,”
IEEE Trans. Autom. Control, vol.35, no.6, pp.673–686, Jun. 1990.
Tim Koenings received the B.Sc. degree and

the M.Sc. degree in electrical engineering and
information technology from the University of
DuisburgEssen, Duisburg, Germany, in 2009
and 2011.
He is currently working towards the Ph.D. de-
gree in the Institute for Automatic Control and
Complex Systems (AKS), Faculty of Engineer-
ing, University of DuisburgEssen. His research
interests include model-based and data-driven
control methods, fault-tolerant control systems,
and their application in industrial and automotive systems.
Steven X. Ding received Ph.D. degree in electri-

cal engineering from the Gerhard-Mercator Uni-
versity of Duisburg, Germany, in 1992.
From 1992 to 1994, he was a R&D engineer at
Rheinmetall GmbH. From 1995 to 2001, he was
a professor of control engineering at the Univer-
sity of Applied Science Lausitz in Senftenberg,
Germany, and served as vice president of this
university during 1998 to 2000. Since 2001, he
has been a professor of control engineering and
the head of the Institute for Automatic Control
and Complex Systems (AKS) at the University of Duisburg-Essen,
Germany. His research interests are model-based and data-driven fault
diagnosis, fault-tolerant systems and their application in industry with a
focus on automotive systems and chemical processes.
Shane Dominic received his Diploma (com-

bined Bachelor’s and Master’) in electrical en-
gineering and information technology from the
University of Duisburg-Essen, Duisburg, Ger-
many, in 2010. From 2010 to 2015 he worked at
the Institute of Automatic Control and Complex
Systems (AKS) at the University of Duisburg-
Essen. He got his Ph.D. degree in 2016.
His research interests include model-based
control, economic process optimization, neural
network-based nonlinear system identification,
regression techniques for time varying systems, and their application
to industrial systems.
Xu Yang (M’12) received the B.E. degree in

automation and the Ph.D degree in Control Sci-
ence and Engineering from University of Sci-
ence and Technology Beijing, in 2006 and 2011,
respectively.
He used to be a visiting scholar at the Insti-
tute for Automatic Control and Complex Systems
(AKS) , University of Duisburg-Essen, Germany,
from 2013 to 2014. He is currently an asso-
ciate professor in the School of automation and
electrical engineering, University of Science and
Technology Beijing. His research interests include modeling, process
monitoring, fault diagnosis and fault tolerant control system and their
application in complex industrial process with a focus on hot/cold rolling
mills.

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This article has been accepted for publication in a future issue of this journal, but has not been

Real-Time Optimization of Automatic Control

proposed approach has been successfully implemented in a d v

B. Problem Formulation III. O NLINE O PTIMIZATION OF AUTOMATIC C ONTROL

to unknown/unexpected disturbances or model uncertainties

where col(X) vectorizes X: To successfully generate θ to minimize the quadratic cost

Additionally, it is worth to notice that PI/PID controllers can ∂J −1

time measurements from the Target PC and sends the tuned

B. HIL simulation result

Tuned TCP/IP Real Time

Control Real Time -50

Fig. 5. Residual signals

the current controllers are embedded in the motor electronic 8

The communication between the hardware and the Target 2

PC is realized through CAN bus, where during the HIL 1

Real−Time Optimization Results

5000 5200 5400 5600 5800 6000

Motor Speed without Optimization

Fig. 7. HIL simulation result

realized by adding a proportional gain in the control system.

9 according to [29] is given in Fig. 6. The post-filter Rf (z) can

[1] M. Blanke, M. Kinnaert, J. Lunze and M. Staroswiecki, Diagnosis and

Tim Koenings received the B.Sc. degree and

Steven X. Ding received Ph.D. degree in electri-

Shane Dominic received his Diploma (com-

Xu Yang (M’12) received the B.E. degree in

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