A method includes obtaining data associated with operation of a model-based industrial process controller. The method also includes identifying at least one estimated impact of at least one operational problem of the industrial process controller, where each estimated impact is expressed in terms of a lost opportunity associated with operation of the industrial process controller. The method further includes presenting the at least one estimated impact to a user. The at least one estimated impact could include impacts associated with noise or variance in process variables used by the industrial process controller, misconfiguration of an optimizer in the industrial process controller, one or more limits on one or more process variables, a quality of at least one model used by the industrial process controller, a quality of one or more inferred properties used by the industrial process controller, or one or more process variables being dropped from use by the industrial process controller.

A method includes obtaining data associated with operation of an industrial process controller and identifying impacts of operational problems of the industrial process controller. The method also includes generating a graphical display for a user, where the graphical display presents one or more recommended actions to reduce or eliminate at least one of the impacts of at least one of the operational problems. The method further includes triggering at least one of the one or more recommended actions based on input from the user. The method could also include executing one or more analytic algorithms to process the obtained data and identify the operational problems of the industrial process controller. Each of the one or more analytic algorithms could be instantiated as a container, and multiple containers could be instantiated and executed as needed. Results of executing the one or more analytic algorithms could be transformed into a standard format.

A method includes obtaining data identifying values of one or more controlled variables associated with an industrial process controller. The method also includes identifying periods when at least one of the one or more controlled variables has been moved to an associated limit by the controller. The method further includes, for each identified period, (i) identifying a standard deviation of predicted values for the associated controlled variable and (ii) determining a control giveaway value for the associated controlled variable based on the standard deviation. The control giveaway value is associated with an offset between the associated controlled variable's average value and the associated limit. In addition, the method includes identifying variances in the one or more controlled variables using the control giveaway values and generating a graphical display identifying one or more impacts or causes for at least some of the variances.

An actuator simulator card that is programmable with one or more actuator simulation models is provided. The actuator simulator card may include a first interface configured to communicate with a programmable computer, a second interface configured to communicate with an actuator controller, and a simulation module in communication with each of the first interface and the second interface. The simulation module may be configured to receive at least one actuator simulation model corresponding to at least one actuator from the first interface, receive excitation signals and command signals for operating the actuator from the second interface, and determine simulated feedback signals based on the excitation signals, the command signals, and the actuator simulation model.

A method includes obtaining data associated with operation of a model-based industrial process controller. The method also includes identifying at least one estimated impact of at least one operational problem of the industrial process controller, where each estimated impact is expressed in terms of a lost opportunity associated with operation of the industrial process controller. The method further includes presenting the at least one estimated impact to a user. The at least one estimated impact could include impacts associated with noise or variance in process variables used by the industrial process controller, misconfiguration of an optimizer in the industrial process controller, one or more limits on one or more process variables, a quality of at least one model used by the industrial process controller, a quality of one or more inferred properties used by the industrial process controller, or one or more process variables being dropped from use by the industrial process controller.

A method includes obtaining data associated with operation of an industrial process controller and identifying impacts of operational problems of the industrial process controller. The method also includes generating a graphical display for a user, where the graphical display presents one or more recommended actions to reduce or eliminate at least one of the impacts of at least one of the operational problems. The method further includes triggering at least one of the one or more recommended actions based on input from the user. The method could also include executing one or more analytic algorithms to process the obtained data and identify the operational problems of the industrial process controller. Each of the one or more analytic algorithms could be instantiated as a container, and multiple containers could be instantiated and executed as needed. Results of executing the one or more analytic algorithms could be transformed into a standard format.

A system includes an apparatus and a processor. The apparatus includes a set of actuator elements that move between two positions. Each actuator element is comprised in: exactly one first subset out of a plurality of non-empty first subsets and exactly one second subset out of a plurality of non-empty second subsets. The processor is configured to generate one or more control commands for a group of subsets out of the first and the second pluralities of subsets in response to a number of moving elements which, if released from the first extreme position during a second sampling cycle, enables production by the apparatus during the second sampling cycle of a sound.

A system includes an apparatus and a processor. The apparatus includes a set of actuator elements that move between two positions. Each actuator element is comprised in: exactly one first subset out of a plurality of non-empty first subsets and exactly one second subset out of a plurality of non-empty second subsets. The processor is configured to generate one or more control commands for a group of subsets out of the first and the second pluralities of subsets in response to a number of moving elements which, if released from the first extreme position during a second sampling cycle, enables production by the apparatus during the second sampling cycle of a sound.

A controller is configured to control a system by generating a control input to an actuator changing a state of the system in accordance with the control input. The controller includes an interface configured to receive data indicative of dynamic response of the actuator and a tuner configured to determine the maximum rate of change of the control input during a control cycle using the received data indicative of dynamic response of the actuator. The controller also includes a receiver configured to receive measurements of the state of the system and a solver configured to determine a current value of the control input for controlling the controlled system based on the state of the controlled system subject to constraints on operation of the system and a constraint on the maximum rate of change of the control input, and to cause the actuator to change the state of the system according to the current value of the control input.

A system includes an apparatus and a processor. The apparatus includes a set of actuator elements that move between two positions. Each actuator element is comprised in: exactly one first subset out of a plurality of non-empty first subsets and exactly one second subset out of a plurality of non-empty second subsets. The processor is configured to generate one or more control commands for a group of subsets out of the first and the second pluralities of subsets in response to a number of moving elements which, if released from the first extreme position during a second sampling cycle, enables production by the apparatus during the second sampling cycle of a sound.