Control device and control method

Abstract

A control device includes a timing detection unit, a setpoint path generation unit, and a control computation unit. The timing detection unit detects a timing at which an event indicating a change in a target setpoint or an event indicating application of a disturbance occurs, as a generation start timing at which generation of a path of a generation setpoint is started. The setpoint path generation unit determines the path of the generation setpoint in response to determination of the generation start timing at which generation of the path of the generation setpoint is started and outputs, in every control cycle, the generation setpoint that follows the determined path. In every control cycle, the control computation unit calculates a manipulated variable by performing control computation using a process variable and the generation setpoint as input values.

Claims

1. A control device, comprising: processing circuitry configured to detect a timing at which an event indicating a change in a target setpoint or an event indicating application of a disturbance occurs, as a generation start timing at which generation of a path of a generation setpoint is started; determine the path of the generation setpoint in response to determination of the generation start timing at which generation of the path of the generation setpoint is started and outputs, in every control cycle, the generation setpoint that follows the determined path; and in every control cycle, calculate a manipulated variable by performing control computation using a process variable and the generation setpoint as input values and output the manipulated variable to a control target, wherein the processing circuitry is further configured to determine the path of the generation setpoint to make the generation setpoint reach the target setpoint in a setpoint reaching period specified in advance, the generation setpoint being changed in accordance with a curved path, and an amount of change in the generation setpoint gradually become zero.

2. The control device according to claim 1, wherein the processing circuitry is further configured to determine the path of the generation setpoint that is an elliptic arc path.

3. The control device according to claim 1, wherein the processing circuitry is further configured to set an initial value for the generation setpoint to a value specified in advance.

4. The control device according to claim 1, wherein the processing circuitry is further configured to determine an initial value for the generation setpoint based on the target setpoint, a coefficient specified in advance, and a deviation between the target setpoint and the process variable at the generation start timing or an amount of change in the target setpoint before and after the generation start timing.

5. The control device according to claim 1, wherein the processing circuitry is further configured to set an initial value for the generation setpoint to a sum of the target setpoint and a value specified in advance or a difference between the target setpoint and the value specified in advance.

6. A control method, comprising: detecting a timing at which an event indicating a change in a target setpoint or an event indicating application of a disturbance occurs, as a generation start timing at which generation of a path of a generation setpoint is started; determining the path of the generation setpoint in response to determination of the generation start timing at which generation of the path of the generation setpoint is started; outputting, in every control cycle, the generation setpoint that follows the path determined in the determining step; and in every control cycle, calculating a manipulated variable by performing control computation using a process variable and the generation setpoint as input values and of outputting the manipulated variable to a control target, wherein, in the determining step, the path of the generation setpoint is determined to make the generation setpoint reach the target setpoint in a setpoint reaching period specified in advance, the generation setpoint being changed in accordance with a curved path, and an amount of change in the generation setpoint gradually become zero.

7. The control method according to claim 6, wherein, in the determining step, the path of the generation setpoint that is an elliptic arc path is determined.

8. The control method according to claim 6, wherein, in the determining step, an initial value for the generation setpoint is set to a value specified in advance.

9. The control method according to claim 6, wherein, in the determining step, an initial value for the generation setpoint is determined based on the target setpoint, a coefficient specified in advance, and a deviation between the target setpoint and the process variable at the generation start timing or an amount of change in the target setpoint before and after the generation start timing.

10. The control method according to claim 6, wherein, in the determining step, an initial value for the generation setpoint is set to a sum of the target setpoint and a value specified in advance or a difference between the target setpoint and the value specified in advance.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a block diagram illustrating a configuration of a control device according to a first embodiment of the present invention;

(2) FIG. 2 is a flowchart illustrating an operation of the control device according to the first embodiment of the present invention;

(3) FIGS. 3A and 3B are diagrams for describing a process of determining a setpoint path in the first embodiment of the present invention;

(4) FIGS. 4A and 4B are diagrams illustrating examples of a control response in the first embodiment of the present invention;

(5) FIGS. 5A and 5B are diagrams for describing a process of determining a setpoint path in a second embodiment of the present invention;

(6) FIGS. 6A and 6B are diagrams for describing a process of determining a setpoint path in a third embodiment of the present invention; and

(7) FIGS. 7A and 7B are diagrams for describing issues in the related art.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Principle of Embodiments of Invention

(8) In embodiments of the present invention, overshoot due to control in response to application of a disturbance or a change in a target setpoint is suppressed by generating a setpoint path having characteristics as follows:

(9) (A) A generation setpoint reaches the target setpoint in a setpoint reaching period specified in advance; and

(10) (B) The generation setpoint changes in accordance with a curved path, and an amount of change in the generation setpoint gradually becomes zero with time.

(11) With the characteristic (A), it is guaranteed that the generation setpoint reaches the target setpoint in the setpoint reaching period by setting the setpoint reaching period to a value smaller than or equal to a time interval defined by a operating condition of a control target even if the embodiments of the present invention are applied to the control target for which the target setpoint is repeatedly changed or a disturbance is repeatedly applied at the time interval defined by the operating condition of the control target. Accordingly, an issue in the related art disclosed in Japanese Patent No. 4310804 can be addressed.

(12) In addition, with the characteristic (B), since the generation setpoint takes a continuous behavior even when the generation setpoint reaches the target setpoint, a smooth and less-disturbed control response can be realized even if the embodiments of the present invention are applied to controllers having derivative compensation. Accordingly, an issue of the setpoint ramping function included in ordinary controllers can be addressed.

(13) Examples of a path that satisfies the characteristics (A) and (B) include an elliptic arc path. When the generation setpoint path is implemented as an elliptic arc path, the path can be generated by setting two parameters, i.e., the setpoint reaching period and intensity. Among these parameters, the value of the setpoint reaching period is set to a value smaller than or equal to a time interval that is defined by an operating condition of the control target. In this way, it is guaranteed that the generation setpoint reaches the target setpoint at the specified timing even if the embodiments of the present invention are applied to a control target for which the target setpoint is repeatedly changed or a disturbance is repeatedly applied. Thus, the generation setpoint based on the preceding target setpoint change or the preceding disturbance application no longer affects the following generation setpoint path, and the reproducibility of a control response is maintained every time the target setpoint is changed and every time a disturbance is applied.

(14) The intensity is a parameter for determining the initial value for the generation setpoint. As the initial value for the generation setpoint is closer to the value of the process variable, the control response becomes slower; however, an amount of overshoot can be suppressed. Conversely, as the initial value for the generation setpoint is closer to the value of the target setpoint, an amount of overshoot increases; however, the control response can be made faster.

First Embodiment

(15) A first embodiment of the present invention will be described below with reference to the accompanying drawings. FIG. 1 is a block diagram illustrating a configuration of a control device according to the first embodiment of the present invention. The control device includes a process variable input unit 1, a target setpoint input unit 2, a timing detection unit 3, a setpoint path generation unit 4, a control computation unit 5, and a manipulated variable output unit 6. The process variable input unit 1 inputs a process variable PV measured with a measuring instrument. The target setpoint input unit 2 inputs a target setpoint SP.sub.+ specified by a user of the control device. The timing detection unit 3 detects a timing at which an event indicating a change in the target setpoint SP.sub.+ or an event indicating application of a disturbance occurs, as a generation start timing at which generation of a path of a generation setpoint SP is started. The setpoint path generation unit 4 determines the path of the generation setpoint SP in response to determination of the generation start timing for generating the path of the generation setpoint SP and outputs, in every control cycle, the generation setpoint SP that follows the determined path. The control computation unit 5 calculates, in every control cycle, a manipulated variable MV by performing control computation using the process variable PV and the generation setpoint SP as input values. The manipulated variable output unit 6 outputs the manipulated variable MV to the control target.

(16) An operation of the control device according to the first embodiment will be described below with reference to FIG. 2. FIG. 2 is a flowchart illustrating the operation of the control device.

(17) The process variable PV is given from a device, such as a measuring instrument or a sensor (e.g., a temperature sensor) and is input to the control computation unit 5 and the timing detection unit 3 via the process variable input unit 1 (step S1 in FIG. 2). If the control variable PV is not used to detect the generation start timing (described later), the process variable PV need not be input to the timing detection unit 3.

(18) The target setpoint SP.sub.+ is set by a user and is input to the setpoint path generation unit 4 and the timing detection unit 3 via the target setpoint input unit 2 (step S2 in FIG. 2). If the target setpoint SP.sub.+ is not used to detect the generation start timing (described later), the target setpoint SP.sub.+ need not be input to the timing detection unit 3.

(19) The timing detection unit 3 determines whether the present time point is the generation start timing for generating the path of the generation setpoint SP (step S3 in FIG. 2). Examples of the generation start timing for generating the path of the generation setpoint SP include trigger timings such as events and alarms detected by general industrial measuring instruments. Examples of the generation start timing include

(20) (a) a timing at which the process variable PV becomes larger than or equal to a certain process variable upper limit,

(21) (b) a timing at which the target setpoint SP.sub.+ becomes larger than or equal to a certain setpoint upper limit,

(22) (c) a timing at which a deviation (SP.sub.+PV) becomes larger than or equal to a certain deviation upper limit,

(23) (d) a timing at which the process variable PV becomes smaller than or equal to a certain process variable lower limit,

(24) (e) a timing at which the target setpoint SP.sub.+ becomes smaller than or equal to a certain setpoint lower limit,

(25) (f) a timing at which the deviation (SP.sub.+PV) becomes smaller than or equal to a certain deviation lower limit,

(26) (g) a timing at which a timing indication signal is received from an external device, and

(27) (h) a timing at which a specified period T has passed since the change in the target setpoint SP.sub.+.

(28) The timing detection unit 3 determines that the target setpoint is changed or a disturbance is applied when at least one of the events (a) to (h) occurs and determines that the timing of the event is the generation start timing for generating the path of the generation setpoint SP. Which of the events (a) to (h) is or are to be used is decided upon depending on a target to which the control device according to the first embodiment is applied.

(29) If it is determined that the present time point is not the generation start timing for generating the path of the generation setpoint SP (NO in step S3), the setpoint path generation unit 4 outputs the generation setpoint SP that follows the already determined path to the control computation unit 5 (step S4 in FIG. 2).

(30) If it is determined that the present time point is the generation start timing for generating the path of the generation setpoint SP (YES in step S3), the setpoint path generation unit 4 determines the path of the generation setpoint SP (step S5 in FIG. 2).

(31) It is assumed in the first embodiment that the path of the generation setpoint SP is implemented as an elliptic arc path and that the initial value for the generation setpoint SP is directly set by the intensity described above.

(32) As illustrated in FIGS. 3A and 3B, the generation setpoint SP(t) at a time t is expressed by Equation (1) representing an elliptic arc path as follows:

(33) $\begin{array}{cc}\mathrm{SP}\left(t\right)=b+\left\{\left({\mathrm{SP}}_{+}-b\right)\frac{\sqrt{t\left(2a-t\right)}}{a}\right\},& \left(1\right)\end{array}$
where a denotes a setpoint reaching period taken for the generation setpoint SP to reach the target setpoint SP.sub.+ from the generation start timing for generating the path of the generation setpoint SP, b denotes the intensity, which is a value for setting the initial value for the generation setpoint SP, and t (0ta) denotes an elapsed time from the generation start timing for generating the path of the generation setpoint SP. FIG. 3A illustrates the case where a disturbance is applied, and FIG. 3B illustrates the case where the target setpoint SP.sub.+ is changed.

(34) In the first embodiment, since an initial value SP(0) for the generation setpoint SP is directly set by the intensity b, SP(0) is equal to b (SP(0)=b). As the setpoint reaching period a or the intensity b increases, the overshoot suppressing effect increases; however, the control responsivity decreases. Conversely, as the setpoint reaching period a or the intensity b decreases, the overshoot suppressing effect decreases; however, the control responsivity increases.

(35) The value of the intensity b is set in advance separately for the case where a disturbance is applied and the case where the target setpoint SP.sub.+ is changed. For example, when any of the events (a), (c), (d), and (f) occurs regardless of the fact that the target setpoint SP.sub.+ is kept unchanged or when a signal indicating application of a disturbance is received from an external device (event (g)), the setpoint path generation unit 4 uses the value of the intensity b set in advance for the case of application of a disturbance. For example, in the case where the first embodiment is applied to a control device that controls temperature (process variable PV) in a reflow oven, a control device (external device) that controls transportation of printed circuit boards is capable of sending a signal indicating application of a disturbance to the control device of the first embodiment at a timing at which printed circuit boards are put into the reflow oven. The value of the intensity b can be decided upon by a simulation performed in advance or a test performed at the production site.

(36) When a signal indicating a change in the target setpoint SP.sub.+ is received from an external device (event (g)) or if the specified period T has passed since the change in the target setpoint SP.sub.+ (event (h)), the setpoint path generation unit 4 uses the value of the intensity b set in advance for the resulting target setpoint SP.sub.+ after the change. For example, in the case where the first embodiment is applied to a control device that controls temperature (process variable PV) in a furnace for chemical manufacturing, the value of the intensity b can be set in advance for each value for the target setpoint SP.sub.+ since how the target setpoint SP.sub.+ is changed is known in advance.

(37) Note that the specified period T may be 0 or may be larger than 0 depending on the operating condition of the control target or the like. In addition, in the case where a notification is received from an external device, the notification may be delayed with respect to application of a disturbance or a change in the target setpoint SP.sub.+. Accordingly, the setpoint reaching period a needs to be set by taking these periods into account in advance.

(38) The setpoint path generation unit 4 then outputs the generation setpoint SP(t) that follows the path (Equation (1)) determined in step S5 to the control computation unit 5 (step S6 in FIG. 2). At the generation start timing for generating the path of the generation setpoint SP, the value SP(0)=b is output as described above.

(39) The control computation unit 5 calculates the manipulated variable MV on the basis of the process variable PV input from the process variable input unit 1 and the generation setpoint SP(t) input from the setpoint path generation unit 4 to make the process variable PV match the generation setpoint SP(t) (step S7 in FIG. 2). Examples of a feedback control computation algorithm include PID control computation. Since the PID control computation is a common technique, a description thereof is omitted.

(40) The manipulated variable output unit 6 outputs the manipulated variable MV calculated by the control computation unit 5 to the control target (step S8 in FIG. 2). The destination to which the manipulated variable MV is actually output may be, for example, an actuator that actuates a valve or the like or a relay or power conditioner (thyristor unit) that actuates a heater or the like.

(41) The above-described process including steps S1 to S8 is performed in every control cycle until the control ends (YES in step S9 in FIG. 2) in response to an instruction from a user, for example.

(42) In each control cycle, the generation setpoint SP(t) calculated using Equation (1) is output from the setpoint path generation unit 4 (step S4). In addition, when the elapsed time t since the generation start timing (t=0) for generating the path of the generation setpoint SP(t) reaches the setpoint reaching period a, the generation setpoint SP(t) reaches the target setpoint SP.sub.+. Thereafter, the setpoint path generation unit 4 maintains the generation setpoint SP(t) at the target setpoint SP.sub.+ (SP(t)=SP.sub.+) without using Equation (1) until the next generation start timing for generating the path of the generation setpoint SP(t) comes.

(43) FIG. 4A is a diagram illustrating an example of a control response when the target setpoint SP.sub.+ is changed in the first embodiment, whereas FIG. 4B is a diagram illustrating an example of a control response when a disturbance is applied in the first embodiment. As in FIGS. 7A and 7B, SP denotes a shaping amount of the generation setpoint SP(t) relative to the target setpoint SP.sub.+ (difference between the target setpoint SP.sub.+ and the generation setpoint SP(t)).

(44) A simulation result illustrated in FIG. 4A indicates that a desirable control response for which overshoot of the process variable PV is suppressed can be obtained and high reproducibility is realized in the first embodiment. Similarly, a simulation result illustrated in FIG. 4B indicates that a control response for which overshoot is suppressed can be obtained and high reproducibility is realized.

(45) An advantage of typical PID control is that it enables intuitive adjustment even if the model of the control target is unknown. The setpoint path generation technique applied to such control is often desired to have flexibility to the applied environment and good control reproducibility, rather than strictness emphasizing coherence of the physical model. In the first embodiment, overshoot of the process variable PV can be suppressed by implementing the path of the generation setpoint SP as an elliptic arc path, and the reproducibility of a control response can be realized even if the first embodiment is applied to a control target for which the target setpoint SP.sub.+ is repeatedly changed or a disturbance is repeatedly applied. In addition, as is apparent from comparison of FIG. 7B with FIG. 4B, since a decrease in the process variable PV due to application of a disturbance can be made smaller in the first embodiment than in the related art disclosed in Japanese Patent No. 4310804, the influence of the disturbance can be reduced and the control responsivity can be improved.

Second Embodiment

(46) A second embodiment of the present invention will be described next. Since the configuration of the control device and the flow of the process in the second embodiment are similar to those of the first embodiment, a description will be given using reference signs used in FIGS. 1 and 2. Differences between the second embodiment and the first embodiment are the process of determining the path of the generation setpoint SP(t) (step S5 in FIG. 2) and the process of outputting the generation setpoint SP(t) (steps S4 and S6 in FIG. 2).

(47) In the first embodiment, the initial value SP(0) for the generation setpoint SP(t) is directly set by the intensity b. In contrast, in the second embodiment, the initial value SP(0) for the generation setpoint SP(t) is determined using the target setpoint SP.sub.+, the intensity b, and a deviation I (=SP.sub.+PV) at the generation start timing for generating the path of the generation setpoint SP(t) or an amount of change I (=SP.sub.+(t)SP.sub.+(t1)) in the target setpoint SP.sub.+ before and after the generation start timing.

(48) As illustrated in FIGS. 5A and 5B, the generation setpoint SP(t) at a time t is expressed by Equation (2) representing an elliptic arc path as follows:

(49) $\begin{array}{cc}\mathrm{SP}\left(t\right)=\left({\mathrm{SP}}_{+}-bI\right)+\left\{bI\frac{\sqrt{t\left(2a-t\right)}}{a}\right\},& \left(2\right)\end{array}$
where a denotes a setpoint reaching period and t (0ta) denotes an elapsed time from the generation start timing for generating the path of the generation setpoint SP. FIG. 5A illustrates the case where a disturbance is applied, and FIG. 5B illustrates the case where the target setpoint SP.sub.+ is changed.

(50) As described above, I in Equation (2) denotes a deviation (SP.sub.+PV) at the generation start timing for generating the path of the generation setpoint SP(t) or the amount of change (SP.sub.+(t)SP.sub.+(t1)) in the target setpoint SP.sub.+ before and after the generation start timing. Here, SP.sub.+(t) denotes the target setpoint SP.sub.+ after the change, and SP.sub.+(t1) denotes the target setpoint SP.sub.+ before the change. In the second embodiment, the intensity b is set in advance as a coefficient (fixed value) which the deviation (or the amount of change in the target setpoint SP.sub.+) I is multiplied by.

(51) In the second embodiment, the initial value SP(0) for the generation setpoint SP is equal to SP.sub.+bI (SP(0)=SP.sub.+bI). As in the first embodiment, as the setpoint reaching period a or the intensity b increases, the overshoot suppressing effect increases; however, the control responsivity decreases. Conversely, as the setpoint reaching period a or the intensity b decreases, the overshoot suppressing effect decreases; however, the control responsivity improves.

(52) At the generation start timing for generating the path of the generation setpoint SP, the initial value SP(0) is output from the setpoint path generation unit 4 (step S6 in FIG. 2). In each control cycle thereafter, the generation setpoint SP(t) calculated using Equation (2) is output from the setpoint path generation unit 4 (step S4 in FIG. 2). In addition, when the elapsed time t since the generation start timing (t=0) for generating the path of the generation setpoint SP(t) reaches the setpoint reaching period a, the generation setpoint SP(t) reaches the target setpoint SP.sub.+. Thereafter, the setpoint path generation unit 4 maintains the generation setpoint SP(t) at the target setpoint SP.sub.+ (SP(t)=SP.sub.+) without using Equation (2) until the next generation start timing for generating the path of the generation setpoint SP(t) comes.

(53) The rest of the configuration of the second embodiment is as described in the first embodiment. In this way, advantageous effects similar to those of the first embodiment can be obtained also in the second embodiment. The intensity b need not be changed in the second embodiment although the intensity b needs to be changed every time the target setpoint SP.sub.+ is changed in the first embodiment.

Third Embodiment

(54) A third embodiment of the present invention will be described next. Since the configuration of the control device and the flow of the process in the third embodiment are similar to those of the first embodiment, a description will be given using reference signs used in FIGS. 1 and 2. Differences between the third embodiment and the first embodiment are the process of determining the path of the generation setpoint SP(t) (step S5 in FIG. 2) and the process of outputting the generation setpoint SP(t) (steps S4 and S6 in FIG. 2).

(55) In the first embodiment, the initial value SP(0) for the generation setpoint SP(t) is directly set by the intensity b. In contrast, in the third embodiment, the initial value SP(0) for the generation setpoint SP(t) is set to the sum of the target setpoint SP.sub.+ and the intensity b, which is a value specified in advance, or a difference between the target setpoint SP.sub.+ and the intensity b.

(56) As illustrated in FIGS. 6A and 6B, the generation setpoint SP(t) at a time t is expressed by Equation (3) representing an elliptic arc path as follows:

(57) $\begin{array}{cc}\mathrm{SP}\left(t\right)={\mathrm{SP}}_{+}b\left\{1-\frac{\sqrt{t\left(2a-t\right)}}{a}\right\},& \left(3\right)\end{array}$
where a denotes a setpoint reaching period and t (0ta) denotes an elapsed time from the generation start timing for generating the path of the generation setpoint SP. FIG. 6A illustrates the case where a disturbance is applied, and FIG. 6B illustrates the case where the target setpoint SP.sub.+ is changed.

(58) The symbol in Equation (3) indicates that the symbol is used in a circumstance where the generation setpoint SP(t) is increased due to application of a disturbance for decreasing the process variable PV or due to an increase in the target setpoint SP.sub.+ when the initial value SP(0) is smaller than or equal to the target setpoint SP.sub.+, that is, in the case of SP(0)SP.sub.+, and indicates that the symbol + is used in a circumstance where the generation setpoint SP(t) is decreased due to application of a disturbance for increasing the process variable PV or due to a decrease in the target setpoint SP.sub.+ when the initial value SP(0) is larger than the target setpoint SP.sub.+, that is, in the case of SP(0)>SP.sub.+.

(59) At the generation start timing for generating the path of the generation setpoint SP, the initial value SP(0) (=SP.sub.+b) is output from the setpoint path generation unit 4 (step S6 in FIG. 2). In each control cycle thereafter, the generation setpoint SP(t) calculated using Equation (3) is output from the setpoint path generation unit 4 (step S4 in FIG. 2). In addition, when the elapsed time t since the generation start timing (t=0) for generating the path of the generation setpoint SP(t) reaches the setpoint reaching period a, the generation setpoint SP(t) reaches the target setpoint SP.sub.+. Thereafter, the setpoint path generation unit 4 maintains the generation setpoint SP(t) at the target setpoint SP.sub.+ (SP(t)=SP.sub.+) without using Equation (3) until the next generation start timing for generating the path of the generation setpoint SP(t) comes.

(60) The rest of the configuration of the third embodiment is as described in the first embodiment. In this way, advantageous effects similar to those of the first embodiment can be obtained in the third embodiment. The intensity b need not be changed in the third embodiment as in the second embodiment although the intensity b needs to be changed every time the target setpoint SP.sub.+ is changed in the first embodiment.

(61) The control device according to each of the first to third embodiments can be implemented by a computer including a central processing unit (CPU), a storage device, and an interface and a program for controlling these hardware resources. The CPU performs the process described in each of the first to third embodiments in accordance with the program stored in the storage device.

(62) The embodiments of the present invention are applicable to various types of control, such as temperature control.