Development of nonlinear control algorithms for implementation in distributed systems

Thesis submitted in fulfilment of the requirements for the degree Master of Technology: Electrical Engineering in the Faculty of Engineering at the Cape Peninsula University of TechnologyIn the past decade, the need for flexibility and reconfigurability in automation has contributed to the rise of the distributed concept in control systems engineering. The IEC 61499 standard is used to define a distributed model for dividing various components of an industrial application in automation process and complicated control of machinery into function blocks. Such function blocks have the flexibility to be distributed and interconnected across a number of controllers. However, this new standard for automation faces two main challenges: the complexity in designs of distributed systems and the lack of utilization of the standard in industry. Most applications of controllers based on functional block programming are for linear systems. As most of industrial processes are nonlinear there is a need to extend the functional block approach for implementation of nonlinear controllers. Design complexity involves the exact modeling of the system in function blocks to obtain its accurate behaviour and the lack of utilization of the standard is understandable because new technologies are not easily accepted in industry due to their high prices and risks of compromising the performance at the production level. The thesis describes a methodology for design and implementation of nonlinear controllers for nonlinear plants in IEC 61499 standard compliant real-time environment of TwinCAT 3 and Beckhoff Programmable Logic Controller (PLC). The first step is to design the nonlinear controllers and simulate the closed-loop system in MATLAB/SIMULINK software. Then the new engineering based concepts to transform the obtained closed-loop system model to an IEC 61499 Function Block Model. This is accomplished by applying one method which involves a complete model transformation between two block-diagram languages: Simulink and TwinCAT 3. The development tools that support the transformation algorithm in the thesis sets the foundation stone of the verification and validation structure for IEC 61499 function blocks approach. The transformed model of the closed-loop system is downloaded to the Beckhoff PLC and is simulated in real-time. The obtained results demonstrate that the developed methodology allows complex nonlinear controllers to be successfully transformed to IEC 61499 standard compliant environment and to be applied for real-time PLC control of complex plants