Multi-variable controller with integrated optimization procedure

Common control concepts in the process industry today are still almost exclusively based on PID controllers and also include manual intervention by the plant operator. In processes with complex dynamics, linked process variables or limitations, PID controllers reach their limit.

Additional weak spots are product or load changes which are generally carried out partly or completely by the plant operator. This causes variations which prevent optimum quality being maintained at all times.

However, if a process is to be operated close to the capacity limit, while at the same time minimizing waste and assuring the required quality, consideration of these precise boundary conditions in the controller strategy is absolutely essential.

By carefully applying advanced modern control procedures (Advanced Process Control, APC), the process industry has real leverage available for reducing costs and increasing quality. Advanced Process Control establishes process optimization as a link between the planning and scheduling functions of the execution level as well as the process control functions of the control level.

Of all the modern control procedures, Model Predictive Control (MPC) has emerged as the most suitable approach in numerous applications. MPC simplifies the handling of complex plant dynamics, permits the early elimination of faults, takes into consideration the plant limitations, and allows complex process control strategies.

INCA MPC

This procedure is also used by INCA MPC, a multi-variable controller of the latest generation. INCA MPC differs from classic MPC controllers due to a series of functional extensions. Modern modeling methods, automatic step test and modeling methods, bumpless switching between different models (multi-model handling), expansions for batch process optimization, non-linear predictions, and a high quality of control are setting new standards and enable the control of non-linear processes as well as plant-wide optimization.

A web-based INCA MPC, available since July 2015, significantly reduces the time required for implementation and can handle stricter IT security rules.

The INCA MPC software itself runs on a separate PC/server with Windows 7, Windows 8 or Windows 10 operating systems.

Note:

INCA MPC can be used together with SIMATIC PCS 7 V7.1, V8.0, V8.1 and V8.2. In SIMATIC PCS 7 V8.2, INCA MPC or INCA Sensor can be integrated via the APC (advanced process control) coupling module of the SIMATIC PCS 7 Industry Library as of V8.2 Update 1.