MULTIVARSABLE CONTROL OF WEB PROCESSES

A thesis submitted in conformity with the requirements for the degree of Master of Applied Science Grauate Department of Electrical and Cornputer Engineering University of Toronto

@ Copyright by Gaby Saad 2000

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In loMng memory of my father, George Saad

Multivariable Control of W e b Processes Gaby Saad

Master of Applied Science

Graduate Department of Electrical and Cornputer Engineering University of Toronto 2000

Abstract
Web-handling machinery abound in industries that process long, thin material such as nIm,paper, textiles and even thin metals. Ail the processing is done as the materid is rewound into a roU.

Closed Ioop control i required to regdate the line (web) speed, and the tension of the web in the s various processing stations. These s p d', ions are met using actuators that essentiaiiy 'pullnon the web to create the desired tension. UntiI recently, industry has relied exciusively on the classicd PID controller that is tuned online by aa operator.
This thesis takes a novel approach-it studies the appticability of recent advances in optimal frequency domain control techniques, namely H control, to web processing. Vanous models of the ,

winding process are developed and used to design N controllers. These are experimentdy verified , on an industriai machine at the University of Toronto.

Acknowledgements
1would Lre to thank m y supervisor Bruce Rancis for all the academic, financial and moral support

he provided as a mentor.
It goes without saying thst 1am indebted to the Natural Sciences and Engineering Research Council

of Canada for aU their hanual support for the past two years, and VRP Web Technologies for providing me with an interesting experimentai testbed for my education in the area of controi engineering.
Iyvespent sorne great times here in Tomnto with the wonderhl group of people that make up the
Systems Control Group. 1 am especially grateful to Shahriar Mirabbasi for making m y transition

to SCG as smooth as possible.

This past year has been especiaily tough-1 wodd never have survived it without the constant support of Ken Pu, Weixuaa Liu, Karak Shaw and Walid Cheaib.

Most importantiy however, 1 thank my parents and family f r being the wind beneath my wings. o

Contents
1 Introduction
1.1 The VRP/Rotoflex web machine 1.2

............................. Rom r d web dynamics to the scope of this thesis . . . . . . . . . . . . . . . . . . . 1.2.1 Orgaaization of this thesis . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
....................................... Mathematical tools to mode1 the web . . . . . . . . . . . . . . . . . . . . . . Teasion variation i the contact region . . . . . . . . . . . . . . . . . . . . . . n Modeiing tension variation in a fiee span . . . . . . . . . . . . . . . . . . . .

1 2
3

7
8

2 Modeling and Current Control Technology of W e b Procesees

2.1 W e b dynamics 2.11 2.1.2 2.1.3

2.2

9
9
11
15

biler dynamics 2.2.1

.......................................
...................

Umoundroilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Interaction between the web and the roiIers

17
18

222 ..
2.3

Overall mode1 for N-span web systems . . . . . . . . . . . . . . . . . . . . . . . . . . 19 2.3.1 Reduced order mode1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.4.1

2.4 Control of web processes: Industrial practice

...................... Centrahed contml . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

........................ .............................

22 26
28

3 Modern ikequency Domain Multivariable Design

3.1 Notation and mathematical prelirninaries

29
29

3.1.1 3.1.2

Si@

and system n o m

Some usefulmatrix identifies

...........................

31

3.2 9&, Control

3.2.1
3.2.2
3.2.3

... The Linear Matrix Inequaiitiea Way . . . . . . . . . . . . . . . . . . . The bounded real lemma . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lineas matrix inequalities and semidehite programming
ControUer synthesis

31

31 36

...........

3.3

................................ Extensions of the basic theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.1 3.3.2

38
42
43
48

a.stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Gain-scheduied control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 Control of W e b Processes
4.1 Reduced order web mode1
4.1.1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
..............................
51

How good is the modei?

4.1.2

413 ..
4.1.4
4.2.1

Nominal performance of the L I system . . . . . . . . . . . . . . . . . . . . . 51 T The effect of radius change . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Single shaft control: a modular methodology
Nominal controk design

..................

64

4.2 F'ullorderwebmodel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
4.2.2

Gain-scheduled design

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
7Q

5 Conclusion

5 1 How do our controllers fme-advantages and disadvantages of 'Hm control .

......

80

5.2 Future directions in web research

.............................

82
83

A Guide to control design with matlab

A.1 Defining the plant

A2 .

..................................... Deeigningthecontroiier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
..............................

83
85 87

A.3 Design for the NI-order mode1

Bibliography

Summary of Notation and Terms

Web Terminology
A rouer that accumulates material A r o k that gives out materid A r o k that simply supports a web span Two transport rollers pressed against each other to ansure no-slip contact A r o k that is actuated using a motor A rouer that is not driven The portion of web between two rollers Also caiied the Belt Equation-it is an inequaiity that reIates the tension drop across a roller A swiveiing platfonn that corrects the lateral sway of the web Direction paralle1 to web's Iongitudinal direction A device that measures web tension A rouer that cm be displaceci to change span length and hence control tension Sideways motion of web dong the length of the roller Transverse vibration of the web

Driuen Roller Passive Rol ter

R t e Span
Capstan's Fonnula

Steering Guide

Machine Direction

h a d Cell Dancer Roller

Web Weuve Web Flutter

Web SymboIs
Radius of roller without web (for transport roiiers r = ro) Radius of mUer (with or without web on) Inertia of bare roller Inertia of roller with web on External torque appiied to rouer Total kictiond torque on rouer Static fkiction torque Damping coeicient Anguiar position of roiier Peripheral speed of rouer Web's density Web's linear density (dong machine direction) Web's modulus of elasticity Web's cross sectional area Web's width (lateral direction) Web's thickness Tension in web Span length Stress in web Strain i web n

Signals and Systems

Signah or Systems (depending on context) Linearized signais Laplace transf'orm of signal y Trader matrut of system G The pnorm of vector x. If unspecified, p=2 The p n o m of signa3 x. If unspecified, p=2 The p n o m of a system G. If unspecfied p = oc Singular values of system G

Maximum aingulat value

vii

Chapter 1

Introduction
The term web is nsed to describe any long, thin, continuous and flexible materid such as paper, film and textiles. W b procedng rnachinery is used extensively in industry because it is a cost e effective method of material h d l i n g and processing.
A simple example of a web process i a magnetic tape reader: The web in this case i the tape itself, s s

which i transported fkom one mUer (the unwinder) to another (the rewinder). A magnetic head s reads the information on the tape as it is conveyed from one end to the other. Other examples of web handling machinery include textile manufacturing processes, printing pressas and so forth.

A schematic diagram of the VRP/Rotoflex machine is shown in Fig. 1.1. The web ia pulied fiom the unwinder to the rewinder via its tende force (this i an interna1 force that is generated while the s machine is operating). In a rnanufacturing industry, the web typicdy undergoes various processing stages, each of which both requires a certain tension level in the material and also affects the tension
in the web. Moreover, to increase throughput, manufacturers are running web processing machines at ever increasing speeds. These changes in industry have placed a high demand on more accurate
control of the web's motion and tension.

Section 1.1. The VRP/Rotoflex web m&e

Figure 1.1: Schemstic of the machine at the University of Toronto

11 .

The VRP/Rotoflex web machine

In reference to the achematic (Fig. Ll), the web machine at the University of Toronto consists of

three driven rollers the two winders and the S-wrapped nip section. The remaining rollers are a,ii
passive and help support the moving web. Each of the three active roilem is equipped with a shaft encoder to measure its angular speed. On some industrial machines, brakes and clutches are used to control (more poorly, yet more cost-dectively) the tension. The web tension is measuseci using a strain-gauge based load ceil. There are two of these tension tramducers, one in the rewind zone and the other in the unwind zone. These are separateci fiom the respective winder by a passive rouer to make sure that the angle of wrap (subtended by the

material on the traasducer) remaias constant throughout the winding process. The radii of the winders are measured via ultrasonic sensors.

The steeruig guide is uaed to correct the lateral sway of the web during machine operation. A light sensor is used to deteet the edge of the material, which in hirn rotates the guide and forces t ha web to vaer t o m & the proper lateral position (much lk a steering wheel tunu, a car left or right). ie

Sction 1.2. Ekom red web dynamics to the scope of t b the&

Contrer of the machine ie implemented via VRP's Multiple Tension Speed ControlIer(MTSC).The MTSC consists of four shaft control modules ptoviding torque commands to the motor drives, three tension control modules, two diameter modules and a reference speed module. The MTSC gives the user the c a p e to impiement various control schemes, both open and closeci loop. The MTSC &O implernents a Syatem State Controlln; which govarns the overall operation of the m c i e for ahn, example the startup and shutdown procedures.

AU processing i done via a digital signai procesaing board. s

1 2 Ekom real web dynamics t o the scope of this thesis .

The web is an example of a continuum and this makes it dinicult to obtain a good and simple mathematical model for the system. The dynamics of the web are described by a set of highly nonlinear partial differentiai equations that govem the motion of aU elastic bodies. The interaction between the roiier and the web further complicates the modehg because the physics of the contact region is neither hilly understood nor weii modeled. That being said, it is important to derive a simple model that at least approximates the behaviour of the system.

The behaviour of the web during the winding process i complex (the interested reader i referred s s to [36,37, 351 for a broad discussion on all aspects of web processing). Figure 1.2 depicts two of
the typicd anomalies of web motion.
1

Figure 1.2: Flutter and Weam during machine operation

Web weave is the sideways motion of the span, while web flutter i its transverse vibration. These s &ts are undesirable becaiise they Iead to a poorly wrapped end product. The mechanismg that lead to weave and flutter are not, and caanot be, weii modeled, because they are numerous and complicated. For instance, weave is generated when a roll i initidly poorly wrapped or when s

Section 1.2. h m d web dpamics to the scope of thLs thesis

rollers are not mounted perfectly p d e l . Web Butter i analogous to the vibrating string problem, s that is, giVM a portion of web between two rollers (a fke span), with a nominal tension, then it

behaves iike a taut string, and i amenable to dassical vibration analysis. s

This thesis will not adcimas the aforementioned problems. There is, however, ample litereture that

deah with weave [45,38, 10,471 and web flutter contrd [29,24]. We wl focw on longitudinal (i.e.,
machine irection) tension dynamics.

There is a wedth of literatnre o n the control of longitudinal tension, m g i n g f h m the mundane

to state of the art (an excellent overview of web tension control i given in [54]). Most methods

s ologies however are based on a moddar control design process, that i, the controi problem of the
multivariable plant is reduced to a number of SIS0 control problem. The coupling between the subsystems is reduced, when possible, by feedfomrd control otherwise it is simply ignored. Some attempts have been made in more formal decentralized control techniques [56,39] and fuzzy control

[3Y. These design tediniques are d bmed on mode18 derived h m physicd principles. A novel l
attempt at LQG control wae mada in [7,30] whereby the mode1 was obtained by recent techniques
in subspace identification.

This thesis studies the application of 3, optimisation to web control. Whst is H 1 ',
d
r

control?

Figure 1.3: One degree of freedorn controller

Figure 1.3 shows the typical one degree-of-keedom control syatem, consisting of the fsmily of
plants P

+ A, and a controller K in the standard codguration. The sensitivity function S = (1- (P+ A)K)-L maps the reference signai r to the error signal e, that is, e = Sr. The e f k t

of a disturbance d on the output y i aLso given by S. It i clear then that for good tracking and s s disturbance rejection, we shodd try and make S as mail as possible; the control objective is to

Section 1.2. &om real web dpamics to the scope of this thesis
choose K so that S has a desireci shape.

It is not dear how a given choi of K &ects the shape of S since the sensitivity function is a nonnear function of the controuer. One way to deal with the problem is to design based on the open loop system. That is, instead of deaihg with the dosed loop tramfer function, we shape the quantity PK. Since the mode1 P i typically available, a c o n t r o k K can be design& so that the s s product PK has a desirable shape-one that would ensure that S i small. This technique is called open loop shaping.
For SISO systams, open loop shaping i typicdy done using lead lag compensation. Robustness s i incorporated into the design by pre-specifying quantities such as gain rnwgin and phase margin. s

T i begs the following questions: hs

1. b it possible to shape the closeci loop traflsfer fwiction immediately, without resorting to shaping PK?

2. How can these ideas be extended to znuitivariable systems?

3. Can we attach an optimality criterion to the control design process?

, Figure 1.4 illustrates the bode plot of a SISO system G(s). The R
over aii frrguencies, attained by the bode plot, and i denoted by s

n o m i the maximum value, s

IIClloo.

Consider the constraint shown in Figure 1.5 where the transfer function forrns an upper bound for
the set of acceptable sensitivity functioas SCjw). That is, for al1 equencies w , we want

which is the same as requiring that

Setting W :=

h,we see fiom (1.1) that 11WSlloD 1. Clearly, if we wish to shape S to be bounded 5

nom above by M, then we have to study the 3L, n o m of the transfer function WS. And that, in a nutsheil, is what Tloo optimisation ig all about.
s The goal of t h thesis i to show how the ideas of optimal frequency domain control techniques can be be applied to solve an industrial control problem.

Section 1.2. Rom real m b dyntllpl*cs to the scope of t6is thesis

.---\ nom

Figure 1.4: The N ,

n o m of a transfer function

Figure 1.5: The ')loo n o m of a transfer function

Section 1.2. Rom real web dp-CS

to the scope of this thesis

121 ..

Organhation of this thesis

We discuas at length the procedure that i used to obtain a mode1 of a web machine in Chapter 2; s both a IheaOaed model and a reduced order model (for stiff web) will be derived, and we end the chapter with a g e n d discuagion on curent control technology such as the one used in the MTSC. I Chapter 3 we review the fairly recent formulation of H control in the context of linear matrix n ', inequalities. T i technique proves to be Iess restrictive on the system's structure than the classical hs solution obtained in the late eighties, and can be extendeci quite naturdy to deal with gainscheduiingypartial pole placement, and mixeci-objective controller synthesis.
Chapter 4 delves into controller design and implementation on the research machine at the University of Toronto. The designs are based on both the reduced and f i l order models. The results il
WU then be compareci to the existing controller.

This thesis is an appiication of recent advances in process control techniques. The models that are
derived assume that there i no s& s i in the web, and if this condition is not met the controiier is no longer valid. It i therefore necessaty to impose a logic based controler that determines when s the web i slack, and command the motors in a different fashion when that happens. s

Chapter 2

Modeling and Current Control

Technology of Web Processes
This chaptec outlines the physicai principles used to model web processes. We first study one
dimensional tension dynamics of web, then rouer dynamics. The equations we derive are combined
to form a model for the o v d system, which are then reduced using simplifying assumptions. We

end this chapter with a discussion on current control philosophy.

2 1 Web dynamics .
Every eiastic body abject to external forces has a 3x3 stress tensor associated with it. This
coasisfs of six independent quaritities, namely thtee normal stresses and three shear stresses. The

tensor associateci with the web in a fkee span is a function of both position and t h e . One may

proceed to express the constitutive relationships for the elastic body and impose the continuity and
compatibility constraints to obtain a set of highly noaiinear partial dinerential equations [48]. For the purpose of analyais and control design, this is not practical. W e therefore mort to simpiifjhg assumptions that wiU Iead to a more tractable formulation of the plant model.

Section 2.1. Web dynm*c9

21.

Mathematical tools to mode1 the web

Web dynamics are g o ~ e ~ n e d Newton's laws of motion. A system S of particles subject to a net by

extemal force FM behaves according to the relation F = mscrs, where rns is the total m s of & as S, an as i the acceleration of the centre of m s . T i form of Newton's laws i convenient to s a s hs s anaiyae systems whose kinematic and dynamic properties we are interested in. IIouever, in the case of web handng machinery, we are concemed with the dynamic properties in dinerent regions o space (the variou frae spans) and not the t h e ewlution of the properties of soma portion of f
the web. Newton's laws may be rewritten to describe the dynamics of a region of space. This procedure is known as Control Volume Analysis and is described in ali textbooks on mechanics of continua.

The fundamental principles of Control Volume Anaiysis are the Iaws of conservation of mass and

momentum. These are used extensiveiy to understand the physics of web motion.
Conservation of Mass:

The mte of

moss

accumulation in a control uolume (CV), kt egual to the sum of the net rate

of

mass inflow into the CV and the nate of mass genemtion uithin the CV.

Conservation of Momentum: The net edernal impube applied to a contml uolume, is equal to the m m o the net change in f momentum in the CV, the net outflow o momentum jbrn the CV, and the momentum genemted f
wthin the CK

212 ..

Tension variation in the contact region

As the web i transported h m the unwind roll to the rewind roll, if experiences a contact force s

from each of the rollers it embraces. The dynamics of the contact region is compIex, and modem day theories in tribology and contact mechanics suggest that there exist microscopie regions in which the web usticks" to the ro11er (i.e., th- i no relative motion between thern) and regions where slip s occurs. There need wt be a d a t i v e ordering of t h e stick-slip regions; however it is p r a e t i d to assume, as Brandenburg [52] postulates, that the contact zone may be q t into three distinct regions as seen in Figure 21 There i an entry r g o of relative slip, foliowed by a stick zone .. s ein (characterized by rolling contact between the web and rouer), foiiowed by an exit region of slip.

Section 2.1. Web dmcs

wb e

* 'F
eatn
E

Zoat

"

=
s . .

. Exit * Exit srip

* '

ZOiM

Figure 2.1: The Contact Region

Brandenburg furthe. argues that if tension varies at a sutnciently slow rate, then the entry region of slip vanishes. This assumption is welI founded if the web's high frequency dynamics are ignorecl. s Practically speaking? it is imperative that the no-siip condition prevail so that there i traction between the two surf'es and the tension in the web can be controlled.
It may also be possible that the stick zone completely vanishes. If one uses Coulomb's simple friction model, the existence of either a stick-slip or a pure slip zone is a function of the normal force, N,

and the appiie torque. Indeed, the weli-known belt

~,e*@r (Capstan's formula), (where /3 i the wrap angle, p i the coefkient of kinetic fkiction, and T the tension in the web s s , upstream of roiier n), is applicable and its derivation can be found in ail standard texts on the mechanics of materials [9]. The greatest possible tension &op aaoss the rouer occurs when the entire wrap angle i chazacterized by a condition of slip-it signals the point when control over the s s state of the system i lost.
equation

<

How then can someone determine whether slip or stick-slip contact will prevail? This is done via a

simple model of kiction. C u o b s model of friction assumes that static friction exists in a system olm'

if the applied force (torque) is las than some saturation value, which is a function of the normal force of contact and the co&cient of static friction, The friction is then identical to the applied
force (torque). If this limit i surpassed, the fictional force is then taken as a constant, with a s vaiue of pN.

Section 2.1. Web dynamites

213 ..

Modehg tension variation in a fhe span

T obtain the Misential equation that describes the variation of tension i open *ans, we make o n use of the hw of conservation of ma=, as defined i Section 211 The control volume used in the n ...
analysie i iIluated in Figure 2.2; it indudes the region of embraee of the upstream roiler and the s
hee span, enclhg at the point of contact of the dowmtream roller.

Figure 2.2: The control volume used

It i a k t that there is a direct relationship between the force apped to an elastic material and s the resuiting amount of stretch. Assuming that the web is perfectly elastic, the tension and the stretch are dizectly proportionai. Engineering strain, c, is defned ap the ratio of material extension to the original length in the material (i.e., the percentage increase i length). The stress, o,L the n

ratio of internal force in the material (Le., tension) to the cro8&sectionalarea For elastic materials, o = Ee, where E is Young's modulus o elasticity. f
Consider, as in Figure 2.3, a portion of the web material of mass m and initial length Io.

I [ Unstrctched Wcb
1

St~~ichcd Web

Figure 2.3: Linear demity of the web

* Defining the linear density of the unstretched web as A, = so' we see that once it is stretched to a length of 1 = lo + At, its linear density becornes

Section 2.1. Web dyn-CS

Figure 2.4: Magnifiecl view of the control volume

We see in Figure 2.4 a rnagnified view of the control volume taken around span n of an N span system. The web enters the frea span with a linear velocity of wn-i m/s and exits at wn m/s. The subscript n wiii be attached to d properties of the nt&span ( n - 1' then represents the preceding i ' span). Note that in Figure 2.4, the location x dong a span starts just beyond the slip zone of the upetream r o h . We shall also place the superscripts + and - to denote properties at x = O carid
x = I,,respectively.

We c m now apply the law of conservation of mass (continuity equation). The net mass infiow is simply

q-l

The rate of mass change i the control volume i given by n s

whae we have ignored the slip zone since its length i negligible compared to the span Iength. s Since no material was magicaily iqjected into the span (hence rate of mass generation is O), the continuity equation i simply given by s

Equation 2.2 is the most g e n d expression of one dimensional mas continuity in a free span.

The distribution of linear density dong the Iength of the span is generally cornplex, and thus (2.2)
i rather unidormative. It cm, howavar, be massaged to a useful form upon introducing hirther s
simplifying assumptiona.

We begin by noting that, in general, the m s of the web in a span i negligible (compared to the as s uUernal stress in the material). Consider the control volume shown i Figure 2.5 and note that it n

Section 2.1. Web dmcs

13

starts just beyond the slip zone of the upstream rouer. There is a skin hictional force, f,,acting

on the face of the web as it moves across the air, which we wiil asaume to be distributed unifonaly across the face, Web Motion

Skiu Friction with air

+x
Figure 2.5: Force d y s i s on a the control volume

A straightforward momentum balance in the control volume gives

Indeed, if we consider a dinerential contml volume, then under the msumption that the fiction i s

d o r m l y distributed, we h d that
G n fn -= - = constant,

&

r,

which implies that

Although the behaviour of different webs under load varies &om material to material, we begin by making the standard assumption that the elastic deformation is Hookeian (Le., on = T,JA = E,
applies, where A is the material's cross sectional area). W further assume that the material i e s

fairly stif. Under those assumptions, (2.1) leads to

Combining (2.5)-(2.2), and after some aigebraic manipulation, we get

Section 2.1. Web dyn-CS

where T:v represents the awage span tension (i.e., the tension at midspan).
Frthemore, if we neglect the 65ctionai force (i.e set f = O), then (2.3) simpnes to TL = ,
=

TT. This in turn means that the tension is the same throughout the span, and we cm drop
the superscript. Moreover, if we assume that the span length remainri constant, we recover the

continuity equation as it appears in the Litaratuce [52, 44, 46, 541:

The term imrolving &ln in (2.6) usually appeam when a web machine incorporates a dancer roil for tension regdation. In this case, a routine application of Newton's laws would give an exact expression of how the span length changes in the presence of a dancer. T i exercise i not relevant hs s to this thesis, and shall be omitted, we direct the interested reader to [46, Appendix C. It is l important to note that this neglected term aLso accounts for tension generation when one presses against the web as it is moving, and as such enters the equation as a disturbance. The Iength of a span connecting a winder with a transport rouer i a huietion of the winder's radius. s The foilowing i a derivation of the length of the fixe span between a winder and a transport rolier. s Figure 2.6 shows the kas span between an unwinder, and a transport rouer. The web must be tangent to both these rollers.

Figure 2.6: Length of free span between roiler and unwinder

The idnite stiffness assumption

W e b processing machines typically handle materials that are very stifF, auch as paper; this justifies the use of the small strain mode1 (2.5). W can take this one step further by assiiming that the e materiai is pdectly rigid under tension. Rearranging (2.6) to

and assuming E = oo Unplies that wn-1 = wn

+ 51,.

2.2

Roller dynamics

Figura 2.7 depicts the forces acting on roller n, with radius r,, and inertia J,,. The externiil forces

that act on the roiler are the applied torque Un, any Wctional torque F it experiences. There and , is also the moment that is appiied by the web on the roUer, which of course is a direct consequence of the contact forces behreen the two d i s c e s . T i h hard to compute as we desaibed earlier, but hs although it may be cornplex to calculate the stress profile in the contact ama, the totd fiction force can be easily determind as the difference in the tensions of the web upstream and downstream of the roller. T i result holds tnie since the web is assumeci masaieas, and applyhg the law of hs conservation of momentum, we see that the net force on a CV containhg the contact region must
be zero. Of course, the net force on such a CV is the difference of the outgoing and incoming

tension and the net contact force. We shall denote the downstream and upstream tensions by Tnci and T respectively If a rollet i dnven, it is r e f d to as an active roller. Otherwise it i passive , s s

and is calied an idler.

Thus for transport roller n, whose inertia i constant, the equation of motion is &en by Newton's s
law as

Since we are more interested in the iinear (tangentid) speed Vn of the rouer, and since V = $n, ,

Section 2.2. RoIIer dyaafplCcs

direction of motion

Figure 2 1 Forces acting on roller n .:

(2.9) may be re-expressed as

where Vn is taken to be the linear speed of the roller at the point of contact with the web.

A rewinder has no doWflStTeam tension, while an unwinder has no upstream tension*. Thus (2.10)
simplifies to

and

for a rewinder and an unwinder, respectivelyt.

As a winder loses (or takes in) material, its radius changes. This happeas i a step fashion, that is, n the radius demases (inmeases) by the thidmess of the web &er one revolution of the roiIer. T i hs
change can be appraximated by a linear funetion. Arbitrarily selecting the initiai angular position 'The unwinder feels no ttpstmam tension applying a retarcng turque, on the othet hand whea we deai with the unwind zone, the upstream tension i the wrap tension which is trarisfered through the zone. s 'It may seem rather peeiil*r that the tpm "1,. h a not been diffkrentiated. For Jn, one m u t be csrrhtl when applying the law of conservation of momentiiill that the Ioss of inertia of the system is due to the web being removed h m the winder, and hence inesth is not 'lest'. Also, V repments the point on the winder where the web enters , (or is Iost) and this point chimges with tirne.

Section 2.2. Rouer dyriamics

17

of 8 roller n to zero, and defining rno to be the initial radius of the roi@ and e the web's thidmess,
we have,

which, when diffkrentiated, gives

The moment of inertia, J,, for a winder i comprised of two components: the moment of inertia of s the shaft on which the roll rests, J , and the moment of inertia of the actual web that is wrapped n,
around it. Thus,

where W i the widt h of the web, p i its derisity, and rn, is the bare shaft radius. s s

As the materid is wound into the rewinder, it i possible (frequent if tension control i poor) that s s the end roll is not perfectly round. This i due to many factors such as materid creasing, or the s formation of air pockets between the dXerent layers of web. The result is a winder which is more
eiliptic than cirdar.

Ti phenomenon has the foilowing repercussions (some of which are lesa detrimental) on the rouer hs
mode1 presented in (2.9): 1. The expression for the winder's moment of inertia i not exact since the roll no longer takes s the shape of a hoilow cylinder. 2. If the radius sansors are used in the controiler, the measumnents no longer give an accurate value for the torque applied by the web on the rolk.

3. It i wry l M y that the maas center i now offset h m the axis of rotation, thus adding an s s additional torque to the force balance. Suppose Mg represents the weight of the roll, and a i s

Section 2.2. R o k dynamks

18

the distance between the mass centre and the centre of rotation, letting B = O represent the
angle in which the mass centre is verticdy below the centre of rotation, then this disturbance

i force cm be c a i d t e d v a Mga sin(@).

4. The radius variation results in sma changes i the span length. These changes are also n

periodic in nature. R e f d g t o (2.8), and noting that changes in span length and radius are

md, thm i = - r T L T , .

Suppose that 1 = 1, rt = 0.04 and r,(8) = 0.15(1+ 0 0 sin 8). .1 Asauming that the web moves at lm/s, a simple caldation then shows that +w would be in
the order of 0.01 m/s. Though smad, recall that i enters the tension equation (2.6) and is

pre-multiplied by the web stif6iess. W n g our attention back to the term

h in (2.10), we note that its variation during the winding

process has both a slow trend (conespondhgto the slow change in overall radius and inertia) and

a f a t more destructive trend (correspondhg to the fast change in the roll profile). This change is (as are items 2 and 3 listed above) periodic in nature. These "disturbances"are not completely independent of the state of the system. For instance, the eccentricity of a poorly wrapped roll wiIl increase as the radius inmeases. Also, since the machine is
typicaIly run at a constant speed, as the spool radius increases, the rate of radius change is slower,

hence the disturbance frequency is smaller. On the other hand, the size of the radius wiation also hcreases, leading to a diaturbance that is higher in amplitude.

2.2.2

Interaction between the web and the roliers

In view of the analysis in Section 2 1 2 the velocity of the web, at euery instant, is equal to the .., peripheral speed of the roller. Having established that the slip zone occurs as the web leaves the r o k (and not upon entry, or that would violate traction), we may write, w, = V. That i , , s the velocity of the web as it leaves free span n matches the tangential speed of the downstream r l e (which is given the same subscript). The no-slip condition fiirther guarantees that the iinear olr acceleration of the web matches the tangential acceleration of the roiler (at the point of contact).

Section 23. O m d modd f8r N-span web systems

23 .

Overall model for N-span web systems

Figure 2.8 illustrates a typical N-span machine. The rollers are labelled n = O, 1,. .. ,N starting with the unwinder. As before, the terms r,,, A,(, F represent the radius, inertia, input torque I, , and fictionai torque of rouer n. The spans are numbered n = 1, ...,N starting with the unwind zone, and the correspondhg tension wiil be denoted by T (For the actual experimental machine. . we shaii Iabel the rollers n = a, b,c starting with the rewinder, and the spans Ta and Tbshail represent the rewind and unwind zone tensions respectively. We do this to conform with the convention that i currently used by VRP.) a

Figure 2.8: N-span web systern

The following summarzes the assumptions made to derive the model:

The web is assumed to be massless.

The web is very stifF, and its elastic model i Hookeian. s

a

The web thickness i small compared to the shaft radii. s

There is no slip between web and roUers.
There are no laterai stresses developed in the web, that is, the model is one dimensional.

Web properties, such as cross-sectionalare% density and elasticity, temain constant throughout the material and for aiI tirne.

Section 23 Overd modd for N-span web systems ..

O

20

There ie no Mctional force acting on the web, except for the traction force with the rolier.

The afommentioned assumptions lead to the following set of nonlinear Merential equations that describe the dynamics of the web aystem:

The state of the system is taken to be the vector z =

*

i given by u = s

... u~]'. Although technidy,

[Vo ... VN T~ ...rN]. ~

the quantities
TO, r N ,

h input vector e

Li and IN are also

states of the system, we treat them as independent parameten. During the control design proceus,

these values are t y p i d y @ed The radii are measured and can therefore be used to adapt the contro11er during machine operation. The teare regarded as disturbances in the tension equations. Although a span's length stays roughly constant throughout operation, its rate of change may be appreciable as we saw eariier.

Throughout this thesis, we shail adopt the folIowing convention. Al1 setpoint values shall be given

an overbar symbol, for instance the reference tension is denoted by T ~Deviations fiom the setpoint . shall be given lowercaae cbaracters (e.g. un, T represent speed and tension respectively). ,

Section 23 O ..

d modd for N-span web sysfenu

21

The fiictional torque Fn i comprised of a static friction component which we denote Fn, and a s
viscous component equal to

$v,,

where 4, is the damping coefficient. We s h d assume that the

static fnction is compensated for the by the input totque, that i Unreelly means Un+ Fn. s

The ody other nonlinearity i (2.13) appears in (2.13d) where there are terms involving the product n
of f emion and speedEquation (2.13d) can be reeqressed as d ln-(Tn rn) (EA- T~- ~ n(Vn vn) = ) dt

+ - (EA

pn-1-

rn-1) (vn-i

n (EA -T,)(Vn

+ vn)

Vnrn- (EA -Tn-i)(Vn-l+

d +un- 1) + EA-ln dt d un-1) + R - l ~ n - + EA-C. ~ dt

Removing al steady state values and recognizing that i linehed tension equation:

<< EA,

we end up with the foiiowing

The tenn

v,-i~n-l d e d temion tmwfer in iiterature. is

231 ..

Reduced order mode1

We saw earlier that if we take the limiting case when EA = m, and assuming thare is no diange in span length, the tension dynamics d u c e to Vn-1 = Vn- Rewriting the velocity equations a s

and noting that &, = % = ...= VN = V , we find by adding the equations i (2.15) that n
d M-V
dt

= -CV

1 + C -(In,
,=O

where

Section 2.4. Control of web processes: ludustrial practice

22

Equation (2.16) simply modeis the rigid mode of (2.13). Note, howem, that as in the case of the full ordar model, this equation is applicable only if thete i no slack in any of the tension zones. s
Uaing (2.15), we aiso flnd that the tensions are given by

2.4

Control of web processes: Industrial practice

We now use Equations (2.13a) to motivate the control design procedure that is used in industry-

These techniques are implemented in the MTSC used in the machine at the University of Toronto.

It i cielear from the preceding sections that the tension dynamics are a huiction of the difFerence s in peripheral speeds of the upstrearn and downstream apans and the tension tmnsferrd by the incoming web. The differential equations for a two span web system' are given by

' s we wanied earlier, we now adopt the foliowing notation: the subscripts a, b, c represeat the rewinder, nip and A unwinder roLIers, and Ta !the rewtnd and anwind zone tensions,l i

Section 2.4- Control of web p r o ~ e s hdustrid practice :

23

where Tarepresents the wound on tension. The system has three torqw inputs, LIi for i = a,6,c, aad thme outputs, Ta, T and the nip speed P . b $

This modal motivates d o u s cmtrd schemes that could be used to regdate the machine speed, and the two zone tensions. Thare ara three dynamic systems that, interconnacted, make up the web system; the rewinder togethar with zone a, the nip section and the unwinder together with
zone b. The web, threading all three driven rollers, cornecta these three sections. Indeed, inmeashg Ta ha9 repercuesions on the speed of the nip section, which in tunr a k t s the tension in the unwind zone, On a similar note, sny torque applied to the nip affects the tension in both the upstream and downstream zones.

For example, consider the subsection that consists of the rewinder and the rewind zone. In the Laplace domein, the equations that describe the rewind tension are thus given by

Combining (2.18) and (2.19) we find that

with Da= Jalas2+ J' + bal& + (bava +~ : E A ) T i is the most general expression of how the .h s span tension is reiated tu Ua, and T),. Vb

(va

Figure 2.9 iiiustrates the control structure used in the closed loop Tension/Torque mode of operation. Notice that the control signal U' is generated by the tension error, and suppose the control law is given by Va = K,(T,

- Ta). torque applied to the rewind shaR is not intluenced The

and 6u.= V. - Yb:

by either the nip speed or the unwind tension. C1e;irl~the design is incapable of rejecting the e f k t that either of these two quantities has on the tension..

Now suppose in (2.19) we set

+yb

t ~ h e r e three hear speeds in the given model that are very close to each otber because of the high materiai am stiniress. Typicaily a aip is chosea as the rnasttr speed, and this i what i9 hown as the machine apeed s

Section 2.4. Control of web processes: Iadmtrial practice

Figure 2.9: Web tension control in closeci loop Tension/Torque mode

At steady state, 6va is simply the required ciifference between the rewinder's speed and machine
speed to maintain a setpoint tension, and vb shouid be O. The trander function fiom 6v, to Tais

We may treat 6v, as an auxiliary control input, and usa it to design a controiier to regdate the tension. Since contrary to our assumption, 6v. is not an independent control signal, we must use an additional controller to regulate it. Ti lesds to the cascade controller structure known as the hs closed loop Tension/Speed mode. T i is Uustrated in Figure 2.10. hs
Equation (2.21) is a f h t order lag element,whose time constant and steady state gain are dependent

on the overall machine speed. To remedy the steady state gain variation, the PI gains are typically scaied Mth the desireci machine speed. The o v e r d torque input is then given by Ua= K (K.( f a ,

Ta) +

d on (2.41), and Kav i the speed s controlk for the rewinder. This mode clearlly has an advantage over direct torque control since

- V.), where Ka is a tension contmller designed b

the control input is iduenced by both the tension reference and the machine speed reference; that
i , a change in the desireci machine speed is less detrimental to the rewind tension performance. s

Zn addition to the aforementioned feedbads solutions, indwtry also implements feedforward control
to achieve perfect control. Simply put, the idea is to invert the plant, by applying the necesaary

Section 2.4. Control of web processes: hdwtrial prectice

Figure 2.10: Tension control in ciosed loop Tension/Speed mode

torques to accelerate the miIers, provide tension to the system and compensate for friction. Rom a practical point of view, open loop control does not provide stable error dynarnics to mode1 uncertainty and disfurbances that affect the tension, and i invariably used in conjunction with a s feedbaek controuer. This mode i necessary if no feedback is used (that is, the plant is controlled s in open loop) and is illustrateci in Figure 2 1 . .1

The nip wlocity is regulated with a PID loop as shown in Figures 2.9 and 2.10, and the unwind
controller mirrors that of the rewinder. To set the controiler gains, one proceede as foilows [51]. First remove the web h m the machine, and set the PID gains for the speed controller so that the desired speed response i achieved. s Next, rethread the roilers with the web, and tune the gains of the tension controiler. It requires considerable experience to do this tuning well.

Section 2.4. Control of web processes: h d u s ~ a l practice

Figure 2.11: Combining feedforw~sd and feedback control to regulate the span tension

2.4.1

Centralized control

In the absence of feedforward (inverse) control, the afarementioned control schemes are decentraiized in spirit, and the interconnections between the subsystema Iead to performance degradation. On the other hand, it is attractive to use a modular design methodology because this would Iead to a more portable controller.

i & Consider for example the scenario of c

loop Tension/Torque control iUustrated in Figure 2.9.

Clearly, any deviation of the nip's peripheral speed would lead to a change in the tension of the

rewind zone. The decentralized control philosophy handlea this problem by simply treating the error in nip speed as a disturbance to the rewind zone tension dymmcs. This strategy of course overlooks that the disturbance i in fact a function of the state of the system (which makes it a s feedback problem). This le& to questiom regardhg the robustness of the controller, as weU as what the appropriate disturbance mode1 candidates would be.
Operating the machiDe in Torque/Speed mode gives the designer p a t e r flexibility with regard to
rejecting the disturbance of a change in machine speed. Still, we have only considered the rewind

section and the tension there & & s

the nip speed.

Tuning the controUers i a different matter altogether-there is no magicai recipe that indicates how s

Sectn 2.4. ControI of web pro ce me;^: Indwtnal pzactice

27

the gains should be seiected. Resorting to the model (2.20), one may conduct a SIS0 analysis of the model and design an appropriate controiler. To that end, the designer m u t negIect the interactions betneen the sub~stems.Ultimately, ta ensure good performance, the gains are chzuiged online until
the system responae i deemed acceptable. s

I d t y , a web machine does have pmnouced coupling asnong its subsystems, and there i no n s teason to assume that a modular control design strategy i good by any standard. Experiments s seem to show th& without a feedfonmudcomponent to the overall control law, the coupling between the subsystems is poorly rejected.

Chapter 3

Modern Frequency Domain

Multivariable Design

'FI-'
Controllcr

Figure 3.1: The standard representation of control systems

M s contml systems can be represented by the block diagram in Figure 3.1. The plant admits ot
two inputs: the exogenous signai ( w ) that includes disturbance, reference signais and noise, and

controlled inputs (u). The overall system operates in closed loop by feeding back the measured
outputs (y) to the controller. The fidelity of the controiler ia measured by the output z.

Industrial processes typically use PID controllers. That h,a controiler structure K i nxed a priori, s and is made to work for the partidar application by tuning various gains. This procedure, though practicai, i not equipped with a useful measure of performance. Moreover, since the controlier s structure is fixed, a search for the best possible performance would be restricted to the output

Section 3.1. Notation and methematid preliminaries

signals that may be generated by a dcl= of admissible control actions.

T measure the performance of a system, one must dbthgubh betareen the different responses that b
resuit rom a set of cadidate contmiIers. The dosed Ioop plant (depicted in Figure 3.1) maps the exogenous inputs w into outputs z, aad the mapping WU henceforth be rderred to as T , If r . represents the output error and w the plant disturbances, then the objective would be to design K
such that the Sizen of Tm is s m d . Moreover, if the size of the mapping i the srnailest over al1 s

permissible disturbances, then the corresponding control is said to be optimal.

We gave, in the introduction, a briefovemiew of the reiationship between 31- control and ciassical kequency domain control techniques. W saw that the goal of Rm optimisation i to design a e s contmiler so that the frequency response of the ciosed ioop system is bounded above by a funetion that the designer deems acceptable. In this chapter we describe how such controllers may be designed.

31 .
311 ..

Notation and mathematical preliminaries

Signal and system norms

Given an n-diiemional vector x, its pnonn is given by lxlp = Izil~)Lk.particular, the In Euclidean norm is the case when p = 2. The quantity lxlp gives an indication of what the length of the vector i. s

(z:

The pnorm of a (vator) signal z(t), defineci on some i n t d 1, is given by

where Iz(t)1 can be any vector norm, though we shall restrict ourseIves to the Euclidean nom. The
space of ail measurable signais, defined on 1 with a finite pnorm is denoted &(I). ,

A system G maps input vector signals w to output vector signah z. We shail deal exclusively with hear finite-dimermional systems. A system C with date vector x may be realized by a state-space

Section 3.1. Notation and mathematid p r M i u i e s

description (A,B, C, that i, D), s

[:]
The t r a d e r ma*

:] [u]
+ D, which we write as

of G i given by ~ ( s = C(sI - A)-% s )

The set of d rational, proper and stable tramfer matrices (systems) & ais0 form a Wace. T i leads i hs to the dennition of the Hardy space RRP as those matrices whose pnorm is finite. Of particular interest are the spaces R3C2 with n o m

and 7Z')loo with n o m

The term & ( j w ) in (3.2) Lo the complex conjugate transpose of dw).The term a [ ~ ( j w ) in ] (3.3) is the maximum singular value of GW), i simply the square root of the maximum which s eigenvaiue of & ( j w ) ~ ( j u ) .

The above systern norms have a remarkable property that may be derived by simple l'ctiond
analytic arguments [15]. It turns out that, given an impulsive input, the 2-nom of a transfer
m a t h provides an upper bound for the 2-nom of the output. On a similar note, given any C2

signal of unit nom, the m-nom of the system gives an upper bound on the 2-norm of the output. That is to Say that the nom, which war introduced in the context of closed loop shaping, rnay aiso be interpreted as the worst possible amplification of an input s g a ' Bnonn. T i viewpoint inls hs
is usefd i developing computational machinary to solve the 'Hm control problem. n
+

For the remahder of this thesis, unle88 otherwb s p d e d .

II II s h d represent the infinity n o m of the trandier function,

Section 3.2. '1 ControI.. . The Linear Matrix laequaiities Way ) , 312 ..

Some usefid matrix identities

Matrix Inversion Formula

Given a symmetric, partitioned matrix H =

[t,E]

witb C inverti&, d&e X = A l3c-l~~.

If X is al80 invertible, then

The Schur

A real, square,symmetric matn* H i said to be positive d e f i t e (denoted H > O) if X'HX > O for s crll nonzero vectom x. This i equivaient to the condition that ail eigenvalues of II are positive. For s a partitioned matrix H as above, the condition can be reduced to an equivalent pair of conditions,
nwdy,

H>O *A>O

and A - B C - ' B ' > O .

(3.5)

The derivation of these formdae can be found i [21]. n

32 .
321 ..

X Control. .. The Linear Matrix Inequalities Way ,

The bounded real lemma
control problem.

Over the past three or so decades, several solutions have been given to the H ',

One of these methods draw a close connection between 'Hm control and the more traditional LQG control. The goal of LQG design was to h d a control law u that minimises llzllz for a system with nonaam initial conditions (or equivalently- a syatem that is excited by an impulsive disturbance

T i problem can be solved by a simple application of the calculus of variations (an extension hs h s of dinerential caldus to function spaces). T e interesteci reader i referred to excellent texts such as [34, 251 for the details on this technique. The problem of W, optimisation csn be cast in the same h e m & when used in mnjunction with game theoretic techniques [28,6,20]. T i thesis, hs
w).

Section 32 ..
ho-,

R ControL ..The Lia- Mat& InqualitIles Way ,

32

will adopt the (more recent) appmach of linear mat& inequaiities [18]to solve the 7(,

problem.

W e begin by deriving conditions that an LTI system must satisfy so that it is stable and Roo n o m i less than a pre-specified lemi 7. T this end, suppose we are given a system G, with state s o representation (A, B, C, , input vector w and output z. D)
Theorem 1 (Bounded Real Lemma) For any 7 > O, the system G is stable and llTtull < 7 i/ and onfg if 3P > O such that

Before we give the proof of the bounde real le-,

we need the following result.

Lemma 1 Given the state equation x = Az + Bw un'th A stable, if w f L2, then

Without any loss of genetality, assume that x ( 0 ) = O and that 11 Bll = 1. T e response x ( t ) h corresponding to some w ( t ) i [13] s

The stability of the system impliea that there exist positive constants ki and k2,such that IleAtII 5
kieekzt.

Thus we have

Rom Schwam's inequaliw we see that

, Section 32 ? ControI.. The Lheat Mah?x InequirIities Way .. t

33

Thas given c > O, we can always h d ti such that the above integral i bounded from above by 4 2 . s

On a similar note,

One can always select a t h e t 2 such that W > tz the above inequality is bounded by c/2. CIearly, for any r > O, we caa always select tz such that [s(t)l < E for t > t*, which completes the proof.
O

Proof of the bouaded seal lemma:

(e-) Tnequality (3.6) implies system stability from Lyapunov theory and the Schur complement formuia. Spdcaiiy, the (1,l) entry in the oRL: i A'P + P A which has to be negative, hence the s
s system i stable,
By the Schur complement argument, (3.6) is quivalent to 7 1 < O and

Multiply the latter by y and set Q := yP to get

Let w E L2be nonzero but arbitrary and let x denote the correspondhg state, starting at x(0) = 0.

Pre- and post-multiply the above with d w' and d

(Az Bw)'Qx

[ ] E l ' respectively
W'

to get

+ x'Q(Az + Bw) - 72w'w + t'z < 0.

De&Ung V ( x )= dQz, we may rewrite the above equation as

Section 32 ?&, ControL .. The LiBear Matrix inequafities Way ..

34

Since A i stable and w E 4, x(m) = O (Theors

1). This leads to llzlll

< rllwllz and therefore

d

llTNill 7 T get a strict inequaIity, we note that perturbing 7 to 7 - e (for a sufiiciently s . b c > O) preserves inapuality (3.6), and t h in turn implies that llTIGv 7. 11 < (*)

The proof of necasity i rather lengthy so the h e details will be omitted. It is, however, a s standard resdt in network theory [l, 201, although (3.6) typically takes on the form of an equation
rather than an inequaiity.

W e begin by augmenthg an additional output to the cloeed loop system. That i , we dehe s

where r > O. Since lTvl 7, can dways find a sufnciently s m d r such that ITI < 7. It lnl< we IeI foUows that C := 7*l- T;(ju)Te(jw) > O Vu.
The system a, adrnits the fo110wi.ng statespace representation:

@CA[-C';d

- A J ~ C'D

B y21- D D ' '

1T i in hs

For O, to be positive deflnite for a w, it must not have any zeros on the imaginary &. d S
turn meam that the Hsmiltonian matrix

where R = T21 D'D* has no eigenvalues on the jw-axis [20, pages 111-41. Note that H is simply the state mat* of O;l.

Since A i stable, the realization of 9, has no uncontroiiztbleor unobservable modes on the imaginary s

axis. Theiefore, the condition IIT'II < 7 impiies that there exists a positive definite soltition P the Riccati equation

to

Section 32 ?fa .. ControI. . The Lhear MatriK h q u a l i t i s Way

(see for example, [40, Appendix C) Condition (3.9) impiies l.

Simplifying and applying Sehur't3 complement formula then leads to BRL(G,P) < 0.
O

Aithough the proof of sufficiency of the botmded real Iemma is straightforward, that of necessity

i admittedly not so intuitive. In the 1970's, Willems formalized the concept of power and energy, s and appiied it to control system analysis [53]. More recently, a comection was drawn between ?Cm
control and Wiems's dissipativity theory [Il, 4 1 T i connection will be outiined next. 1. hs

The system G interacts with its environment through its input and output variables, w and z, which together give a me88ure of how much power (anergy supply mte), p, i supplied to it. T i s hs energy may either be stored or dissipated. T i is formalized in the foliowing definition. hs

Deflnition 1 (Dissipative Systeme) A heur dyamic systern G with supply mte p is said to k dbipative with respect to p if then d t s a podtive definite function V ( s )= ~ P X called the , storuge function, such that for (il2 timw to, and t l , and comsponding states q and xi,

The storage function represents the energy stored in the system (such as kinetic or potential energy). The quantity p(w (t),z ( t ) )dt i the amount of energy that is supplied to the system during the s
time interval ( t a , t i ) . Cledy, if the sum of the initiai energy stored in the system and the energy supplied to it over a period of time is larger than the energy stored at the end of that period, then some energy must have been dissipateci. Inequality (3.10) is dubbed the dissipation inequaiity. It is an expression of the natusal tendency of a systern to lose energy through ita resistive dements. It may also be expresaed in difhential

iorm as ~ [ x ( t ) ] p(t)

Turning our attention back to (3.8), ne see that for p = y u f w - t'z, we recover a dissipation inequality. The proof of necessity was required because although (3.8) leads nat u r d y to IJT,, II < 7 , the validity of the converse is not as transparent. In view of Definition 1, it is clear that a systern T that satisfies the infinity n o m botmd must ais0 be dissipative with respect to p = q w ' w - d i . ,

Section 32 ?lm Control.. The Lin..

Matrk Inequalities Way

32 .2 .

Linear matrk inequalities and semidefinite programming

A Iinear matriz inqudity (LM)i an bequality of the forme F ( x ) 2 O, where F ( z ) = Po + s

zi for some given real, symmetric matrices Fo, ...,F,, end where x i ...xn are the elements xi&

of a real vector x.

The term semidefinite pmgmm refm to a constrained minimization problem over P. To be minimized ia a h c t i o n a l z = d x where c and x are vectors in i , being bixed. The decision Pc variable x is constrained to lie in a set X defined by the LM1 F (x) 2 O. Summarizing, the problem i s min z = c's
set. F ( x ) 20. The set X i convex; that ia, if s l , E X,then so is crxi (1 a)x2, s ~ where O 5 a 1. W shall e use BX to denote the boundary of the constraint set. Let 5 denote a minimizer of (3.11). Equation (3.11) i not amenable to the l o d minimization techniques that are standard in calculus s (i.e., hding x that leads to the vsnishing of the derivative of the objective function) because the cost is linear, and the prob1e1n i one in constrained optimisation. It ia possible to convert (3.11) s into an unconstrained optimisation problem by prescribing an infinite cost to ali points outside the feasible set X. The revised optimisation problem takes the form min L = 2

+ -

+ pg[F(z)],

(3.12)

where g i a wnvex barrie function that i infinite for BU x t hat violate F ( x ) > 0, and p is a scang s s factor. The optimisation problem in (3.12) is an unconstrained conuez optimisation problem, whose min-

imizer

c m be

found by solving

$$

= O, or numerically using Newton's method (i.e., solving

xk+l =

- V ~ L ( X ~ ) - ~ V iteratively until xk converges). L(X~)

The minimizer s(p) of (3.12) necessarily lies in the interior of X, whereas 5 is known to lie in a X
because z is linear in the decision variables. Remarkably, given a sequence of scale factors pk that converges to zero, then it i a f& that (see Figure 3.2 for an ilIustration of this) iimp,,o %(pk)= 1 s .

Section 3 2 *Hoa Control.. . The Linear Matrix hequslities Wsy ..

Figure 3.2: Here we minimize the cost z = - x i x2, subject to the constraint O xi,x2 5. A logarithmic barrier function g = - log[xix2(5 - xi) - x2)] i used. Clearly, as the scale factor p (5 s i reuced, we approach the minimieer (5,5). s

<

This is the essence of interior point techniques. The constrained optimisation problem of (3.11)
was converted to the sequentiai unconstrained optimisation problem given in (3.12). For a more
~ ~ O ~ O U S treatment

of this subject, consult [16,26].

We now turn our attention back to the bounded real lemma, where we seek to find P

> O that

satisfies (3.6). The latter turns out to be a convex constraint on the set of positive definite matrices.

To see that this is indeed true, consider the following example, where for simpiicity, we consider a system with dimx = 2.

The problem i stated as s

The space of symmetric 2 x 2 matrices i s spanned by 3 independent matrices, which we denote by Pi, and 4. Any symmetric matrix can thus be written as P = aifi a 2 4+a3P3,where the & +

Section 3.2. ?ioD ControL The Linear Ma&X kiequalities Way

ai's represent decision mhbles.

..

T e conetraint set of (3.13) can thus be rewritten as h

The decision vector is taken to be q = [

t ~

a 3

, and one mey reaily verify that for eny

two vectors qi and 92 that result in a positive definite matrix, then so does their convex combination.
Next, we require a baprier function for the constraint set, that is a function that i convex and s

idhite everywhere except the feasible region. One such function is viable from the following theorern.

Theoram 2 The function f ( A ) = - log det A is a strictly wnuex jbnction on the set of positive definite Hermitian matrices.
For a pmof of this see [21, pages 46671.

In the Newton iterations, the gradient and Hessian for the barrier function O ( x ) = - log det F ( z ) are given by g i ( z ) = - TkfiF(x)-', i = 1,. ..,n and Hi, = ' E ~ F ( X ) - ' F ~ F ( X ) i ,~ = 1,. ..,n for - j respectively,
Rom a computational point of view, one does not have to have the exact value of the minimuni for
a given pk.

before reducing the latter's value. Indeed the bulk of the research that took place early tbis d e d e was concerned with 6nding &tient dgorithms that move towards the optimum dong the central path. The most &ective aigorithma are the primal-dual interior point techniques, and their extension to semidennite progrma is explaineci in detail in [50].

T i section follows [18]. hs

Theorem 1 fumishes us with an ineqdty that needs to be met for a system to be stable and achieve

a prescribed performance levelr; th& i the system (A, B, C, ) i known a priori. Our goal is to s D s

determine the closed Loop system matrices in which the control dynamics GK are embedded. Thus

(3.6) is nonlinear in the variables of interest (i.e., the positive defiaite matrix P, and the controk parameters)+

Cousider an nth-dimensionalopen Loop plant as s h m i Figure 3.1, and let w E P n a f HPPl and y E W. Let the plant admit the following minimal state r-ation

L ,

uEW

2 ,

where we have sesumed that D, = O since that simplifies the ensuing math. Let

be a state representation of a controller of order k.

To ascertain that a controlier exists, we must insist that the (A, Bu, be both stabilizable and Cy) detectable.

The closed loop system matrices are thus given by

where

Applying the bounded real lemma to the closed loop system, and after a little rearrangement, we

find that there mu& arist P > O such that

where

The advantage of formulation (3.17) ia that the controller parameters are now isolated. Although at b t glance condition (3.17) rnay seem no easier to satisfy, it turns out that existence of 8 to
satisfy (3.17) is equident to

where W pand WQdenote tuo matrices whose columns span the null spaces of P = [BI O

va]

and Q respectively (for a proof of t h , see [18]). This i known in the literature as the separution s lemrna Equations (3.18) do not depend on the controiler parameters, however, they entail both P

and ifs inverse.

Since P and P-I
are positive definite, they may be partitioned as

where R,S > O IPXn,M , N E I P ~ X,Y E PX*. and ~ Plugging (3.19) into (3.18), and aRer some mat& manipulations, we end up with the following theorem (an explicit derivation can be fond in [ 8 ) l].

Section 3 2 R Control.. , The Linear Matrix hequaties Way .. ,

41

Theorem 3 (Existence of ysuboptimal Controllara) Giuen a performance leuel 7, o controltw for the system gium in ( . 4 mn be found if and only i then aUt synmetic matrices R 31) f and S satisfbn'ng the follouring eystern of inequalities:

Application of Theorem 3 to 'Hm control produces a pair of positive dannite matrices (R, S) that

s 31) satisfy (3.20). Our ultimate goal i to determine P > O that satisfies ( . 7 . Remarlrably, by the
scxalled completion lemmu, given symmetric matrices R, S > O that also satisfy (3.20c), we can

find matrices M , N E wXk X , Y E PX* s t (3.19)if rank(I - RS) 5 k. For k = n, and that a w this condition is trivially satisfied because I - RS can have r d of at most n-that is, if (3.20) is satisfied, then we c m dways find a controk with the same order as that of the plant. To find reduced order controllers, we must find R and S that also satisfy the raak condition.
In order to reconatnict P E

> O, aelect a matrix N that satisfies NN' = S - R-' 2 0.

as given in (3.19). Setting X = I and comparing the remaining three entries in the matrix inversion formula, we find that M = -RN and Y = I + NtRN.
Now that a P has been detenaineci, (3.17)becornes affine i the controiier parameters, which in tum n
can be found by solving a second semidefinite pmgram.

One may also derive expiicit formuiae for the controlier parameters which are computationally more dicient- T i algorithm is implemeated hs

in the function hinf loi in Matlab's LM1 toolbox; the details can be found in [l?].

Section 3.3. Extensions of the basic theory

33 .

Extensions of the basic theory

The optimal controller satisfies the

quencies.

eqwlizing pmperty [23]-that

i, B [ T , ( ~ w ) ~ 7 over all fies =

This seamin&

innocent property wreaks havoc when designing for a reai plant. As shown in the model's stable poles. From

[42,49], the equalizing property resulte in a controiier that WC&

a physical perspective, this i sensible since the best controller should try and malce the dosed loop s system as close to identity as possible. Note that no such cancellations occur to unstable poles inherent in the aystem since that would violate interna1 stability. If the stable poles are sufkiently

far from the Maglliary axis, this phenornenon poses no real threat to performance. On the othar hand slow poles which reappear in the closed loop system, mnke the response sluggish. To see t hat this i true, consider a SIS0 system consisting of a plant P = 3 and controiler K = 7 , s where n, d, c, x,y are polynomial terms, in the standard feedbaek configuration. The closed loop system
i then given by s
nxcxz c(nxl+dxy).

Although the factor c cancels out in this transfer huiction, the poles

associated witb if still appear in the system's intemal model, and any mismatch between the model

and the r d system would lead to an undesirable response if c represents a mode that is close to
the Maginary axis.

One solution to this problem is to pre-process the exogemus signals with a filter whose poles are
chosen to be the lightly damped modes of the plant model (this i done only in the controiler design s process and is not actually implemented). This solution simply adds states to the o v d system

and resdts in an ullflecessarily higher order controller.

The linear matRx inequality approach provides a more elegant solution- pole placement. The idea
i to impose an additional constraint on the location of the closed loop poles. For instance, suppose s
we require that the d component of all the closed loop poles be less thad -a. Then we have to

h d P > O that satisfies (3.6) and

+Onemay constrain the closed hop poles in convex regions of the complex plane; see (141.

Section 3.3. Extensions of tbe M c theory

332 ..

Gain-scheduled control

The techniques outlined in the beginning of t b chapter apply to linear time-indant systems. R d systems are always nonlinear, and a LUiearized mode1 is used for the purpose of controller design. The validity of the modd is only local about the operating region, and the performance of the controller is bound to degrade, and perhaps even becorne tuutable as the operating conditions change. One can approxbate a nonlinear plant by a f d y of linear models parametrized by the operating condition; the system tem trhen said to be linear paremeter varying (LPV).
There is little formal design methodology that synthesiaes contro11em with an a priori guarantee
that the dosed loop system WU be stable. Shamma and Athans [43] for instance show that for

sufficiently slow parameter variation, a controller that interpolatesbetween the operating conditions
remains stabilizing. Of course, one may &O grid the parameter space, and manually switch between

controllers designeci at the grid points, leaving questions as to what is the best way to switch between the controilers.

Using the linear matrix inequality approach to 'Hm design provides a solution to the gain-scheduling problem. As will be shown, though, this technique is nomally cornervative at the price of making the solution computationally elegaat.
Polytopic parameter dependent systems Consider a plant C(p) whose state representation depends afEnely on a time-varying real-vaiued hs parameter vector p = 011,. ..,p,) ,where pi E [h,E]. T i defines a convex polytope with vertices

VI,

...,v,

(where r = 2 9 ) , that is at any given instant t

The symbol Co represents the conuez hull, that i the set of ali convex combinations of VI,. ..,vr. s
For example, consider a system that depends on two parameters, pi and pz. The vertices of the
polytope are given by

Section 3.3. Extensioas of tbe basic theoqy

44

Given at Borne instant a panuneter p(t), it c m be formed as a convex combination of the vertices
as follows:

where

The parameter dependent system then lies in the polytope of system matrices given by

where

(4, Di) i a state representation of the system at vertex i. Bi, Ci, s

Stability and performance of linear parameter varying systems

Centrai to the development of the bounded real lemma was Lyapunov's stabity theory. For an L I T

system, stability ia equivalent to the existence of a quadratic Eunction (previously cded the storage function) V = d P z , with P > O, such that v < 0, x # 0 It is a fact that Cor noniinear systetns . (that admit a unique solution), the existence of auy positive definite function of the state that is monotonically decreasing dong ail possible system tmjectories (except at the origin) i sufecient s to establish stability.
In thhi contact, for G@)to be stable, then the existence of a positive definite function V ( x ,p ) ,

with v < O for x # O and p, establishes the stability of the LPV system. Constraining V to be a quadratic fiuiction of x only, that i V = z'Pxf,leads to a conservative test of stability known in the s literature as quadmtic stabity. As long as the parameter varies in at least a piecewise continuous fhshion (to ensure the differential equation admits a solution), then test guarantees stability for an a r b i t r d y fast rate of parameter variation.

In a gimilar manner, the notion of Rm parformance may be extended to LPV 8ystems.

Section 3.3. Extensions of the basic theory

45

Detlaition 2 (Quadratic 'Hm peflormance) A pofptopic pammeter dependent system G @) ,given

bv

is said to have quadrutic 31, performance 7 M m the exogenous signal w fo the output z if then
&b a m t i urz

P > O, independent of p, such that oRL(G@)? ) < O for al& P permissible values of

P.
Since the s s e matrices depend f f i e l y on the varying parameter vector, then due to convexity, ytm one needs to test the d d i t y of the bounded real lemma only at the vertex points.

The statement of Dennition 2 provides the condition under which a given system achieves quadratic
7& performance. To synthesize contmiiers, we consider a plant G@) with representation

D, Equations (3.16)-(3.19) are applicable to the gain-scheduled case. The matrices Bu,, Cgand
Dw are assumed not to vary so that W pand WQin (3.18) do not depend on p. T y p i d y , if the plant's actuators and sensors are parameter indepandent, and their dynamics are incorporated in the modei, the aforamentioned matrices would be constant, and at least in this context, the above
assumption poses no real limitation.

The solvability conditions for a controller are then givea by the following theorem.

Theorem 4 (Convax solvability conditions for gain-rcheduled controllers) Caven the pamrneter dependent system (3.22) where the pammeter lies in the polytope

Section 3.3. Extensions of the bssic t h e q

46

then them & B un polytopic conhller that guomntees quadmtic R perfownance if and only if , t h m b t synmetric matrices R and S satisfing the jollowing system of inequolitzes:

To design a gain scheduled controller, we must Bnd R and S satisfying (3.23), fiom which a storage function P can be determineci wing (3.19) as explained previously. The storage function ensures stability for aU plants in the given polytope. R e d that in the previous section, we showed that

we do not need the controlier parameters to calculate P;this is done after the initial optimisation. Given a P that guarantees quadratic Ra performance over the entire polytope, a controller is calculated at each vertex. Thus, we end up with a polytopic parameter dependent controHer.
s Given any admissible puameter, the control action used i simply an interpolant of the vertex controllers. For instance, in the case of the two parameter example outlined above, suppose that
the vertex controllers are given by K., = 1 ...4, then the control action at that instant is giwn i
by

It shouid be ciear fiom the development that controllers synthesized using the above methodology wilI be conservative. This i true for a number of reasons: s
1 The design methodohgy guards against arbitrarily fast parameter variation rates. . 2. A fixeci storage h t i o n i used. One may d o w the storage fiinction P to be a parameter s

dependent.

Section 3.3, Exfemions of the WC theory

47

These 'shortco~' be put in the context of linear matrix inequalities. However, the controller may synthesis pmblem then becornes non-conm, and thus more diflicult to solve. They are however addresseci in [2].

There are other Ra related techniques for controk scheduiing that allow the varying panuneters to enter the p h t mode1 i a fractional way. T i technique is discussed in [32,4], and exploits the n hs technique of robust design.

Chapter 4

Control of Web Processes

T i chapter appliesH hs ',
optimisation to the control of web processes. The a h is to describe the
techniques with which a controiier can be designed by applying it to the two span system available

here at the University. The methodology can easily be extended to treat machines wit h more spans
by using the modeis given in Chapter 2. W e begin by detailing the design procedure based on the

reduced order model, after which we treat the full order model.

4 1 Reduced order web model .

We derived in Chapter 2 a model that i applicable to stB material, that i web with an infinite s s s modulus of elasticity. The implication of this assumption i that the peripheral speeds of aU rollers
are the same.

There are good reasons to deal with the reduced order model-it describes the behavior of web processing weU at I w fiequenues. For materials that are typically used, the use of load cells ro o meapure the span tensions set serious limitations to the controller's performance. This is true because the bad celi itself i a d y n d c system (it may be modeled as a mass resting on a stiff s spring), it ie therefore difficult to discern be-n the plant's aad the sensor's contribution to the measurements at higher fkequencies. It is for this reason, amongst others, that industry has taken an a n d interest in the possible use of observers to estimate tension. Until such time when observers

Section 4.1. Reduced order web modei

49

replace the more traditional load celi, it seems reasonable to work with a model that does give a
good enough description of the plant at small fiequencies.

The equations for a general A-span system are given i (2.16) and (2.17). For a 2-span Bystem n (where the reninder, nip and unwinder are now labeied a, O, c respectivdy, Ta, represent the Tb
rewind and uwind zone tensions respectively and u i the m c i e speed) the equations are given s ahn

in state form by

The quantities . and 6 rcpreaent disturbances to tension which arise fkom processes such as 6 6

machine vibration, unbalanced rolis (for example, unround roiis) and web steering. The term 6 , represents the dXerence between the actud load torque on the nip and the one predicted by the load d . i These disturbance are not exogenous, they are dependent on the system's state, and we indude thern here just to point out that they remit in discrepancies between the mode1 and the actual system.
Extensive identification has shown that the dynamic friction terms in the real machine are d d l y nonliaear in nature. The model in (4.1) uses the b a t linear approximation for the fiction. We
neglect the static m i o n terms, although the torque inputs may be used to compensate for them.

Table* 4.1 summarizes the values of the various parameters in the system.
'These values are obtained via identification of the three bare rollers. The experiments were conductecl by S. Dejak and are inciuded i his thesis* n

Section 4.1. Reduced order m mode1 b

Parameter
J.
Rewinder Pmpedies

1 Description

Value
0,01745 0.00393 0.59 0.0415-0.15 0.03223 0.00606 0.6 0.0395 0,02336 0.00387 0.4 0.0415-0.15 1100 0.168 1.5 x

Nip Pmperties

Bare shaft inertia (kg m2) ba Viscous damping coefficient (N m s) Static friction torque (Nm) ra Radius (m) Jb Bare shaR inertia (kgm2) bb Viscous damping coefficient (N m s) Pb Static friction torque (Nm) r b Radius (m)
. .

Untuinder

Properties

Web Pmperties

Jc Bare shaft inertia (kgm2) bc Viscous darnping coefncient (Nm s) Staticniction torque (Nm) T, r, Radiug (m) p Web density (kg/m3) W Web width (rn) e W b thickness (m) e
Table 4.1: Machine and web properties

IO-^

Section 4.1. R e d u d order web model

411 ..

How good i the model? s

The model given in (4.1) attributes any dinerences between the measured and simulatecl values of
speed and tensions to the disturbances 6 ,

and dV. Figures 4.1 and 4.2 compare expeiimental data with the model for &, db, . = O. The experiment w s conducted under fedback control, and 6 a the control signals m e used to drive the simulation.
tfb

There is a discrepaney between the mathematical model and the physical system. Thie is most visible in Figure 4.1, where clearly the model does not desaibe the speed response of the web &e. There are several fadors that attriiute to the discrepancy, n d y ,
a

h e d i a t e l y upstream and downstream of the nip section there are undriven rollers. As the

web traverses thesa idlers, some tension i developed in the material to both overcome the s
fkictionai forces and accelerate the undriven rollen.
w
0

Uncertainty in the model parameters.

The filtered tension measurements are used for the simulation.

Fortunately, the tension mode1 is a lot more forgiving to inaccuracies in the friction model, the ody visible change being some offset in the steady state value. The mathematical model captures the details of the axperimental data rather weli in both spans as can be seen in Figure 4.2.

The vaiidation experiments were conducted under feedbadc control. It may of course be argued
that the controiler filters the driva inputs which in tiun rnay not be rich enough to excite some
modes of the system. Fortunately though, open loop experiments are consistent with the identified

reduced order model.

4.1.2

Nominal performance of the LTI system

We start the design process by M

g the d u e s of the radii, and hding the optimal controller for that configuration. We begin by showing that a blind application of R design may Iead to , less than desirable resuits. The state space representation of (4.1) when r, = O.lm i given by s

Section 4.1 R e d u d order web model

fime

(s)

Figure 4.1: Cornparison of mathematical model and actual data for the nip section.

(a)Rewind Zone

(b) Unwind Zone

Figure 4.2: Cornparison of modded and a c t d tension in both the rewind and unwind zone. Note: The simuiated plot i intentiody displaceci by 1 N downward in order to make the plots more s 0 visible*

Section 4.1. Reduced order web modei

rhere z = vfq,,, denotes the system's state, and y = [T~/T~,,, u/%, T~/T,,~~]' its output, which has been scaied with respect to its mBximum value because the tensions and speed have different scales. We ignore the dynamics of the tension semors which have highly osciiiatory modes associated with them (as one may easily ver@ by applying an impulsive input to them). Consequently, the tension measurements are noisy, and smoothing filters are used. A block diagram
of the control aystem is shown in Figure 4.3,

Weight selection

The control objective i to track the desired output trajectory s

optimal in the H ',

is sense. To that end, we define the enor signal e = y, y whose energy we seek .

y&, so that the performance

to minimhe. Furthemore, we penaiize the frequency content of this error signal using a shaping
weight We. i a weli known f a t that to track some reference signal, a model of that signal needs It s to be incorporateci into the controller? This specification ain be captured by incorporating the

referenee model into W,, alternatively adding it into the loop as we have done in Figure 4.3. Note or that since we wish to tradc step signals, whose model W an integrator, we cannot use the former technique since this violates the solvability conditions (given in the theoretical development).

The plant P i formed fiom the series conneetion of the web model (4.2) with the output filter* s

+Thisi the celebrated internai model principle. s 'This fitter was implemented on the machine h m the outset.

Section 4.1. Reduced order web madel

Figure 4.3: Block diagram used for contmller design. Note the setpoints are scaled to their maximum value.

The scaie faetor R normatizes the reference aignal r = [pa

G] to 1, and is given by

which corresponds to a maximum tension of 130N and 1118Ximur.n speed of 5m/s.

Without any penalty on the plant input, the response becomes almost instantanaus at the price

of unreasonably high torques. We therefore penaliae the control effort via a shaping filter Wu, and solve a mhe sensitivity optimieation problem. In a typical machine, one needs to Limit the input's
bandwidth to ensure some degree of robustness, and also the maximum input should be limited so as to make sure that the drives do not saturate. The Latter constraint does not translate to anH ', requirement, and th* is where it is necessary to adapt the weight to make sure it provides a good controUer. For this parti& machine, a suitable weight is

The physicd motivation behhd th* weight is as foiiows: the zero at the origin forces no penalty
on steady date input (a dnve that iir unable to meet this requirement is cleariy a bad choice). The

Section 4-1, W u c e d order web mode1

55

pole at s = -10 then represents the cutoff fiequency which gives a fIlEiXimum bound on the input constraint. The M h e r off it is phced h m the irnaginary axis, the more dinerentiating action the

input weight imposes.

The error weight,given by W,= 1013, Ieads to a remarkably fast response in the zone tensions and speed. The weight is chosen to be diagonal in structure and each entry is used to specify, in some sense, the bandwidth of that particular channel. We impose no bandwidth limitation on the error &ght because we penaiize the integrai of the emr which naturally roils o f at high frequencies. f One nzay of course hope to achieve higher performance by using a dynamic weight, but in our
experience, this was unnecessary for this particular machine.

The goal of the optimisation then is to minimize the quantity

where S i the sensitivity function given by S = (I+GK)-' (the quantity KS i commonly refmed s s
to as the input aensitivity function, and it can be uaed to prescribe robustness in the design).

In Figure 4.3, we have intentionaiiy removed the terms 6 and cibthat appear in (4.1). The i because , s the influenceof output disturbances on the output is the same as that of the reference signai on the error. That i, both transmissions are given by the sensitivity function, The disturbance rejection s pmblem can also be placed in the context of sensitivity shaping. Any specification on disturbance rejection may be incorporated into the weight W,.
Suppose, for example, we consider the adverse &ect that unround rollers have on the tension response. As claimed in Chapter 2, such a disturbance is periodic in nature, with a Gequency equal to the frequency of rotation. To reject such disturbance, one must then include in the weight W, the filter

where w is the fiequency of the disturbance. The quanttities Ci and c2 specify the shape of the filter around the disturbance fkequency that is to be rejected. Ideaily?we would use a ilter with purely imaginary poles, but that would violate the solvabiiity conditions. The sharper and higher the
filter, the better it perfotms at sinmoida1 disturbance rejection. For the machine at the University of Toronto, we found that the conditions did not warrant the inclusion of this term.

Section 4.1. Reduced order m b model

Using the problem setup iilustrated in Figure 4.3, a controiier was synthesised using the weights given. The resuiting controlier i 1 2 order, and wae determiaed ushg Matlab's hiaf&i[l9] s ~ function that solves the LMI presented in Cbapter 3. The design was made on the continuous time model given in (4.2) and dticretbed using the bilinear trmform, with a sampling fiequency of 400Hkt. A description of the code used to design the controller ie deferred ta the Appendix.

Figura 4.4 illustrates the response to a ION step reference in Ta.The time constant i approxhately s 0.38, and the theoreticai simulation doeely resembles the experimental output. The amplitude of the noise is 0.5N,which i well below the industrial standard of regulating the tension to with 10% s of the setpoint,

Figure 4.4: System response to a ION refarence step in Ta.Dashed: reference signal; Thin Solid: experirnental resdt; Thidt Solid: simulation

s Although the response to a step in Fai good, we do not advocate this design because of the poor response in speed. Figure 4.5 illustrates the system's response to a 0.6m/s step change in machine
speed. Although the response time is very fiut, the system taLes about 5s to settie. The reason
tThis sampling freqtiency and dkretiaation technique i usecl for the implementation of a1 controllers designed s l for the web machine at the University of Toronto.

Section 4.1. Reduced order web modd

57

for this i the pole-aem candation effect that was discussed in Chapter 3; the open loop pole s at s = -0.16 reappeani in the c l 4 loop system because of the modal mismatch, leading to a s o puasitic mode. One poseible solution i to solve the 'Ho.optimisation with pole placement lw s

-0

Time (s)

Figure 4.5: Response of the system to a 0.6m/s step change in speed

constrainta. Although this solves the probiem weli both i simulation and practice, we fnd the n foilowing technique leads to alightly better performance.
Instead of avoiding the pole-zero eancellation, we apply a state feedbadc control to shifk the slow pole forthsr away fkom the imaginary axis (see Figure 4.6). The same enor and input weight is used

as before. The state feedback gain Ka does not prevent pole-zero canceilation, it simply e m e s that no parasitic mode lingers on after performing the optimisation.
For this design, we have placed the closed loop poles at s = -10, -10, -10, giving the following
state feedback m & a

The r d t i n g controuer (exciuding the integrators) may be represented by the staterepresentation

(AK,BK, 9 03x3 ) g i m in (4-6) and (4.7) CK

Section 4.1. Reduced mder web model

The response of the system to step changes in Po, Tb and V are shown i Figures 4.7, 4.8 and 4.9 n
respectively.

The response times to tension and speed steps are approximately 0.2s and 0.5s respectively. As
expected, ail signais track their respective setpoint change-there

is no parasitic s o mode that lw

deteriorates the performance. The plots also i b t r a t e decouphg between the signals; for example,

a change in Faha9 Little d e c t on either Tbor u. More importantly though, a change n fi does not
deet the tension i the upstream and downstream zones-a n

feature that is much harder to corne

by using a modutat approach.

Section 4.1. R e d u d order web model

Figure 4.6: Problem setup with date feedback

413 ..

The effect of radius change

As material is transferred from the unwinder to the rewinder, the linear mode1 of the plant changes.
As a resuit, there is performance degradation that depends on the radius of the spool.

The reduced order modei is &st order, and its only state i the machine speed; the tensions are s outputs that depend dgebraically on the torque inputs. Recd that the state equation i given by s

This says that the diff'ential equation that describes the machine speed depends on the inertia and damping of the oumll system. The pole of the h z e n open loop system is located at

which changes as the radii change. For a machine that handles a spool of radius 15cm,there i a s change of Iess than 10%i the pole aver the entire operathg region. T i should corne as no surprise n hs since material i simply being trandemed, and the overail inertia does not diange considerab~~t. s
f ~ l t h ~ thegmass does not change, the i e t a does since it not only depends on the mass of the web but also ~ h nri
the radius.

Sethiin 4.1. Reduced order web model

1
h

' 0.5 UI

w
I

O O

0.5

1.S

2.5

3.5

4.5

Time (s)
Figure 4.7: Response to a step change in Fa

Section 4.1, Reduced order web model

0.8
-0.6

E 0.4 .. ;
0.2 O O

I
1
t
I

1
3

0.5

1.5

m (s) e

2.5

3.5

4.5

Figure 4.8: Response to a step change i Tb n

Section 4.1. Reduced order web model

1A

t 0.5 >
O O
I
I

0.5

1.5

2.5 Time (s)

3.5

4.5

Figure 4.9: Response to a step change in

Section 4.1, Recfuced order web model

64

The more dominant difference occurs because at difirent radii, the torque required to maintain a c r a n tension i Miment. Figure 4.1.3 depicts the change in performance over the dinerent r d ; eti s the controiler was designed for a radius of lOcm and as one might expect, the reeponsiveness to a change in Tais tster at a d e r radius. T i matches physical intuition since the inertia i hs s las, and less torque is required to move the r o k . The diference in the speed rsgponse is hardly visible, and this should also be expected since the overall damping stays fairly constant over the
entire region of operation.

The real machine L a lot more forgiving to changes in d u s because of the unmodelied dynamics. That is, a change in the input torquea is partly diseipated in the idler rollers. Conversely, when the
machine is in operation, the iasrtias of the idlers hdp regulate the measured tensions. Fortunately,

s expariments show that there i Little degradation in the performance over the entire operating region
(see Figure 4.11).

The reduced order model, though simple, involves a strange combination of the radii and inert ias. The technique of gain-scheduling, though effective, wouid prove to be too cornervative since it deals with systems where the parameter entera affinely. For machines that pmcess larger spools of web, a simpler schedung scheme may be used. A controller may be designed for each of the extreme cases ra=4.15cm and r. = 15an (these are the minimum and maximum spool radii), and at every s hs instant, the control action used i an interpolant of the two designs. T i strategy offm no clear
advantage over the fuced radius design for the smaii machine at the University, though it may prove to be superior for lazger machines. 4.1.4

Single shafk control: a modular methodology

Universaliy, practice in industry is to design controilem loop-by-loop, with both f e e d f o m d and feedback components. A description of the various control schemes was given in Chapter 2. At the request of VRP Technologies, we have designed single shah & contmUers-that i, except s drives a single motor (e.g., for some feedfomd components, each error signal (e.g., @ - Ta) the rewinder). The model useci for each loop poses no limitation to control design, so that the ' , design approach is overkill. It does, however, bighght some of the advantages of using the H centraIized approach.

Tirne (s)
(a) Simulated response to a 26N step change in Ta

@) Simulateci respoase to a im/s step change in u

Figure 4.10 Effect of radius change on the system's performance. Dotted Line: r = h m , Soiid , Line: r, = lun and Daahed Line: r, = 1 c 5m

Section 4.1. Reduced order web rnodef

0.8

1.2

1.4

1.6

1.8

2.2

Time (s)

Figure 4.11: The respoase to a 10N tension change over the entire operating region. Dashed: 5m Reference Signal, Dotted: ru km,Thick: ru = IOcm, Solid: r, e 1 c

Section 4 L Reduced order m b mode1

67

The modular Noo approach &O has indisputable advantages. First, it can more easily be ported to
0 t h machines that have dinerent configurations. Also, tuning the controIle., though not tupnkey,

i neverthelem d e r to do-that is, the operator needs to worry about o d y one loop at a t h e . s Wh8t follows describes the procedure with which a moddar control design cm be done.
Suppose that the torque at the nip ie given by
n

where 6 is used to control the nip's velocity. This f e e d f o m d signal decouples the nip motor fiom the rewind and unwind zones,
M r some dgebraic manipulations, we find that the tensions defined in (4.1) are given, in tenns e

of ubt by

The signal vb is used to regdate the speed of the nip-that

then 4 = K,( u). If the "load compeasation" defined in (4.9) perfectly decouples the nip motor fiom the rewind and unwind zones, y shoud not be affected by either T or Tb. Although the . exact charactes of vb is not known a priori, since it depends on the closed ioop system, it may be treated as a disturbance to the tension equations given in (4. IO). The torques U, and U , j may be used to compensate for the remaining terms in (4.10). For instance, we may define

is, if Kv represents the speed controller,

and likewise with Uc, d t i n g in a very simple equation for Taand Tb,namely, r

T = ,va a 1

1 and T = -,v,. b

(4.11)

These algebraic manipulations are overly sirnplistic. The tension measurements are filtered, and thus these fdorward terms are never perfect in practice. Nevertheles, we use equations (4.11) as a basis for control design.

Section 4.1 * Reduced osder web model

Figure 4.12: Setup for rewind tension controiier

n The setup shown i Figure 4.12 was used to design controllers for both the rewind and unwind
tension zones. The same setup was used to design a speed controller. For the tension controiier, the plant P consists of the simple model (4.11) in series with the filter F ( s ) = to a 15N step change to

A.The responses

and Pb and a 0.5m/s step change to 5 are shown in Figures 4.13, 4.14 and 4.15, respectiveiy. C a g s in the setpoint tensions have Little effect on the speed response; hne this is to be expected since the torques they exert on the nip are cornpensateci for. On the other
hand, a change in the set-point speed is felt directly in the tension respomes, and leads to very poor performance. Note that no feedforward component was incorporated into the signals U, and
CI,. Ti i because aithough the interactions become less pronounced, the controiiers no longer hs s

track the reference signals owing to the radius changes. The modular approach is also more sensitive to radius change. The data set shown here comespons

to controllers designed for ru= 4cm and rc = 15an. The t h e constant for the rewind zone contmLler

i a p p r h a t e l y 0.58, while that of the unwind zone i 0.2s. T i cornes a no surprise, since the s s hs s
controller designed for T assumes the nnwinder is heavier than it r e d y is. b

A gain scheduied contmller b readily designable for the moduiar approach owing to the simplicity of the model. To see how an adsptive tension controller may be designed, note that (4.10) may be d r written as ( e ignoring the last two terms in each of the equations)

Section M. Reduced order web model

1
L
A

----

go.5
>

I
1
I

O O

0.5

1.5

2.5 Time (s)

3.5

4.5

Figure 4 1 : Response to a 15N step change to fa .3

Section 4.1. Reduced order web modei

0.8

0.4

1 I
1

0.2

O O

0.5

1.5

2.5 Time (s)

3.5

4.5

Figure 4.14: Response to a 15N step change to Pb

Section 4.1. Reduced order web model

1
A

-0.5
>

,- --I
oi O
t

I i 1
I
I

-5

0.5

1.5

2.5 Time (s)

3.5

4.5

Figure 4.15: Response to a 0.5m/s step change to 8

Section 4.2. l5z.U order web mode1

72

Suppose the rewind tension controiler, designed according to the model (4.12a), b given by uo =

K(= - Ta), the a c f d con troll^ L given by raKa. .F then

4.2

Full order web model

The full order noniineau model of a general N-span syetem was given in (2.13). For a two span
system, the equations are given by

The quantities ka and kb are the efl'tive stifniess of the rewind and unwind zones respectively,

and can be found by

where A i the materiai's cross-sectional m , E its modulus of elasticity and li the span length. s a
The modulus of elasticity is no longer assumeci infinite; however, it i a m e d large so that the s

conesponding strain i small. The peripheral speeds of the rollers, though distinct, are very dose s
to each other.

A linear parameter varying model is readily derived around an operating machine speed R. This linearisation was performed in Chapter 2 and Ieads to

P o o
O

o o p
O
0

2 0
0
0

0
0

Section 4.2.

N order web mode1 I

73

s where we have recagnized that Va, & cc; (because the merence in these quantities i s m d ) ,and E >> Ta, kfl'. The A matru in (4.14) varies as a function of the spool rad5 and the operating

4.2.1

Nominal controlier design

We begin the control design procedure by fiezing the value of r. at 10m, and the operating speed at lm/s. For values of &,kb > >OON/rn, the reduced order model conthues to do vefy well. Indeed, the added compiication of resorting to the full order model are not warranted in terms of performance improvement. As the materid becomes more elastic, a nominal control design baaed on the i n f i t e s t f i e s s assumption i no longer stab%zing. s
We design a controller based on the full order model where ka = kb=400N/rn, la = ib =Im and

the remaining parameters in (4.14) are the same as those given in Table 4.1. The parameter r, is fiozen at a value of ra=lcm and the operating machine speed ia taken to be lm/s. The controller
designeci in Section 4.1.2 destabifizes this plant.

Figure 4.16: Block diagram used for N order controller design 1

Figure 4.16 illustrates the block diagram used for control design. A good choice of weights i s
-

h"X'ati not to say that no controiier exists that i designed based on the reduced order that also works for the s s full order model-

Section 4.2. E order web model W

74

W = z13 and Wu= 0.0513. The plant P consists of the model (4.14) in series with same output . ater that appears in (4.3) is used here. The matrix R is given in (4.4). The control problem is solved with the additiod constrauit that the closed loop poles X satisfy ReX < -1.5. T i hs
condition ensures that no polezero canceiiation, near the imagmarY axis, occurs in the design. The resulting controllet is of order 13, and the response of the system to changes in Fa, and fj, q
applied simultaneously are shown in Figure 4.2.1. Figure 4.17: Responsa to step changes in f",

% and Tb

-20
1 1

IO

Time (s)

Sdan

4.2. lW.l order wieb model

75

Removing the pole placement constraint r d t s in a controiler that is seemingly better (in tarms of

time constants aad decoupling between the three outpute). It is however not robust to changes in the s s e panmeters and h m not advocated The minimum achievabie 7, however, does occur ytm for a cancelling controller, ao that enswing a certain degree of closed loop stabity (the value a) cornes at the cost of increazhg 7. By placing l a s penalty on the plant input, it is possible to make the responee times of Figure 4.2.1 faster. The input weight, however, has been chosen to puantee that the plant input signal i at least realizable by the motors that are cunently installecl in the s machine at the University. The biggest challenge in designing a controller foc the hl order model il i ensuring that the input signal i in fsEt practically achievable. s s
For a range drad around the nominal value of r. =10an, the controller continues to be stabilizing. However, starting with ra =4m, we h d that a couple of closed loop poles appear at X = 5 f 124 and hence the resulting systeni is unstable. T i design i therefore not robust to a large change hs s in the apoolb radius. Although the probiem may be cast in robust performance design fiamework,

we look into the technique of gain-scheduling to find a solution.

4.2.2

Gain-scheduied design

We begin k t by redefining the inputs in the followhg way:

Recd t hat this is necessary becauae the algorithm for gain-scheduled control design requires that the matru B be parameter independent. From (4.14), it is clear that there are two parameters t h t r d t in a time varying speed, namely, the operating speed and the radius of the rewind spool (for a given system, the other raius can be uniquely determined). A design is conducted about an
operating machine speed of lm/s. Although there is only one varying parameter in the system, it enters the state equations in a nonlinear f a o n , and hence the theory of Chapter 3 i not applicable. One way to get around this s f 9 technicality i to d&e four varying parameters, m = s = $, pa = and p~ = f that are computed online baseci on the radius measurements. Adrnittedly, this will lead to a cornervative design, but at le& it provides a formal solution to the plant variation problem.

k,

Section 4.2. Rdl order web modd

Figure 4.18: Block diagram used for full order controiler design

The control setup given in Figura 4.18. The same weights are used for the control design, resulting in a 1 3 order controller for each of the 16 vertex systems. The gain-scheduled controller is stabilizing ~ ~ for d values of pennissible r d . In particular, the response of the closed loop system when the i radius i ra=4cm i shown i Figure 4 1 . s s n .9 Suppose the vertices vl

[ ... vis 1 of the parameter polytope are formed in the following way:

At some instant t, suppose the parameters take on the values p i , . ..,p.+ Define the parameters cri

for i= 1,2,3,4 as foliows:

= The gain scheduied controller K is then formed fiom the

e.

vertex controllers

Ki,..,K l6 in the .

Section 4.2.

order web mode1

Figure 4.19: Response

Section 4.2. EUI order web model

fbllowing way:

78

There is littledect of fieeaing the value of the operating speed, both in the fked and gain-scheduled controiler designs. That is, t ha designs are robust to variations in the operating speed.

Chapter 5

Conclusion
The thesis studied the application of recent advanceci control design methods to an industrial

two-span web-handling machine. Two models were used for the purpose of control design:
1. Reduced order model: The web i assumed to be infiniteiy stiff so that the whole machine s
runs as one rigid body.

2. Full order model: The web i assumed to be elastic, thus introducing flexible modes to the s model.
Both models are time-varying because of the nature of the winding process. The twespan web machine consists of three roileni coupled by the web. Curent controi technology

de& with the coupng using leedforward control, and a feedback controller is med to correct for

i m o d e h g mors. In fact, d recent research efforts in control of web processes have adopted the
modular methodology.

T i was the hs

k t attempt at designing

a true centralized controiier. In

particular, we use an optimal Grequency domain control design technique, namely 'W, control.

Section 5.1. How do ouc contn,Uers f w a c i ~ ~ ~ t saiid disadvaatsges of 'Ha control ges

80

5.1

How do our controllers fare-advantages and disadvantages of

X control ,
The notion of UoptimRlityni hard to seil. The r e m n is threefold; the controiler is optimal with s respect to a particular choice of weighting fiinctions, the controller is optimal with respect ta an optimization criterion, and M y , the controller is optimal with respect to a specific plant model,

which does not describe exactly the true physical plant* Ultimately, the controiier's performance was judged on the response of the actual physical plant-and that provd to be good with respect to the currently applied control technique.
Using the reduced order model, we made the foilowing observations:

1. As compared to the rnodular design approach, the centralized design h more insensitive to the rad of the spoois when the total radius of the initial spool i srnail. A scheduling scheme s is not necessary in that case, and the information from the radius sensors is unnecessary. On the other hand, the rnodular approach requires the radius measurements to get good performance, Thus if the radius measurements are erroneow, as they were in the machine at the University, it is hard to achieve even a basic requirernent such as tracking.
2. The moditiar approach can never deal perfectly with the coupling between the three rollers.

T i is because when "load compensationn i applied, the feedforward si@ hs s

measurements are noisy.

uses fltered

tension measurements rather than actual tensions. T i is unavoidable because the Ioad cells' hs

Thus our design technique has the foUowing merits. Once the systemTsparameters are identified, there is little effort in obtaining a controller that performs well in terms of a cont roller t hat achieves tracking, decouples the d e c t of the three sections we. and has good transient behaviour (fast response tirne, and no overshoot). The operator no longer has to go through a series of physicd arguments to juatify what action muet be taken to reduce the coupling between the systems-that is a byproduct of the design procwis.

On a negative note, however, there are fundamental limitations to the centralized control technique. Fi,the theory is mathematicdy intensive, so that the knowlege is not easiiy transferable to a machine operator. in terms of design and implementation, sophisticated software tools axe

Section 5+1. Kow do our controIIers f e a v n a e and d i s a d v a n t ~ ')Cm control m-dstgs of indispensable in the design proeess. Secondly, contmller tunllig i not turnltay-it s

81

is not possible

s to change one parameter to tweak the performance one way or the othet. Findy it i axtremeiy M d t to debug the controlles should something go hdamentaily wrong. This i because of the s very nature of the controller-the torque applied to each of the motonr depends on al1 the error signals. This problem is not prevalent in the modular approach because a operstor needs only to n worry about one loop at a tirne*

The mast important (and poesibly detrimental) shortcoming of the centraliaed appmach i rooted s in the nature of the mode- assumptiom. We reiterate that the controiler i only valid if the web is s s taut; othmise the model does not deedbe the process, and the resulting controller i invaiidated. in web-handling, there is a very thin line between when the web is alack and when it i not. It s is t h d o r e rather n a t d to reiy on the cascade control structure that is currently used-that is, all the roilers are speed controUed, and the error in tension simply generates a desired speed ciifkentia1 that is achieved by the windece. T i concept is fundamental; the modular appmach hs
is valid whether the web i taut or not because the plant model is valid in either case. On the s other hand, the centralized model that we use, and hence any controlier we design, requires that the material is not slack. The thesis &O treats the N order web model. As the material becomes more elastic, the controuer 1 designed baeed on the reduced order model is no longer stabiliaing. In this case, the operator must

design a aew controiier that i appiicable to more flexible material. The controller was not designed s to be robust for aii possible spool r d . As a result, in this case, as opposed to the reduced order model, robustness had to be earned. We opted to design a Linear parameter varying controller to amount for the radius changes; the c o n t r o k thus depends on fairly accurate radius mewurements. The LPV controlier is stabilizing and provides good performance for all possible spool raciii.
Regardlem of the practical applicability of the Ra approach, the thesis does give an indication of what modem control techniques can provide to an industriai process. In cornparison to existing technoIogy, there were clear advantages to usingformal design techniques. At the same t h e , t here are inherent problems associated with the new approach.

Section 5.2. fiture ckstions in web researcb

5.2

Future directions in web research

There are fundamental limitations in web processing.

The k t d e in control engineering is that a controUer i as good a the actuators and sensors s s that are used in the system. The load cells that me the tension have their own dynarnics. In fact, every industrial tension controlier typicdly Glters the tension output using a filter with a time constant of at Ieast 100ms.

This fact has certainly motivated a wealth of reseaxch into the design of tension obsewers-not only
beause that would lower the cost of the machine^^ substantially, but also because the controllers can be designeci with a higher bandwidth, and therefore, better performance. Currently the problem s with designing good observers i the presence of the idler rollers, in which it is possible that the
contact region is completely characterized by slip. In that case, the system becomes unobservable.

Of course, if in the near future, effective strategies are deveioped for tension estimation, an obsemerbased controller holds promise for even better performance.
More crucial though is a need in industry to develop good identification routines. There ia ample

"modehn of web procesaes in the literature, however, what is la,cking i experimentd verihation s of these models. For instance, a control engineer needs to know the exact impact of ignoring the idlers, what component of the measured tension is r e d y informative and what may be attributed
to load ceU dynamics, more complete actuator models and so forth- These technicalities make the modei imperfect, and hence a controiler that passes itself as "optimal" may be far nom that. For

these reasons, relying instead on black box models may a c t u d y prove to be beneficial.

Appendix A

Guide to control design with matlab

AU matlab code i written in verbatim. Anything after the % sign is a comment. The symbol>> s
signines commamis that are execute in matlab. The control design nles requin the LMI control

toolbax[l9].

A.l

Defining the plant

The function funweb accepts aa an argument the radius of the rewinder spool. It generates a state space model of the reduced order model in series with the output filter defined in (4.3). The syntax

is as follows:

The function i given beiow. s

function Csys] = funweb(ra1

X Web properties
rho 1100; U = 0.168; e -0 .OOOlS/(lzpi) ; prW2 pi*rho*Y/Z;

% Density X Width

X Thicherr/(O.pi)

Section A.I. Definimg the pplent

% Bare shaft inertias JOa = 0.01746; # Revinder i a e r t i a Jb 0.03223 ; X Nip inertia X Unwinder inertia JOc 0.023363;

--

X Bar8 shaft radii = 0.0415; rb = 0.0395;

rO

Y, Unuinder/Rewinder radius

% Nip radius

Rmin

% Minimum and maximum radius of spool mx 0.0415; R a = 0.15;

+

X ra: radius of rewinder (argument to filaetion) X rc: radius of unwinder, calculated from ra using the fact that the t o t a l cross sectional area i s consemed $6
Ct8

rc = sqrtccts-ra-2) ;
% Inertia of winders with spool on Ja JOa + prW2*(ra. -4 rO"4); Jc $Oc + prW2*(rc. -4 ~ 0 ' 4 );

Rmaxm2+Rmin-2;

--

X Daaping Coefficientr X Rewiader ba = 1/254-4878; bb = 1/166.0867; X Nip bc = 1/258.3219; X Unwinder

STATE REPRESENTATION OF PLANT %XX'X'rC'tL den = Jcwa*2*rb02 + (Sb*ra2+Ja*rba2)*rca2;

XrC FORMING 'f A r

X C-matrix cTa = (-ba* (Jc*rba2+Jbrrc"2)+Ja+rba2*bc+bb* Ja*rcn2)d a ; / cTb = (bc*Cra2*Jb+rb^2* -ba*rba2*Jc-bb+ra62*Jc)/den; Ja)

C

[cTa;l;cTbI ;

Section A.2.

D~rrninp controfler the

X Defining the output f i l t e r F=pck(-10,4,2.6,0); %F=l/(O.ls+l) Filter = daugCF, 1 , F) ;

X Scaling the output to its maximum valua X Ta-mar,Tb-max = 130N; V-wm = Sm/s refi = ainv(adiag(130, S. 130) ) ;
X Dverall open loop plant sys = smult (web-aig. Filte-ef
i);

A.2

Designing the controller

Once the plant i defined, a controlier can be designed using the function uebsf. This implements s the pre-state feedback to shift the slow polefi away fiom the imaginary axis. The argument of this
huiction is the radius of the rewinder spool, and it returns the optimal Raocontroller, the output feedback gain and the closed loop trader matrix. The syntax is as followa:

>> ra = 0.1 ; >> [K,ksf ,PclJ = websf (ra) ;

The functioa i included below. s function [Cont , ,PclJ ksf

X Define the open loop veb system web funttebcra) ;

X Extracts state space [a,b,c,a = ItissCweb) ;

websf (ra)

Section A.2. Designhg the controiier

% Find state-feedback gain t o place ail pole8 at 8-10 kaf = place (a, b ,[-10, -10, -101) ;

X Nev A-mattix. a f t e r applying s t a t e feedback, and X new web mode1 a = a b*ksf ; web = ltisys(a,b,c,d) ;

X The scale factor matrix (correrponding t o T a m . V_max.Tb_max ref = diag( [130,6,130]) ; X Output feedback gain that mst be applied in the machine ksf = ksf* (ref *c) *-1; X Integrator matrix: l/s 1-3 53 l t i s y s (zeros(3) ,eye(3) ,eye(3) ,zeroe(3) ) ; X Form general system interconnection: X The plant P ha8 -three reference inputs -tu0 outputs : integral of e r r o r Cie) x X and plant input (KI X See block diagram i n Chapter 3 f o r an i l l u s t r a t i o n of this X The output P i r the generalized plant, and r is a two entrg vector X r[# of controller inputs ,# of controller outputs] p , r ] = s c o ~ e c t ( ~ r ( 3 ) ' , j i e ; K>K:ieJ,jie:r-G*,S3, W K a ,ueb); j,
X Define the weights X Error veight W = daug(lO,lO,lO) ;
Uu

% P l a n t input weight l t i s y s ( ~ t f ~ , 0 . 0 1 *01,C.l i l ) ; X Transfer function: ~1 X Wu(s) = 0.01s/(0*1s+1) Wu = sdiag(Uu,Wu,iiu) ;

X Augment the plant P sith above ueights Paug = &t(P,sdiag(W,~u,eye(B)));

X Synthesize L i n f i a i t y controller uaing the linear matrix % inepiulities approich: go minimum achievable g m a K- controller a m;
[g,KJ = hinfimi(Paug,r);

Section A.3. Design for tbe fuu-order model

X Form cloaed loop system with inputs being the reference values and P s ~ o ~ C t ( ' r ('3,)GK,KrG, *;'':-a Pcl = slft(P,smult(S3,K)) ;
% outputs, the scaled tensions and speed, and the control effort 'G:Kt ,wb) ;

X Geaerate actual contiauous time controller as the seriea comection % of the scale factor (to acale error w .r.t maximum values) , the % integrator and the controllel: found above. ref i = siri+(rdiag(i30,6,130) ; K = 8113P1t(refi8S3,K) ;

X Plot step response mlot (Pd. 'st ') ;

Once the controiier is determineci, it has to be discretized. The sampling fiequency of the research machine i 4Hz. The discrete tirne state representation (A,B, C,D)can be found as follows: s

Given a controller K, we have writt m a utility f l t OC(K , ilaname) that automatically generates ie f the C-code in the file f ilenme .h. That is the commaad

generates the file controiIer.h that defines the function controller(double* e ,double* u) . The function inputs are the signals that are paased to the controlier, and outputs the control signals that are applied to the motor drives.

A.3

Design for the full-order model

The matlab code for full order model foiIows that of the tcduced order model exactly, except that the weights used are Mixent, and the plant model is different. To design a controller with an
additionai poIe+placementconstraint, suppose the generazed p h t is given by P, and the controk i an n x m transifer matrix. Suppose 8lso that we wish to place the poles left of a = -1, then the s foiiowing commands generate the c o n t r o k K:

Section A.3. Design for the firll-order model

The afioremmtioned routine i performed by the h c t i o n webfo. The gain-schedded controller s requires the definition of a polytopic plant P. Once this i avaable (see the file webgs for the s matlab irnplemention of the idem in Chapter 4), the following matlab fimction designs a gainscheduied controller:

>> N-in = 3; N-out = 3; X Number of controller inputs and output8 >> r = IN-in N-out] ; >> Cg,K] = hinfg88,r) ;

The routine simg8 (KI then simulates the reeponse of the gain-scheduled controller.

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