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A Physically Regularized Control-Oriented State Model and Nonlinear Model Predictive Control Framework for an Ice Rink Refrigeration System

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Abstract
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Energy-intensive refrigeration systems require predictive models that remain informative under counterfactual control trajectories, not only on archived operation. This paper develops a control-oriented multi-step state model and a nonlinear model predictive control framework for an indoor ice-rink refrigeration system. Historical state, control, and exogenous variables are encoded jointly with an admissible future control trajectory, and a normalized thermal-balance residual is added to the training objective. A lightweight conditioned transformer predicts ice temperature, return-glycol temperature, supply-glycol temperature, and compressor power over a 30 min horizon. The selected weakly regularized model with regularization coefficient λphys = 0.001 decreases the normalized thermal-balance root-mean-square error on the horizon tail by 30.29% relative to the base model while increasing the average ice-temperature root-mean-square error by only 1.90%. In a surrogate-based counterfactual four-day evaluation, the resulting nonlinear model predictive controller reduces predicted daily energy by 4.84%, terminal violation share by 17.32%, mean absolute terminal ice-temperature deviation by 18.74%, and the mean objective value by 30.82% relative to historical admissible setpoint tracking. The mean full control cycle time is 0.0311 s, confirming real-time feasibility for a 5 min supervisory update interval. All controller results are surrogate-based rather than field-deployed and therefore represent receding-horizon benchmark results under learned-model evaluation, not realized field savings.

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  • Proceedings of the Institution of Mechanical Engineers, Part I: Journal of Systems and Control Engineering
  • Joni Backas + 1 more

In this article, we devise a nonlinear model predictive control framework for the energy management of nonhybrid hydrostatic drive transmissions. The controller determines the optimal control commands of the actuators by minimising a cost function over a receding horizon. With our approach, the velocity-tracking error is minimised while keeping the fuel economy of the system high. The hydrostatic drive transmission system studied in this article is a typical commercial work machine, that is, there is no energy storage or alternative power source in the system (a nonhybrid hydrostatic drive transmission). We evaluate success with a validated simulation model of the hydrostatic drive transmission of a municipal tractor. In our experiments, a detailed system model is used both in the system simulation and in the prediction phase of the nonlinear model predictive control. The use of a detailed model in the nonlinear model predictive control framework places our design as a benchmark for controlling nonhybrid hydrostatic drive transmissions, when compared to solutions using simplified models or computationally less intensive control methods as in earlier work by the authors. Our nonlinear model predictive control approach enables numerically robust optimisation convergence with the utilised complex nonlinear model. Above all, this is accomplished with stabilising terminal constraints and distinctive terminal cost, both based on an optimal steady-state solution. In addition, a simple method to generate initial guesses for optimisation is introduced. When compared with the performance of a controller based on quasi-static models, our results show notable improvement in velocity tracking while maintaining high fuel economy. Furthermore, our experiments demonstrate that framing energy management as a nonlinear model predictive control provides a flexible and rigorous framework for fast velocity tracking and high energy efficiency. We also compare the results with those of an industrial baseline controller.

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The article studies the trajectory tracking control problem of underactuated marine vehicles via the nonlinear model predictive control (NMPC) strategy, where practical control and state constraints present. It is a well-known challenging issue that the conventional NMPC is not applicable for underactuated marine vehicles, due to the fact that there does not exist a local static continuous state-feedback controller to stabilize the underactuated dynamics. To resolve this issue, this article proposes to construct an auxiliary time-varying tracking controller to aid terminal constraint design in the NMPC framework, where the time-varying tracking controller borrows the ideas from Lyapunov's direct method and backstepping approach. Based on this, a novel NMPC algorithm is designed to ensure trajectory tracking control of underactuated marine vehicles. Furthermore, a systematic parameter design approach is developed. Under the designed parameters, we show that the tracking error system is input-to-state stable (ISS). Finally, the effectiveness of the designed algorithm is verified by thorough simulation and hardware experiments.

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Algebraic approach to nonlinear finite-horizon optimal control problems of discrete-time systems with terminal constraints
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This paper proposes a method to solve nonlinear finite-horizon optimal control problems of discrete-time polynomial systems with polynomial terminal constraints. Algebraic equations with all variables at each time step, which are independent of variables at other time steps, are derived from the necessary conditions for optimality by eliminating variables recursively. The candidates of the optimal solution are obtained by solving these equations, and algorithms to find all of these candidates are also proposed. Because of its structure, the proposed method is suitable for nonlinear model predictive control that needs only the initial optimal control law. A simple example to illustrate the methodology and a practical example with the nonlinear model predictive control framework are provided.

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