Closed-loop Identification of an Industrial Extrusion Process

Abstract

This paper deals with the challenging problem of closed-loop identification for multivariable chemical processes and particularly the estimation of an open-loop plant model for a lab-scale industrial twin-screw extruder used in a powder coatings manufacturing line. The aim is to produce a low order efficient model in order to assist the scaling-up and the model-based control design of the manufacturing process. To achieve this goal, a two-stage indirect approach has been deployed which relies on the a-priori knowledge of the controller parameters in order to extract good estimates of the open-loop dynamics of the underlying process. As input excitation signals we have used multiple single variable step tests at various operating conditions (current industrial practice) carried out manually in order to generate the data-set which captures the dynamics of the extrusion process. In order to increase the efforts for obtaining a suitable plant model, we have employed various identification techniques, such as Prediction Error Methods (PEM) and Subspace Identification Methods (SIM) in order to generate candidate closed-loop models that fit to the original input-output process data. Then, a comparison of the estimated models was performed by means of the mean square error and data fitting criteria in order to select the model that best describes the dynamic behaviour of the extrusion process. Model validation based on closed-loop step responses also used as verification of the results.