Automatic tuning of robust constrained cross‐direction controllers

Summary The paper machine cross‐directional (CD) process is a large‐scale spatially distributed system. It is known to be severely ill‐conditioned as the gain rolls down to zero for some of the process directions. Model uncertainties in the process are inevitable resulting in a challenging robust control design problem. CD actuators are subject to min–max constraints while slice lip actuators are subject to additional bending moment limits. Because of the large number of input constraints, the industrial practice is to tune the CD controller assuming inactive constraints. The robustness of CD feedback loops to model uncertainties under constrained internal model control satisfies an integral quadratic inequality. This work develops an automatic tuning algorithm that guarantees robust stability and performance of the constrained CD feedback loop. Spatial response models are identified in a prediction error frame delivering bounds on the CD process pseudo‐singular values. The CD controller is synthesized online through a linear matrix inequalities feasibility problem taking into consideration the modal space uncertainty rising from the uncertainties in the estimated parameters and the expected variations in the dynamic response. The developed tuning technique is suitable for paper machines producing different grades of paper as the CD process spatial and dynamic responses change for each grade. The performance of the tuned constrained internal model control controller is validated through comparing it to an industrial CD controller that has been implemented in paper mills as part of a commercial product. Copyright © 2015 John Wiley & Sons, Ltd.