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Systems Control
Editors Note: The Guest Editor of this spe- invited sessions each year at two meetings: vited session at the 1987 American Control
cia1 section of the Magazine is Eugene King the American Control Conference and the Conference and then served as Guest Editor,
of Alcoa who is Chair of the IEEE Control IEEE Conference on Decision and Control. evaluating these candidate papers and others
Systems Society Technical Committee on Selected papers from the invited sessions can included here. We thank Gene for his efforts
Industrial Systems Control. Part of the tech- serve as the nucleus for a special edition of and look forward to additional special sec-
nical committee activities is to help organize the Magazine. Gene helped organize an in- tions proposed by technical committees.
ABSTRACT: This paper presents the devel- steels, particularly in the automotive indus- even before the confirming measurement is
opment of a state-variable design approach try. Studies were conducted to develop the made. Further, the multiple-input/multiple-
to control strip temperature in a continuous steel compositions and to establish the pro- output variables typically associated with a
anneal process producing a variety of high- cess for producing these high-strength steels. heat-treating process are systematically co-
strength low-alloy steels. In this process, a It was determined that the ability to manip- ordinated based on linear quadratic control
steel strip passes continuously through five ulate and control the heating and cooling of design so as to yield the best possible control
consecutive heat-treating operations to a steel strip is an effective way of achieving performance.
achieve desired metallurgical properties for a wide range of high-strength products with In this paper, the CAL process is de-
the automotive market. Each operation is unique properties from a limited number of scribed, the design of the strip temperature
controlled by an individual controller de- compositions. This effort culminated in Sep- control system as applied to a furnace section
signed to maintain the tight strip tempera- tember 1983, when a state-of-the-art contin- of the CAL is presented, and performance
tures required for the product mix. To uous anneal line (CAL) was brought on of the control system is discussed.
achieve this goal, linear quadratic Gaussian stream at Inland [l].
control techniques were used to develop the The decision to apply modem control to
the CAL was based on a belief that superior
Process Description
control system.
strip temperature control performance could The CAL process is designed to produce
Introduction be achieved. For a typical heating furnace steel strips with thicknesses ranging from
control [2], when measurements deviate from 0.48 to 2.16 mm and widths from 610 to
In the late 1970s, the Inland Steel Com- the desired value, new steady-state set points 1525 mm. The maximum line speed is 137
pany recognized the increasing need in the are calculated from an implicit heat-transfer m/min and the maximum furnace capacity is
marketplace for high-quality, high-strength model using an iterative procedure. The con- 65 metric tons/h, with a yearly production
trol systems response is inherently very slow rating of 363,000 metric tons. The line is
Presented at the Special Seminar of the Associa- due to a transport delay in strip temperature designed to produce a diverse range of prod-
tion of Iron and Steel Engineers and the IEEE measurement and the need to wait for a new ucts with tensile strengths ranging from 275
Control Systems Society on The Application of steady state to be reached before taking the to 1380 MPa.
Modem Control in the Metals Industry, February next control actions. Using modern control, The strip heat-treating units of CAL are
26, 1987, Pittsburgh, Pennsylvania, and at the
explicit linear equations represent the dy- the annealing furnace, water quench, and the
1987 American Control Conference, Minneapolis,
namics of the heating process, with a Kal- aging furnace, as shown in Fig. 1. The an-
Minnesota, June 11, 1987. Christopher D. Kelly,
Dhani Watanapongse, and Kenneth M. Gaskey are man filter to predict strip temperatures in the nealing furnace has a preheat, heat, soak,
with Inland Steel Company Research Laborato- furnace. This allows strip temperature de- and gas-jet cool section. The three sections
ries, 3001 E. Columbus Drive, East Chicago, IN viations anywhere in the furnace to be pre- of the aging furnace are reheat, overage, and
46312. dicted in real time and control actions taken fast cool. Strip temperature is measured by
A
ANNEALING
U L T R A HIGH
STRENGTH , m F *
-r,
FURNACE./
*--eA
'
T; '\\
bAGING FURNACE4
COIL
DESCRIPTION
SETUP
AND
UPDATE MODELS -
e LINE SPEED
WELD TRACKING
STRATEGY
ws
PREHEAT HEAT SOAK JET REHEAT OVERAGE
CWL
DISTANCE ~~
Fig. 2. Product thermal cycle with temperature tolerances. Fig. 3. Schematic of process control system.
April 1988 33
of a predictor, Kalman filter, and linear con-
troller. The predictor calculates the strip
temperature along the entire length of the
strip. The Kalman filter then ensures that the
calculated strip temperatures are correct by
using the exit strip temperature measure-
ment. The linear controller then adjusts the
U + control set points to minimize any differ-
TZIO TZ8
ences between the calculated and desired
strip temperatures along the length of the
strip.
.~-....~.....
~ ...
.
Strip Temperature Predictor
The predictor is a linearized model that
calculates strip temperature changes caused
by process perturbations around a nominal
TZ9 TZ7
operation condition. The predictor calculates
the strip temperatures in real time. To de-
velop the predictor, the transport term in Eq.
( I ) is linearized by dividing the strip length
EXIT STRP
into segments or nodes using the following
ENTRY STRP
TEMPERkTURE TEMPERATURE difference approximation for the partial dif-
PYROMETER PYROMETER
ference, with L being the length between
-
V
- temperature measurements and 73,- I being
the previous nodes strip temperature.
Fig. 4. Schematic diagram of the physical CAL heat section. dTS,ldt = (TS, - TS,- 1)lL (2)
The radiation term in Eq. (1) is linearized
strip temperature so that the temporal change view factor, U the Stefan-Boltzmann con- around a nominal operating condition using
in heat energy at a particular location is equal stant, e the emissivity of the steel, and TZ the Taylor series expansion. In addition, the
to the transport heat energy plus the radiation the zone temperature. radiation from the zones on each side of the
heat energy, where c,, is the specific heat of strip is accounted for by separately consid-
steel, p the density of steel, U the strip ve-
dTSldt = -udTSldL + K(TZ4 - TS4) ering the left and right zone temperatures.
locity, TS the strip temperature, t the time, (1) Substituting the linearized transport and ra-
Vthe volume element (width X gage x node where K = (AFue)/(cpVp). diation expressions into the nonlinear equa-
length), L the node length, A the radiation The heat section controller is shown sche- tion yields the following linear state-variable
surface area (width x node length), F the matically in Fig. 5 . The controller consists form, where ATS, ATL, and ATR represent
the deviation from nominal of the strip tem-
perature, left control zone temperature af-
fecting the strip, and right control zone tem-
AIM STRIP FEED-FORWARD
TEMPERATURE CONTROL perature, respectively, and TS,, TL,, and
PROFILE SET POINTS TR, are the nominal operation point condi-
tions.
dATS/d? = -(u/L)(ATS, - A T S , _ l )
-
LINEAR OUADRATIC
TYPICAL + 4K(TL:ATL + TR:ATR
SECTION
CONTROLLER
PROCESS
MEASURED EXIT - TS;ATS,) (3)
Am1 1988 35
Controller Matrix Model was accomplished using the MIT Control ature estimates and the desired strip temper-
Design Package [6]. ature profile derived from the product ther-
The final controller matrix model has 36
The control gains were suboptimized for mal cycle requirements. To accomplish this
states and 15 inputs. The 36 states are de-
the following reasons. First, since any feed- function, the controller is implemented on-
fined by the 21 strip temperature nodes, the
back that attempts to correct the integral con- line using a set of algebraic equations.
10 zone temperatures, and the five rate of
trol action is unnecessary, the gains relating To allow the controller to operate over the
zone temperature changes (integral). The 15
the feedback of the integral control action to entire operating range, a gain set was cal-
inputs are defined by 10 zone temperature
the control set points were zeroed. Second, culated off-line for each of the nominal op-
set points and the five control inputs to the
off-line simulations showed that when the erating conditions. Then, as a new coil en-
integrators.
desired zone temperatures did not provide ters the line (new operating condition), the
Cost-Weighting Matrices the required strip temperatures, the control appropriate gain set for this condition is used
system tried to achieve the required strip by the controller.
Given the control model defined, the cost- temperatures while maintaining the incorrect
weighting values must be determined. The
desired zone temperatures. Therefore, even
design decision was made that relates the though the zone temperature feedback pro- Performance Evaluation
balance between the magnitude of the con- vided a derivative-type feedback, the gains The control system has been in routine op-
trol action (matrix R) and the magnitude of relating the feedback for zone temperature eration since July 1984. It is currently on-
error in the strip temperature (matrix Q) of were reluctantly zeroed. control 90 percent of the time. The 10 per-
the cost-function equation, where J is the Figure 6 shows detailed controller gains cent off-control is due primarily to nonrou-
scalar cost value, x the strip and zone tem- for a typical zone, Zone 5 , based on all 2 1 tine operations, such as stop and go line op-
perature states, and U the zone temperature
strip temperature node errors. The strip nodes eration, and improper transitions resulting in
set points. that Zone 5 directly affects are shown above unrealistic control requirements.
the bottom axis. It can be seen that Zone 5 The following analysis of the control sys-
J = S'x'Qx + uTRu dt (7) responds to each strip temperature node error tem performance will focus on the control
systematically, i.e., the gains are largest action for the heat section over a 12-h time
Both Q and R were chosen to be diagonal around Zone 5 and trail off on both sides of period. This analysis also includes a gage
matrices. To calculate the Q and R matrices, the zone. This behavior is not unexpected, change transition.
a design decision is required to define the since the strip should be most responsive to Figure 7 shows the Kalman filter bias ad-
maximum allowable error for each zone and the zone that it is in and should anticipate justment, the error between the measured and
strip temperature and the maximum allow- the strip temperature errors that will enter the desired exit strip temperature, and the con-
able control for the integral and proportional zone. trol action of the last zone temperature con-
action of the zone temperature set points. The controller completes the feedback loop troller. (Due to labeling convention, the last
The cost-weighting matrices are chosen so of the control system. It is driven by the zone is Zone 9 and not Zone IO.) The top
that Q is the inverse of the square of the difference of the Kalman filter strip temper- plot shows the Kalman filter bias adjustment
maximum allowable error and R is the in-
verse of the square of the maximum allow-
able control [ 5 ] .
The elements in the Q matrix were chosen
so that a high-cost penalty was placed on * .
strip temperature errors and a no-cost penalty
was placed on zone temperature errors and
integral control action errors. This allows the
controller to react to strip temperature errors
Zone 5
and to be nonresponsive to zone or integral
errors. The elements in the R matrix must be Gain
nonzero and were chosen to balance the al-
lowable control action with an acceptable
strip temperature error. The actual values
were tuned using off-line simulation of a
heat-transfer model of the heat section and
the controller to check if the balance of con-
trol action and strip temperature error did not
produce poor transient response. This pro-
cedure provided good response when the
control system was finally used on-line with
very little fine-tuning of the gains required.
t STRIP TRAVEL
Control Gains
The control gains were calculated from the
t==l * * * * *
0 1 2 3 4 6 0 7 8 91011121314161017181920
30
HEAT 0 Gage Change
IC, +in
EXIT STRIP
TEMP ERROR
(DEG. C)
I Dhani Watanapongse
ZONE 9 received the B.S.I.E. de-
(DEG. C) gree from Chulalongkoon
University in Thailand
and the Ph.D. degree
in industrial engineering
ELAPSED TIME (MINUTES) from Purdue University in
Fig. 7. Extended time control system performance. 1969. He is currently Sec-
tion Manager of Process
Modeling, Inland Steel
References Research Laboratories,
as applied to the exit strip temperature node
East Chicago, Indiana. He
of the predictor. It shows that a corrective
[I] K. M. Gaskey, V. R. Hoffman, and D. G. is active as a committee
ability such as a Kalman filter was needed Crosby, Design of Inlands New Continu- member of AISE, ISS-PTD, and AISI. He cur-
to improve the predicted strip temperatures. ous Anneal Line, AISE Annual Conven- rently serves as AISE Director on the American
The middle plot shows that the exit strip tion, Oct. 15, 1984. Automatic Control Council Board of Directors.
temperature is maintained to within the [2] J. A. Kilpatrick and E. J . Seeman, Com- His research interests are in rolling deformation
k 10C well within the required product tol- puter Control of a Continuous Anneal Line, pmessing, application of estimation and control
erance of k23C. This shows that the over- AISE Rolling Mill Conference, Mar. 25, theories, and on-line sensor technology. He has
all control was able to achieve the desired 1985. authored technical papers, presented talks, and or-
[3] T. A. Veslocki, C. C. Smith, and C. D. ganized technical sessions in modeling and control
objective. The bottom plot shows the last
Kelly, Automatic Slab Heat Control at In- in rolling, and co-organized a seminar on Appli-
heat zone temperatures. This curve indicates
lands 80-in. Hot Strip Mill, AISE Iron and cation of Modem Control Theory in the Metals
that the control action did occur in a reason- Steel Engineer, p. 47, Dec. 1986. Industry.
able fashion to control the strip temperature [4] M. Athans, Modern Control Theov-Study
along the length of the strip. Guide, MIT, 1974.
In addition, the bullet at 540 min shows a [5] A. E. Bryson and Y. C. Ho, Applied Optimal
satisfactory system response at a gage change Control, Waltham, MA: Blaisdell, 1969.
transition. [6] N . R. Sandell and M. Athans, Manual of
Fortran Computer Subroutines for Linear,
Quadratic, Gaussian Designs, MIT, 1974.
Acknowledgments
The development and implementation of
this continuous anneal line control system Kenneth M. Gaskey re-
was done with the contributions and support Christopher D. Kelly re- ceived the B.S.M.E. de-
of many Inland people. The authors wish to ceived the B S.E.E de- gree in 1961 and the
acknowledge the following for their signifi- gree from Michigan State M.S.M.E. degree in 1963
cant contributions to the control system de- University in 1979 and the from Purdue University.
M.S.E.E. degree from the He currently works as a
sign: Mitch Lapman, Lewis (Skip) Kim-
Illinois Institute of Tech- Scientist at Inland Steel
berly, Phil Papesh, and Dave Lueck of the
nology (Chicago) in 1984. Research, East Chicago,
Process Automation Department; Jim Cun- Currently, he is Senior Indiana. He has authored
diff and each of the operators in the Oper- Research Engineer, Steel papers and presented talks
ating Department; and Cliff Smith, Dick Products Division, Pro- on various topics dealing
Pelc, John Sinclair, Bob Gray, Karey Pie- cess Modeling Section at with heat transfer and
ters, Ron Kordys, and Dennis Namovice of Inland Steel Research control in continuous pro-
the Research Department. Laboratories. East Chi- cesses.
37