Thesis Work: Stepwise introduction of Model Predictive Control - an MPC/PID hybrid

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General information

ABB Ability System 800xA is our flagship product for industrial automation and it includes AC800M, a controller family for process control. Control applications for the AC800M controllers are developed using our own development tools, and these applications control the production processes in the factories through the plant equipment such as pumps and valves.

In a factory, most of the control loops are controlled by PID controllers. However, for some control loops it's not possible to get acceptable control performance with PID control alone and then more advanced controllers are desirable. One commonly used advanced controller is the Model Predictive Controller (MPC). It calculates the control signal with optimization using a plant model and, unlike the PID, it can handle advanced constraints. MPC is often used to control PID controller setpoints, but it can also be used to directly control the plant equipment. In both cases, MPC makes great use of today's better models that are obtained with machine learning.

It is common to start with PID control and if that doesn't give acceptable performance, then more advanced controllers are considered. One obstacle is then that replacing a PID controller causes interruptions in the production. In a novel approach, MPC control is introduced stepwise by connecting the MPC control signal as feedward to the existing PID controller. In this hybrid approach, you keep the familiar PID controller for setpoint control and at the same time you can have advanced constraint handling from the MPC controller.

Compared to PID controllers, MPC controllers use great amounts of CPU and RAM to execute. Historically, due to hardware limitations, they are not executed in our current AC800M controllers, but instead in stand-alone PCs. For MPC controllers with direct impact on plant equipment, like the novel hybrid MPC/PID, you want to have the MPC controller in the AC800M controller. With our latest AC 800M controller architecture and hardware, it should be possible to execute all MPC controllers in the AC 800M controller itself.

The goal of this Master Thesis is to implement an MPC/PID hybrid in our latest AC800M controller.

Details:

• 2025 January - June
• Master Thesis: 30 credits
• Work for one or two students
• Location: Mainly on site at ABB Malmo

Your responsibilities

• Extend our MPC control service prototype from previous thesis work to make it possible to use it for MPC/PID hybrid control.
• Implement MPC-PID hybrid control in our latest AC800M controller.
• Evaluate the MPC/PID hybrid controller implementation.

Your background

• Master Program in Engineering
• Advanced level courses in computer science
• Basic knowledge of C/C++
• Advanced level courses in automatic control
• Basic understanding of the MPC controller

More about us

Bring your very own sense of pride and purpose as you help us drive forward the Fourth Industrial Revolution - creating a sustainable future for our planet, and your career. Join ABB and harness the power of our diverse global network, as you collaborate with and learn from our world-class teams. Above all, challenge yourself every day. Let's write the future, together.

Join us. Be part of the team where progress happens, industries transform, and your work shapes the world. Run What Runs the World.

Positions are filled continuously. Apply with your CV, academic transcripts, and a cover letter in English. Welcome to apply!

A Future Opportunity
Please note that this position is part of our talent pipeline and not an active job opening at this time. By applying, you express your interest in future career opportunities with ABB.

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