Controller-embedded MPC can help drive improvements in quality, throughput, yield and energy efficiency.

Rockwell Automation will release PlantPAx model predictive control (MPC) software, which, for the first time, embeds fully functional MPC technology into Logix controllers to help maximise equipment performance. When used in process applications ranging from consumer to heavy industries, PlantPAx MPC can improve overall control in a single machine or an entire line to help maximise throughput, increase yield, reduce quality variability and improve energy usage.

PlantPAx MPC is included in the latest release of the PlantPAx modern distributed control system.

“By embedding MPC into the control system, PlantPAx MPC simplifies integration and improves ease of use,” said Christo Buys, Business Manager - Control Systems, Sub-Saharan Africa, Rockwell Automation. “It also delivers several performance advantages over single-loop PID controllers. These include better multivariable coordination, predictable handling of outside disturbances, improved management of long or complex processes and predictive response to process constraints, all resulting in maximising equipment performance while safely operating within process limits.”

Multivariable Coordination: PlantPAx MPC delivers better coordination of multivariable actions in complex process applications to maximise controller performance and maintain quality. A single control-system-based MPC module supports up to five separate MPC applications, and each of those applications can support up to 10 controllable variables and 10 manipulated variables.

Predictably Handle Outside Disturbances: The software provides the ability to measure disturbance variables that can’t be controlled, such as ambient humidity. Once detected, the system can predictably respond to these disturbances as needed to keep the process optimised.

Manage Long and Complex Processes: Both operators and control systems can struggle when managing long and complex processes for applications, such as dryers and kilns. PlantPAx MPC uses dynamic explicit modelling to identify and program the specific responses and requirements for these processes.

Predictive Response to Constraints: PlantPAx MPC dynamically predicts process behaviour against identified constraints and makes proactive adjustments to maintain process performance within identified limits.

Maximise Equipment Performance: Dynamic and steady-state constraints can be enforced in the software to maximise equipment performance up to its limits. For example, enforcing a flooding constraint in a distillation process can help feed levels at their highest without the risk of flooding.