Industrial process controller and method of process control

Claim 2

An industrial process controller for controlling a process variable responsive to a set point, said controller comprising: difference means for determining a difference signal between a process variable and a set point; timing synchronization means operatively connected to said difference means for generating a synchronized timing reference signal responsive to said difference signal; feedforward control means operatively connected to said difference means and said timing synchronization means for generating a lead/lag feedforward signal responsive to said difference signal and said synchronized timing reference signal; proportional and derivative control means operatively connected to said difference means and said timing synchronization means for generating a proportional output signal and a derivative output signal responsive to said difference signal; and combining means operatively connected to said feedforward control means and said proportional and derivative control means for combining said proportional and derivative output signals of said proportional and derivative control means with said lead/lag feedforward signal to thereby generate a combined output command signal therefrom to control gain between the process variable and the set point of the industrial process.

Claim 3

An industrial process controller according to claim 1, further comprising feedforward characterization means operatively connected to said proportional and derivative control means and said combining means for characterizing said feedforward signal and generating a command signal therefrom to thereby control gain of the industrial process.

Claim 4

An industrial process controller according to claim 2, wherein said feedforward characterization means comprises means for generating a function signal responsive to said command signal and means for changing said function signal responsive to said proportional and derivative output signals of said proportional and derivative control means.

Claim 5

An industrial process controller according to claim 1, wherein said proportional and derivative control means further comprises means for generating an integral signal and means for blocking said integral signal thereof responsive to said feedforward signal.

Claim 6

An industrial process controller according to claim 1, further comprising feedback characterization means operatively connected to said difference means and said combining means for providing thereto a characterized feedback control signal to said difference means.

Claim 7

An industrial process controller according to claim 1, wherein said difference means comprises means for determining a process variable value and means for subtracting a predetermined set point value therefrom.

Claim 8

An industrial process controller according to claim 1, wherein said timing synchronization means comprises timing reference generating means for generating a timing reference signal and characterization means for characterizing said timing reference signal based upon said difference signal generated from said difference means to thereby synchronize said lead/lag feedforward signal.

Claim 9

An industrial process controller according to claim 7, wherein said characterizing means comprises means for generating a function signal responsive to said timing reference signal and said difference signal and means for changing said function signal responsive to said feedforward signal.

Claim 10

An industrial process controller according to claim 1, further comprising tracking means for generating a tracking signal responsive to said feedforward signal and means for balancing said feedforward signal responsive to an input signal external to the industrial process controller.

Claim 11

An industrial process controller according to claim 1, further comprising storing means for storing said command signal for control of the process variable.

Claim 12

An industrial process controller according to claim 1, further comprising means for receiving a process variable signal by the process controller indicating a process condition to control and means for receiving a set point signal by the process controller indicating a desired condition to control.

Claim 13

An industrial process controller for controlling a process variable responsive to a set point, said controller comprising: difference means for determining a difference signal between a process variable and a set point; timing synchronization means operatively connected to said difference means for generating a synchronized timing reference signal responsive to said difference signal; feedforward control means operatively connected to said difference means and said timing synchronization means for generating a lead/lag feedforward signal responsive to said difference signal and said synchronized timing reference signal; PID control means operatively connected to said difference means and said timing synchronization for generating an output signal responsive to said difference signal, said PID control means comprising means for generating a proportional signal, an integral signal, and a derivative signal, and means for blocking said integral signal thereof responsive to said feedforward signal; combining means for combining said output signal of said PID control means with said lead/lag feedforward signal to thereby generate a command signal for the process variable; feedforward characterization means operatively connected to said PID control means and responsive to said combining means for characterizing said command signal generated by said combining means, said feedforward characterization means comprising means for generating a function signal responsive to said command signal and means for changing said function signal responsive to said output signal of said PID control means; and feedback characterization means operatively connected to said difference means and said combining means for providing thereto a characterized feedback control signal responsive to said command signal to thereby control gain between the process variable and the set point of the industrial process.

Claim 14

An industrial process controller for controlling a process variable responsive to a set point, said controller comprising: difference means for determining a difference signal between a process variable and a set point; timing synchronization means operatively connected to said difference means for generating a synchronized timing reference signal responsive to said difference signal; feedforward control means operatively connected to said difference means and said timing synchronization means for generating a lead/lag feedforward signal responsive to said difference signal and said synchronized timing reference signal; PID control means operatively connected to said difference means and said timing synchronization for generating an output signal responsive to said difference signal, said PID control means comprising means for generating a proportional signal, an integral signal, and a derivative signal, and means for blocking said integral signal thereof responsive to said feedforward signal; combining means for combining said output signal of said PID control means with said lead/lag feedforward signal to thereby generate a command signal for the process variable; feedforward characterization means operatively connected to said PID control means and responsive to said combining means for characterizing said command signal generated by said combining means, said feedforward characterization means comprising means for generating a function signal responsive to said command signal and means for changing said function signal responsive to said output signal of said PID control means; and feedback characterization means operatively connected to said difference means and said combining means for providing thereto a characterized feedback control signal responsive to said command signal to thereby control gain between the process variable and the set point of the industrial process.

Claim 15

An industrial process controller according to claim 12, wherein said timing synchronization means comprises timing reference generating means for generating a timing reference signal and characterization means for characterizing said timing reference signal based upon said difference signal generated from said difference means to thereby synchronize said lead/lag feed forward control signal.

Claim 16

An industrial process controller according to claim 13, wherein said characterizing means comprises means for generating a function signal responsive to said timing reference signal and said difference signal and means for changing said function signal responsive to said feedforward signal.

Claim 17

An industrial process controller according to claim 12, further comprising storing means for storing said command signal for control of the process variable.

Claim 18

An industrial process controller according to claim 12, further comprising tracking means for tracking said feedforward signal and means for balancing said feedforward signal responsive to an input signal external to the process controller.

Claim 19

An industrial process controller for controlling a process variable responsive to a set point, said controller comprising: difference means for determining a difference signal between a process variable and a set point; timing synchronization means operatively connected to said difference means for generating a synchronized timing reference signal, said timing synchronization means comprising a timing reference signal and characterization means for characterizing said timing reference signal based upon said difference signal generated by said difference means, said characterizing means comprising means for generating a function signal responsive to said timing reference signal and said difference signal and means for iteratively changing said function signal; feedforward control means operatively connected to said difference means and said timing synchronization means for generating a lead/lag feedforward signal responsive to said difference signal and said synchronized timing reference signal; PID control means operatively connected to said difference means and said timing synchronization means for generating an output signal responsive to said difference signal, said PID control means comprising means for generating a proportional signal, an integral signal, and a derivative signal, and means for blocking said integral signal thereof responsive to said feedforward signal; combining means for combining said output signal of said PID control means with said feedforward signal to thereby generate a command signal for the process variable; and feedforward characterization means operatively connected to said PID control means and responsive to said combining means for providing a characterized feedforward signal to said command signal, said feedforward characterization means comprising means for generating a function signal responsive to said command signal and means for iteratively changing said function signal responsive to said output signal of said PID control means.

Claim 20

An industrial process controller for controlling a process variable responsive to a set point, said controller comprising: difference means for determining a difference signal between a process variable and a set point; timing synchronization means operatively connected to said difference means for generating a synchronized timing reference signal, said timing synchronization means comprising a timing reference signal and characterization means for characterizing said timing reference signal based upon said difference signal generated by said difference means, said characterizing means comprising means for generating a function signal responsive to said timing reference signal and said difference signal and means for iteratively changing said function signal; feedforward control means operatively connected to said difference means and said timing synchronization means for generating a lead/lag feedforward signal responsive to said difference signal and said synchronized timing reference signal; PID control means operatively connected to said difference means and said timing synchronization means for generating an output signal responsive to said difference signal, said PID control means comprising means for generating a proportional signal, an integral signal, and a derivative signal, and means for blocking said integral signal thereof responsive to said feedforward signal; combining means for combining said output signal of said PID control means with said feedforward signal to thereby generate a command signal for the process variable; and feedforward characterization means operatively connected to said PID control means and responsive to said combining means for providing a characterized feedforward signal to said command signal, said feedforward characterization means comprising means for generating a function signal responsive to said command signal and means for iteratively changing said function signal responsive to said output signal of said PID control means.

Claim 21

An industrial process controller according to claim 17, further comprising feedback characterization means operatively connected to said difference means and said combining means for providing thereto a characterized feedback control signal to said difference means.

Claim 22

An industrial process controller for controlling a process variable responsive to a set point, said controller comprising: difference means for determining a difference signal between a process variable and a set point; timing synchronization means operatively connected to said difference means for generating a synchronized timing reference signals, said timing synchronization means including timing reference generating means for generating a timing reference signal and characterization means for characterizing said timing reference signal based upon said difference signal generated from said difference means; and feedforward control means operatively connected to said difference means and said timing synchronization means for generating a lead/lag feedforward signal responsive to said difference signal and said timing synchronization signal to thereby more effectively control gain between the process variable and the set point of the industrial process.

Claim 23

An industrial process controller for controlling a process variable responsive to a set point, said controller comprising: difference means for determining a difference signal between a process variable and a set point; timing synchronization means operatively connected to said difference means for generating a synchronized timing reference signals, said timing synchronization means including timing reference generating means for generating a timing reference signal and characterization means for characterizing said timing reference signal based upon said difference signal generated from said difference means; and feedforward control means operatively connected to said difference means and said timing synchronization means for generating a lead/lag feedforward signal responsive to said difference signal and said timing synchronization signal to thereby more effectively control gain between the process variable and the set point of the industrial process.

Claim 24

An industrial process controller according to claim 19, wherein said characterizing means comprises means for generating a function signal responsive to said timing reference signal and said difference signal and means for changing said function signal responsive to said feedforward signal.

Claim 29

A method according to claim 22, further comprising the step of characterizing the feedforward signal responsive to the command signal and the proportional and derivative output signals.

Claim 30

A method according to claim 23, wherein the step of characterizing the feedforward signal includes the steps of generating a function signal responsive to the command signal and changing the function signal responsive to the proportional and derivative signals.

Claim 31

A method according to claim 22, wherein the step of generating the proportional and derivative output signals further includes the steps of generating an integral signal responsive to the difference signal and blocking the integral signal responsive to the feedforward signal.

Claim 32

A method according to claim 22, further comprising the steps of generating a feedback signal responsive to the command signal and characterizing the feedback signal responsive to the process variable.

Claim 33

A method according to claim 22, wherein the step of determining the difference signal includes the steps of determining a process variable value and subtracting a predetermined set point value therefrom.

Claim 34

A method according to claim 22, further comprising the step of generating a timing reference signal for the lead/lag feedforward signal.

Claim 35

A method according to claim 22, further comprising the steps of tracking the feedforward signal and balancing the feedforward signal responsive to an external input signal.

Claim 36

A method according to claim 22, further comprising the step of storing the command signal for control of the process variable.

Claim 37

A method according to claim 22, wherein the step of determining a difference signal is preceded by the steps of receiving a process variable signal for indicating a process condition to control and receiving a set point signal for indicating a desired condition to control.

Claim 40

A method according to claim 32, wherein the step of determining the difference signal includes the steps of determining a process variable value and subtracting a predetermined set point value therefrom.

Claim 41

A method according to claim 32, further comprising the steps of tracking the feedforward signal and balancing the feedforward signal responsive to an external input signal.