Fault-Tolerant Control Study and Classification: Case Study of a Hydraulic-Press Model Simulated in Real-Time

Society demands more reliable manufacturing processes
capable of producing high quality products in shorter production
cycles. New control algorithms have been studied to satisfy this
paradigm, in which Fault-Tolerant Control (FTC) plays a significant
role. It is suitable to detect, isolate and adapt a system when a harmful
or faulty situation appears. In this paper, a general overview about
FTC characteristics are exposed; highlighting the properties a system
must ensure to be considered faultless. In addition, a research to
identify which are the main FTC techniques and a classification
based on their characteristics is presented in two main groups:
Active Fault-Tolerant Controllers (AFTCs) and Passive Fault-Tolerant
Controllers (PFTCs). AFTC encompasses the techniques capable of
re-configuring the process control algorithm after the fault has been
detected, while PFTC comprehends the algorithms robust enough
to bypass the fault without further modifications. The mentioned
re-configuration requires two stages, one focused on detection,
isolation and identification of the fault source and the other one in
charge of re-designing the control algorithm by two approaches: fault
accommodation and control re-design. From the algorithms studied,
one has been selected and applied to a case study based on an
industrial hydraulic-press. The developed model has been embedded
under a real-time validation platform, which allows testing the FTC
algorithms and analyse how the system will respond when a fault
arises in similar conditions as a machine will have on factory. One
AFTC approach has been picked up as the methodology the system
will follow in the fault recovery process. In a first instance, the fault
will be detected, isolated and identified by means of a neural network.
In a second instance, the control algorithm will be re-configured to
overcome the fault and continue working without human interaction.