Optimization-based controller tuning is challenging because it requires formulating optimization problems explicitly as functions of controller parameters. Safe learning algorithms overcome the challenge by creating surrogate models from measured data. To ensure safety, such data-driven algorithms often rely on exhaustive grid search, which is computationally inefficient. In this paper, we propose a novel approach to safe learning by formulating a series of optimization problems instead of a grid search. We also develop a method for initializing the optimization problems to guarantee feasibility while using numerical solvers. The performance of the new method is first validated in a simulated precision motion system, demonstrating improved computational efficiency, and illustrating the role of exploiting numerical solvers to reach the desired precision. Experimental validation on an industrial-grade precision motion system confirms that the proposed algorithm achieves 30% better tracking at sub-micrometer precision as a state-of-the-art safe learning algorithm, improves the default auto-tuning solution, and reduces the computational cost seven times compared to learning algorithms based on exhaustive search.

Controller tuning and parameter optimization are crucial in system design to improve closed-loop system performance. Bayesian optimization has been established as an efficient model-free controller tuning and adaptation method. However, Bayesian optimization methods are computationally expensive and therefore difficult to use in real-time critical scenarios. In this work, we propose a real-time purely data-driven, model-free approach for adaptive control, by online tuning low-level controller parameters. We base our algorithm on GoOSE, an algorithm for safe and sample-efficient Bayesian optimization, for handling performance and stability criteria. We introduce multiple computational and algorithmic modifications for computational efficiency and parallelization of optimization steps. We further evaluate the algorithm’s performance on a real precision-motion system utilized in the semiconductor industry applications by modifying the payload and reference stepsize and comparing it to an interpolated constrained optimization-based baseline approach.

This article presents the guided Bayesian optimization (BO) algorithm as an efficient data-driven method for iteratively tuning closed-loop controller parameters using a digital twin of the system. The digital twin is built using closed-loop data acquired during standard BO iterations, and activated when the uncertainty in the Gaussian Process model of the optimization objective on the real system is high. We define a controller tuning framework independent of the controller or the plant structure. Our proposed methodology is model-free, making it suitable for nonlinear and unmodelled plants with measurement noise. The objective function consists of performance metrics modeled by Gaussian processes. We utilize the available information in the closed-loop system to progressively maintain a digital twin that guides the optimizer, improving the data efficiency of our method. Switching the digital twin on and off is triggered by our data-driven criteria related to the digital twin’s uncertainty estimations in the BO tuning framework. Effectively, it replaces much of the exploration of the real system with exploration performed on the digital twin. We analyze the properties of our method in simulation and demonstrate its performance on two real closed-loop systems with different plant and controller structures. The experimental results show that our method requires fewer experiments on the physical plant than Bayesian optimization to find the optimal controller parameters. Note to Practitioners—Industrial applications typically are difficult to model due to disturbances. Bayesian optimization is a data-efficient iterative tuning method for a black box system in which the performance can only be measured given the control parameters. Iterative measurements involve operational costs. We propose a guided Bayesian optimization method that uses all information flow in a system to define a simplified digital twin of the system using out-of-the-box methods. It is continuously updated with data from the system. We use the digital twin instead of the real system to perform experiments and to find optimal controller parameters while we monitor the uncertainty of the resulting predictions. When the uncertainty exceeds a tolerance threshold, the real system is measured, and the digital twin is updated. This results in fewer experiments on the real system only when needed. We then demonstrate the improved data efficiency of the guided Bayesian optimization on real-time linear and rotary motor hardware. These common industrial plants need to be controlled rigorously in a closed-loop system. Our method requires 57% and 46% fewer experiments on the hardware than Bayesian optimization to tune the control parameters of the linear and rotary motor systems. Our generic approach is not limited to the controller parameters but also can optimize the parameters of a manufacturing process.

Ensuring safety is a key aspect in sequential decision making problems, such as robotics or process control. The complexity of the underlying systems often makes finding the optimal decision challenging, especially when the safety-critical system is time-varying. Overcoming the problem of optimizing an unknown time-varying reward subject to unknown time-varying safety constraints, we propose TVSAFEOPT, a new algorithm built on Bayesian optimization with a spatio-temporal kernel. The algorithm is capable of safely tracking a time-varying safe region without the need for explicit change detection. Optimality guarantees are also provided for the algorithm when the optimization problem becomes stationary. We show that TVSAFEOPT compares favorably against SAFEOPT on synthetic data, both regarding safety and optimality. Evaluation on a realistic case study with gas compressors confirms that TVSAFEOPT ensures safety when solving time-varying optimization problems with unknown reward and safety functions.

In this paper, we consider a cyber-physical manufacturing system (CPMS) scenario containing physical components (robots, sensors, and actuators), operating in a digitally connected, constrained environment to perform industrial tasks. The CPMS has a centralized control plane with digital twins (DTs) of the physical resources, computational resources, and a network manager that allocates network resources. Existing approaches for the allocation of network resources are typically fixed with respect to controller-dependent run-time specifications, which may impact the performance of physical processes. We propose a dynamic network management framework, where the network resource allocation schemes are controller-aware. The information about the controllers of the physical resources is implemented at the DT level, and metrics, such as regret bounds, take the process performance measures into account. The proposed network management schemes optimize physical system performance by balancing the shared resources between the physical assets on the plant floor, and by considering their control requirements, providing a new perspective for dynamic resource allocation. A simulation study is provided to illustrate the performance of the proposed network management approaches and compare their resource allocation performance efficiencies.

We present a reinforcement learning-based solution to autonomously race on a miniature race car platform. We show that a policy that is trained purely in simulation using a relatively simple vehicle model, including model randomization, can be successfully transferred to the real robotic setup. We achieve this by using a novel policy output regularization approach and a lifted action space which enables smooth actions but still aggressive race car driving. We show that this regularized policy does outperform the Soft Actor Critic (SAC) baseline method, both in simulation and on the real car, but it is still outperformed by a Model Predictive Controller (MPC) state-of-the-art method. The refinement of the policy with three hours of real-world interaction data allows the reinforcement learning policy to achieve lap times similar to the MPC controller while reducing track constraint violations by 50%.

Adaptive control approaches yield high-performance controllers when a precise system model or suitable parametrizations of the controller are available. Existing data-driven approaches for adaptive control mostly augment standard model-based methods with additional information about uncertainties in the dynamics or about disturbances. In this work, we propose a purely data-driven, model-free approach for adaptive control. Tuning low-level controllers based solely on system data raises concerns on the underlying algorithm safety and computational performance. Thus, our approach builds on GOOSE, an algorithm for safe and sample-efficient Bayesian optimization. We introduce several computational and algorithmic modifications in GOOSE that enable its practical use on a rotational motion system. We numerically demonstrate for several types of disturbances that our approach is sample efficient, outperforms constrained Bayesian optimization in terms of safety, and achieves the performance optima computed by grid evaluation. We further demonstrate the proposed adaptive control approach experimentally on a rotational motion system.

In this paper we propose a hierarchical controller for autonomous racing where the same vehicle model is used in a two level optimization framework for motion planning. The high-level controller computes a trajectory that minimizes the lap time, and the low-level nonlinear model predictive path following controller tracks the computed trajectory online. Following a computed optimal trajectory avoids online planning and enables fast computational times. The efficiency is further enhanced by the coupling of the two levels through a terminal constraint, computed in the high-level controller. Including this constraint in the real-time optimization level ensures that the prediction horizon can be shortened, while safety is guaranteed. This proves crucial for the experimental validation of the approach on a full size driverless race car. The vehicle in question won two international student racing competitions using the proposed framework; moreover, our hierarchical controller achieved an improvement of 20% in the lap time compared to the state of the art result achieved using a very similar car and track.