Probe-Conditioned Memory for Actuator-Deadband-Aware Koopman MPC in Industrial Sealing

Jul 16, 2026

Upload by Skyler

Industrial sealing and dispensing lines reuse pressure chains, nozzles, substrate paths, and vision interfaces across recipes, yet narrow-bead changes can be masked by actuator deadband: delivered pressure updates only after direction- and history-dependent thresholds are crossed. Commissioning is treated as the recipe-specific controller setup and retuning interval. A physical cell supplies pressure-to-width calibration and a fixed probe sequence to build an anonymized digital twin. The actuator-deadband-aware Koopman MPC uses probe-conditioned memory for rapid initialization, achieving 0.0487 mm tracking MAE versus 0.2492–0.3956 mm baselines, with PCM ablation increasing error to 0.0655 mm.

LanguageEnglish

CategoryResearch & Report

FormatPDF

Pages13

Reading Time33 min

Introduction

Commissioning and initialization challenge

Actuator deadband and practical pressure nonlinearity

Control mismatch and missing probe-conditioned memory

Method Overview

Probe-conditioned memory (PCM)

Actuator-deadband-aware Koopman MPC (AK-MPC)

Experimental Evaluation

Benchmark setup and comparisons

Ablation study on PCM contribution

Probe-Conditioned Memory for Actuator-Deadband-Aware Koopman MPC in Industrial Sealing Yue Wu arXiv :2607 .07043v1 [ ee ss . SY] 8 Jul 2026 Abstract—Industrial sealing and dispensing cells often reuse a pressure chain, nozzle, substrate path, and vision interface across product recipes. For a narrow bead recipe, however, a calibrated static pressure can remain correct while small corrective moves are absorbed by actuator deadband; delivered pressure changes only after a direction- and history-dependent threshold is crossed. Commissioning is defined here as the target setup and retuning interval after such a recipe change. A physical gluing and dispensing cell provides pressure-to-width calibration, a fixed probing sequence, signal-interface limits, residual scales, and actuator bounds. The controller comparison is then run on an anonymized digital twin calibrated from those measurements. The actuator-deadband-aware Koopman model predictive controller (AK-MPC) initializes from probe-conditioned memory (PCM) that links the pressure setpoint to probe-inferred actuator behavior, a predictor, a controller prior, and a fallback filter. During commissioning, a sixteen-move probe selects a nearby historical case, fits the current pressure-width relation, updatesa small local dynamic correction, and supplies a feasible recedinghorizon pressure policy. In the main 1.00 mm benchmark, where delivered-pressure loss is visible in the probe, AK-MPC reaches 0.0487 mm tracking mean absolute error (MAE) over 60 paired cases; the calibration-only inverse, adaptive proportionalintegral, online recursive-least-squares ARX, and probe-fitted ARX controllers range from 0.2492 to 0.3956 mm. This large gap reflects the full constrained Koopman-MPC and onlinecorrection workflow. The isolated PCM contribution is measured by ablation: removing PCM raises the error to 0.0655 mm. In this regime, a short actuator characterization makes historical runs useful before much target data are available. Index Terms—Industrial informatics, industrial sealing, actuator deadband, calibrated digital twin, probe-conditioned memory, actuator-deadband-aware Koopman MPC, fast commissioning. I. INTRODUCTION Industrial sealing, gluing, and dispensing lines convert a pressure or extrusion command into a geometric quality variable such as seal width or glue-line width. A pressure actuator imposes material flow, substrate and tooling conditions shape the deposited bead, an inspection device measures width, and the controller updates the next pressure move. Vision-guided sealant dispensing and force/vision monitoring have made the sealing signal path increasingly measurable [1], [2] . Closed-loop gluing and robotic gluing digital twins further show how measurement and control can be integrated around the deposited bead [3], [4] . Human-in-the-loop commissioning studies and recent sealing data reviews indicate Yue Wu is with the School of Automation, Xi’an Jiaotong University, Xi’an 710049, China, and also with Xinjiang Cigarette Factory, Hongyun Honghe Tobacco (Group) Co., Ltd., Urumqi 830000, China. Corresponding author: Yue Wu ([e-mail: wuyue0619@stu.xjtu.edu.cn](e-mail: wuyue0619@stu.xjtu.edu.cn)). that deployment still depends on recipe-specific setup and production records [5], [6] . Here, commissioning denotes the recipe-specific controller setup and retuning interval after a recipe change. The harder deployment problem is controller initialization during that interval, when the static bead map is only one part of the new operating regime and target data remain scarce. Low-width recipes expose a practical actuator nonlinearity. In proportional pneumatic valves, spool overlap can create a dead zone in which a range of command positions gives little or no flow [7] . Compact pneumatic platforms and bipolarpressure systems further show that inflation/deflation, pressure polarity, and valve switching are part of practical pressureactuation dynamics [8], [9]

FAQs

What problem does the document address in industrial sealing commissioning?

It targets recipe-specific controller setup and retuning after bead-width changes, where static calibration alone is insufficient and target data are scarce for re-identifying actuator behavior.

How does actuator deadband affect delivered pressure after switching to a narrow recipe?

Small corrective moves can be absorbed by the actuator deadband, so pressure changes are reflected only after a direction- and history-dependent threshold is crossed.

How does AK-MPC use probe-conditioned memory during commissioning?

AK-MPC initializes from PCM that links the pressure setpoint to probe-inferred actuator behavior, then selects a nearby historical case, refits the pressure-width relation, applies a local dynamic correction, and outputs a feasible receding-horizon pressure policy.

Jul 16, 2026

Upload by Skyler