Nathan P. Lawrence

R. Bhushan Gopaluni, Aditya Tulsyan, Benoit Chachuat et al.

Over the last ten years, we have seen a significant increase in industrial data, tremendous improvement in computational power, and major theoretical advances in machine learning. This opens up an opportunity to use modern machine learning tools on large-scale nonlinear monitoring and control problems. This article provides a survey of recent results with applications in the process industry.

Tobi Michael Alabi, Nathan P. Lawrence, Lin Lu et al.

The carbon-capturing process with the aid of CO2 removal technology (CDRT) has been recognised as an alternative and a prominent approach to deep decarbonisation. However, the main hindrance is the enormous energy demand and the economic implication of CDRT if not effectively managed. Hence, a novel deep reinforcement learning agent (DRL), integrated with an automated hyperparameter selection feature, is proposed in this study for the real-time scheduling of a multi-energy system coupled with CDRT. Post-carbon capture systems (PCCS) and direct-air capture systems (DACS) are considered CDRT. Various possible configurations are evaluated using real-time multi-energy data of a district in Arizona and CDRT parameters from manufacturers' catalogues and pilot project documentation. The simulation results validate that an optimised soft-actor critic (SAC) algorithm outperformed the TD3 algorithm due to its maximum entropy feature. We then trained four (4) SAC agents, equivalent to the number of considered case studies, using optimised hyperparameter values and deployed them in real time for evaluation. The results show that the proposed DRL agent can meet the prosumers' multi-energy demand and schedule the CDRT energy demand economically without specified constraints violation. Also, the proposed DRL agent outperformed rule-based scheduling by 23.65%. However, the configuration with PCCS and solid-sorbent DACS is considered the most suitable configuration with a high CO2 captured-released ratio of 38.54, low CO2 released indicator value of 2.53, and a 36.5% reduction in CDR cost due to waste heat utilisation and high absorption capacity of the selected sorbent. However, the adoption of CDRT is not economically viable at the current carbon price. Finally, we showed that CDRT would be attractive at a carbon price of 400-450USD/ton with the provision of tax incentives by the policymakers.

Nathan P. Lawrence, Ali Mesbah

Goal-conditioned reinforcement learning (RL) concerns the problem of training an agent to maximize the probability of reaching target goal states. This paper presents an analysis of the goal-conditioned setting based on optimal control. In particular, we derive an optimality gap between more classical, often quadratic, objectives and the goal-conditioned reward, elucidating the success of goal-conditioned RL and why classical ``dense'' rewards can falter. We then consider the partially observed Markov decision setting and connect state estimation to our probabilistic reward, making the goal-conditioned reward well suited to dual control problems. The advantages of goal-conditioned policies are validated on nonlinear and uncertain environments using both RL and predictive control techniques.

Daniel G. McClement, Nathan P. Lawrence, Johan U. Backstrom et al.

Meta-learning is a branch of machine learning which trains neural network models to synthesize a wide variety of data in order to rapidly solve new problems. In process control, many systems have similar and well-understood dynamics, which suggests it is feasible to create a generalizable controller through meta-learning. In this work, we formulate a meta reinforcement learning (meta-RL) control strategy that can be used to tune proportional--integral controllers. Our meta-RL agent has a recurrent structure that accumulates "context" to learn a system's dynamics through a hidden state variable in closed-loop. This architecture enables the agent to automatically adapt to changes in the process dynamics. In tests reported here, the meta-RL agent was trained entirely offline on first order plus time delay systems, and produced excellent results on novel systems drawn from the same distribution of process dynamics used for training. A key design element is the ability to leverage model-based information offline during training in simulated environments while maintaining a model-free policy structure for interacting with novel processes where there is uncertainty regarding the true process dynamics. Meta-learning is a promising approach for constructing sample-efficient intelligent controllers.

Nathan P. Lawrence, Philip D. Loewen, Shuyuan Wang et al.

We propose a framework for the design of feedback controllers that combines the optimization-driven and model-free advantages of deep reinforcement learning with the stability guarantees provided by using the Youla-Kucera parameterization to define the search domain. Recent advances in behavioral systems allow us to construct a data-driven internal model; this enables an alternative realization of the Youla-Kucera parameterization based entirely on input-output exploration data. Perhaps of independent interest, we formulate and analyze the stability of such data-driven models in the presence of noise. The Youla-Kucera approach requires a stable "parameter" for controller design. For the training of reinforcement learning agents, the set of all stable linear operators is given explicitly through a matrix factorization approach. Moreover, a nonlinear extension is given using a neural network to express a parameterized set of stable operators, which enables seamless integration with standard deep learning libraries. Finally, we show how these ideas can also be applied to tune fixed-structure controllers.

Daniel G. McClement, Nathan P. Lawrence, Michael G. Forbes et al.

Meta-learning is a branch of machine learning which aims to synthesize data from a distribution of related tasks to efficiently solve new ones. In process control, many systems have similar and well-understood dynamics, which suggests it is feasible to create a generalizable controller through meta-learning. In this work, we formulate a meta reinforcement learning (meta-RL) control strategy that takes advantage of known, offline information for training, such as a model structure. The meta-RL agent is trained over a distribution of model parameters, rather than a single model, enabling the agent to automatically adapt to changes in the process dynamics while maintaining performance. A key design element is the ability to leverage model-based information offline during training, while maintaining a model-free policy structure for interacting with new environments. Our previous work has demonstrated how this approach can be applied to the industrially-relevant problem of tuning proportional-integral controllers to control first order processes. In this work, we briefly reintroduce our methodology and demonstrate how it can be extended to proportional-integral-derivative controllers and second order systems.

Nathan P. Lawrence, Philip D. Loewen, Shuyuan Wang et al.

We propose a framework for the design of feedback controllers that combines the optimization-driven and model-free advantages of deep reinforcement learning with the stability guarantees provided by using the Youla-Kucera parameterization to define the search domain. Recent advances in behavioral systems allow us to construct a data-driven internal model; this enables an alternative realization of the Youla-Kucera parameterization based entirely on input-output exploration data. Using a neural network to express a parameterized set of nonlinear stable operators enables seamless integration with standard deep learning libraries. We demonstrate the approach on a realistic simulation of a two-tank system.

Shuyuan Wang, Philip D. Loewen, Nathan P. Lawrence et al.

We adapt reinforcement learning (RL) methods for continuous control to bridge the gap between complete ignorance and perfect knowledge of the environment. Our method, Partial Knowledge Least Squares Policy Iteration (PLSPI), takes inspiration from both model-free RL and model-based control. It uses incomplete information from a partial model and retains RL's data-driven adaption towards optimal performance. The linear quadratic regulator provides a case study; numerical experiments demonstrate the effectiveness and resulting benefits of the proposed method.

Thomas Banker, Nathan P. Lawrence, Ali Mesbah

Reinforcement learning (RL) and model predictive control (MPC) offer complementary strengths, yet combining them at scale remains computationally challenging. We propose soft MPCritic, an RL-MPC framework that learns in (soft) value space while using sample-based planning for both online control and value target generation. soft MPCritic instantiates MPC through model predictive path integral control (MPPI) and trains a terminal Q-function with fitted value iteration, aligning the learned value function with the planner and implicitly extending the effective planning horizon. We introduce an amortized warm-start strategy that recycles planned open-loop action sequences from online observations when computing batched MPPI-based value targets. This makes soft MPCritic computationally practical, while preserving solution quality. soft MPCritic plans in a scenario-based fashion with an ensemble of dynamic models trained for next-step prediction accuracy. Together, these ingredients enable soft MPCritic to learn effectively through robust, short-horizon planning on classic and complex control tasks. These results establish soft MPCritic as a practical and scalable blueprint for synthesizing MPC policies in settings where policy extraction and direct, long-horizon planning may fail.

Maricela Best McKay, Nathan P. Lawrence, Brian Wetton et al.

The Gauss-Newton matrix is widely viewed as a positive semidefinite approximation of the Hessian, yet mounting empirical evidence shows that Gauss-Newton descent outperforms Newton's method. We adopt a function space perspective to analyze this phenomenon. We show that the generalized Gauss-Newton (GGN) matrix projects the Newton direction in function space onto the model's tangent space, while a Jacobian-only variant obtained by applying the least squares Gauss-Newton matrix to non-least squares losses projects the function space loss gradient onto this same tangent space. Both projections eliminate distortions from the model's parameterization. Specifically, the evolution of the prediction-target mismatch depends on the model's parameterization through the matrix $JJ^\top$ where $J$ is the Jacobian of the model with respect to its parameters. The projections effectively replace $JJ^\top$ with the identity. We call this effect error whitening. Once the parameterization is removed, the prediction-target mismatch evolves according to dynamics dictated by the structure of the loss and the projection produced by the optimizer. Error whitening is a special property of Gauss-Newton descent that rigorously distinguishes it from Newton's method. We empirically demonstrate that Gauss-Newton optimizers follow the theoretically predicted function space dynamics and outperforms Newton's method, Adam, and Muon across case studies spanning supervised learning, physics-informed deep learning, and approximate dynamic programming.

Nathan P. Lawrence, Thomas Banker, Ali Mesbah

The reinforcement learning (RL) and model predictive control (MPC) communities have developed vast ecosystems of theoretical approaches and computational tools for solving optimal control problems. Given their conceptual similarities but differing strengths, there has been increasing interest in synergizing RL and MPC. However, existing approaches tend to be limited for various reasons, including computational cost of MPC in an RL algorithm and software hurdles towards seamless integration of MPC and RL tools. These challenges often result in the use of "simple" MPC schemes or RL algorithms, neglecting the state-of-the-art in both areas. This paper presents MPCritic, a machine learning-friendly architecture that interfaces seamlessly with MPC tools. MPCritic utilizes the loss landscape defined by a parameterized MPC problem, focusing on "soft" optimization over batched training steps; thereby updating the MPC parameters while avoiding costly minimization and parametric sensitivities. Since the MPC structure is preserved during training, an MPC agent can be readily used for online deployment, where robust constraint satisfaction is paramount. We demonstrate the versatility of MPCritic, in terms of MPC architectures and RL algorithms that it can accommodate, on classic control benchmarks.

Pritam Dash, Ethan Chan, Nathan P. Lawrence et al.

Unmanned Aerial Vehicles (UAVs) depend on onboard sensors for perception, navigation, and control. However, these sensors are susceptible to physical attacks, such as GPS spoofing, that can corrupt state estimates and lead to unsafe behavior. While reinforcement learning (RL) offers adaptive control capabilities, existing safe RL methods are ineffective against such attacks. We present ARMOR (Adaptive Robust Manipulation-Optimized State Representations), an attack-resilient, model-free RL controller that enables robust UAV operation under adversarial sensor manipulation. Instead of relying on raw sensor observations, ARMOR learns a robust latent representation of the UAV's physical state via a two-stage training framework. In the first stage, a teacher encoder, trained with privileged attack information, generates attack-aware latent states for RL policy training. In the second stage, a student encoder is trained via supervised learning to approximate the teacher's latent states using only historical sensor data, enabling real-world deployment without privileged information. Our experiments show that ARMOR outperforms conventional methods, ensuring UAV safety. Additionally, ARMOR improves generalization to unseen attacks and reduces training cost by eliminating the need for iterative adversarial training.

Nathan P. Lawrence, Seshu Kumar Damarla, Jong Woo Kim et al.

With the rise of deep learning, there has been renewed interest within the process industries to utilize data on large-scale nonlinear sensing and control problems. We identify key statistical and machine learning techniques that have seen practical success in the process industries. To do so, we start with hybrid modeling to provide a methodological framework underlying core application areas: soft sensing, process optimization, and control. Soft sensing contains a wealth of industrial applications of statistical and machine learning methods. We quantitatively identify research trends, allowing insight into the most successful techniques in practice. We consider two distinct flavors for data-driven optimization and control: hybrid modeling in conjunction with mathematical programming techniques and reinforcement learning. Throughout these application areas, we discuss their respective industrial requirements and challenges. A common challenge is the interpretability and efficiency of purely data-driven methods. This suggests a need to carefully balance deep learning techniques with domain knowledge. As a result, we highlight ways prior knowledge may be integrated into industrial machine learning applications. The treatment of methods, problems, and applications presented here is poised to inform and inspire practitioners and researchers to develop impactful data-driven sensing, optimization, and control solutions in the process industries.

Nathan P. Lawrence, Michael G. Forbes, Philip D. Loewen et al.

Deep reinforcement learning (RL) is an optimization-driven framework for producing control strategies for general dynamical systems without explicit reliance on process models. Good results have been reported in simulation. Here we demonstrate the challenges in implementing a state of the art deep RL algorithm on a real physical system. Aspects include the interplay between software and existing hardware; experiment design and sample efficiency; training subject to input constraints; and interpretability of the algorithm and control law. At the core of our approach is the use of a PID controller as the trainable RL policy. In addition to its simplicity, this approach has several appealing features: No additional hardware needs to be added to the control system, since a PID controller can easily be implemented through a standard programmable logic controller; the control law can easily be initialized in a "safe'' region of the parameter space; and the final product -- a well-tuned PID controller -- has a form that practitioners can reason about and deploy with confidence.

Nathan P. Lawrence, Philip D. Loewen, Michael G. Forbes et al.

We introduce a method for learning provably stable deep neural network based dynamic models from observed data. Specifically, we consider discrete-time stochastic dynamic models, as they are of particular interest in practical applications such as estimation and control. However, these aspects exacerbate the challenge of guaranteeing stability. Our method works by embedding a Lyapunov neural network into the dynamic model, thereby inherently satisfying the stability criterion. To this end, we propose two approaches and apply them in both the deterministic and stochastic settings: one exploits convexity of the Lyapunov function, while the other enforces stability through an implicit output layer. We demonstrate the utility of each approach through numerical examples.

Daniel G. McClement, Nathan P. Lawrence, Philip D. Loewen et al.

Meta-learning is a branch of machine learning which aims to quickly adapt models, such as neural networks, to perform new tasks by learning an underlying structure across related tasks. In essence, models are being trained to learn new tasks effectively rather than master a single task. Meta-learning is appealing for process control applications because the perturbations to a process required to train an AI controller can be costly and unsafe. Additionally, the dynamics and control objectives are similar across many different processes, so it is feasible to create a generalizable controller through meta-learning capable of quickly adapting to different systems. In this work, we construct a deep reinforcement learning (DRL) based controller and meta-train the controller using a latent context variable through a separate embedding neural network. We test our meta-algorithm on its ability to adapt to new process dynamics as well as different control objectives on the same process. In both cases, our meta-learning algorithm adapts very quickly to new tasks, outperforming a regular DRL controller trained from scratch. Meta-learning appears to be a promising approach for constructing more intelligent and sample-efficient controllers.

Nathan P. Lawrence, Gregory E. Stewart, Philip D. Loewen et al.

Deep reinforcement learning (DRL) has seen several successful applications to process control. Common methods rely on a deep neural network structure to model the controller or process. With increasingly complicated control structures, the closed-loop stability of such methods becomes less clear. In this work, we focus on the interpretability of DRL control methods. In particular, we view linear fixed-structure controllers as shallow neural networks embedded in the actor-critic framework. PID controllers guide our development due to their simplicity and acceptance in industrial practice. We then consider input saturation, leading to a simple nonlinear control structure. In order to effectively operate within the actuator limits we then incorporate a tuning parameter for anti-windup compensation. Finally, the simplicity of the controller allows for straightforward initialization. This makes our method inherently stabilizing, both during and after training, and amenable to known operational PID gains.

Nathan P. Lawrence, Gregory E. Stewart, Philip D. Loewen et al.

Reinforcement learning has been successfully applied to the problem of tuning PID controllers in several applications. The existing methods often utilize function approximation, such as neural networks, to update the controller parameters at each time-step of the underlying process. In this work, we present a simple finite-difference approach, based on random search, to tuning linear fixed-structure controllers. For clarity and simplicity, we focus on PID controllers. Our algorithm operates on the entire closed-loop step response of the system and iteratively improves the PID gains towards a desired closed-loop response. This allows for embedding stability requirements into the reward function without any modeling procedures.