Digital Twin-Based MPC for Industrial MIMO Automation: Intelligent Algorithms

This study proposes an intelligent control algorithm for multiple-input multiple-output (MIMO) industrial processes. This algorithm is based on the integration of a digital twin (DT), model predictive control (MPC), a genetic algorithm (GA), and a neural network (NN). The developed architecture employs a hybrid MPC scheme incorporating an additional NN correction branch. The workflow includes input data pre-processing, operating point linearization and NN training, computation of the optimal control sequence over a receding horizon, closed-loop control and adaptation based on prediction error. This innovative hybrid control law uses a linear state-space model as the base predictor and a compact NN superstructure to compensate for unmodeled nonlinearities. The GA searches for the optimal sequence of control actions while respecting process constraints and ensuring stable use of the NN correction. The methodology was tested on a phosphoric acid purification process. Compared to baseline MPC, the proposed algorithm increased purification efficiency to 95.1%, reduced the integral tracking error by 11.4%, and decreased the control signal amplitude by 10–15%. Selecting the appropriate reagent supply and vacuum modes ensured stable operation despite fluctuations in the raw material. These results confirm the effectiveness of DT-based hybrid control in applications requiring precision, adaptability, and strict constraint compliance. The approach is scalable and can be applied to other continuous production systems within Industry 4.0 initiatives.