Apparatus and Methods for Non-Invasive Closed Loop Step Testing Using a Tunable Trade-Off Factor

An integrated multivariable predictive controller (MPC) and tester is disclosed. The invention system provides optimal control and step testing of a multivariable dynamic process using a small amplitude step for model identification purposes, without moving too far from optimal control targets. A tunable parameter specifies the trade-off between optimal process operation and minimum movement of process variables, establishing a middle ground between running a MPC on the Minimum Cost setting and the Minimum Move setting. Exploiting this middle ground, embodiments carry out low amplitude step testing near the optimal steady state solution, such that the data is suitable for modeling purposes. The new system decides when the MPC should run in optimization mode and when it can run in constrained step testing mode. The invention system determines when and how big the superimposed step testing signals can be, such that the temporary optimization give-away is constrained to an acceptable range.