The Challenges of Using Reinforcement Learning for Controlling Industrial Energy Systems
Authors: Tobias Lademann, Théo Vincent, Jan Peters, Matthias Weigold
Organizations: Institute for Production Management, Technology and Machine Tools (PTW), Technical University of Darmstadt · DFKI GmbH, SAIROL · Department of Computer Science, Technical University of Darmstadt · Hessian.ai, Technical University of Darmstadt
Reinforcement learning has shown promising results for optimizing the control of industrial energy systems, yet most existing studies remain limited to the application in simulation environments. We investigate the challenges of deploying reinforcement learning in a real-world industrial energy system, considering a thermal heating network as a use case. We formulate the task as a Markov Decision Process and systematically analyze the associated challenges along the structure of the formal description, including partial observability, action space design, reward design, and the simulation-to-reality gap. The challenges are grounded in an existing real-world deployment, where reinforcement learning achieves operational stability but shows a significant performance gap compared to simulation.
Reinforcement learning (RL) has achieved remarkable success in real-world decision-making across diverse domains, including gaming, robotics, online advertising, public health, and natural language processing. Despite these advances, a substantial gap remains between RL research and its deployment in many practical settings. Two recurring challenges often underlie this gap. First, many settings offer limited opportunity for the agent to interact extensively with the target environment due to practical constraints. Second, many target environments often undergo substantial changes, requiring redesign and redeployment of RL systems (e.g., advancements in science and technology that change the landscape of healthcare delivery). Addressing these challenges and bridging the gap between basic research and application requires theory and methodology that directly inform the design, implementation, and continual improvement of RL systems in real-world settings. In this paper, we frame the application of RL in practice as a three-component process: (i) online learning and optimization during deployment, (ii) post- or between-deployment offline analyses, and (iii) repeated cycles of deployment and redeployment to continually improve the RL system. We provide a narrative review of recent advances that address the statistical challenges arising across these three components, including methods for enhancing sample efficiency during online deployment, maximizing data utility for post- or between-deployment inference, and designing sequences of deployments for continual improvement. We also outline future research directions in RL that are use-inspired -- aiming for impactful application of RL in practice.
Constrained Reinforcement Learning (RL) has emerged as a significant research area within RL, where integrating constraints with rewards is crucial for enhancing safety and performance across diverse control tasks. In the context of heating systems in the buildings, optimizing the energy efficiency while maintaining the residents' thermal comfort can be intuitively formulated as a constrained optimization problem. However, to solve it with RL may require large amount of data. Therefore, an accurate and versatile simulator is favored. In this paper, we propose a novel building simulator I4B which provides interfaces for different usages and apply a model-free constrained RL algorithm named constrained Soft Actor-Critic with Linear Smoothed Log Barrier function (CSAC-LB) to the heating optimization problem. Benchmarking against baseline algorithms demonstrates CSAC-LB's efficiency in data exploration, constraint satisfaction and performance.
Industrial automation increasingly demands control strategies that balance operational performance with strict energy efficiency requirements. A common approach to solving this multi-objective problem, particularly within the framework of reinforcement learning (RL), is to formulate a single, scalar reward function that linearly combines the competing objectives. However, the manual weighting of these different objectives is heavily reliant on domain intuition, incredibly time-consuming, prone to human bias, and frequently fails to uncover optimal trade-off solutions. This work addresses the critical challenge of automating the weight selection process to systematically and efficiently discover the Pareto front of optimal trade-off policies. We formulate the weight selection process as a multi-objective Bayesian optimization (MOBO) problem and evaluate its sample efficiency against a standard uniform grid search baseline. Using a physical Quanser Aero 2 testbed configured for 1-DoF pitch control, our results demonstrate that the MOBO approach, utilizing the expected hypervolume improvement (qEHVI) acquisition function, consistently outperforms uniform grid sampling. MOBO achieves superior hypervolume and maximum spread, successfully identifying high-quality, diverse trade-off policies with a reduced evaluation budget, thereby enabling highly efficient energy-aware control in complex mechatronic systems.