As industrial processes grow in complexity, traditional Proportional-Integral-Derivative (PID) controllers are often insufficient for handling their non-linear, multi-input dynamics. We propose using advanced Deep Reinforcement Learning (DRL) to prove its advantages in these complex environments. To do this, we rely on the Industrial Benchmark (IB). The IB is a realistic simulation that tests DRL algorithms against the key challenges of industrial applications: high-dimensional state spaces, delayed effects, and conflicting multi-criterial objectives. This testbed highlights DRL's core trade-off: while its final policies can often be unstable, its unique strength is the ability to autonomously discover optimal, non-obvious policies in multi-dimensional spaces where simple controllers fail. In this paper, we propose a novel hybrid PID-RL controller that leverages DRL's discovery capability while ensuring Reliability. After developing a multi-objective reward function to make DRL viable, we use a twin-delayed deep deterministic (TD3) agent as a discovery tool to find the optimal, non-obvious settings for the IB's 'Gain' and 'Shift' parameters. By feeding these discovered parameters to a simple, tuned PID controller, our hybrid model successfully combines all three characteristics: it achieves the optimal Performance and Efficiency of the best DRL agent with the Reliability of a classical controller. This work demonstrates a practical methodology for using DRL to augment, rather than replace, trusted industrial control systems.
A significant limitation of Deep Reinforcement Learning (DRL) is the stochastic uncertainty in actions generated during exploration-exploitation, which poses substantial safety risks during both training and deployment. In industrial process control, the lack of formal stability and convergence guarantees further inhibits adoption of DRL methods by practitioners. Conversely, Iterative Learning Control (ILC) represents a well-established autonomous control methodology for repetitive systems, particularly in batch process optimization. ILC achieves desired control performance through iterative refinement of control laws, either between consecutive batches or within individual batches, to compensate for both repetitive and non-repetitive disturbances. This study introduces an Iterative Learning Control-Informed Reinforcement Learning (IL-CIRL) framework for training DRL controllers in dual-layer batch-to-batch and within-batch control architectures for batch processes. The proposed method incorporates Kalman filter-based state estimation within the iterative learning structure to guide DRL agents toward control policies that satisfy operational constraints and ensure stability guarantees. This approach enables the systematic design of DRL controllers for batch processes operating under multiple disturbance conditions.
Runze Lin, Ziqi Zhuo, Junghui Chen +2
State Key Laboratory of Industrial Control Technology, Institute of Cyber-Systems and Control, Zhejiang University, Hangzhou 310027, China · Department of Chemical Engineering, Chung-Yuan Christian University, Taoyuan 32023, Taiwan, R.O.C.
Deep reinforcement learning (DRL) in industrial control often suffers from lag and overshoot due to purely reactive control based on the current tracking error. To achieve anticipatory control without high computational overhead, we introduce a predictive formulation that augments the DRL state space with target velocities and future reference horizons. Evaluating eight configurations using proximal policy optimization (PPO) on a 1-degree-of-freedom (1-DoF) helicopter testbed, simulation results showed a 9-fold error reduction, lowering the mean absolute deviation from 2.73° to 0.31°. However, zero-shot transfer to physical hardware revealed a sim-to-real gap. Interestingly, a simpler configuration using a single, further look-ahead horizon matched the real-world top performance of the most complex model (1.11°). Overall, evaluating various combinations of prediction horizons and target velocities demonstrated that highly granular predictive data is not necessarily required for physical transfer.
Georg Schäfer, Jakob Rehrl, Stefan Huber +1
Josef Ressel Centre for Intelligent and Secure Industrial Automation, Salzburg University of Applied Sciences, Salzburg, Austria · Paris Lodron University of Salzburg, Salzburg, Austria
In safety-critical sectors such as robotics and automotive engineering, the deployment of Deep Reinforcement Learning (DRL) is often hindered by the black-box nature of deep neural networks. This lack of transparency poses significant challenges for regulatory compliance and human-agent trust. This paper presents an experimental study aimed at making high-performance continuous control DRL systems interpretable. A policy distillation framework is implemented using the classic Inverted Pendulum benchmark. A high-performance Twin Delayed DDPG (TD3) agent serves as an opaque, continuous teacher model, whose policy is distilled into an interpretable student surrogate based on a shallow Decision Tree. By leveraging a custom physics-aware feature and "Noisy Oracle Rollouts" for dataset generation, the distillation process achieves performance equivalent to the expert teacher. Furthermore, comparative control theory analysis reveals a fundamental trade-off: transitioning from continuous to discrete rule-based control induces high-frequency Bang-Bang actuation and a stable bimodal limit cycle. Simulation results indicate that Bounded-Input Bounded-Output (BIBO) stability is maintained while providing both global and local interpretability for safe autonomous systems.
Shaker Al-Tamari, Waled Kadour
Dept. of Electrical and Computer Engineering RPTU Kaiserslautern-Landau Kaiserslautern, Germany