Probe-Conditioned Memory for Actuator-Deadband-Aware Koopman MPC in Industrial Sealing

Abstract

Industrial sealing and dispensing cells often reuse a pressure chain, nozzle, substrate path, and vision interface across product recipes. For a narrow bead recipe, however, a calibrated static pressure can remain correct while small corrective moves are absorbed by actuator deadband; delivered pressure changes only after a direction- and history-dependent threshold is crossed. Commissioning is defined here as the target setup and retuning interval after such a recipe change. A physical gluing and dispensing cell provides pressure-to-width calibration, a fixed probing sequence, signal-interface limits, residual scales, and actuator bounds. The controller comparison is then run on an anonymized digital twin calibrated from those measurements. The actuator-deadband-aware Koopman model predictive controller (AK-MPC) initializes from probe-conditioned memory (PCM) that links the pressure setpoint to probe-inferred actuator behavior, a predictor, a controller prior, and a fallback filter. During commissioning, a sixteen-move probe selects a nearby historical case, fits the current pressure-width relation, updates a small local dynamic correction, and supplies a feasible receding-horizon pressure policy. In the main \(1.00\) mm benchmark, where delivered-pressure loss is visible in the probe, AK-MPC reaches 0.0487 mm tracking mean absolute error (MAE) over 60 paired cases; the calibration-only inverse, adaptive proportional-integral, online recursive-least-squares ARX, and probe-fitted ARX controllers range from 0.2492 to 0.3956 mm. This large gap reflects the full constrained Koopman-MPC and online-correction workflow. The isolated PCM contribution is measured by ablation: removing PCM raises the error to 0.0655 mm. In this regime, a short actuator characterization makes historical runs useful before much target data are available.