A method of creating and using an adaptive DMC type or other MPC
controller includes using a model switching technique to periodically
determine a process model, such as a parameterized process model, for a
process loop on-line during operation of the process. The method then
uses the process model to generate an MPC control model and creates and
downloads an MPC controller algorithm to an MPC controller based on the
new control model while the MPC controller is operating on-line. This
technique, which is generally applicable to single-loop MPC controllers
and is particularly useful in MPC controllers with a control horizon of
one or two, enables an MPC controller to be adapted during the normal
operation of the process, so as to change the process model on which the
MPC controller is based to thereby account for process changes. The
adaptive MPC controller is not computationally expensive and can
therefore be easily implemented within a distributed controller of a
process control system, while providing the same or in some cases better
control than a PID controller, especially in dead time dominant process
loops, and in process loops that are subject to process model mismatch
within the process time to steady state.