Feedback loop design and tuning
PID, cascade, feedforward and ratio control — structured loop design, identification, tuning and commissioning for stable, responsive and robust closed-loop operation.
Information according to § 5 TMG (German Telemedia Act):
Dr. Rafał Noga
Im Kampfeld 10
29365 Sprakensehl
Germany
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Phone: +49 175 617 6792
E-mail:
VAT ID (§ 27a UStG)
DE457893621
Academic title
Dr. (doctorate awarded in Spain)
Responsible for content according to § 55 Abs. 2 RStV: Dr. Rafał Noga (address as above).
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Data controller
Dr. Rafał Noga
Im Kampfeld 10, 29365 Sprakensehl, Germany
E-mail:
Replace drifting loops and conservative setpoints with model-based predictive control — APC/MPC, soft sensors, digital twins, real-time optimization.
Industrial AI is a layered stack — not a single product. Each layer builds on the one below, and each has documented ROI of 6–18 months. A diagnostic call identifies which rung your plant is on and the fastest path to the next one.
Live virtual replica of your plant — model + state estimation + RTO/MPC integrated. Enables what-if analysis, operator training, and enterprise optimization.
Explore →Compute the economically optimal operating point every 30 minutes. $1–15M/year per major process unit. Requires APC as executor.
Explore →Multivariable closed-loop control — track optimal setpoints, handle disturbances, enforce constraints. Payback 3–12 months.
Explore →Detect bearing wear, fouling, and equipment degradation from vibration, acoustic, and current data. Deployable independently of the process control stack.
Explore →Detect process drift and abnormal events before they become quality failures. Prerequisite to deploying APC.
Explore →Estimate unmeasured quality variables and synchronize models with the plant in real time. Enables tight quality control without expensive analyzers.
Explore →Sensors, analyzers, historian (AVEVA PI, OPC UA). The foundation — without clean data, nothing above it works.
A 30-min diagnostic call maps your current position and the fastest path to measurable ROI.
Book a Diagnostic CallPhD-level theory combined with 20+ years of live control deployments — across process industry, energy, and autonomous systems.
Schedule a 30-minute call to discuss your process challenges and explore potential solutions.
Selected project summaries — all under NDA, anonymised by default.
Economic NMPC for a large-scale industrial cryogenic system at 1.9 K. First-principles thermo-hydraulic model, optimisation-based state estimation, and supervisory control.
Energy-efficient autonomous operation of a multi-MW cryogenic installation.
NDA · anonymised Wind Energy · Feedback ControlFunctional architecture, dynamic simulations, feedback control, Economic NMPC, parameter optimisation, and On-Board Diagnostics for a large wind turbine.
Improved load management, fault detection, and turbine lifetime.
NDA · anonymised Airborne Wind · Trajectory OptimisationFlight automation for an airborne wind energy system: non-linear models, UKF state estimators, feedback control, and online 3D trajectory optimisation for autonomous kite operation.
Autonomous power-generation flights with continuous online re-planning.
NDA · anonymised Avionics · Soft SensorNon-linear state estimation for a paragliding variometer, fusing barometric and IMU data to deliver low-latency vertical speed and total-energy readout.
Sub-second latency energy display for real-time thermal navigation.
Deep theoretical foundation plus many years of hands-on practice in R&D contexts, developing new types of systems where the solution is not obvious at the start. We adapt language to the audience and deliver key insights in a compact and engaging way.
PID, cascade, feedforward and ratio control — structured loop design, identification, tuning and commissioning for stable, responsive and robust closed-loop operation.
Advanced controls enable efficient operation of non-linear systems with strong couplings, operated across a wide range of conditions under strict constraints.
Combine models with available sensors to improve accuracy, reduce the need for expensive sensors and estimate non-measurable variables.
Scheduling, logistics and resource allocation at plant level, and trajectory optimization for machines to increase throughput, reduce wear and lower energy costs.
Evaluate ideas and operating strategies without touching production. Parametric/sensitivity studies guide investment; models enable optimization and operator training.
Train operators offline to reduce interruptions and waste. Cover standard tasks, complex situations and safety-critical scenarios.
PhD-backed teaching and hundreds of public talks. Key knowledge delivered compactly and engagingly, tailored to experts, decision makers or technicians.
Cutting-edge, industry-standard tools chosen per application. Seamless integration with existing software and collaboration via version control.
Peer-reviewed papers, conference proceedings, and theses on Model Predictive Control, state estimation, and cryogenics at CERN.
arXiv:2403.00382
IECON 2018 - 44th Annual Conference of the IEEE Industrial Electronics Society
5th IFAC Conference on Nonlinear Model Predictive Control (NMPC), Seville. IFAC-PapersOnLine, 48(23), pp. 440-445
PhD Thesis, University of Valladolid
53rd IEEE Conference on Decision and Control (CDC), pp. 3530-3535
18th International Conference on Process Control, Tatranská Lomnica, Slovakia
18th IFAC World Congress, pp. 3647-3652
19th IEEE International Conference on Control Applications (CCA), Yokohama, Japan, pp. 1654-1659
Technical Report, CERN
MSc Thesis (Joint: Univ. Valladolid, ENSIEG Grenoble, Univ. Karlsruhe, Politechnika Gdańska)
A guided web wizard for complete VFD configuration of booster pump systems. Enter a few on-site measurements — the tool calculates all 30+ VFD parameters tailored to your specific installation. Covers PID settings, analog input scaling, sleep/wake thresholds and motor identification. Free, online, mobile-friendly. No engineering background required.
When complex control logic must be adapted and deployed across many machine variants or installations, rebuilding it manually is the bottleneck. I build engineering toolchains that turn structured configuration into deployable artifacts: controller settings, PLC code, HMI objects, tests, commissioning checklists, and documentation — consistently, with fewer errors, faster.
The same engineering pattern repeats across projects; commissioning is slow or error-prone; knowledge is concentrated in a few experts; quality varies between sites or machine variants.
"First stabilize the engineering logic — then industrialize it."
Discuss your engineering workflowSee how much you could save with Advanced Process Control. Enter your approximate annual costs below.
Get a personalized feasibility study
We reply with a tailored analysis within 2 business days.
Ranges based on published industrial implementations (steel, cement, HVAC). Results vary by process. See sourced case studies →
Send us one week of historian data and we will return a concise 1-page diagnostic report: bottleneck identification, control loop health, and a realistic improvement estimate — at no cost and no commitment.
NDA signed before data exchange. Results delivered within 5 business days.
Focused on practical results across manufacturing, process industry, energy, robotics, logistics and machine building.
Flight state estimation and closed-loop control for paragliders and kite-based systems — observer design, stability augmentation, and autonomous guidance, backed by 1,000+ hours of hands-on paraglider flight.
Reduce cycle time and raise throughput on CNC machining, robotic milling and assembly lines. Contour error compensation, feed-rate optimization and deflection prediction cut scrap and raise surface quality.
Handle nonlinear batch and continuous processes — chemicals, pharma, cement, steel and food. When large disturbances, operation close to constraints, or model mismatch cause the control system to operate uneconomically during transients — and RTO setpoints lose validity — Economic MPC embeds the economic objective directly into the feedback loop.
Maximize renewable energy yield, dispatch battery storage for price arbitrage, cut building HVAC energy by 17%+, and minimize greenhouse heating cost — with time-varying prices and weather forecasts built into the controller.
Embed trajectory optimization and model-based control to increase precision, reduce component wear and lower energy draw — with embedded solvers meeting hard real-time budgets on standard PLCs or microcontrollers.
Control collaborative robots to ISO 15066 force limits, plan collision-free motions for manipulation and assembly, and operate legged or wheeled robots across unstructured terrain — constraint satisfaction guaranteed by design.
Optimize AGV routing and speed profiles in warehouses, reduce crane sway, synchronize multi-robot fleets and replan paths in real time under uncertainty. Constraint-aware MPC replaces conservative fixed-speed profiles.
Guidance and control for drones, UAV swarms, underwater vehicles and ships — from time-optimal trajectories to dynamic positioning and fault-tolerant attitude control under actuator saturation and model uncertainty.
Predictive torque and current control for VFDs, switched reluctance and permanent magnet motors. Reduce torque ripple, extend lifetime and meet grid fault ride-through requirements in turbomachinery, oil & gas and industrial drives.
Detect bearing wear, gearbox degradation, and blocked filters from live sensor data — before failure occurs. Often as simple as a microphone and suitable signal processing.
Book a free 30-minute consultation to discuss your challenges.
Clarify data, goals & constraints; identify quick wins.
Digital twins, first MPC/estimators; prove potential.
Proof-of-concept on process/machine, tune parameters.
Industry-grade implementation, training, tuning & support.
Agile in 2-week sprints – with clear, usable deliverables after each sprint.
Four engagement types with clear scope, high-quality execution and professional standards. Remote or on-site.
Uncover bottlenecks and opportunities using data analysis, on-site observations and feedback from your team. From insights to business cases and a practical roadmap.
20 years across the full lifecycle: requirements, architecture, implementation, testing, deployment and documentation on PCs, industrial systems, SCADA and embedded.
Hundreds of talks in five languages. Operator training with digital twins; engineer training in advanced control, state estimation, optimization; team mentoring.
Provide the technical expertise to assess and hire the right people, leveraging a broad network to find strong candidates.
Custom solutions where it matters, and standard tools where they fit best.
Short reaction times and pragmatic delivery to keep momentum.
Maintenance, tuning, support and knowledge transfer to sustain performance.
Data analysis plus workshops with operators and management to uncover real problems.
Use simulation and optimization to save experimental time and reduce risk during development and commissioning.
Carefully weigh risks and benefits; enable progress via controlled trials of new parameters and approaches.
Two-week sprints with usable results each time; quick adaptation to changing requirements and experimental findings.
Strong foundations in mathematics, physics, computer science, control systems and optimization - applied to real problems.
Models as simple as possible — geometry and basic physics for linear control design, minimal nonlinear extensions only when simulation demands it. Complexity is justified by the control problem, not assumed.
Compact, clearly scoped work packages (5–10 days) and light-touch support — so you keep development in-house, protect your IP, and build no long-term external dependencies.
For startups bringing complex dynamic systems to real-world operation: drones, robotics, aerospace, mobile machines, energy tech, industrial automation. Remote-first, occasional on-site possible.
Prototype of an estimator or controller, simulation/test harness (SIL/HIL), critical module refactoring, experiment design + on-site test days + evaluation report.
60–90 min review call weekly or biweekly while your team implements. Focus: architecture, controller concept, robustness, estimator design, test design, log analysis. Written notes with decisions, risks, and next steps.
3–5 jointly defined gates (e.g. "before first field test", "after stable closed-loop", "before scaling"). Per gate: review + written findings + Go/No-Go recommendation + risk register.
1–2 compact workshops tailored to your system: architecture paths, sensor/IMU integration, observers/filters, vibration damping, loop shaping, test design, KPI definition, tuning workflow. Deliverable: training materials + playbook.
NDA standard. You keep IP ownership and control of development. No hidden licensing. Transparent fixed-price or day-rate billing to match your budget. Always handed over so your team can continue independently.
Goal, constraints, status, risks — then a concrete proposal.
Agile execution in two-week sprints across all packages, including clear deliverables after each sprint.
Understand the problem, data and objectives; identify quick wins and a sensible path forward.
Deliverables: analysis report + concise technical proposal.
Get startedRecreate the setup in simulation, build first models/estimators, run realistic studies to assess potential.
Deliverables: simulation study report + draft plan for experimental proof of concept.
Learn moreBring simulation into reality, run controlled tests, adapt parameters and validate performance on site.
Deliverables: test plan + on-site report + tuned settings.
Learn moreEngineering aides or operator-training tools based on models; designed for non-experts.
Deliverables: working prototype + brief user guide.
Harden to industrial standards with documentation, safety and quality gates - ready for scale.
Deliverables: codebase and docs aligned with agreed standards.
Deploy on the machine or process. Operator training, extensive testing and final documentation.
Deliverables: commissioning report, training materials, SOPs.
Maintenance, tuning, adaptations and knowledge transfer - ongoing or punctual.
Deliverables: per-sprint updates and improvement notes.
Defined jointly upon agreement to match your specific needs and constraints.
Deliverables: as agreed, per-sprint outcomes and documentation.
Below you will find typical cooperation models as they are practical in the technical SME sector (engineering/development/plant environment). The daily rates shown are starting prices ("from") net plus VAT and will be specified in the offer based on the specific project context.
Regardless of the billing model, development is agile:
Suitable for: Plannable capacity, regular reviews, quick support ("keep-the-lights-on" + minor enhancements).
Billing: Monthly contingent (e.g., X days/month), optionally with defined response times.
Purpose: Quickly clarify scope, make risks/dependencies visible.
Result: KPI target picture, system boundaries, data/interface list, integration plan, effort estimate, and offer model (T&M or milestones).
Purpose: Quick external start, then internal anchoring.
Service: Setup, stabilization, knowledge transfer, optionally recruiting support (role profile, interview support) and structured onboarding of internal owner.
An internal FTE with a €100,000 gross salary costs the company (roughly calculated) about ~€720 per productive day.
→ Internal full cost per productive day: 144,000 / 200 = ~€720/day
The specific conditions typically depend on:
Depending on the project, cooperation can also be structured as Solution-on-Demand:
It can be agreed that we will not sell or license the developed solution to direct competitors of the customer (e.g., as industry/competitor exclusivity for a defined period and/or market), with scope and limits to be precisely defined contractually.
The models above are proven standards — individual structures are also possible. Whether daily rate, milestones, retainer, license model, or exclusivity: We design the cooperation to fit scope, risk, budget, and your procurement/compliance process.
The cooperation possibilities are practically unlimited – we will find a clean, fair way.
Note: This page is for general information and does not constitute legal advice. The specific terms are bindingly regulated in the respective offer and contract.
Answer 5 quick questions to evaluate if your process is ready for Advanced Process Control.
Your process shows strong potential for Advanced Process Control.
Short and clear: practical notes on control, optimization and digitalization.
Many manufacturers don't lose time because the control algorithm is too hard. They lose time because the path from expert knowledge to deployed engineering is too manual. Deployment toolchains fix that — and Siemens, Beckhoff, Rockwell, and MathWorks are already proving it.
The AI revolution is real — but how many neural networks are actually running industrial control loops? Analysis of 672 studies, 148 real-world implementations, and 10 confirmed production deployments reveals the gap between hype and hardware.
Google Trends shows a 5–10× synchronized jump in searches for advanced process control, digital twin, and soft sensor in August 2025. Here is the timeline that explains it.
Why predictive control delivers robust quality.
Most process plants quietly lose 5–15% of throughput and energy efficiency through poorly tuned loops. Here are the five symptoms to look for — and what each one costs.
A practical decision framework for choosing between physical analyzers and model-based virtual sensors — with cost ranges, lag times, and the hybrid approach most plants miss.
Before spending on a consultant or a commercial APC platform, run through this checklist. It identifies whether your process has the prerequisites for advanced control.
Common questions about Advanced Process Control and working together.
MPC is an advanced control strategy that uses a mathematical model of your process to predict future behavior and optimize control actions. It excels at handling multi-variable systems with constraints, delivering better performance than traditional PID control.
Timelines vary by scope. A diagnostic phase typically takes 2-4 weeks. A full proof-of-concept can be completed in 2-3 months. We work in agile 2-week sprints with deliverables at each stage.
Published reference implementations report: ~17% primary energy reduction in buildings (ETH Zurich / Siemens, IEEE TCST 2016), temperature variability halved in cement kilns (Holcim / ABB, 2008), and slab quality out-of-spec cut from 59% to 12% in steel reheating furnaces (Dillinger, 2011). Reference payback periods: 6–18 months. Every process is different — a 30-minute discovery call is the fastest way to estimate the realistic opportunity for your system.
Both. Many phases can be done remotely, including data analysis, model development, and simulation. On-site presence is valuable for commissioning, operator training, and initial diagnosis.
Process industry (chemicals, pharma, food & beverage), manufacturing, machine builders, and energy generation. Any industry with complex, multi-variable processes can benefit.
Yes — a mutual NDA is standard practice and we sign before any data or process details are shared. We work comfortably in export-controlled and security-sensitive environments.
We structure every engagement in phases with clear deliverables and exit points. If a phase shows the expected benefit is not achievable, we say so — and stop — rather than continuing to invoice. A failed proof-of-concept early is far cheaper than a failed deployment late.
Yes. We work at the data layer — if your historian or data infrastructure exports standard formats (OPC-UA, CSV, REST), we can interface with it regardless of DCS or SCADA vendor. PLC-level and vendor-specific control system integration requires collaboration with your automation team or vendor.
The code and models developed remain the intellectual property of Dr. Noga. The client receives a perpetual use license included in the development price. Exclusive licenses and non-compete agreements (NCA) are available and negotiable. Details are defined in the contract.
Primarily alone — which means senior-level attention on every task, no junior handoffs, and no account-manager overhead. For projects requiring additional capacity, I have a trusted network of specialist engineers I can bring in under the same quality and confidentiality standards.
Have more questions?
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Dr. Rafał Noga
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Verified Credentials
Verifiable excerpts from work certificates and recommendation letters — documenting hands-on experience in optimization, model predictive control, and state estimation.
Note: Company names are for context on previous positions and do not represent client endorsements.
Documented Tasks (verbatim excerpts)
Performance Rating (very good)