Automated Process Control System Research Articles

Development of a model of the process of development of manufacturing defects in automation means

In automated process control systems, automation equipment (sensors, converters, amplifiers, etc.) with technical defects arising during their manufacture, which are one of the main causes of failures, is widely used. The paper establishes the possibility of using the laws of nonequilibrium thermodynamics as the basis for determining the relationship between the controlled parameters of automation equipment and the parameters of the displayed medium, which made it possible to build a deterministic model of the development of production defects and, ultimately, determine the directions for changing and adjusting the technological processes of production of automation equipment. A method has been developed for implementing a guaranteed forecast of changes in the parameters of automation equipment based on solving the evolution equation using optimal filtering algorithms, which is the subject of research. The purpose of the work is to improve the quality and reliability of automation equipment by improving the monitoring of defects arising in the production of instruments, functional units and sensors of automation equipment. The article solves the following problems: analysis of existing approaches to the problem of manufacturing defects and methods for their detection and setting a research task; modeling of the process of development of production defects causing changes in the technical condition of automation equipment; development of a decision-making method based on guaranteed prediction of the technical state of automation equipment. The methodology of work is based on the methods of thermodynamic description of the kinetics of processes (when developing a model of the process of development of production defects that cause a change in technical condition) and methods of assessment and forecasting based on optimal filtering algorithms (when developing a decision-making method based on guaranteed foresight of technical condition). The results of the work include a model of the process of development of manufacturing defects that cause a change in the technical condition of automation equipment, and a decision-making method based on a guaranteed forecast of the technical condition of automation equipment. Conclusions. The paper establishes the possibility of using the laws of nonequilibrium thermodynamics to determine the relationship between the controlled parameters of automation equipment and the displayed medium, and to build a deterministic thermodynamic model of the development of production defects. Disclosed is an equation of evolution of technical state of automation equipment based on a deterministic kinetic model of processes occurring in a multicomponent medium, and an observation model which takes into account errors caused by instability of external effects and measurement errors. Disclosed is a method of implementing a guaranteed forecast of change in parameters of automation equipment based on solving the evolution equation using optimal filtering algorithms, which are used to solve estimation and prediction problems.

Optimization of the penetration testing process in automated process control systems using machine learning algorithms

Optimization of the penetration testing process in automated process control systems using machine learning algorithms

Mathematical modeling of the flat ingot casting process or solving automation problems

Aluminum alloys are widely used in the production of aircraft due to their strength, lightness, corrosion resistance, and necessary electrical conductivity. At the same time, aluminum ingots used in further processing of the space industry must be of high quality. Technological problems and defects arise when temperature, speed, and other technological parameters of casting are not observed, or when modes change. At the same time, foundry processes are partially automated; the human factor significantly affects product quality and work safety. Therefore, automation of these complex processes using mathematical models to predict casting parameters is an urgent task. The goal of the work is to create mathematical models available for use in automated process control systems (APCS), as well as for the development of a digital twin. The work presents simplified formulas for modeling the temperature distribution of an aluminum ingot during the casting process, cooling the metal when moving along a metal path, and test calculations of the temperature distribution inside the ingot when the ingot reaches a fixed length. The results of this work can be used to improve the efficiency and accuracy of controlling the process of casting aluminum ingots, to eliminate emergency situations.

WEB APPLICATION «ELECTRONIC READER’S DIARY» BY AGILE TECHNOLOGY

The article relate to the development of an reader’s electronic diary by AGILE technology. It is needed for reader competency of primary school students. The current students were born in a new information environment. They master information and software faster than adults (for example, gadgets, tablet PC, mobile devices, etc.) The disadvantage is this information environment is reluctance to read. One of the stimulation tools to reading is electronic reader’s diary technology applied in the educational process. The regular reader’s diary is a report about books read. The aim of the reader’s diary is skills reflection and development of the critical analysis skills formation. The project software is designed for primary school students (age 7-10 years). Independent reading skills form at primary school age. It improves cognitive interests of school students, enhances knowledge, and is the formation of a harmoniously developed personality. The electronic reader’s diary stimulates the knowledge interests and consolidates the reading material by AGILE technology and additional interactivity with the school students. The research relates to the architecture of the developed solution, in particular, the issue of the «automated process control system of education system resources» integration. Also, the article contains the map of the developed graphical user interface screen and describing main electronic reader’s diary screens. This research will be intended to boost cognitive and creative activity of students.

RESEARCH AND CONSTRUCTION OF A MATHEMATICAL MODEL USING DISCRETE PROGRAMMING METHODS FOR THE MIXING AND MELTING OF COPPER CONCENTRATES

This paper describes the construction of an optimal schedule for a metallurgical workshop using discrete programming, and in particular, the method of branches and boundaries. In this regard, a heuristic approach to solving this problem is proposed, which includes: building an initial graph that satisfies the constraints of the optimization problem, as well as sequential search optimization of the initial graph according to a given criterion. To test the effectiveness of using the task of forming a melting schedule as part of the operational control subsystem in the converter department, experimental studies were conducted. Considering that the creation of the automated process control system of the copper plant provides for the introduction of systems using modern software and hardware controls, cargo flow control, and an automated conversion process control system, the efficiency of using optimal melting schedules will significantly increase.

Flow-through moisture meter for measuring grain moisture as part of an automated grain moisture control system

The methods of increasing the accuracy and efficiency of the production process, as well as ensuring high quality of final products in the grain processing industry, are investigated. It is shown that to solve the problem of insufficient quality control of grain materials, an automated system for monitoring the properties and characteristics of bulk granular materials is necessary. The features of the construction of automatic and automated systems for monitoring the properties and characteristics of bulk granular materials are considered. Measurement methods and control devices of the main technological parameters used in the management of grain processing facilities are briefly described. It is proposed to include a flow moisture meter in the automated grain moisture control system. The physical properties of grain and grain materials, measurement conditions and instrumentation for grain moisture control are analyzed. The use of devices based on the dielkometric method in the subsystem of an automated process control system is discussed. The application of intelligent sensors of a measuring system with a complex multilevel hierarchy is described. The structure of the interconnection of measuring devices for intellectual support of humidification processes and quality control of the studied materials is given. A functional diagram and metrological characteristics of a prototype grain moisture monitoring device, a flow moisture meter, are presented. The metrological characteristics of this device meet the requirements of the grain processing industry and allow it to be used as part of a humidity control system

Technology of Intellectualization of Automated Process Control Systems Based on a Software and Hardware Complex

Technology of Intellectualization of Automated Process Control Systems Based on a Software and Hardware Complex

Преимущества интеграции автоматизированных систем управления технологическим процессом угольных шахт с системами определения местоположения

Coal mining companies, especially those involved in underground operations, are currently at different stages on their way to digitalization and face a number of challenges, which are described in the article. One group of such problems is the difficulties concerned with the coal mine dispatching control. The paper shows how a properly selected approach, i.e. the integration of various automated process control systems with positioning systems, provides a solution to these problems and offers significant advantages both regarding the industrial safety and maximizing the economic effect. Examples of such integration are given for the conveyor transport control system, for the air and mine gas control systems as well as a CCTV systems with positioning systems within the Smart Mine® complex. An assessment of the current technical basis for the implementation of this approach is given, and the advantages of using a single platform for subsystems of the multi-functional safety system and production management systems are shown.

Analysis of the State of Moisture Control to Ensure and Regulate the Quality of Grain and Grain Products

The article discusses the methods for determining the maturity of grain and describes its behavior during harvesting, to optimize the selection of the grain moisture state, discusses the requirements for the choice of measurement method and the design of moisture control measuring devices, as well as its high accuracy and the possibility of measuring from field conditions, collection, storage, transportation, and industrial processing and release of finished products of granular materials. The purpose of the study is to improve the efficiency of control and management of complex technological processes and moisture control devices for granular bulk materials of plant origin through the development of systems for automatic and automated control of the electrophysical characteristics of grain products and to increase the reliability of quantitative and qualitative assessments of production and technological measurement information. To achieve this goal, it is necessary to conduct analytical and experimental studies of the possibility of creating an express method for controlling the moisture content of grain and products of their industrial processing and the development of a moisture meter for automated control of raw material parameters during acceptance and storage at grain processing enterprises. The article discusses the scientific and methodological foundations for measuring the electrophysical characteristics of grain products of agricultural production and the implementation on this basis of the functional subsystem of information support by the Automated Process Control System for Controlling the Mass Ratio of Moisture of Plant Origin Materials. A critical analysis of the current state of the theory and practice of automatic control of electrophysical characteristics of grain products and the identification of the trend of their further development and improvement are carried out. A mathematical model of the interaction of a high-frequency field with a granular material has been constructed, where the influence of the elastic properties of the grain on the electrical characteristics of the electromagnetic wave, which distinguishes its behavior in the field of a high-frequency wave from many other dielectrics, has been substantiated, and the influence of a large number of various disturbing factors has been studied, often the measurement results cannot be applied in the control of the technological process due to the uneliminated error, which is the cause of inaccurate information. Primary measuring transducers of electrophysical parameters of grain products are proposed, and their mathematical models are considered. A functional scheme of the measuring device based on the dielcometric method of moisture control of grain and granular materials has been developed, and metrological characteristics have been given.

EXPERT ASSESSMENT OF THE THERMODYNAMIC STATE OF THE "METAL-SLAG" SYSTEM IN REDUCING AND OXIDIZING CONDITIONS

A new approach has been developed to assess the thermodynamic state of the "metal-slag" system in the production of cast iron and steel using the parameters of interatomic interaction. As a result of computational and analytical studies of the indicators of the melting products of the blast-furnace and steelmaking processes, the regularities of the coordinated change in the chemical compositions of the metal and slag melts were revealed. A close relationship has been established between the integral indicators of metal (ZY) and slag (, e), characterizing the chemical and structural state of their melts. As a criterion for evaluating the thermodynamic matching of melts of the "metal-slag" system when it tends to equilibrium, an analytical expression is proposed in the form , which can be implemented in automated process control systems to solve the problems of controlling the thermal and slag modes of iron production and steel of the required composition.

Обзор основных компонентов, особенностей и решений безопасности автоматизированных систем управления технологическими процессами

The structure, main components and tasks of typical automated process control systems (ACS) are described. The main distinctive features of automated systems and their impact on the design of an information security system (ISMS) are determined. A brief overview of the problems of information security of automated process control systems is given. The basic principles that must be taken into account when creating.

Моделирование работы газотурбинной установки SGT5-4000F с исследованием влияния режимных и климатических факторов на устойчивость горения в камере сгорания

When regulating gas turbine units, it is necessary to be confident in the stable combustion process in the combustion chambers, considering the dynamics of the processes and changes of external climatic factors. Many scientific studies are devoted to the problems of experimental research and mathematical modeling of processes in combustion chambers. The possibilities of flame failure, expansion of the lower limit of combustion, determination of the stable position of the flame front and other issues have been assessed. Even though the problem of design of mathematical models and their use remains relevant. The purpose of this research is to model and study the influence of operation and climatic factors on the stability of combustion in the combustion chamber of the SGT5-4000F gas turbine unit. The subject of the research is the SGT5-4000F gas turbine unit with a low-emission combustion chamber. The simulation model of the gas turbine unit has been developed in the environment of dynamic modeling of technical systems SimInTech. The research is carried out using theoretical methods of calculating fuel combustion, thermodynamic foundations of the theory of gas turbine engines, methods of mathematical and simulation modeling, as well as data from the archive of automated process control systems. A simulation model of SGT5-4000F gas turbine unit has been developed. It is distinguished by the ability to assess the proximity of the compressor operating mode to the stability limit and determine the boundaries of stable combustion procedure in the combustion chamber, considering environmental climatic factors. The authors have studied the stability of the compressor and combustion chamber. The results of the experimental studies of a gas turbine unit in the operating load range from 113 to 282 MW and in the range of outside air temperature from –12 to 30 °C have shown that the combustion process in the combustion chamber is unvarying over the entire operational stress spectrum. The results obtained are verified by comparing model values with technological parameters of a gas turbine unit taken from the archive of the power plant control system. The authors have assessed the influence of electrical load on the performance indicators of a gas turbine unit at outdoor temperatures of +30, +15 and –12 °C. According to the results of simulation modeling, the model of SGT5-4000F gas turbine unit is found to be adequate. The developed model can be used as a tool at the stage of functional and technological design of automated control systems for the development of effective automatic control systems.

New approach to evaluating the thermodynamic consistency of melts in the ‘metal-slag’ system based on interatomic interaction parameters

The article presents a new approach to evaluating the thermodynamic state of the ‘metal–slag’ system during metal smelting in oxidizing-reducing conditions. The interaction between the metal and slag is analyzed using the model of the structure of metallurgical melts, which considers cooperative ion exchange processes and interatomic interaction parameters. As a result of analyzing experimental data on the compositions of reacting melts during pig iron and steel smelting, criteria were developed for assessing the degree of achieving the equilibrium in the system regarding sulfur. The charge state parameters of the metallic system ZY and the slag system Δe, the slag stoichiometry index ρ, and the charge state parameter of the melt components Zi were used. The regularity of a consistent formation of metallic and slag melts has been established, which is evidenced by a significant correlation between the chemical equivalent of the metal composition ZY and the slag Δe. Analytical dependences were obtained in the form of ZY = f(Δe,ρ). The identified patterns and criteria can be integrated into automated process control systems for regulating the slag regime and producing high-quality pig iron and steel.

CYBERSECURITY RISKS MANAGEMENT OF INDUSTRIAL CONTROL SYSTEMS: A REVIEW

Industrial control systems (ICS) form the basis of critical infrastructures, managing complex processes in various sectors of industry, energy, etc. With the increasing frequency and complexity of cyber threats, effective management of ICS cybersecurity risks is critical. This paper is devoted to the analysis of approaches used in the field of cybersecurity risk management of automated process control systems. The study examines the cybersecurity risks of ICS and the role of international standards in managing cybersecurity risks. The results of the analysis carried out in this paper can serve as information for the development of new reliable cybersecurity risk management systems for ICS.

PROBLEM STATEMENT AND MODELING OF AN ENERGY TECHNOLOGY SYSTEM FOR THE JOINT PRODUCTION OF SULFURIC ACID AND CONDENSED SULFUR DIOXIDE

The article develops a mathematical model for the quantitative assessment of technological parameters of energy-technological systems for the production of sulfuric acid and condensed sulfur dioxide. When modeling, the system was considered as energy-technological, taking into account the need to reduce its negative impact on the environment, due to both industrial emissions of harmful substances and emissions of unused thermal energy. In this regard, it was envisaged to process part of the sulfur dioxide according to a cyclic scheme. To increase the intensity of the technological system and the processes occurring in it, the use of oxygen and the provision of a high concentration of sulfur dioxide in the gas mixture before the stage of its catalytic oxidation in the contact apparatus was envisaged. To reduce the total volume of reactants, an increase in pressure in the system was assumed. The carried out formalization and object-oriented decomposition of the simulated system made it possible to identify 6 functional subsystems (blocks), each of which can be modeled and investigated independently. The accepted high level of formalization made it possible to include a minimum set of real system parameters in the model. The model is capable of development and can be concretized by introducing additional parameters and mathematical models of technological functions into consideration. The developed model is recommended to be used for operational modeling of combined systems for the production of sulfuric acid and condensed sulfur dioxide in the preparation and optimization of initial data for their design. After testing and setting up the model in practice, it can be used in an automated process control system, including when creating adaptive control systems.

Model for describing mivar networks in the format of bipartite and tripartite oriented graphs for decision-making and information processing in machine-building AI

Nowadays, there is a strong trend towards the creation of autonomous systems. For their development, it is required to make decision-making systems, which in this article are proposed to be implemented using mivar technologies of logical artificial intelligence. The paper considers the problem of choosing a specific implementation of the mivar approach using the example of bipartite and threadbare oriented graphs of mivar networks. Purpose – to give an example of activation of parameters and rules when solving the problem of route planning in a two-dimensional logical space. To consider the features of the subject area of automated process control systems and analyze three-sided graphs for decision-making and information processing in mechanical engineering. New ways of developing mivar networks based on three-sided and multi-sided graphs are considered for the implementation of the rules for choosing the type "if ..., then ..., else ...", in which some parameters can be filled in when the condition is met, and others when the condition is not met. The approach described in the paper to the creation of decision-making systems based on mivar technologies allows to achieve a higher degree of autonomy in order to further replace the role of a human operator in automated process control systems in production.

Microservice information and management system for digitalization of document flow of APCS projects

A microservice information management system (IMS) that allows automation the preparing process of the required documentation for the developed projects of the automated control systems for technological processes (APCS) is proposed. The main requirements for digitalization of document flow of such projects are outlined. The functionality of all services implemented in the IMS is considered. A data storage method is determined that consider the specifics of storing not only structured information (for example, about specific equipment models, specialists, etc.), but also information about special JSON models used in the process of the service operation or calculating the configuration of an automated process control system project. The principle of forming documents on automated process control systems projects in the proposed IMS is shown. The work is aimed at increasing the efficiency of the development and deployment of automated process control systems projects for companies offering comprehensive solutions for technological processes automation at industrial enterprises. Keywords automatic control system for technological processes (APCS), information management system, microservice architecture, digitalization, document flow

ИМПОРТОЗАМЕЩЕНИЕ АВТОМАТИЗИРОВАННЫХ СРЕДСТВ УПРАВЛЕНИЯ ТЕХНОЛОГИЧЕСКИМИ ПРОЦЕССАМИ

The causes of the existing problems of the industrial automation market are determined and an analysis of analogues, proven components of industrial automation in the Russian Federation market is carried out. The use and purchase of sanctioned equipment is complicated by the fact that manufacturers of "unfriendly" countries indicate individual identification numbers on the manufactured equipment. With the help of a single identification database, the manufacturer controls the volume of equipment supplies to serviced industrial facilities in other countries. If the volume of supplies exceeds the annual limit, the equipment manufacturer asks the customer to send the disabled equipment for examination, or sends its specialist to the serviced enterprise. In case of detection of resale of the supplied equipment in the Russian Federation by parallel import, this enterprise ceases to fall under warranty service and later personal sanctions are imposed against it. This article discusses the issue of the process of import substitution of automated process control systems in the territory of the Russian Federation. The main focus is on analyzing the current state of the industry, identifying the main problems and determining the prospects for the development of domestic manufacturers. After analyzing the topic, the authors conclude that import substitution is a key factor in ensuring the technological independence and security of the country, as well as stimulating innovation and development of the Russian economy. Import substitution of automated process control systems is one of the priority areas of development of the Russian economy. The main purpose of this process is to ensure the technological sovereignty of the country by creating and using domestic developments that are not inferior in quality and functionality to imported analogues.

Principles of Constructing a HIL Simulation Stand for Debugging Automated Process Control Systems based on the Baget PLC

The problem of constructing a HIL simulation stand for researching a technological process using programmable logic controller (PLC) "Baget" is described in this article. Issues of modeling technological processes are currently extremely relevant, since modeling is a mandatory stage in the automated process control systems development. An adequate model of the technological process allows debugging and verification of automated process control system algorithms without using real equipment, reducing financial costs and the probability of emergency situations. The HIL modeling method involves partial use of real equipment as part of the model. The inclusion of standard components of the original object in the model does not require detailed mathematical model and at the same time provides a more complete correspondence to the original. Due to using a computer from the original object, the stand software operates under conditions close to the real technological process, which improves the quality of the simulation results. The HIL modeling stand includes the following components: control computer of automated process control system; programmable logic controller PLC "Baget"; simulation computer. The stand for the basic element of an automated process control system allows to speed up the process of prototyping and debugging even in the case of complex systems, because it will be easier to build the entire system from correctly functioning elements. Another advantage of this approach is that the stand is not tied to a specific type of technological process or to a narrow area of production — the stand allows the use of ready-made models, the development of new models, and the inclusion of various function libraries. The simplicity of the stand design with this approach is combined with a full range of functionality. By connecting additional software, you can create more complicated and detaild model. This stand is also capable of serving both for debugging PLC algorithms and as a simulator for maintenance personnel of a real control object, because the stand operator can simulate failures and errors of standard equipment, emergency situations at the control object. Using C and JavaScript programming languages for development ensures portability and ease of expanding the capabilities of the modeling software. The development of complex systems based on HIL modeling allows saving resources and effectively solving assigned problems, therefore the proposed approach to building stands will be in demand in the process of developing an automated process control system based on the PLC "Baget".

Комплексная оценка трудноформализуемых вентиляционно-технологических процессов на угольных шахтах

Introduction. Automated process control systems, as a set of characteristics related to the ability of an object to satisfy certain needs, are one of the most important indicators of the quality of complex technical systems consisting of a large number of interacting mechanisms, apparatus and instruments. Their failure can lead to accidents and emergencies, resulting in large economic losses, destruction of industrial facilities, and sometimes human casualties. Methodology and research methods. The solution to the assigned problems is based on modern methods of artificial intelligence, automatic control theory, mathematical modeling of technological processes, and mathematical statistics; graph theory; decision theories; apparatus of mathematical logic; set theory and systems analysis. Discussion of research results. The article presents the results of studies of the patterns of ventilation and technological processes in coal mines. It has been established that studies of patterns in coal mines are becoming more relevant in connection with the formulation of the task of modernizing production and the Russian economy as a whole. It has been revealed that the methodological foundations for the synthesis of control decisions that ensure the achievement of a stable state make it possible to formulate acceptable organizational and managerial decisions and evaluate their effectiveness using metered characteristics of the proximity of vaguely described states. Conclusion. Based on the research carried out, new theoretical and applied problems were posed and solved, system connections and patterns of the ventilation technological process (VTP) were identified, models, methods and algorithms for automated ventilation technological process control systems (ACVTP) were developed, aimed at increasing the efficiency of the technical air supply system coal mines. The theoretical foundations for modeling and controlling ventilation and technological processes have been created, including concepts, models, methods and control algorithms. The research results can be useful in controlling ventilation and technological processes. Conclusions on the article. The article presents the results of studies of ETP conducted in coal mines. It has been established that, using the developed methodology, it is possible to: design high-tech equipment with specified quality indicators for intelligent control systems; choose from a variety of structural diagram options the best in terms of operational efficiency; carry out structural-parametric adjustment and change the types of mathematical models, both for an individual element and for the ETP as a whole; identify the weakest points in the HTP automated control system and adapt the methodology for controlling ventilation and technological processes, evaluate the effectiveness of using structural redundancy. Suggestions for practical applications and directions for future research. The research results can be useful when carrying out mining operations at all enterprises where air supply is necessary.