Automated Process Control Research Articles

CONTROL DE MICRO MECANIZADO NO CONVENCIONAL BASADO EN ANÁLISIS DE PARÁMETROS MULTIVARIABLES UTILIZANDO UN SISTEMA DE INFERENCIA DIFUSA

Non-conventional manufacturing processes, such as pulsed electrochemical machining, are strategies for manufacturing metal components that optimize tool life. This is achieved by implementing non-traditional techniques based on electrolysis to remove metal in a controlled environment without generating contact between the tool and the workpiece. These characteristics allow a reduction in the resources required for the development of components with complex morphology on high-strength materials in many application fields, such as aerospace, medical, and precision tools. However, the characteristic features of non-linearity in this kind of process increase the complexity of the development of automatic control through traditional algebraic techniques in the regulation of uniform material wear. In this context, a non-traditional solution based on techniques derived from artificial intelligence bounded by fuzzy logic and genetic algorithms is presented for the tuning and automatic control of the pulsed electrochemical machining process. Furthermore, the efficiency is evaluated by analyzing the over-cutting phenomenon and the precision in developing linear polygonal machining on a micrometer scale. Keywords: Modern manufacturing, fuzzy logic, automatic control, electrolysis, genetic algorithms.

ТЕОРЕТИЧЕСКИЕ АСПЕКТЫ АВТОМАТИЗАЦИИ ПРОИЗВОДСТВЕННО-ХОЗЯЙСТВЕННОЙ ДЕЯТЕЛЬНОСТИ НА ПРЕДПРИЯТИЯХ ПОЛИГРАФИИ

Automation of production and economic activities at printing enterprises involves the use of advanced digital solutions or technological equipment with automatic configuration and process control functions. The key benefits of automation include speeding up order processing, increasing the accuracy of calculations, optimizing the utilization of process equipment, reducing operating costs, and increasing the efficiency of planning and managing production processes. Digital solutions enable monitoring of financial and operational flows, leading to increased productivity and profitability. The object of this research is production management systems, automated information systems, as well as methods and technologies used to optimize work processes at the stages of production of printed products. The purpose of the study is to summarize the theoretical foundations for improving the efficiency of production and economic activities in printing enterprises by using automation capabilities. Research methods: analysis of literature and scientific sources on existing theories and practices of automation in printing, graphic method, deduction and induction, systematization. The scientific novelty of the study lies in the generalization of modern approaches to automation of production, technological, economic and managerial aspects of the activities of printing enterprises, as well as in a brief overview of currently proposed digital solutions in this area.

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.

AI and the transformation of industrial work: Hybrid intelligence vs double-black box effect

It is uncertain how the application of artificial intelligence (AI) technology transforms industrial work. We address this question from the perspective of cognitive systems, which, in this case, includes considerations of AI and process transparency, resilience, division of labor, and worker skills. We draw from a case study on glass tempering that includes a machine-vision-based quality control system and an advanced automation process control system. Based on task analysis and background literature, we develop the concept of hybrid intelligence that implies balanced AI transparency that supports upskilling and resilience. So-called fragmented intelligence, in turn, may result from the combination of the complexity of advanced automation along with the complexity of the process physics that places critical emphasis on expert knowledge. This combination can result in the so-called “double black box effect”, given that designing for understandability for the line workers might not be feasible: expert networks are needed for resilience.

Machine vision-based online detection method for color characteristics of cobalt extraction solution

Cobalt, as a rare metal, plays an important role in strategic resources due to its physical, chemical, and mechanical properties in applications. In order to achieve automatic control of the cobalt extraction process, it is necessary to conduct online detection of the color characteristics of the cobalt extraction solution. Unfortunately, due to the lack of online automatic detection methods for the color of cobalt extraction solution, the automatic control of the extraction process has not yet been achieved. Currently, the color of cobalt extraction solution needs to be observed and judged by operators based on experience. This will result in significant detection errors and time lag. To change this situation, an online detection method for color features of cobalt extraction solution based on machine vision is proposed in this article. Firstly, we establish a real-time image acquisition environment for detecting object colors, and then use the Gaussian filters and K-means algorithm to denoise and segment the image. In order to correct color distortion in images caused by ambient light, we measure the color feature values of a set of standard color cards using the machine vision system and a standard spectrophotometer. Based on this test data, we establish chromaticity correction models for the extraction solution using back propagation (BP) network and radial basis function (RBF) network, respectively. The models can correct the color characteristic values of the extraction solution, overcome environmental interference, and thus obtain more accurate color characteristic values of the extraction solution. The established model can be used for online automatic color detection of cobalt extraction solution. The modeling results indicate that in the established color measurement environment, the RBF network model outperforms the BP network model in color feature detection accuracy.

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.

ТЕОРЕТИЧЕСКОЕ ОБОСНОВАНИЕ ТЕХНОЛОГИЧЕСКОГО ПРОЦЕССА ПОСЕВА ДРАЖИРОВАННЫХ СЕМЯН САХАРНОЙ СВЕКЛЫ ВЫСЕВАЮЩЕЙ СИСТЕМОЙ ПНЕВМАТИЧЕСКОГО ДЕЙСТВИЯ

A promising direction in the development of seeding machine designs is the creation of pneumatic seeding systems based on jet pneumoautomatics. The introduction of seeding systems with automatic process control will allow us to obtain fundamentally new ways of programmed sowing of seeds, fertilizers, herbicides. The purpose of the study is to determine the dependence of the aerodynamic lift on the aerodynamic properties and size of the seeds, the vacuum in the suction cup, its size and the distance between the seed and the suction cup. A model is presented reflecting a program of sequentially performed operations aimed at dosing seeds with a single dosing element, including a suction cup and a cell. The continuous flow of the dosing process is ensured by superimposing the algorithms of the process of individual dosing elements with a time shift, which negatively affects the quality of dosing due to the tight connection of individual operations between the components. The analysis of the time diagram of the algorithms' functioning showed that even with a constant speed of the drill, the uniformity of seed dosing by pneumomechanical and mechanical seeding systems depends on changes in the sliding of the support and drive wheel due to different physical and mechanical properties of the soil and various loads arising when overcoming friction forces in the apparatus. The object of analytical research is the technological process of the pneumatic seeding system, its temporary modes of operation, their relationship with operational, structural and technological parameters, which mainly determine the quality of seed distribution at the bottom of the furrow. The aerodynamic lifting force in the seeding system was considered. Calculations have shown the presence of a directly proportional dependence of the aerodynamic lifting force on the aerodynamic properties and size of the seeds, the vacuum in the suction cup, and the size and distance between the seed and the suction cup.

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.

Investigation of quality related process variables in pultrusion by correlation of numerical and experimental data with application of an inline data acquisition system

The pultrusion process is an efficient technology for the continuous production of fiber reinforced polymers. While the process is industrially established for decades, the interactions between process parameters and material quality of pultruded profiles are – despite various studies – not fully understood yet. Due to the complexity of the process and the variety of materials, it is difficult to identify generic and quality related process relationships. Based on a novel multidisciplinary approach, this paper investigates the correlation between simulation data and experimental based process- and quality data. Therefore, a pultrusion-specific epoxy resin is characterized and modelled and thermo-chemical process simulations are performed. A for pultrusion unique inline quality assurance and data acquisition system was developed, built-up and applied during the production of a rectangular, glass-fiber reinforced profile. The analyzed data involves cure variables, die pressure, temperature, pull-speed and -force, ultrasonic data, surface waviness and roughness and void content. As main result, the position of gelation at the profile’s centerline in respect to the die length was determined as important criteria to maintain a sufficient material quality. Furthermore, a correlation between the die pressure and an insufficient degree of cure was identified. No significant influences of the process parameters on the material quality could be observed as long as the process stayed in a stable process window. This indicates that no severe quality losses have to be expected at higher production rates. The methods and results developed in this work are applicable for the implementation in an automated process control in pultrusion.

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.

Analyzing the Automatic Power Level Control Effect of a Signal Generator in RF Power Sensor Calibration by a Direct Comparison Transfer Method and a Millimeter Wave Application.

Most calibration laboratories prefer the Direct Comparison Transfer Method (DCTM) for a reliable and accurate calibration of power sensors in the radio frequency (RF) scope. Most studies suggest using this calibration method, with its automatic power level control (APLC) of RF signal generators. The APLC is preferred to keep the output power level of the signal generator the same, while the power sensor is calibrated and the reference power sensor is connected to the measurement system. The known APLC mechanisms are also explained for the DCTM, and a comparison of the calibration factor values carried out with and without the automatic power level control process in the DCTM is also given in this study. RF power sensor calibrations with coaxial and waveguide connector types are examined with DCTM in this study as well. This study shows that the DCTM, unless with APLC, should be applied for the waveguide power sensor's calibration at millimeter wave frequencies.

Testing the modulation of self-related automatic and others-related controlled processing by chronotype and time-of-day

We assessed whether self-related automatic and others-related controlled processes are modulated by chronotype and time-of-day. Here, a shape-label matching task composed of three geometrical shapes arbitrarily associated with you, friend, and stranger was used. Twenty Morning-types, and twenty Evening-types performed the task at the optimal and non-optimal times of day (i.e., 8 AM, or 8:30 PM). Morning-types did not exhibit noticeable synchrony effects, thus proving the better adaptation of these participants to non-optimal moments of the day as compared to Evening-types. Contrary to our predictions regarding the absence of automatic-processing modulation and the presence of controlled-processing influences by time-of-day, we found an influence on self-related but not others-related processing only in Evening-type participants. Although brain structures are not directly tackled, we argue that such modulation may be due to the dependence of the activation of the ventromedial prefrontal cortex (VMPFC), an essential component of the self-attention network on circadian rhythms.

Raises advance using borehole hydraulic technology

Based on an analysis of existing methods for raises advance, the safest, most productive, and low-cost method is hydraulic well technology. This method offers advantages such as low operation and flow rate, flexibility in managing concentration and volume of work, safety, and compatibility with traditional mining technologies. Studies on raises advance using borehole hydraulic technology have demonstrated the process’s effectiveness in rock mass destruction by water pressure jets. Effectiveness depends on the rocks’ physical and hydrotechnological properties, hydrodynamic characteristics, and water jet impact technology on the ore mass. The primary design parameter is the maximum radius of rock mass destruction, directly proportional to the axial dynamic pressure of the jet at the nozzle exit and inversely proportional to the ore’s uniaxial compressive strength. Dependencies of relative dynamic pressure changes on the water jet’s relative length were also identified. The hydraulic jet method’s effectiveness is ensured by simplified technology, high penetration speed, and savings on energy and materials. Consequently, stationary and mobile modular-type hydraulic monitor complexes have been developed based on the NKR-100MPA or KBU-1 drill-ring, providing automatic control of the hydrodisintegration process using water pressure jets.

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.

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.

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.

TRAINING AND RESEARCH SYSTEM OF PERSONNEL MANAGEMENT IN CYBERPHYSICAL SYSTEM

In the existing conditions in various companies, it is possible to observe an increase in the complexity of automation of many processes. Therefore, there is a need for distributed automated systems. They are required to operate under the constraints of real-time control and communication in manufacturing processes. In cyber-physical systems, a fully synergistic integration of control computation with physical devices and processes is implied. In addition, the incorporation of a cyber-physical system into automated plant systems will provide opportunities for unifying automated process control. Due to the automated control of production and enterprise as a whole, it is possible to form a controlled system, from order to realization. It is proposed to form a training and research system to work with cyber-physical system. Intelligent support for specialists within cyber-physical systems is associated with corresponding performance requirements. An illustration of a schematic of a training and research system for personnel management in a cyber-physical system is presented. A schematic of the training subsystem is shown. Instrumental examination within the research subsystem provides opportunities to realize the creation of an information support structure. An illustration of the schematic diagram of the analysis research subsystem is presented. A structure for conducting automated modeling of processes within a cyber-physical system is shown.