Complex Technological Processes Research Articles

Modeling of Transformation of Quality Indicators in the Process of Mechanical Processing of Products with High Physical and Mechanical Properties

Complex technologies are technologies which consist of a certain set of stages and technological processes. Using the theoretical basis of the systemic and synergetic approaches, the technological process of manufacturing of such parts has been represented as a process of qualitative and quantitative changes of the object. Taking into account the phenomena of technological heredity, it has been assumed that physical and mechanical properties, in particular, tensile strength, proportionality limit, relative narrowing and resilience, as well as characteristics of the quality of the treated surfaces and processing accuracy can be transformed during the complex technological process. To describe the transformation processes of quality indicators, a set of experimental studies of the roughness of the treated surface during machining of parts with high physical and mechanical properties has been carried out and mathematical models have been obtained. To determine the conditions of the integrated technology, it has been proposed to use a complex of dimensionless characteristics - relative changes of the coefficients of the mathematical model. The obtained mathematical models of the processes of mechanical treating of steel 38HN3MFA make it possible to determine the processing conditions that ensure the formation of a given set of quality indicators.

Innovative technologies in the production of curd

At the moment, the Russian Federation has mastered various methods of making dairy products. Cottage cheese is considered one of the most beloved goods of the population. This is explained not only by its taste, but also by its nutritional and bioavailability. Future progress in the production of cottage cheese must be achieved both through the introduction of comprehensive mechanization and automation of production processes, and through the use of investments for the technical reequipment of equipment and the installation of new lines. During the reconstruction and modernization of production facilities, mainly automated lines of manufacturing plants from Germany, Denmark, Poland, Bulgaria are installed. At some factories, work continues on the lines for the production of acid curd Ya9-OPT (Russia). In this regard, it is important to improve the existing and create new equipment for the production of curd and curd products. Along with the development of new methods for the production of curd and curd products, in order to increase their competitiveness, it is quite reasonable to use technologies with a closed method of conducting the process, i.e. it is necessary to exclude the influence of the human factor on a complex technological process. For the successful sale of products, it is necessary to expand the range of cottage cheese products, improve their quality and price competitiveness, develop production with a high proportion of prepackaged and packaged products with a design that meets consumer demand. It is necessary to increase the degree of factory readiness of products for direct consumption.

NEW SURVEYING TASKS IN AUTOMATED INDUSTRIAL ENTERPRISE MANAGEMENT SYSTEM

In 2018, the Pavlodar petrochemical plant introduced a modern system of maintenance and repair, designed to modernize and improve the production process. A maintenance system consisting of subsystems allows: - organizing a system for managing the condition of the company fixed assets taking into account the current condition of the equipment; - receiving information about the performed maintenance, repair or replacement works, about reducing the risks of unplanned production downtime; - determining the feasibility of repairing or replacing equipment based on the total cost of maintenance; - establishing the validity of planning for the procurement of spare parts and materials for scheduled repairs; - reducing the risk of missing spare parts in case of emergency shutdown of equipment. The process of implementation and expansion of maintenance subsystems is ongoing. The Engineering Data Creation and Management (EDCM) system is being introducing using AVEVA solutions. The introducing and integration of EDCM is carried out with the IBM Maximo subsystem of the maintenance system based on a three-dimensional digital plant model, created in the AVEVA Everything 3D software. A brief description of the process of creating a three-dimensional model of an industrial enterprise, its connection with a maintenance system, as well as the transformation of surveying information through the lens of the development of digital transformation of surveying information when creating digital twins of industrial enterprises, using the example of creating a 3D model of PNHZ for an engineering data management system is given. As a result of the 3D modeling development in the framework of the widespread introduction of digitalization in manufacture, surveying works received a new launch for development. It should be noted that surveying measurements are the key to the success of a complex and multi-stage technological process for creating and operating a digital spatial twin or 3D plant model in a TOPO system.

ОБГРУНТУВАННЯ ВИБОРУ ЗАСТУПНОЇ СХЕМИ ЛЕП ДЛЯ МАТЕМАТИЧНОГО МОДЕЛЮВАННЯ ЕНЕРГОСИСТЕМ НАПРУГОЮ 20 КВ

In the current global economic crisis and acute shortage of energy resources, increasing importance is attached to energy saving measures, economical and careful consumption of raw materials, materials, electricity and heat, environmental safety of industrial production. During the reconstruction of existing power supply systems of industrial enterprises, modern progressive solutions should be considered and implemented, morally and physically obsolete electrical equipment should be replaced, namely the introduction of new electrical equipment for transition from 6/10 kV to 20 kV in Ukrainian power systems. It is also necessary to pay attention to the improvement of power supply circuits and distribution networks, the implementation of complex automation of complex technological processes, rational compensation of reactive power at all levels of power supply systems. In the power system, the main transport link is the power line. Power lines (transmission lines) are long conductors suspended at a safe distance from the ground overhead lines (overhead lines) or cable lines (overhead lines) in which conductors are insulated from each other and from the environment and protected by insulation and armor electricity. Power lines are the most massive elements of the power supply system, they connect the individual nodes of its circuit. Longitudinal and transverse parameters are distinguished in alternative schemes. The load current flows through the longitudinal parameters, voltage is applied to the transverse ones. The replacement circuit of the electrical network consists of replacement circuits of the following elements: power lines, transformers, reactors, capacitors, loads, power sources. Calculating the steady-state modes of power systems, the substitution schemes of the elements are given in a single-line design, because the parameters of all phases are symmetrical. In local and local electrical networks with a relatively short length and low rated voltage, the conduction currents are small compared to load currents. Therefore, in typical electrical calculations of these networks, the capacitive conductivity of the lines is not taken into account. However, for these networks, the accounting of capacitive conductivities is necessary when considering some modes, the existence of which in itself is due only to the presence of capacitive conductivities. For example, the mode of single-phase ground fault in a network with isolated or compensated neutral or analysis of the modes of operation of neutrals of electrical networks of different voltage classes cannot be performed without taking into account the capacitive conductivity of these networks. When switching the power system of Ukraine to the nominal voltage of 20 kV, it should be taken into account that the transmission line will be replaced in the sections of both the overhead power line and cable power line, namely 35, 10, 6 kV. The replacement scheme must describe all the characteristics and properties of the elements of cable and overhead lines in accordance with real conditions. Thus, it is not expedient to use simplified substitution circuits that neglect energy parameters and properties of conductors to study the parameters of transmission lines. The use of a complete "P" -shaped scheme for the analysis of the parameters of transmission lines and transmission lines for a voltage of 20 kV is the basis of mathematical modeling of the transmission system in the distribution networks of our country.

Experimental validation of complex mathematical model of screw reactor coupled with particle model describing pyrolysis of lignocellulosic biomass

As in every complex technological process design, pyrolysis reactor design and optimization require a mathematical model of sufficient complexity. Aside from properties of utilized feedstock, reaction temperature and residence time of solid and gaseous phase are the main parameters in pyrolysis reactor design. Screw pyrolysis reactor, also known as auger reactor, is a well-known and studied reactor type suitable for pyrolysis of heterogeneous materials. In this work, a complex mathematical model of a screw pyrolysis reactor coupled with a particle model is proposed. Primary pyrolysis reactions as well as secondary tar cracking reactions were taken into account. In addition, heat and mass transfer inside a solid particle and heat transfer between both phases and the reactor wall were considered. Experimental results obtained at a pyrolyzer temperature of 650, 700 and 750 °C and residence time of solid phase of 7, 9.6 and 15 min were compared with data predicted by the mathematical model. Both, tar and gas yield predicted by the model at 700 and 750 °C showed a good agreement with experimental data at all solid phase residence times. However, the model predicted higher gas production compared to the experimental one at 650 °C. The value of relative deviation of char yield remained under 2% under all pyrolysis conditions. The proposed model can be used for simulation and optimization of industry-scale screw pyrolyzers. However, its validity should be verified on wider operation temperature range.

OF PLASTIC PROPERTIES OF AISI 316L STEEL BY METHOD OF REGISTRATION OF MACROLOCALIZATION FIELDS

Selective laser melting is one of the modern methods of manufacturing parts in the production of machine-building equipment, a special place is occupied by complex technological processes used in the manufacture of high-load units of pneumatic-hydraulic system from heat-resistant alloys. The studies were performed on samples made of powder material AISI 316L stainless steel martensite class. Tests to determine the mechanical properties were performed in accordance with ISO 6892 on an INSTRON test machine. The control of the surface roughness was performed using a BioBase device. From microstructural analysis and testing the method of registration of macrolocalization fields of the working zone samples, it was found that the destruction began from the surface of the samples from the microconcentrators due to different roughness.

Investigation of plastic properties of AISI 316l steel by method of registration of macrolocalization fields

Selective laser melting is one of the modern methods of manufacturing parts in the production of machine-building equipment, a special place is occupied by complex technological processes used in the manufacture of high-load units of pneumatic-hydraulic system from heat-resistant alloys. The research was carried out on samples made of powder material - stainless steel AISI 316L martensite class. Metallographic studies showed that the density of the sample is 99.83%, the structure of the samples is a martensitic structure of equilibrium constructed tracks. Tests to determine the mechanical properties were performed in accordance with ISO 6892 on an INSTRON test machine. From the tensile diagram it was found that the yield strength was 376.56 MPa, the maximum point of temporary resistance of the sample - 615, 40 MPa 319 seconds after the start of the test. The control of the surface roughness was performed using a BioBase device. The working area of the tensile sample consisted of two areas: a roughness area of 5 μm, which accounted for 80% of the working part of the sample (zones A and Б) and 20% of the working part of the sample (zone Б), the roughness was 17 μm. According to the results of microstructure studies and studies by the method of registration of macrolocalization fields of the working zone of the samples, it was found that the destruction began from the surface of the samples from microconcentrators due to different roughness. It is established that the surface and subsurface layer with increased roughness in comparison with the main body has a smaller elongation by 10.84%. From microstructural studies of the working zone in the area of the gap, it was found that the destruction began from the surface of the samples between zones A and Б. During the research in zone A and Б, one of the concentrators of the gap was detected. As a result of the study, it was found that the destruction began with the surface of the samples and the place of change of its roughness. The mechanism of deformation of the sample from AISI 316L steel is shown, the scheme of extraction of tail sections of tracks and crack propagation in the conditions of tensile testing of the sample is constructed.

Modeling the impact of shell wall thickness thinning on the stress state

A large number of fire-flame-proof substances, complex technological processes, characterizes oil and gas industry. Ensuring safety and preventing accidents are important issues for oil and gas industry. Modeling in modern software systems contributes to assessing the current situation and making the right decisions to extend safe operation life and increase equipment reliability. The wall thickness of a shell, even before putting in operation, is differential. In this paper, the effect of shell wall thickness thinning on the stress state is considered, taking into account the possible permissible deviation within the limits of GOST. The purpose of research is to prove the necessity and importance of taking into account uneven distribution of wall thickness for calculations. The object of study is cylindrical shell made from steel 09G2S. The thinning zone varied along the length of the study object. According to calculations result in SolidWorks software package, thinning, within the permissible possible deviation, at low pressures does not pose a danger. In case of increase in pressure up to 6 MPa and above, which is often used in complex technological processes, it leads to stress increasing in shell wall, which can contribute to strength characteristics deterioration. The results of research emphasize the importance of taking into account all features of a research object in 3D modeling, because it is at the heart of a new promising method of production management, like a digital twin.

Creation of a chemical-technological system digital twin using the Python language

Currently, when modeling complex technological processes in cyber-physical systems, procedures for creating so-called "digital twins" (DT) have become widespread. DT are virtual copies of real objects which reflect their main properties at various stages of the life cycle. The use of digital twins allows real-time monitoring of the current state of the simulated system, and also provides additional opportunities for engineering and deeper customization of its components to improve the quality of products. The development of the "digital twin" technology is facilitated by the ongoing Fourth Industrial Revolution, which is characterized by the massive introduction of cyber-physical systems into production process. These systems are based on the use of the latest technologies for data processing and presentation and have a complex structure of information chain between its components. When creating digital twins of such systems elements, it is advisable to use programming languages, that allow visualization of simulated processes and provide a convenient and developed apparatus for working with complex mathematical dependencies. The Python programming language has similar characteristics. In the article, as an example of a cyber- physical system, a chemical-technological system based on a horizontal-grate machine is considered. This system is designed to implement the process of producing pellets from the apatite-nepheline ore mining wastes. The article describes various aspects of creating a digital twin of its elements that carry out the chemical-technological drying process in relation to a single pellet. The digital twin is implemented using the Python 3.7.5 programming language and provides the visualization of the process in the form of a three-dimensional interactive model. Visualization is done using the VPython library. The description of the digital twin software operation algorithm is given, as well as the type of the information system interface, the input and output information type, the results of modeling the investigated chemical-technological process. It is shown that the developed digital twin can be used in three versions: independently (Digital Twin Prototype), as an instance of a digital twin (Digital Twin Instance), and also as part of a digital twins set (Digital Twin Aggregate).

Optimal inspection for missions with a possibility of abortion or switching to a lighter regime

Many real-world critical systems, e.g., aircrafts, manned space flight systems and submarines, complex technological processes utilize mission aborts to enhance their survivability. Specifically, a mission can be aborted when a certain malfunction condition is met and a rescue or recovery procedure is then initiated. In this paper, we consider systems with observed degradation when a decision to abort a mission or to continue operation is executed at inspection. If this degradation is larger than the optimally predetermined level, then a mission is aborted, whereas if it is smaller, a system continues its operation either under the initial (full load) regime or under the lighter regime with the decreased load. The latter option also depends on the observed value of degradation at inspection. An optimal problem minimizing the expected costs with respect to the relevant levels of deterioration and inspection time is formulated and analytical relationships for the probabilities of interest and expected cost rates are derived. A new virtual age-based approach to age recalculation after the switching of regimes is proposed. A detailed illustrative example is presented.

Videostream in the system of visual communication of radio stations

The article considers the video stream as a component of the visual content of Ukrainian radio stations. It is determined the specifics of the used video streams and development tendencies. It was studied out that in general, Ukrainian radio stations are focused on the global trend, which is to strengthen the visual component, so they try to use a new form of communication. Although this process is not very active. Realtime video broadcasts have heterogeneous forms; they are represented by different typological groups. It depends largely on the size, financial capacity and the needs of radio stations. The most complex technological process is observed on non-commercial radio stations.

Analysis of modeling, optimization and control methods of multifactor operations and complex technological processes

Analysis of modeling, optimization and control methods of multifactor operations and complex technological processes

Software implementation of a virtual laboratory bench for distance learning

The article discusses the functional development and integration into the educational process of a virtual laboratory stand, with the aim of digitalizing the educational processes of higher education without loss as educational services related to the completeness of mastering professional competencies in specialized engineering courses. The developed laboratory stand allows simulating technological processes implemented in an apparatus consisting of four connected tanks. Modeling such a complex technological process with many interconnected elements is necessary for the most detailed research and synthesis of automatic control systems for multiply connected objects. The program simulates two control loops, each of which can be switched to manual or automatic operation. To realize the maximum adequacy of the mathematical model, the program provides for the possibility of taking into account the influence of the actuators on the regulation process.

Исследование способов снижения пускового тока при запуске высоковольтных двигателей

The operation of high-power industrial electrical installations, particularly in metallurgy and the oil and gas industry, is associated with complex technological processes that require increased attention to the equipment used, as such equipment is used in complex and dangerous production conditions and in continuous operation facilities. High-voltage air and gas compressors are objects with increased electrical energy consumption and have significant starting currents. These circumstances affect both the shape of the supply voltage and the state of the energy system in general. Currently, the development of methods for limiting inrush currents is an urgent task for objects used in industrial enterprises. Introducing a compressor into the technological process is sometimes requires prior coordination of its start with the equipment in operation, especially that with a high power consumption. The paper studies the existing control system as well as ways to upgrade the system to improve its energy performance.

Features and Benefits of Digital Technologies in Agricultural Enterprises

This article substantiates that innovation is objectively necessary to ensure sustainable development of agricultural enterprises and the agricultural sector. The study notes that the introduction of digital technologies such as the Internet of Things, cloud computing, big data, blockchain, artificial intelligence, robotics can be widely applied in the agricultural sector. It is noted that the agricultural has a number of specific features: a variety of biological objects that are affected; various and complex technological processes, distribution of controlled parameters over a large area; high risks of the external environment. In this regard, the use of technologies for working with large data arrays is especially important here. The smart Agriculture concept will allow monitoring the growth of crops, a decision-making system for irrigation and the choice of fertilizers. The main goals of introducing digital technologies into agricultural production are to increase labor productivity, increase the quantity and quality of products. The introduction of digital technologies will make it possible to manage the quality of agricultural products through the introduction of modern breeding and genetic developments, provide an individual approach to the maintenance and feeding of livestock and poultry. The use of digital technologies has a positive environmental effect and will reduce the harmful impact on the environment. Updating the technological base of agricultural production through the use of digital technologies will allow controlling costs and increasing the economic efficiency.

ОБЛІК НА ПІДПРИЄМСТВАХ РЕСТОРАННОГО ГОСПОДАРСТВА: ТЕОРЕТИЧНИЙ АСПЕКТ

One of the most important components of the service sector in Ukraine is the restaurant business because many enterprises operate in this field. Restaurant enterprises include not only restaurants but also canteens, diners, bars, cafés, buffets, delicatessen shops, cafeterias, kitchen factories, etc. The proper organization of accounting is an important component that ensures the efficiency of the enterprise in this industry. The restaurant business is a very specific type of activity. It combines production, retail and service sector. In this regard, accounting at restaurants has certain features. The process of cooking dishes from food ingredients in the kitchen is an element of production activity; the sale of manufactured dishes and purchased goods is an element of retail trade; the establishment of trade margins and an element of services is for the organization of consumer leisure, so accounting is non-standard here. Unlike production enterprises, restaurant enterprises do not have work in progress and stocks of finished products in the warehouse, except for culinary departments that produce ready-to-cook products. There are described the existing approaches to accounting in restaurants in Ukraine: trade and production approach, an approach to reflecting the receipt of stocks, using and selling of ready meals and purchased goods. The positive and negative sides of these accounting methods are defined and recommendations to increase the efficiency of accounting at restaurants are given. Two groups of restaurant business enterprises depending on the complexity of the technological process are defined and the accounting methods for each of them, which do not contradict the regulations, are described. Despite the greater labour intensity of the production method, we consider it correct to apply the production method of accounting to the restaurant business entities with a complex technological process.

Analysis of the features of multifactorial operations and complex technological processes in the processing of high-precision parts

Analysis of the features of multifactorial operations and complex technological processes in the processing of high-precision parts

ТЕХНОЛОГІЯ ВИРОБНИЦТВА ЯК ВИЗНАЧАЛЬНИЙ ЧИННИК ВИБОРУ МЕТОДУ ОБЛІКУ ВИТРАТ

The article is devoted to the analysis of widely used methods of cost accounting. The legal framework governing the implementation of cost accounting in Ukraine is detailed. The analysis of the modern researches devoted to a choice of a method of the account of expenses and calculation of prime cost is presented. The key components of the production cost of manufactured products are detailed. A comparative description of domestic and foreign methods is presented, detailing the advantages and disadvantages of each method. Also, among the advantages of the normative method and the standard-costing method are the following: cost planning, the ability to predict the amount of costs for future periods, timely detection of deviations and finding out the reasons. The out-of-order method is characterized by the exact determination of the cost of each individual unit of manufactured products, which is very informative for management accounting. Direct costing is an accurate analysis of marginal revenue, significant integration of financial and management accounting and provides reporting with operational information on current product profitability. The preliminary method is used for the reasons of simple analytical accounting, ease of distribution of overhead costs between shops, simple and clear information in the account. The ABC method allows you to clearly distribute overhead costs, provides information on the total production cost of products for internal users. The target-cost method helps in cost planning at the stage of project development, assessment of market needs and competitiveness, the possibility of operational cost control, cost optimization, transparency of resource used. The expediency of application of each method depending on technological features of the enterprises and kind of economic activity is investigated. In particular, the mining, processing industries, large-scale production with a complex technological process, agriculture will use the normative method and the standard costing method. For enterprises that have implemented the IFRS the direct costing and ABC method are common. Additionally, companies with differentiated production and a wide range of goods uses such methods as well. For large corporations that manufacture a complex expensive product, such as mechanical engineering, manufacture of electronic devices, technology it is common to use target costing method.

An Experimental Study of the Thermal State of a Steel Billet during Hot Rolling

The technology of hot flat rolling is a complex technological process that includes multiple shaping of a steel billet, the temperature of a bullet ranging from 1100 to 900 degrees [1-6]. To deform a workpiece, mill rolls are used. The control over a workpiece thermal state is an important task aimed at the quality of its manufacturing [7-13]. To achieve the goal, a mathematical model is developed for calculating a steel billet thermal state. The model makes it possible to determine a temperature distribution along the whole length of a workpiece. The study results are useful for researchers and developers of the hot rolling technology, and they can be applied in the organization of the rolling process with an allowance for the temperature distribution. Based on the results, the parameters of steel billet production can be adjusted or changed [14-18].

SCADA system algorithm and software

The oil and gas industry is characterized by complex technological processes, the management of which is impossible without the use of modern automation tools (APCs). For monitoring and dispatching control of a large number of remote objects, specialized SCADA systems are used, the main purpose of which is to provide the operator who controls the technological process with complete information about this process and the necessary means to influence it. The Russian control automation market is represented by both domestic and foreign SCADA systems, the most popular of which are: WinCC (Siemens, Germany), InTouch (Wonderware, USA), RSView32 (Rockwell Automation, USA), Genesis64 (Iconics, USA), Vijeo Citect (Schneider Electric, France), Trace Mode (AdAstra), Master SCADA (InSat NPF), Krug-2000 (Krug NPF), SARGON (NVT-Automation). Unlike foreign SCADA systems, Russian SCADA systems have a number of advantages – an acceptable price level, the possibility of operational technical support and, not least, Russian-language accompanying operational documentation. The article presents the control algorithms of the TREI-5B-05 programmable controller of the «ECO» series, which are used in the SCADA system of the oil and gas transport infrastructure. Sets of parameters of a functioning system are obtained. Software has been developed that monitors the functions of the controller and signals a detected failure. A series of tests was developed and tested, with the help of which the correct functioning of the TREI-5B-05 controller was checked on a specialized stand by modeling the errors that occur. The integration of this application with the existing automated operator's seat has been completed. A method for testing the performance of the TREI-5B-05 controller of the «ECO» series, as the most important element of the SCADA process control system in the oil and gas industry, is proposed. The transition to the use of this controller was carried out in accordance with the domestic policy of import substitution. Development of control algorithms and software for an automated system for monitoring the state of technological equipment involved in the transportation of liquid energy resources along oil and gas pipelines, as well as ensuring the smooth operation of the system and reducing its downtime in the event of equipment failure. In the course of the study, a software and algorithmic complex was created and tested to monitor the technical condition of the pump unit and the shut-off device with an electric drive. Special algorithms for testing signals at different values of control parameters have been developed and tested. Protocols are formed for all the tests performed and acceptable parameter values are determined for the specific system built. The analysis of XML files in the controller's memory and in RAM for their integrity is carried out. The developed application allows you to monitor the health of the system, as well as transmit signals about detected errors to the operator's automated control system. Timely signaling of failures in the transport system, in turn, allows you to quickly take measures to eliminate their causes.