Equipment Control System Research Articles

Implementation of Electrical Equipment Control and Security System integrated with Internet of Things

Research on Electrical Equipment Security and Control Systems Using the Internet of Things aims to implement an IoT system for controlling electrical equipment and security systems. The owner of the security location will receive a phone call if an object is detected and can monitor and activate the alarm system while controlling electrical equipment. In addition to saving electricity, it is also intended that the detected object/human will change his mind. This system can be used anytime and anywhere. The specific target achieved is to implement a building security system and control electrical equipment using the internet of things. The method used is the experimental method, namely collecting data from the results of measuring electrical quantities in the system. The equipment used is the SIM800L module, PZEM sensor, PIR module-8 sensor, RTC, PCF8574, shift register 74HC595, ESP 32, Triac, Optocoupler, buzzer, contactor, and other supporting equipment. The results of the study show that the ability of the PIR sensor to detect objects has a sensitivity that is not all the same even with the same type, the sensitivity of the PIR sensor is influenced by the condition of the internet network, the location of the detection room, the length of the pir sensor cable to the esp 32, and the speed of the response of the designed system. Controlling electrical loads using the blynk application with contactor equipment can work effectively if the internet network conditions are stable, the effectiveness of using optocouplers and triacs allows the contactor to receive input quickly and responsively. Keywords: IoT, ESP 32, security, alarm, sensor

Intelligent control algorithms for posture and height control of four-leg hydraulic supports

To address limitations of traditional inclinometers and height sensors in determining the posture and support height of hydraulic supports in coal mining, we propose a novel method predicated on travel measurements of the leg and tail beam cylinders. This method calculates the posture and height of hydraulic supports in mechanized mining. By conducting meticulous kinematic analysis of the hydraulic supports, a skeleton model of the main structural parameters of the hydraulic support was constructed. This approach transforms the traditional geometric relationship solutions of the main structure of the hydraulic supports into solutions based on the coordinate relationships of the main hinge points of the support, resulting in a mathematical expression for solving the support posture and height of the hydraulic supports. Meticulous algorithms for solving the support posture and height of hydraulic supports were developed based on the Newton–Raphson method, secant method, and Broyden’s method. The robustness, stability, calculation accuracy, and speed of these algorithms have been verified through analysis using the skeleton model and field measurement methods. The influence of initial coordinate parameters on the calculation results has been analyzed, and it was determined that the solution method based on the Newton–Raphson method has better robustness, stability, and calculation speed. The results of the research provide a theoretical foundation and technical support for precise, rapid control and intelligent management of hydraulic supports, effectively advancing the development of intelligent control systems for mining equipment.

Anomaly detection in sensor data via encoding time series into images

Detecting anomalies in multivariate time series data is crucial for maintaining the optimal functionality of control system equipment. While existing research has made significant strides in this area, the increasing complexity of industrial environments poses challenges in accurately capturing the interactions between variables. Therefore, this paper introduces an innovative anomaly detection approach that extends one-dimensional time series into two-dimensions to capture the spatial correlations within the data. Unlike traditional approaches, we utilize the Gramian Angular Field to encode the correlations between different sensors at specific time points into images, enabling precise learning of spatial information across multiple variables. Subsequently, we construct an adversarial generative model to accurately identify anomalies at the pixel level, facilitating precise localization of abnormal points. We evaluate our method using five open-source datasets from various fields. Our method outperforms state-of-the-art anomaly detection techniques across all datasets, showcasing its superior performance. Particularly, our method achieves a 11.5% increase in F1 score on the high-dimensional WADI dataset compared to the baseline method. Additionally, we conduct thorough effectiveness analysis, parameter impact experiments, significant statistical analysis, and burden analysis, confirming the efficacy of our approach in capturing both the temporal dynamics and spatial relationships inherent in multivariate time series data.

Design and Testing of a Small-Scale Composting Facility for Sheep Manure Utilizing Aeration and Thermal Treatment

Inner Mongolia has the largest sheep population among China’s provinces, resulting in the production of a substantial amount of sheep manure. If left untreated, this manure can contribute to environmental pollution. However, sheep manure serves a dual purpose: it can be both a pollutant and a valuable source of organic fertilizer. Consequently, there is an urgent need to address the environmental issues arising from manure accumulation and its unused status. In this paper, a viable solution is proposed: the conversion of manure into fertilizer through a composting unit incorporating high-temperature aerobic fermentation technology. This unit, tailored for small farms and individual farmers, integrates critical functions such as ventilation, heating, and turning. Additionally, it boasts excellent thermal insulation, enhancing composting efficiency and enabling precise control over fermentation conditions. This design mitigates heat loss and accelerates maturation, addressing common challenges in traditional composting. The design process encompassed both equipment construction and control systems, with a primary focus on compost fermentation and aeration heating. The components were carefully designed or selected based on theoretical analysis and subsequently validated using simulation software, including EDEM and Fluent. The control system seamlessly integrates a touch screen interface, PLC programming, and control circuits to manage air pumps and electric heaters in response to changes in temperature and oxygen concentration. Furthermore, it controls the motors during the recovery phase. A comprehensive performance evaluation was conducted, revealing notable improvements. Under artificially heated conditions, the maximum temperature of the compost increased by approximately 20 °C, the composting cycle was reduced by roughly 4 days, and the seed germination index (GI) rose by about 9% when compared to natural fermentation. Thus, this device significantly accelerates composting and improves fertilizer quality by increasing the decomposition rate.

Autonomous State Assessment and Active Control System for Cylindrical Battery Inspection Equipment Based on Vibration-Vision Fusion

Autonomous State Assessment and Active Control System for Cylindrical Battery Inspection Equipment Based on Vibration-Vision Fusion

Research on Intelligent Water Treatment Strategy based on DCS Control System

Abstract In a capacity renovation project, the new DCS system as the equipment control system, and the existing AB 1756 series PLC system, there are two control systems bi-directional signal monitoring problems. This paper compares two methods of monitoring bi-directional data transmission, and analyzes and verifies the advantages and disadvantages of the two methods. From the perspective of reliability and safety of implementation, a protocol special communication card was added in the PLC controller card slot of desalination plant, and added a protocol-specific communication card to the PLC system card slot of the secondary reverse osmosis and EDI units. The actual project verification shows that this method can ensure reliability and safety performance while realizing functions.

Development of Static Test Equipment and a System for Lever-Loaded Air Springs

In light of the heavy load applied by traditional air spring test equipment and its complex structural system design, a lever-type torque loading air spring test system is designed. It adopts the principle of Chinese scales to apply the load on the air spring in the form of proportional amplification, which can apply a simulated load on the air spring of 500–800 kg, using the vertical sliding shaft as the transverse limit to make the air spring elongate and compress by 280 mm in the longitudinal direction. The measurement and control system of the test equipment is then developed based on the LabVIEW platform, and the required sensors are selected and installed. The system can achieve real-time data acquisition of the air pressure, load, height and other parameters of the air spring and air spring charging and discharging control. Following the debugging of the function of the test equipment, the function of each subsystem is normal and able to meet the requirements of air spring characteristic and pressure tightness tests. For small spaces, such as laboratories, by reducing the installation of hydraulic and other oil source systems, avoiding the use of large mass blocks to simulate the loading of air spring loads and optimizing the complex installation and debugging process, this miniaturized design for air spring test equipment has benefits for practical applications.

Probing the effect of displacement on electrical contact tribological behavior at the risk frequency of nuclear safety DCS equipment

Purpose This paper aims to study the tribological characteristics of the electrical contact system under different displacement amplitudes. Design/methodology/approach First, the risk frequency of real nuclear safety distributed control system (DCS) equipment is evaluated. Subsequently, a reciprocating friction test device which is characterized by a ball-on-flat configuration is established, and a series of current-carrying tribological tests are carried out at this risk frequency. Findings At risk frequency and larger displacement amplitude, the friction coefficient visibly rises. The reliability of the electrical contact system declines as amplitude increases. The wear morphology analysis shows that the wear rate increases significantly and the degree of interface wear intensifies at a larger amplitude. The wear area occupied by the third body layer increases sharply, and the appearance of plateaus on the surface leads to the increase of friction coefficient and contact resistance. EDS analysis suggests that oxygen elements progressively arise in the third layer as a result of increased air exposure brought on by larger displacement amplitude. Originality/value Results are significant for recognizing the tribological properties of electrical connectors in nuclear power control systems. Peer review The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-03-2024-0098/

Bridging the gap between IT and OT to improve industrial cyber security

Understanding cyber security risks is important for everyone. In this paper you will gain perspective on the cyber security challenges facing organisations today that operate within manufacturing and critical infrastructure industries, across their information technology (IT) and operational technology (OT) teams. You will also gain insight into potential solutions. IT teams have evolved distinctly, prioritising data security, access controls and system hardening in networked computing environments. OT teams manage and operate industrial control system (ICS) equipment with specific requirements around reliability and uptime for the purpose of ensuring physical outcomes in manufacturing or critical infrastructure production environments. IT and OT have traditionally operated separately within organisations because they serve different functions. The lack of interaction and understanding between IT and OT has led to cyber security vulnerabilities and frustration between organisations. IT may want to patch OT systems but get pushback because downtime halts production. OT may distrust IT recommendations because they have historically caused operational disruptions. This tension has caused many organisations to avoid trying to connect these two worlds; however, as digital transformation and Industry 4.0 initiatives bring IT and OT systems together, new cyber risks emerge. Industrial Internet of Things (IIoT) devices, legacy equipment, unpatched programmable logic controllers (PLCs) and obscured asset inventories create vulnerabilities. Despite their differing perspectives and priorities, however, collaboration between IT and OT is essential to secure today’s converged environments. Discover proven steps that can be taken to bridge the gaps between organisations to provide greater security across the enterprise, while strengthening internal teams and improving business outcomes.

Research and Simulation on the Development of a Hydraulic Prop Support System of Powered Roof Support to Increase Work Safety.

The underground mining environment is currently based on technology that uses mainly analogue sensors in machine and equipment control systems. The primary machine performing the most important functions in a mining system is the powered roof support. In order for it to work properly, it is important that it achieves the required power. To ensure this, it is necessary to continuously and precisely monitor the pressure in the under-piston space of the prop. Due to the extreme environmental conditions, pressure sensors should have high sensitivity, large transmission capacity, small size and light weight. To achieve these requirements, the authors of the article propose to implement a monitoring system based on photonics technology. To achieve this goal, several studies were carried out. The range of these studies included simulations, bench tests and tests under real conditions. The obtained test results showed the possibility of developing the control system for the powered roof support, the additional function to supercharge power. Based on the analysis of the obtained test results, assumptions were developed for the development of a power charging system with monitoring sensors. Based on the guidelines obtained from the research results, thedevelopment of the above prototype based on photonics technology is proposed.

A Framework for Real-Time Gestural Recognition and Augmented Reality for Industrial Applications.

In recent decades, technological advancements have transformed the industry, highlighting the efficiency of automation and safety. The integration of augmented reality (AR) and gesture recognition has emerged as an innovative approach to create interactive environments for industrial equipment. Gesture recognition enhances AR applications by allowing intuitive interactions. This study presents a web-based architecture for the integration of AR and gesture recognition, designed to interact with industrial equipment. Emphasizing hardware-agnostic compatibility, the proposed structure offers an intuitive interaction with equipment control systems through natural gestures. Experimental validation, conducted using Google Glass, demonstrated the practical viability and potential of this approach in industrial operations. The development focused on optimizing the system's software and implementing techniques such as normalization, clamping, conversion, and filtering to achieve accurate and reliable gesture recognition under different usage conditions. The proposed approach promotes safer and more efficient industrial operations, contributing to research in AR and gesture recognition. Future work will include improving the gesture recognition accuracy, exploring alternative gestures, and expanding the platform integration to improve the user experience.

Creation of New Types of Power Supply and Life Support Systems for Spacecraft Powered by a Solar Panel

The work of power supply and life support systems of spacecraft is completely based on consumables, delivered from Earth, the mass, and dimensions of which increase in direct proportion to the duration of the space expedition and the number of crew members. Therefore, today a power supply system is used on board a spacecraft that provides onboard electrical energy for the operation of all on-board equipment (engine, control, communications, and heating systems) by generating direct electric current using a generator, converting chemical energy into electrical energy, using fuel cells, powered by supercritical liquid hydrogen and liquid oxygen, delivered from Earth. The life support system, used today on the spacecraft, includes: system for regenerating water from atmospheric humidity condensate in a spacecraft cabin, a water regeneration system from urine, system of generating oxygen and hydrogen during the electrolysis of water in microgravity conditions, a system for utilizing carbon dioxide, removing harmful micro impurities, operating at the expense of internal resources spacecraft during space flight. Thus, the task arises of developing new types of power supply and life support systems, including the development of new and improvement of existing technologies for continuous charging of spacecraft fuel cells with hydrogen and oxygen, generating onboard electricity without the use of “Earth tanks” with supercritical liquid hydrogen and liquid oxygen, improvement of existing oxygen and hydrogen generation systems, regeneration of water from condensate of atmospheric moisture and waste products of astronauts, removal of harmful micro impurities and cultivation of rapidly multiplying microalgae on the spacecraft during a long space flight. The article presents a new type of power supply and life support systems for spacecraft, powered by a solar panel, which includes the developed new technologies: an oxygen and hydrogen gas generator, which makes it possible to economically and easily separately produce oxygen, hydrogen and drinking water to enrich the atmosphere with oxygen and replenish the drinking supplies of the spacecraft cabin, continuously charge the fuel cells of the spacecraft with hydrogen and oxygen, produced for the uninterrupted generation of onboard electricity; a separator for purification of technical wastewaters from harmful solid inclusions and pathogenic microbes and obtaining drinking water from them, regeneration of drinking water from urine, excreted by astronauts, in quantities sufficient for consumption of this water by astronauts during a long space flight; a concentrator that receives a solution with microalgae cells from a space photo bioreactor, growing microalgae under weightless conditions, which utilizes carbon dioxide released during the breathing of astronauts, produces oxygen to enrich the atmosphere of the spacecraft cabin with oxygen through photosynthesis. A concentrator permits to obtain a high-quality concentrate of cells of rapidly multiplying microalgae and supplement the crew's diet by the biggest part of this concentrate, and to replenish the space photo bioreactor with the remainder of the concentrate and nutrient solution in order to obtain enough biomass for a long space flight.

An Intelligent Control Method for Industrial Equipment Based on Distributed Electrical and Electronic Architecture

Abstract The article establishes the objective function of distributed electronic and electrical architecture from three dimensions of economy, quantization and loadability, and constructs a mathematical model for multi-objective optimization based on the satisfaction of constraints. The model was applied and tested in the intelligent control system of automotive industrial equipment. In practical applications, the intelligent control system can automatically reduce the speed to 16km/h to maintain a safe distance and prevent collision when the target vehicle is monitored to enter the lane it is in and the distance between the two cars is less than 30 meters. Under 1500 pcu/h traffic flow conditions, the average delays of vehicles at the intersection through intelligent control were only 8.06 seconds and 8.02 seconds, compared to 20.58 seconds and 23.29 seconds for vehicles under conventional control. Vehicle intelligent control systems based on distributed electronic and electrical architectures have great potential for development and significant safety performance improvement in automotive industrial equipment manufacturing. The research in this paper provides a new perspective and adequate technical support for the intelligent control of future industrial equipment.

Design of Control System for Portable On-Site Start-Stop Test Equipment

Design of Control System for Portable On-Site Start-Stop Test Equipment

Actor modeling of real-time cognitive systems: ontological basis and software-mathematical implementation

The article is devoted to the study of the problem of increasing the reliability of modeling of cognitive systems, to which the authors refer not only human intelligence, but also artificial intelligence systems, as well as intelligent control systems for production, technological processes and complex equipment. It is shown that the use of cognitive systems for solving control problems causes very high rapidity requirements for them. These requirements combined with the necessity to simplify modeling methods as the modeling object becomes more complex determine the choice of an approach to modeling cognitive systems. Models should be based on the use of simple algorithms in the form of trend detection, correlation, as well as (for solving intellectual problems) on the use of algorithms based on the application of various patterns of forms and laws. In addition, the models should be decentralized. An adequate representation of decentralized systems formed from a large number of autonomous elements can be formed within the framework of agent-based models. For cognitive systems, two models are the most elaborated: actor and reactor models. Actor models of cognitive systems have two possible realizations: as an instrumental model or as a simulation. Both implementations have the right to exist, but the possibilities of realizing a reliable description when using the tool model are higher, because it provides incommensurably higher rapidity, and also assumes variability of the modeled reality. The actor model can be realized by means of a large number of existing programming languages. The solution to the problem of creating simulative actor models is available in most languages that work with actors. Realization of instrumental actor models requires rapidity, which is unattainable in imperative programming. In this case, the optimal solution is to use actor metaprogramming. Such programming is realizable in many existing languages.

Development and research of an intelligent control system and protection of electrical network equipment

The key element of an intelligent energy system with an active-adaptive network is relay protection, designed to ensure uninterrupted and stable operation of the energy system. The goal of the work is the development and research of intelligent control systems, protection and automation of electrical networks. Research has been carried out on an intelligent security system to determine the boundaries of restrictions in the use of artificial intelligence. The authors supplemented the existing complex with physical models of the power supply system with a digital twin, an artificial neural network, and studied the complex in order to answer some questions about the use of a neural network in relay protection. An iterative approach to software development, supervised machine learning method, and Python programming language were used. Pychram Community Edition was chosen as the integrated development environment. Intelligent system software has been developed, including a digital twin, an executive part and a neural network model, which makes it possible to recognize types of short circuits in the electrical network. The works of domestic and foreign authors on this topic are considered.

Automated control of the photopolymerization process

Based on an analysis of the quality of manufactured products and existing equipment control systems for additive technologies, the necessary set of controlled parameters of the photopolymerization process was determined. The authors developed and implemented an automated control system, the functioning algorithm of which made it possible to improve the quality of products through the use of an adaptive system for controlling the degree of their polymerization. Keywords photopolymer, additive technology, automation, algorithm

Analysis and Testing of Variable Height Operating Characteristics of Super-Pressure Balloon Airbag Fan

A fan is part of the core equipment of a super-pressure balloon altitude control system, and high-performance fans have a significant impact on the altitude control capability and flight safety of super-pressure balloons. This paper proposes a mixed-flow MIX-140 fan for use with super-pressure balloons. Changes in the fan’s operating characteristics at various flight altitudes of a super-pressure balloon were investigated. First, the performance of the fan at ground level was obtained through numerical simulation and compared with measured data of the prototype to verify the accuracy of the simulation analysis. On this basis, the influences of changes in the atmospheric pressure, temperature, and fan speed on fan performance were investigated through numerical simulation. Furthermore, the MIX-140 fan was compared with an existing fan, and the variation of two parameters, namely, the ratio of inflation volume per unit time and the ratio of inflation volume per unit power, were investigated at different altitudes. Finally, the changes in the operating characteristics of the fan under different high-altitude environments were investigated through actual testing. The results reveal that changes in altitude can lead to significant changes in fan performance, and changes in the atmospheric pressure, temperature, and fan speed affect the fan’s working characteristics. Compared with the existing fan, the MIX-140 fan achieves an average increase of 295.8% in the inflation volume per unit of time, and 14.6% in the inflation volume per unit of power at altitudes of 16–20 km. The performance variation characteristics and testing methods of this proposed super-pressure balloon fan can provide a foundation and reference for the design of a super-pressure balloon control system.

Environmental Risk Assessment of Hydrocarbon-Rich Sludge of a Gas Refinery Using the Integrated Approach of PMBOK Standard Risk Management and FMEA Technique: A Case Study

Background: The present study aimed to assess the potential hazards of hydrocarbon-rich gas refinery sludge from the South Pars Gas Complex-First Refinery, Iran, and to analyze how these risks could impact the project goals based on the Project Management Body of Knowledge (PMBOK) guidelines. Methods: Statistical population of this analytical, cross-sectional survey was 31 health, safety, and environment (HSE) experts from the study refinery selected by purposeful sampling. Environmental, health, safety, and technical risks were categorized and identified using the PMBOK guidelines. Delphi method and 5-point Likert scale questionnaire were employed to assess the significance of each risk. Priority one risks within each category were determined using Primavera Risk Analysis version 8.7 software. Results: Following three Delphi steps, 17 out of 77 primary risks were identified and finalized. The first rank with the highest weight corresponded to time and cost group (the risk of soil contamination via sludge stored in the burn pit due to aliphatic and aromatic hydrocarbons), human resources group (radioactive materials accumulated on the inner surfaces of pipes, valves, pumps, heat exchangers, tanks, boilers and other equipment and the risk of these materials being hazardous for human health), and quality group (failure to supply equipment and quality control systems and personal protective equipment). Conclusion: The research findings pinpointed 17 risks within various domains, encompassing time and cost, human resources, quality, contract, scope, and communication. These identified risks necessitate a comprehensive, integrated approach to risk management for effective mitigation and resolution.

Retracted: Design and Discussion on Information Management and Control System of Agricultural Machinery and Equipment

Retracted: Design and Discussion on Information Management and Control System of Agricultural Machinery and Equipment