Control Systems Of Technological Processes Research Articles

DATABASES AND MODELS TO SUPPORT THE ACCEPTANCE OF TECHNOLOGICAL DECISIONS IN THE PROOFING OF STEEL AT THE LADLE FURNACE INSTALLATION

The need to develop the databases of the «Metallurgy» industry data bank in order to preserve unique industrial and laboratory experimental data, which can be the basis of licensed profile computer programs, is substantiated. Emphasis is placed on the importance of the development of calculation methods for determining the primary properties of ferroalloys, which will ensure that industrial metallurgists receive adequate data for further operational decision-making in the production of competitive and high-quality steel and their introduction into automated technological process control systems. Based on the concept of directional chemical bonding, models have been developed that allow predicting important physicochemical and thermophysical properties that are the limiting factors in the efficiency of interphase interaction processes, in particular, of manganese-containing ferroalloys with sufficient accuracy for industrial use.

Некоторые вопросы управления рисками реализации угроз безопасности информации

The article proposes an approach to assessing the risks of information security of automated technological process control systems, state information systems, municipal information systems, personal data information systems and critical information infrastructure facilities based on the requirements of the legislation of the Russian Federation in the field of protection of these types of information systems, the draft of State Standard R ISO/IEC 27005, planned to be adopted in the near future, and standards for risk assessment within the framework of processes in the life cycle State Standards 59329-59357 published in 2021. These standards are based on State Standard R 57193-2016, which describes the life cycle processes of human-made systems. The problem of processing residual risk in relation to unacceptable risks was considered, after the analysis of which another principle of safety management was proposed. A methodology for assessing confidence in the risk management system was obtained, with the help of which it is necessary to build a risk management system at the objects of critical information infrastructure.

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

The Energy-Saving Control Criterion for Impact Crushing Machines

The purpose of the article is to substantiate the use of a new criterion for controlling the grinding technological process to improve the use of electrical energy. The subject of the study is the process of using electrical energy in impact grinding machines. The set goal is achieved by solving the following problems: analyzing the energy of the grinding process, determining the parameters of raw materials and operating modes of the electric drive that affect the efficiency of electrical energy usage. Based on theoretical research, a mathematical model of energy consumption in grinding processes has been developed. Analytical studies of the resulting mathematical model showed the nonlinear extreme nature of the specific energy consumption of the grinding process with changing raw material parameters and operating modes. This creates the prerequisites both for using specific electrical energy costs as a control criterion and for the use a controlled electric drive to achieve maximum energy savings. The most important result is that the operating modes of grinding machines could be established by more efficient use of electrical energy. The significance of the work lies in the fact that by adapting the operating modes of the electric drive to the current parameters of the raw materials and the state of the equipment make possible to reduce the specific electrical energy consumption up to 15% and this is the basis for using a criterion based on specific costs in control systems for technological processes with grinding impact machines. For further application of the obtained results it is necessary to conduct experimental studies to confirm the increase in the efficiency of electrical energy use.

Комплексная оценка трудноформализуемых вентиляционно-технологических процессов на угольных шахтах

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

MODELING OF THE FLOW ADAPTIVE SYSTEM FOR CONTROLLING THE SOIL TILLAGE

It is well known that one of the significant disadvantages of the development of modern technological processes is the use of aspects of thinking associated with the use of already used design positions. From a practical point of view, there is no single optimal solution for tillage in agriculture. The methodology for solving complex, multipolar problems of quality and efficiency of technology must take into account a significant number of factors and be presented in an accessible form for the response of the working bodies of tillage machines. Precision tillage has great potential. The result of tillage operations can be improved depending on the optimal solution of construction working bodies and technological parameters of cultivating, which, in addition, can be adapted to the tillage technology depending on the local agro-climatic conditions. The article presents the results of the synthesis of the system of adaptive control of soil cultivation by creating a complex technological system with modeling of the structural-matrix schemes and on-stream technological influences of working bodies of machines and external agro-climatic conditions on the agrophysical state of the soil. The research methods are methods of analysis of structural schemes of technological process control systems; system-analog modeling of tillage control systems; structural analysis and synthesis of technological changes in agrophysical indicators of soil tillage. The main results are the structural diagram of the on-stream adaptive control system of the tillage unit for the requirements of precise agriculture; matrix diagram of the imaging and generalized system of equations of on-stream adaptive control of working bodies of tillage machines; system-analog model of the machine-tractor unit with the adaptive control system of working bodies.

Forecast for the Adaptive Tillage System

Precision tillage has great potential. The result of tillage operations can be improved depending on the optimal solution of construction working bodies and technological parameters of cultivating, which, in addition, can be adapted to the tillage technology depending on the local agro-climatic conditions. The article presents the results of the synthesis of the system of adaptive control of soil cultivation by creating a complex technological system with modeling of the structural-matrix schemes and on-stream technological influences of working bodies of machines and external agro-climatic conditions on the agrophysical state of the soil. The research methods are matrix methods of analysis of structural schemes of technological process control systems; system-analog modeling of tillage control systems; structural analysis and synthesis of technological changes in agrophysical indicators of soil tillage. The main results are the structural diagram of the on-stream adaptive control system of the tillage unit for the requirements of precise agriculture; matrix diagram of the imaging and generalized system of equations of on-stream adaptive control of working bodies of tillage machines; system-analog model of the machine-tractor unit with the adaptive control system of working bodies.

PARAMETERS OF FLOWS OF GRAIN MATERIALS

Solving the issue related to the study of flows of loose materials is due to the development of modern sensors of flow parameters of loose materials. In particular, it can be about flow sensors. This type of sensors is one of the most attractive for use in the control and regulation channels of modern automated production control systems in the agricultural and food industry. The issues considered in this article relate to the mechanics of flows of loose materials. The field of mechanics, which studies the static and dynamic aspects of loose materials, is one of the basic branches of mechanics in general. The main focus is on free gravity flow. Grain material is considered as loose material. Taking into account the peculiarities of loose material and the specifics of various industries, the problem of creating flow parameter sensors was and will be relevant. The definition of the object and process for which the sensor is being developed, namely the study of flows of loose materials, is also relevant. The article considered how loose material behaves during free fall from silos in an airless space and also in an airy one. The consumption of bulk materials from the bottom opening of the silo, in most cases, is not stable and leads to the formation of a variable flow of bulk material. After the grain leaves the silos opening, a gravitational flow is formed, consisting of dispersed grains and an air flow. The formed flow of bulk material can be considered as an information factor for determining the consumption of bulk material and a factor in creating effective sensors for automated control systems of technological processes. Formulas for calculating the flow rate of loose material in a gravity flow and the flow volumes at different states were also given in the article.

Information technology for Synthesizing a Grain Mass Flow Multidimensional Optimal Stabilization System with Perturbation Feedback

The article presents a new methodology for creating information technology for designing a combined system for stabilizing the flow of bread mass at the entrance to the thresher of the grain harvester. The characteristic features of this methodology are outlined. This makes it possible to design control systems for technological processes on the harvester taking into account external influences that are stochastic in nature. The stage of creation of the information technology of the synthesis of the optimal combined stabilization system with feedback on the deviation of the bread mass from the average value and correction on the yield change is substantiated.

SENSORS OF FLOWS OF BULK MATERIALS

In such branches of industry as agriculture, pharmaceutical, metallurgical, chemical, mining, and a number of others, it is necessary to determine the mass consumption and amount of loose material, grain, cereals, flour, specific components of chemical and pharmacological materials of cement, and the mass of others. Ways of measuring the consumption and amount of loose materials are a necessary component in the automation systems of modern production processes of the specified industries. Without the use of devices for measuring the consumption of loose materials, it is impossible to improve the production of products of the required quality and competitiveness. That is why issues related to the development, experimental research and use of these flowmeters are quite relevant. Production automation is one of the leading areas of scientific and technological progress. With the change or improvement of production technologies, the introduction of new types of equipment, the automation of production processes requires the development of specific methods and device of measurement. Most of the latest methods of measuring the consumption of bulk material allow you to automate the production process, which in turn makes it possible to reduce the cost of the product. The article considered the main types of sensors that can be used as part of ways of measuring the consumption of loose materials, such as cereals and grains. An analysis of the latest publications was made, both in domestic and in English-language publications. The considered sensors can be part of modern flow meters, the principles of which are based on various measurement methods. According to the fundamental of operation, flowmeters are divided into continuous and discrete, as well as mass and volumetric. The most common flowmeters are those that record flow using strain gauges. As accuracy and compact size allow you to use them in different conditions and with different loose materials. In the article, a lot of attention was paid to impact flowmeters. Based on the analysis of the fundamental of operation of flowmeters, the direction of development of flowmeters with the use of modern technologies to level the influence of flow characteristics on measurement errors will be promising. The results of the conducted review and analysis of flow sensors of loose materials are planned to be used in the future to create a computer-integrated system for identification of flow parameters of loose materials, which will make it possible to use automated control systems of technological processes more variably.

Investigation of the possibility of controlling the formation of physical and mechanical properties of aluminum alloys under pressure crystallization

The study of scientific and technical materials showed that the existing control systems for technological processes of casting with crystallization under pressure are not effective enough. The paper presents a control system capable of real-time measurement, control and correction of the main technological parameters of the process, such as the time and nature of the temperature distribution in the tooling and casting, the rate of pressure imposition on the crystallizing metal, the magnitude of the applied pressure. These parameters have a direct impact on the formation of the properties of the final product. The paper defines the parameters of the response of the control system to fast crystallization processes for the timely prediction of the properties of the final product. The paper proposes a technology for metal processing by pressure prior to the onset of crystallization. In the process of conducting experimental studies in castings, it was possible to achieve the same uniform distribution of components, gas and non-metallic inclusions, as in a superheated liquid metal, bypassing the development of diffusion. As a result of ultrafast application of pressure to a level of 500 MPa on the liquid metal, it was possible to realize the process of compression of the crystal lattice to such limits at which it was possible to exclude the diffusion of components along structural defects. Due to the programmed application of pressure on the liquid and crystallizing one, the idea of controlling the processes of distribution of intermetallic compounds, non-metallic and gaseous inclusions has been realized.

Improving Control Accuracy in Multi-Connected Digital Systems

The presented scientific research is relevant, because currently it is necessary to develop and implement modern control systems for technological processes. This allows increasing the accuracy of control in multi-connected digital systems, the mathematical models of which are built on the platform of the state space method. The purpose of this study is to develop a new method for improving control accuracy in multiconnected digital systems. The methodological framework of this study, determined directly for the qualitative solution of the problem, included analytical expressions that functionally not only eliminate the influence of each state and control on the rest, but also ensure high accuracy of control processes. In this scientific study, the results were obtained, standing for a methodical approach to the synthesis of vector-matrix models of regulators using feedback on the state. The vector-matrix model of the controller, combining the function of monitoring and control of feedback on the state was formed. By using computational capabilities of the mathematical apparatus adopted in the study, the matrices of the system regulators and correction coefficients were calculated. The formulated conclusions affect various aspects of the practical application of the method of determining the feedback matrix by state, deriving an analytical formula for determining the correction coefficients to ensure zero steady-state control error, as well as performing the decomposition of a digital system with the definition of a vector-matrix model of a regulator combining the functions of regulation and supervision. The materials and methods of paper fully correspond to the stated subject and can serve as a qualitative methodological basis for following research in this area

Recommendations for Ensuring Cyber Protection of Industrial Control Systemsof Energy Sector

One of the factors of the state's ability to ensure the security of its own resources and assets in the conditions of an international political crisis and an ongoing hybrid war is the ability to provide cyber protection of critical information infrastructure facilities, such as enterprises of the energy industry, chemical industry, industrial production, etc. Therefore, the cyber security of a critical structure consists primarily in ensuring the protection of technological processes from any unauthorized informational influences that cause incorrect execution of technological processes. On the basis of NIST (National Institute of Standards and Technology) Special Publication 800-53, basic recommendations for ensuring cyber protection of automated technological process control systems are provided.

Оценка пожарного риска в технологическом оборудовании с электрическими нагревателями

An important role in the field of fire prevention of the electrical installations, including electrical heating equipment, is played by the research and development of the risk-based engineering methods for assessing fire safety of the objects. It is also important to find economically sound ways to ensure it. Widespread use of the electrical heating equipment in the technological processes and a significant number of fires from heaters require a fire risk assessment considering power supply and technological process control systems. Current requirements for determining fire risk of the electrical heating equipment are not effective enough. According to the statistics, the electric heaters occupy one of the first places among the electrical equipment as a cause of fires. The article describes a methodology for assessing the probability of fire hazard modes during the operation of electrical heating equipment. Events that contribute to the occurrence of a fire are considered. The most characteristic factors that cause the ignition of electrical elements of the electric heating equipment system are listed. A tree of events leading to the fire occurrence in such systems is presented. Specific features are noted concerning thermal processes in the electrical part of the equipment associated with the possibility of ignition in the electrical elements. Analytical expressions for determining the probability of fire and its components are given. Calculation is based on the reliability indicators of the system and devices elements for protective shutdown of the circuits with fire hazardous modes. The possibility is shown related to practical application of the above methodology for assessing fire risk in the equipment with electric heaters. This methodology also allows to justify the need or sufficiency of fire-fighting technical solutions.

Алгоритм прогнозирования параметров системы переработки отходов апатит-нефелиновых руд

Within the framework of the concept of a circular economy, research in the field of creating technological systems for recycling waste from mining and processing plants occupies one of the key positions. This is connected, on the one hand, with significant volumes of such waste, reaching tens of millions of tons and posing a significant environmental hazard to air and water basins, human health, and, on the other hand, with their rich chemical and mineralogical composition, which makes it possible to call them accumulations of technogenic deposits. In this regard, the task of creating control systems for technological processes of processing such waste and their information support, including support for all stages of the passage of information processes, is urgent. The novelty of the presented research lies in the proposed structure of an intelligent control system for a complex chemical and energy technological system for processing apatite-nepheline ores, as well as in an algorithm for predicting technological parameters, which is part of the information support of the control system under consideration. The algorithm is based on the use of the apparatus of deep recurrent neural networks and Kalman filtering, which is used at the stage of data preprocessing to train the neural network. The paper describes the proposed algorithm for predicting multidimensional time series, adapted to the considered technological process, presents the software executed in the MatLab environment to demonstrate the efficiency of the specified combination of methods for processing technological parameters. In a model experiment, it has been shown that the use of filtering makes it possible to increase the accuracy of the forecast, which is especially noticeable at its large horizons. The practical significance of the research results is the proposed structure of an intelligent control system for the processing of apatite-nepheline ore waste and software for predicting its parameters, which can be used in various decision support systems.

Machine Learning Techniques for Increasing Efficiency of the Robot's Sensor and Control Information Processing.

Real-time systems are widely used in industry, including technological process control systems, industrial automation systems, SCADA systems, testing, and measuring equipment, and robotics. The efficiency of executing an intelligent robot’s mission in many cases depends on the properties of the robot’s sensor and control systems in providing the trajectory planning, recognition of the manipulated objects, adaptation of the desired clamping force of the gripper, obstacle avoidance, and so on. This paper provides an analysis of the approaches and methods for real-time sensor and control information processing with the application of machine learning, as well as successful cases of machine learning application in the synthesis of a robot’s sensor and control systems. Among the robotic systems under investigation are (a) adaptive robots with slip displacement sensors and fuzzy logic implementation for sensor data processing, (b) magnetically controlled mobile robots for moving on inclined and ceiling surfaces with neuro-fuzzy observers and neuro controllers, and (c) robots that are functioning in unknown environments with the prediction of the control system state using statistical learning theory. All obtained results concern the main elements of the two-component robotic system with the mobile robot and adaptive manipulation robot on a fixed base for executing complex missions in non-stationary or uncertain conditions. The design and software implementation stage involves the creation of a structural diagram and description of the selected technologies, training a neural network for recognition and classification of geometric objects, and software implementation of control system components. The Swift programming language is used for the control system design and the CreateML framework is used for creating a neural network. Among the main results are: (a) expanding the capabilities of the intelligent control system by increasing the number of classes for recognition from three (cube, cylinder, and sphere) to five (cube, cylinder, sphere, pyramid, and cone); (b) increasing the validation accuracy (to 100%) for recognition of five different classes using CreateML (YOLOv2 architecture); (c) increasing the training accuracy (to 98.02%) and testing accuracy (to 98.0%) for recognition of five different classes using Torch library (ResNet34 architecture) in less time and number of epochs compared with Create ML (YOLOv2 architecture); (d) increasing the training accuracy (to 99.75%) and testing accuracy (to 99.2%) for recognition of five different classes using Torch library (ResNet34 architecture) and fine-tuning technology; and (e) analyzing the effect of dataset size impact on recognition accuracy with ResNet34 architecture and fine-tuning technology. The results can help to choose efficient (a) design approaches for control robotic devices, (b) machine-learning methods for performing pattern recognition and classification, and (c) computer technologies for designing control systems and simulating robotic devices.

Реалізація математичних моделей матеріального та теплового балансів доменної плавки в складі АСУ ТП ПРАТ "МК "Азовсталь"

On the basis of blast furnace operation data of PJSC "MK "Azovstal", an information system has been developed, which is based on mathematical models of material and heat balances of blast furnace smelting developed at the Institute of Ferrous Metallurgy of the National Academy of Sciences of Ukraine. The calculation of the material balance is carried out according to the "accounting system" of V. P. Izhevskii. The thermal energy model of I. D. Semikin is used to calculate the heat balance, which was developed for use in blast furnace production by O. V. Borodulin. The article describes the information system of calculating mathematical models. The information system allows you to calculate balances in automatic mode (collection of data from automatic control system of technological process (ACS TP) and calculation of material and heat balances for the selected period) and in manual mode (calculation of forecast periods to determine reserves for increasing the energy efficiency of blast furnace smelting). The models were adapted by calculating the material and heat balances of blast furnace melting and determining the inconsistencies. Monthly calculations of the material and heat balances of the blast furnaces were performed to adapt the models installed in the ACS TP of the blast furnace workshop of PJSC "MK "Azovstal". Inconsistencies in the overall material balances of the furnaces (the difference between the total input of materials into the furnace and smelting products) and by components (iron, carbon, etc.) were determined. It was established that when using the estimated amount of blast furnace dust at all blast furnaces of PJSC "MK "Azovstal", the amount of discrepancy between the arrival and consumption of materials lies within the credible range of error (<1,5%). Using the results of the calculation of heat balances, a comparison of the Inconsistencies of the blast furnaces was made (the ratio of the calculated indicators to the actual ones). Mathematical models of balances were implemented as part of the ACS TP of the blast furnace workshop of PJSC "MK "Azovstal" and were used to assess deviations from production norms, consumption of coke and conventional fuel, as well as forecast the possibility of improving the technical and economic indicators of smelting.

Mathematical Modeling and Optimal Control of the Process of Hydrogen Adsorption Production

The paper considers the structure of the mathematical model for 6-bed plant for hydrogen production. The adapting optimal control system for technological process is proposed. The results of numerical imitating calculations of dynamic operating modes of the system are given.

Моделювання металевих розплавів на рівні міжатомної взаємодії

The purpose of the work is to create a complex of basic models for predicting the primary physicochemical and thermophysical properties of metal melts for the targeted formation of a high-quality metal product and increasing its competitiveness. The basis for modeling is the original concept of directional chemical bonding, the core of which is the consideration of metal melts as chemically unified systems, rather than a mechanical mixture of constituent elements, and taking into account the contribution of all components, even in small concentrations. The work uses an important information component, which is a database on the properties of metallurgical melts, which is continuously updated with modern data and contains the results of own and industrial experimental research and literature search (articles, patents, inventions, scientific developments, monographs). The importance of databases is indisputable and requires them to be brought to the inter-branch and inter-university level with open access, as a separate instance for promoting the development of the scientific level and the capabilities of scientists. Adequate mathematical models were developed based on integral parameters of interatomic interaction, and additional consideration of micro-heterogeneity parameters in their structural formation ensured high accuracy of operational forecast (R2≥0.9). A comparative analysis of the obtained melting results with the corresponding calculations based on the JMatPro software complex confirmed the effectiveness of using the interatomic interaction parameters as model ones. The results of the research are recommended for use in industrial conditions for the purpose of targeted formation of the composition and properties of smelting products, as well as reducing energy costs and reducing defects due to the adoption of operational management technological decisions with the help of the integration of the developed models in the automated control systems of technological processes of steelmaking.

ДОСЛІДЖЕННЯ ЗАЛЕЖНОСТІ НАПРУЖЕНЬ ЗСУВУ ПОЛІЕТИЛЕНУ ВІД ТЕМПЕРАТУРИ І ШВИДКОСТІ ЗСУВУ

Polyethylene is increasingly used in various industries such as light, medical and others as a variety of packaging and structural materials. Rheological properties of polyethylene affect products quality. Therefore, knowledge of these properties affects the calculation methods of equipment that produces materials from polyethylene, as well as the control system of technological processes of such industries.When designing equipment for processing polyethylene, namely the forming channels of extruders, flat slotted heads, the question of accurate determination of its rheological properties depending on the temperature and shear rate arises. Depending on the specified rheological properties the geometrical sizes of the specified channels change. These rheological properties are usually determined on the basis of experiments conducted at certain shear rates and temperatures. When designing, there is a need to calculate the geometric dimensions of the forming channels at shear rates and temperatures other than experimental. Therefore, there is a problem of developing a method of calculating these dimensions on the basis of experimental data obtained at other shear rates and temperatures. On the basis of the conducted research, the equation of the dependence of the shear stress of polyethylene on its shear rate and temperature was obtained. In the equation, the shear stress is directly proportional to the conditional viscosity and the shear rate gradient in power, which is the flow index. It is shown that the conditional viscosity of polyethylene is well described by the Arrhenius equation, and the flow index has a quadratic dependence on temperature. The obtained generalized equation of shear stress of polyethylene from its shear rate and temperature will allow to more accurately calculate the geometric dimensions of the forming channels of extruders, slotted heads, as well as to improve control systems for these devices.