Industrial Automation Control Systems Research Articles

A compensation approach for magnetic encoder error based on improved deep belief network algorithm

Magnetic encoders are an important part of industrial automation control systems and are widely used in industrial production. In this paper, a magnetic encoder is designed for angle detection during robot arm motion, but the accuracy is not high in practical applications. Through experiments, it is found that the main error compensation methods at present cannot effectively improve the accuracy of this encoder. Therefore, a hybrid prediction model based on decomposition strategy and deep learning prediction method is proposed in this paper. The hybrid prediction model structure is divided into two main parts: feature engineering based on the variational modal decomposition (VMD) method and a deep belief network prediction model based on particle swarm optimization. Through theoretical analysis, this paper introduces temperature into the prediction feature sequence, and effectively reduces the interference of errors on the prediction results through feature engineering. Experiments prove that the proposed model has excellent compensation effect, improving the accuracy from 0.22° to 0.0025°. The RMSE, Max_error and accuracy (σ) of the proposed model are optimal when compared with the mainstream error compensation methods, such as long short-term memory networks (LSTM), support vector machines (SVM) and deep belief networks (DBN). This proves that the proposed hybrid prediction model has a great improvement in the compensation effect of this magnetic encoder. Our work provides a promising approach that can provide unparalleled value in improving the accuracy of magnetic encoders.

Organization of an engineering center for industrial import substitution

Objectives. Following the imposition of sanctions against the Russian Federation, which included a ban on thesupply of foreign electronic equipment—including automation systems—to Russian enterprises, the continuingdevelopment of science and technology in Russia became a question of ensuring technological sovereignty accordingto the principle of import substitution. According to plans developed by the Ministry of Industry and Trade of theRussian Federation, the policy of import substitution, including automation systems, will ensure the replacement ofimported equipment with domestic counterparts.Methods. Approaches underlying the joint project of MIREA ‒ Russian Technological University and EnvironmentalIndustrial Policy Center to solve the problems of import substitution are described. Various substitution strategiesavailable in the world experience, as well as objective and subjective obstacles to their implementation in Russia,including the insufficiency of domestic regulatory legal acts and previously formed attachments to importedtechnologies and regulatory frameworks, are considered. Distinctive features of contemporary external relations areadduced to the necessity and urgency of developing technological sovereignty. The main functional requirementsfor a software and hardware platform for developing modern automated control systems (ACS) for mechanicalengineering applications, as well as the required capabilities of an engineering center for solving applied problemsof overcoming import dependence, are described. The components of the production of capital goods (engineering)and its role in the product life cycle are shown.Results. The selection of a pilot engineering object comprising a sectional glass-forming machine, along with asoftware-hardware complex including elements of industrial electronics and ACS, is justified. The main functionalelements of the ACS and their interrelations are shown.Conclusions. The results confirm the necessity of achieving complete import substitution for the creation of digitalproducts. Prospects for cooperation with interested organizations are shown.

Enhanced Modbus/TCP Security Protocol: Authentication and Authorization Functions Supported.

The Zero Trust concept is being adopted in information technology (IT) deployments, while human users remain to be the main risk for operational technology (OT) deployments. This article proposes to enhance the new Modbus/TCP Security protocol with authentication and authorization functions that guarantee security against intentional unauthorized access. It aims to comply with the principle of never trusting the person who is accessing the network before carrying out a security check. Two functions are tested and used in order to build an access control method that is based on a username and a password for human users with knowledge of industrial automation control systems (IACS), using simple means, low motivation, and few resources. A man-in-the-middle (MITM) component was added in order to intermediate the client and the server communication and to validate these functions. The proposed scenario was implemented using the Node-RED programming platform. The tests implementing the functions and the access control method through the Node-RED software have proven their potential and their applicability.

Analysis of Anti-jamming Technology of Industrial Automation Control System

Analysis of Anti-jamming Technology of Industrial Automation Control System

The Use of ZigBee Wireless Communication Technology in Industrial Automation Control

With the accelerating process of world industrialization, countries pay more attention to industrial modernization. In order to solve the problems of traditional control technology and system with low accuracy, high energy consumption, and high delay in industrial automation control and the difficulty in adapting to the new industrial production process, the new industrial automation control system is discussed and studied. The industrial automation control is studied, and a new monitoring system is designed for automation control by using ZigBee wireless communication technology. The design of the system data communication scheme is completed by the in-depth study and summary of ZigBee wireless communication technology. The hardware structure and software structure of ZigBee wireless communication module are designed, and the wireless monitoring system using ZigBee is established. Taking the production workshop of a pharmaceutical factory as the monitoring object, the working stability and data transmission efficiency of the model are tested. The experiment shows that the ZigBee wireless transmission model has lower temperature and better stability than the wired transmission system in the working process. Compared with the traditional wired control system, the temperature of ZigBee wireless control system is lower when it works. The difference between the highest temperature and the lowest temperature is 0.1°C. In the overall work flow, the system temperature is lower than that of the wired control. ZigBee wireless control has good stability. Subsequently, the method of manually setting obstacles is used to test the effectiveness of data transmission. The experiment found that in the absence of barrier, the maximum effective transmission distance was 40 meters, and the packet loss rate was very low, which could ensure the timeliness of data. Therefore, this system can be applied to industrial automation control. The research results can provide some reference for the design of new control systems in other industrial control fields. The improved system can also be applied to other industries. ZigBee is a short-range technology for wireless sensor networks, and it is a two-way communication technology with low power consumption, low data rate, and low cost. It can be applied to automatic control and remote control. This provides a platform for wireless networking and control of small and cheap devices. ZigBee will not compete with connection technologies such as Wi-Fi. Meanwhile, it will greatly stimulate the progress of the industrial market.

Security Assessment of Agriculture IoT (AIoT) Applications

Cybersecurity is an important field in our digital world. It protects computer systems and communication networks against theft or sabotage of information to guarantee trouble-free operation in a trustworthy working environment. This article gives an overview of a cybersecurity assessment process and an appropriate Cybersecurity Management (CSM) implementation for future digital agriculture applications. The cybersecurity assessment follows the IEC 62443 cybersecurity standard for Industrial Automation Control Systems (IACS), adapted to Agriculture Automation Control Systems (AACS). However, the research results showed application differences; thus, an expansion of the standard is necessary to fill the existing open security gaps in agriculture. Agriculture differs from industrial control systems because of the outdoor located field area, which requires other forms of security. An appropriate cybersecurity standard for the agriculture domain is not currently available. However, such a standard will be necessary to define generally applicable procedures to protect agricultural assets against cyberattacks. The cybersecurity standards and regulations existing today (2021) are not sufficient for securing the agriculture domain against new and domain-specific cyberattacks. This article describes some of the cyber vulnerabilities identified and provides initial recommendations for addressing them.

Application of Artificial Intelligence in Industrial Automation Control System

Automatic control system is an important part of industrial production and manufacturing. With the rapid development of computer technology, a new generation of intelligent technology represented by artificial intelligence has been applied to industrial automation system. This paper introduces the development of the current industrial automation control system in detail, and then describes the relevant theory of artificial intelligence technology. Finally, it describes the application of artificial intelligence technology in industrial automatic control system and its future development trend. This paper aims to provide a reference for the research of industrial automation control system.

The Design and Research of Electric Automation Control System Based on PLC

In recent years, programmable logic controller (PLC), a new technology for electrical control, has developed rapidly and has been widely used in various production processes and automatic control of production machinery. It has the characteristics of convenient operation, simple and easy to understand, and high reliability, has become one of the most popular, most important, and most applied industrial control devices. It brings new vitality to power automation control technology, improves the efficiency of power work, and becomes one of the important pillars in the field of modern industrial automation control systems. This article aims to study the design of PLC-based electrical automation control system. Based on the analysis of the classification of PLC, the basic structure of PLC and the working principle of PLC, the PLC power automation control system is designed, and the system is simulated and tested. The test results show that the operation effect of the traditional electrical control system can not meet all the automatic working conditions, and the overall performance is poor, while the system in this paper performs well, indicating that the design of this paper is effective.

Multi-source fidelity sparse representation via convex optimization for gearbox compound fault diagnosis

Industrial automatic control systems have high requirements for manufacturing accuracy, which are often adversely affected by the compound fault of rotating machinery such as gearboxes. Compound fault diagnosis has many challenges because of its many types of faults, complex oscillation characteristics, and mutual interference between various vibration sources. Therefore, it is urgently required for the development of a method which can accurately detect gearbox complex multi-source faults. To address the compound fault problem, a novel multi-source fidelity sparse representation method is proposed, which can accurately realize multiple fault diagnosis of the gearbox without the prior knowledge regarding the number of fault sources. Moreover, to ensure the accuracy of signal reconstruction, the gearbox compound failure mechanism is analyzed, from which the sparse dictionaries are established. The multi-source penalty function is constructed to improve the fidelity of the signal and the convexity condition of the objective function is further discussed for the global minimum. Simulations and engineering signals are used to verify the versatility of the proposed method.

Major accidents triggered by malicious manipulations of the control system in process facilities

Security threats on the industrial automated control systems (IACSs) are becoming a growing concern for all the industrial facilities, and in particular for those where large quantities of hazardous substances are stored or handled (e.g. Seveso sites in Europe). Remote (cyber) or physical malicious manipulations of the automated control system of Seveso sites may have consequences comparable to those of conventional major accidents due to internal causes (e.g. loss of containment of hazardous materials, fires, explosions). While consolidated approaches exist to manage and control the cybersecurity of IT and OT systems of a facility, there is an evident lack of procedures to assess the actual link between malicious manipulations of the safety and control systems and the major accidents that can be triggered. In the present study, a specific methodology (PHAROS) was developed to address the identification of major accident scenarios achievable by malicious manipulation of physical components of the plant through the control and safety instrumented systems. The methodology, which exploits a reverse-HazOp concept, also analyses the role of the existing safety barriers in contrasting the chain of events triggered by the malicious manipulation, and may support the definition of design specifications and/or possible IT protection requirements for such barriers. The methodology was applied to a demonstrative case study to understand the features of the results obtained and their potential towards the improvement of the security of the process facility.

PID auto-tuning for simultaneously fulfilling the requirements of relative stability and steady-state error

Proportional-integral-derivative (PID) control is commonly used in industrial automatic control systems. However, it is not straightforward to determine control gains in a PID controller for satisfactory closed-loop performance. Many research works have been devoted to the auto-tuning of PID control gains. In contrast to previous studies, this paper develops an auto-tuning rule for PID controllers to simultaneously satisfy specifications of both steady-state error and relative stability, in which stability is specified in terms of phase margin. To illustrate the proposed auto-tuning rule, a focus servo of an optical disk drive is used, in which a voice coil motor drives a lens to focus a laser beam on a data layer of an optical disk. Experimental results show the effectiveness of the proposed PID auto-tuning process.

Complex of Models for Network Security Assessment of Industrial Automated Control Systems

The modern enterprises apply network technologies to their automated industrial control systems. Along with advantages of the above approach the risk of network attacks on automated control systems increases significantly. Hence there is an urgent need to develop automated monitoring means being capable of unauthorized access detection and of an adequate response to it. The enterprise security system should take into account components interaction and involve the ability of self-renewal throughout the entire life cycle.
 The partial models of functioning of automated control systems of an enterprise under information threats are offered taking into account parameters of states of the enterprise at its different levels, realization of network threats, counteraction measures, etc. For each model it is possible to form the state space of a part of an enterprise and on the basis of the series of tests to define state transition parameters thus enabling model representation in the form of a marked graph. The sequences of states possess the properties of semi-Markov processes so semi-Markov apparatus is applicable. Probabilities of state transitions could be computed as a result of numerical solution of the corresponding system of integral equations by Lagrange-Stieltjes technique.
 Application of Semi-Markov apparatus for the detection of non-authorized activities during data transfer under network scanning attack proved the validity of the above methods. In addition its application results in creation of a set of security assurance measures to be undertaken. Having obtained state transition probabilities the development of integral security indicator becomes possible thus contributing to the enterprise performance enhancement.

Research on redundant control mode of coordinated controller based on dual control cores

Dual CPU redundant operation of PLC is of great significance to the reliability of industrial automation control system. In view of the problems existing in the traditional dual CPU PLC redundancy control mode based on hardware strategy, this paper proposes a dual CPU redundancy control idea based on software strategy, and describes in detail the specific scheme of Dual CPU redundancy software design using A-B ControlLogix series PLC.

Sensor fault detection and diagnosis for a water source heat pump air-conditioning system based on PCA and preprocessed by combined clustering

Abstracts Sensors play essential roles in industrial automatic control systems. The faulty or inaccurate sensors may cause uncomfortable thermal environments, shortened component lifetime and energy consumption loss. Considering the condition-adaptive issue of principal component analysis (PCA) models in fault diagnosis, a data-driven optimized statistical model applied for sensor fault detection and diagnosis (FDD) is proposed in the paper: the subtraction clustering and k-means clustering are combined to identify and classify modeling measurements of unsteady operating conditions. Sensor measurements from a real water source heat pump air-conditioning system is tested and the result shows that the clustering-based statistical model can enhance the ability of dealing with data of multiple operation conditions compared with the traditional PCA model; Different statistical indexes show sensitivity difference in detecting faults in the case of same sensors and same faults.

FPGA-Based Reconfigurable Data Acquisition System for Industrial Sensors

A sensor data acquisition system is an essential part of an industrial automation control system. However, the variety of sensor producer causes the difficulty of protocol's unity. The mechanism which requires the acquisition boards to be powered off when the number or types or manufacturer of sensors is changed is unreasonable. Meanwhile, traditional sensor reading cycle depends more on the embedded program skills. In this paper, to solve these problems, a new method is proposed to design a reconfigurable data acquisition system for industrial sensors, in which field-programmable gate array (FPGA) is adopted as the core controller. We use both dynamic system reconfiguration and static system reconfiguration in our design. Performance of the proposed system is verified in practical application of an automated production system of poly carboxylic acid water reducing agent.

Software-defined networking in cyber-physical systems: A survey

Cyber-Physical Systems (CPSs) rely on networks that interconnect sensors and actuators to perform measurement, supervision and protection functions in different domains, such as transportation and industrial automation control systems. These networks must be able to support mobile wireless CPSs that are demanding new requirements related to flexibility and heterogeneity without compromising the Quality of Service (QoS). However, it is hard to determine, for example, the optimal resource allocation or the most reliable paths without global network information. In this way, the Software-Defined Networking paradigm is being considered as key to overcome such emerging needs. In particular, an SDN controller is able to establish paths between sensors and actuators according to bandwidth, latency, redundancy, and safety considerations. Thus, the goal of this paper is to review the state of the art of SDN approaches applied to mission-critical applications by identifying trends, challenges and opportunities for the potential development of software-defined cyber-physical networks.

Industrial Automation and Process Control System Using Can Bus

Industrial Automation and Process Control System Using Can Bus

PSO-based Optimal PID Controller for Twin Rotor MIMO System

Optimum design methods based on soft computing have proved their excellence in industrial automatic control systems. In this paper, a proposed system is presented to treat the tuning of proportional, integral and derivative (PID) controller parameters to control the behavior of the Twin Rotor Multi-Input-Multi-Output (MIMO) System (TRMS). The system can be decoupled into two paths the main and the tail. The use of Particle Swarm Optimization (PSO) algorithm for tuning the controller parameters aims to get a stable control system. The simulation results reveal significant improvements in the step response characteristic such as reducing the steady state error, rise time, settling time and the number of overshoots in position control of the TRMS. Thus, the PSO based PID controller in this system proves better performance compared to the traditional existing PID one.

Fractional Order Models of Industrial Pneumatic Controllers

This paper addresses a new approach for modeling of versatile controllers in industrial automation and process control systems such as pneumatic controllers. Some fractional order dynamical models are developed for pressure and pneumatic systems with bellows-nozzle-flapper configuration. In the light of fractional calculus, a fractional order derivative-derivative (FrDD) controller and integral-derivative (FrID) are remodeled. Numerical simulations illustrate the application of the obtained theoretical results in simple examples.

Design and application of a real-time industrial Ethernet protocol under Linux using RTAI

Nowadays, Ethernet networks have been extended down into the field of automation control from the upper planning and scheduling level, which caused the generation of a new form of communication using real-time industrial Ethernet fieldbus. This paper presents a feasible Ethernet-based real-time feildbus scenario for industrial automation control systems. It endeavours to gain high performance in general synchronisation real-time control systems with common hardware and software resources. For this purpose, a master-slave pattern is adopted in constructing the communication protocol. The slave nodes are developed based on universal FPGA and ARM chips, and the first slave node is in charge of precise cyclic timing and synchronisation among all slave nodes with time resolution of 20 nanoseconds. The master protocol stack is developed under Linux using Real Time Application Interface (RTAI), which not only provides application interface for user programs but also is responsible for exchanging process data with slave nodes in real time. A case study of merging this fieldbus into EMC2 to control a three-axis milling machine is also discussed and implemented. The experiment results show that this industrial Ethernet fieldbus platform completely meets the demand of open industrial automation control application.