Process Automation Systems Research Articles

Automation of strip-layout design for sheet metal work on progressive die

Abstract Strip-layout design is an important step in the planning stage of sheet metal work on progressive die. It is an experience-driven activity and the quality of strip-layout is highly dependent on the knowledge and skill of die designers. This paper presents an expert system for automation of strip-layout design process. The proposed system is developed using the production rule-based expert system approach of Artificial Intelligence (AI). It comprises six modules to impart expert advices to the user for identifying sheet metal operations, sequencing of operations, selection of proper piloting scheme, number of stations, staging of operations on progressive die and selection of proper dimensions of stock strip. Finally, the system models the strip-layout automatically in the drawing editor of AutoCAD using the output data files of other modules. Usefulness of the system is demonstrated through an example of an industrial component. The system is flexible and has low cost of implementation.

System architecture for process automation: Review and trends

New developments in information technologies are radically transforming process automation. Their impact and benefit derive both from these technologies individually and from their convergence in new system architecture concepts. This paper reviews how process automation system architectures have evolved and discusses future trends. We draw an analogy between the synergistic new technologies being developed today and the technology landscape of the early 1970s—characterized by the near-simultaneous appearance of microprocessors, communication networks, CRT displays—that resulted in the first DCS systems (in particular, the Honeywell TDC2000). Emerging technologies highlighted include wireless, embedded devices, service-oriented architecture, and application infrastructures.

プロセスオートメーションへのシーケンサ応用最新技術

プロセスオートメーションへのシーケンサ応用最新技術

SYSTEM ARCHITECTURE FOR PROCESS AUTOMATION: REVIEW AND TRENDS

New developments in information technologies are radically transforming process automation. Their impact and benefit derive both from these technologies individually and from their convergence in new system architecture concepts. This paper reviews how process automation system architectures have evolved and discusses future trends. We draw an analogy between the synergistic new technologies being developed today and the technology landscape of the early 1970s–-characterized by the near-simultaneous appearance of microprocessors, communication networks, CRT displays–-that resulted in the first DCS system (the Honeywell TDC2000). Emerging technologies highlighted include wireless, embedded devices, service-oriented architecture, and application infrastructures.

Security of distributed control systems: the concern increases

Process automation systems are key to the organizations behind the UK's critical national infrastructure (CNI) as they both monitor and control critical processes involved with the production and transportation of gas, electricity and water. As these systems become more 'open' - using Ethernet, TCP/IP and Web technologies - they become vulnerable to the same threats that exist for normal IT systems.

Machinery health management: a new role for process automation systems

The digital architecture of distributed control systems allows them to reach out and extend their functionality into new domains. Recent developments have seen asset management and safety systems integrated into their structures, and now they can not only monitor the 'health' of all rotating equipment in the plant, but produce summary reports with concise instructions of what to do to maintain operations at peak levels.

My view: One's radical, three's a trend

With two further process automation system vendors introducing integrated safety solutions, last year's radical development is fast becoming this year's established trend. But that doesn't stop some observers having serious reservations.

FDT/DTM technology forum

FDT/DTM software communicates with field instrumentation in a process automation system, and displays the set-up parameters on an engineering console in the control room. It is intended to replace the need for handheld communicators and laptop computers with standardised configuration software -and the need for instrument engineers to go out to the site of the instrument and connect their equipment directly with it. The FDT (field device tool) frame application, as it is called, runs on the central computer and the various instrument manufacturers contribute DTM (device type manager) software modules that are the configuration tools for their products. FDT/DTM was designed for use on systems with Profibus communications, but in theory it could be adapted to any fieldbus.

Simulation of RFieldbus networks

Driven by the demand on more flexibility in manufacturing and process automation systems. investigations are made in the field of wireless communication. In the R-FlELDBUS project a new wireless physical layer type was added to an existing fieldbus system. The resulting R-FIELDBUS systems allow adaptive architectures with mixed wired and wireless segments. To be able to analyse the functional and time behaviour of different configurations, a simulation model of the fieldbus system was also extended by the wireless behaviour.This paper describes the used simulation method. the models of the communication protocol as well as the new added wireless medium type as well as providing some first simulation results.

RFieldbus a survey

More flexible systems in manufacturing and process automation systems require wireless extensions to existing automation networks. The European RFieldbus project was launched to develop a wireless solution for plant floor automation. This paper describes a solution which combines real-time communication (based on PROFIBUS-DP) with mobility (based on radio transmission) and multimedia transmission (based on IP tunnelling via PROFIBUS-DP). The requirements on such a system are listed. The industrial environmental conditions, concerning the radio propagation, are explained and the relevant radio technologies are assessed. The system architecture as well as the device architecture of RFieldbus are presented. The RFieldbus System has been successfully tested in two pilot applications for factory and process automation.

Complex automation and control systems in heavy process industries: An evaluation study

Heavy process industries such as iron and steel plants, cement plants and paper mills have made a considerable investment in Turkey during last decade and a half for capacity improvement and modernization. Process automation systems have held an indispensable part in these investments. The strategic value of automation systems lies in its ability to improve product quality while saving energy and raw material. In this paper the application experience gained over a dozen large and medium size automation projects are summarized and various qualitative and quantitative results are given. Among these results, return on investment (ROI) obtained from few plants occupies prominent place. ROIs found were notably short compared to the economical life cycle to justify the use of automation systems.

Simplified time series representations for efficient analysis of industrial process data

The data storage capacities of modern process automation systems have grown rapidly. Nowadays, the systems are able to frequently carry out even hundreds of measurements in parallel and store them in databases. However, these data are still rarely used in the analysis of processes. In this article, preparation of the raw data for further analysis is considered using feature extraction from signals by piecewise linear modeling. Prior to modeling, a preprocessing phase that removes some artifacts from the data is suggested. Because optimal models are computationally infeasible, fast heuristic algorithms must be utilized. Outlines for the optimal and some fast heuristic algorithms with modifications required by the preprocessing are given. In order to illustrate utilization of the features, a process diagnostics framework is presented. Among a large number of signals, the procedure finds the ones that best explain the observed short-term fluctuations in one signal. In the experiments, the piecewise linear modeling algorithms are compared using a massive data set from an operational paper machine. The use of piecewise linear representations in the analysis of changes in one real process measurement signal is demonstrated.

Online Calculation and Prediction of the Strip Temperature in a Hot Strip Finishing Mill

The paper deals with a physical model for the calculation of the strip temperature in a hot rolling mill. Beside the heat transfer from the strip to the environment in the different mill sections a sub‐model for the material properties of steel including phase transitions is introduced. For the application in a process automation system an online adaptation of the model to the current state of the mill is indispensable. The adaptation is explained in detail.

Selecting human machine interface package in integrating a process automation system

In this paper we propose a framework for evaluating and selecting human machine interface (HMI) packages in integrating a process automation system. HMIs are among main subsystems of many integrated process automation systems. The main objective of this paper is to propose a selection process so that the integrated system could better satisfy strategic goals of the system users. In this paper we assume that strategic goals are expressed in terms of concepts like production flexibility, production reliability, product quality, operation cost, production time and the like.

Ein agentenbasierter Ansatz für die Ferndiagnose und-überwachung von Automatisierungssystemen

Information retrieval and monitoring in a distributed environment are suitable application areas for mobile agent technology. We describe an agent-based software system called RSE (Remote Supervising Environment) that can be used for remote diagnoses, supervision and control of process automation systems. RSE consists of components, frameworks and tools for development, installation and configuration of diagnosis and supervising agents via the Internet. The system is general enough to be applicable in other application domains with similar requirements.

Development of a novel ultrasound monitoring system for container filling operations

Food and drink production represents the largest manufacturing sector in the UK economy and are among the largest UK exporters (£ 8.2 billion in 1995). The industry makes essential contributions to UK wealth creation, to the quality of life within the UK and is seen to add value at each of the major stages of the supply train. Around 45,000 companies are involved in food processing and production in the UK, and 90% of these are classed as small to medium enterprises (SMEs) with less than 250 employees. Most of the SMEs possess little, if any research facilities or research expertise. Food processing represents a field of rapid development and implementation of new approaches in process technology, in particular, automation systems, quality procedures, efficiency improvements and sensor systems for on-line process monitoring and control. The current research programme has been set up to develop an ultrasound monitoring system for container filling. For fluid level measurements, most of the previous research has focused on developing ultrasound monitoring techniques with sensors positioned at the base of the container for ease of operation. The objective of the research described herein was to explore various approaches to ultrasound monitoring to assist determination of the potential benefits of mounting the sensors on the side and top of containers. Three sensing techniques have been identified and explored, and two methods of signal processing have been assessed to determine the optimum approach. The central result of this work was the discovery and utilisation of the non-contact air transmission approach to ultrasound sensing. Ultrasound monitoring from the side or top of containers requires a contact approach and therefore is seen as impractical for a high-speed food processing situation.

Development of data-processing system for automation of production planning and management process

Development of data-processing system for automation of production planning and management process

Hardware and Software Prototype for Supervision, Monitoring and Control Structure

In this paper an hierarchical and modular structure of supervision to control industrial process automation systems is presented. Implementation of such control structure relies on efficient communication tools. This work proposes an experimental prototype including several different devices and several fieldbus standards in order to support different level of communication and decision in the supervision structure.

Methodological problems in the use of information technologies in physical education

The paper considers methodological problems in the use of computer technologies in physical education by applying diagnostic and consulting systems, educational and educational-and-training process automation systems, and control and self-control programmes for athletes and others.

Applications of radial basis network technology to process control

Modern industrial process automation systems are organized as hierarchical systems, with at least three levels: field, direct control, and supervisory level. The paper presents applications of radial basis function (RBF) networks in each one of these levels. The first example illustrates the application of these networks to improve the performance of a control valve. The second example demonstrates the potential of an RBF network to deal with nonlinear processes as direct controller. The third example, illustrates the use of a supervisory system to tune proportional integral controllers, implemented in a distributed environment. These examples do not only present some applications of RBF technologies to process control, but also demonstrate, through practical examples, that this technology can be implemented in existing control systems.