Process Control System Research Articles

WEB APPLICATION «ELECTRONIC READER’S DIARY» BY AGILE TECHNOLOGY

The article relate to the development of an reader’s electronic diary by AGILE technology. It is needed for reader competency of primary school students. The current students were born in a new information environment. They master information and software faster than adults (for example, gadgets, tablet PC, mobile devices, etc.) The disadvantage is this information environment is reluctance to read. One of the stimulation tools to reading is electronic reader’s diary technology applied in the educational process. The regular reader’s diary is a report about books read. The aim of the reader’s diary is skills reflection and development of the critical analysis skills formation. The project software is designed for primary school students (age 7-10 years). Independent reading skills form at primary school age. It improves cognitive interests of school students, enhances knowledge, and is the formation of a harmoniously developed personality. The electronic reader’s diary stimulates the knowledge interests and consolidates the reading material by AGILE technology and additional interactivity with the school students. The research relates to the architecture of the developed solution, in particular, the issue of the «automated process control system of education system resources» integration. Also, the article contains the map of the developed graphical user interface screen and describing main electronic reader’s diary screens. This research will be intended to boost cognitive and creative activity of students.

An RNA evolutionary algorithm based on gradient descent for function optimization

Abstract The optimization of numerical functions with multiple independent variables was a significant challenge with numerous practical applications in process control systems, data fitting, and engineering designs. Although RNA genetic algorithms offer clear benefits in function optimization, including rapid convergence, they have low accuracy and can easily become trapped in local optima. To address these issues, a new heuristic algorithm was proposed, a gradient descent-based RNA genetic algorithm. Specifically, adaptive moment estimation (Adam) was employed as a mutation operator to improve the local development ability of the algorithm. Additionally, two new operators inspired by the inner-loop structure of RNA molecules were introduced: an inner-loop crossover operator and an inner-loop mutation operator. These operators enhance the global exploration ability of the algorithm in the early stages of evolution and enable it to escape from local optima. The algorithm consists of two stages: a pre-evolutionary stage that employs RNA genetic algorithms to identify individuals in the vicinity of the optimal region and a post-evolutionary stage that applies a adaptive gradient descent mutation to further enhance the solution’s quality. When compared with the current advanced algorithms for solving function optimization problems, Adam RNA Genetic Algorithm (RNA-GA) produced better optimal solutions. In comparison with RNA-GA and Genetic Algorithm (GA) across 17 benchmark functions, Adam RNA-GA ranked first with the best result of an average rank of 1.58 according to the Friedman test. In the set of 29 functions of the CEC2017 suite, compared with heuristic algorithms such as African Vulture Optimization Algorithm, Dung Beetle Optimization, Whale Optimization Algorithm, and Grey Wolf Optimizer, Adam RNA-GA ranked first with the best result of an average rank of 1.724 according to the Friedman test. Our algorithm not only achieved significant improvements over RNA-GA but also performed excellently among various current advanced algorithms for solving function optimization problems, achieving high precision in function optimization.

Parameter estimation methods for time‐invariant continuous‐time systems from dynamical discrete output responses based on the Laplace transforms

SummaryIn industrial process control systems, parameter estimation is crucial for controller design and model analysis. This article examines the issue of identifying parameters in continuous‐time models. This article presents a stochastic gradient estimation algorithm and a recursive least squares estimation algorithm for identifying the parameters of continuous systems. It derives the parameter identification model of linear continuous‐time systems based on the Laplace transforms of the input and output of the systems. To prove that the techniques given here work, we have included a simulated example.

Hybrid Model Based Autonomous System for Controlling Double Side Grinding Process

Manufacturing uncertainty is rising due to diverse customer demands and new technologies. These challenges are propelling us into the Industry 4.U (Industrial Revolution 4.0 Upgrade) and Industry 5.0 era, focusing on human-centric manufacturing and value creation, necessitating digital transformation. This transformation relies on the core technologies of the 4th Industrial Revolution (Data Analytics, Connectivity, Autonomy, and Collaboration) to perform value-creating processes autonomously and reliably. To adapt, Industry 5.0-oriented Smart Manufacturing architecture was designed. In this system, process planners collaborate with generative AI to generate optimal process plans based on new specifications, pursuing human-centered manufacturing. The manufacturing system is reconfigured with modular technology, and each process is autonomously controlled as a 4.U/5.0-oriented production system. This paper focuses on developing an autonomous process control system for Industry 4.U/5.0-oriented Smart Manufacturing. The study aims to stabilize the quality of the brake disc grinding process in an automotive parts company. The developed control system has been tested on a car’s brake disc manufacturing line, with experimental results showing the reliability of the DT and AI in controlling the grinding process.

RESEARCH AND CONSTRUCTION OF A MATHEMATICAL MODEL USING DISCRETE PROGRAMMING METHODS FOR THE MIXING AND MELTING OF COPPER CONCENTRATES

This paper describes the construction of an optimal schedule for a metallurgical workshop using discrete programming, and in particular, the method of branches and boundaries. In this regard, a heuristic approach to solving this problem is proposed, which includes: building an initial graph that satisfies the constraints of the optimization problem, as well as sequential search optimization of the initial graph according to a given criterion. To test the effectiveness of using the task of forming a melting schedule as part of the operational control subsystem in the converter department, experimental studies were conducted. Considering that the creation of the automated process control system of the copper plant provides for the introduction of systems using modern software and hardware controls, cargo flow control, and an automated conversion process control system, the efficiency of using optimal melting schedules will significantly increase.

Фосфорды тазалау процесін тиімді бақылау үшін интеллектуалды алгоритмдердің жасалуы және зерттелуі

In a market economy, there is a critical need to introduce optimal control systems for technological processes in industries like non-ferrous and ferrous metallurgy, the chemical industry, and petrochemicals. These systems can help use mineral resources more efficiently, save energy, reduce environmental impact, and increase production efficiency. The active development and implementation of such optimal control systems began in the 1960s-1980s, but significant automated systems have not yet been widely adopted. This is due to the extreme complexity of the physical and chemical phenomena in modern industrial processes, which makes it difficult to create adequate mathematical models. Recently, there has been a trend toward using modern intelligent technologies that can leverage the knowledge, experience, and intuition of experts. The use of artificial intelligence methods in designing optimal control systems has significantly simplified their development, improved control models, and increased efficiency. Therefore, the urgent task is to develop and implement intelligent control models (algorithms) for various technological processes, including those in the phosphorus industry. The text proposes using new intelligent algorithms to control a complex technological process - the purification of phosphorus from arsenic and organics at the Novodzhambyl Phosphorus Plant (NDPP).

Mathematical modeling of heat exchange for efficient automated control systems

The article deals with the problem of mathematical modeling of heat transfer processes, taking into account a large number of factors affecting these processes and a variety of mathematical modeling methods. The article discusses the idea of developing a universal and flexible model that could quickly adapt to different initial modeling conditions and take into account various parameters for further use of the mathematical model in the synthesis of automatic control systems. The paper discusses the main aspects of mathematical modeling of heat transfer and the creation of a mathematical model in distributed heat exchanger parameters with the possibility of changing the properties and parameters of the equipment. The paper analyzes previous studies and identifies the problems of existing methods of mathematical modeling of heat transfer, such as lack of versatility, complexity, and insufficient accuracy. The paper goes on to review different approaches to mathematical modeling of heat transfer, such as models with a group of parameters, models in distributed parameters, and models based on artificial intelligence. The article provides an overview of model implementation methods and their advantages and disadvantages. Based on this analysis, the authors propose a new mathematical model of heat transfer in distributed parameters, which should be universal, easy to use, and accurate in accordance with the requirements of synthesizing automated control systems. The authors also outline the methodology for achieving this goal, which includes the implementation of the geometry of the heat exchanger, the implementation of conditions and mathematical modeling, as well as the study of the influence of parameters and the formation of transients. The general conclusion of the article is that the developed mathematical model of heat transfer can be used to synthesize automatic control systems for heat exchange processes in various industries.

Implementation of Siemens S7-1200 PID Control on Festo Labvolt 3531 Plant Level Controller with Topkapi SCADA Using Modbus Communication Protocol

Plant Festo LabVolt 3531 is a DCS, SCADA and process control system trainer based on the Allen Bradley Controllogix 5572 PLC and Factorytalk View SCADA. This research aims to provide another controller solution that can be used on the Festo Labvolt 3531 plant besides the Allen Bradley Controllogix 5572 PLC and FactoryTalk View SCADA. So that students have alternatives and variations of other technologies in learning. In this research, the Siemens S7-1200 PLC was used as a replacement for the Allen Bradley Controllogix 5572 PLC and Topkapi SCADA as a replacement for FactoryTalk View SCADA. As validation of the test, PID control was used to regulate the water level in both tubes at the Festo Labvolt 3531 plant. The test results for several specified height levels showed that the Siemens S7-1200 PLC with PID control integrated into Topkapi SCADA using the mobus communication protocol was successfully implemented , where the resulting control response has an average steady-state error of less than 2% and the delay between the interface and the device on the plant is 0s.

In‐mold rheology and automated process control for injection molding of recycled polypropylene

AbstractManufacturing plastic parts with secondary feedstocks has risen to the forefront of importance in recent years. However, the variation in molecular weight and rheology of secondary feedstock can lead to inconsistent part quality. This work evaluates the effectiveness of a novel closed‐loop adaptive process control system that adjusts nozzle pressure in response to in‐mold pressure data. Five different recycled polypropylene blends, with a broad distribution of flow properties, were evaluated to determine the effectiveness of the control system at reducing processing variation. The experimental results show that the process control strategy reduced the variation within the mold, as seen by in‐mold pressure curves and calculated in‐mold viscosity values. Additionally, the parameters that control the automated process adjustments were investigated, showing the importance of optimization. The analysis of the correlation between in‐mold rheology and mechanical properties showed a slight variation in the mechanical properties and parts weight with a coefficient of variation of under 5%. Overall, the results demonstrate the ability of pressure‐controlled molding and automated viscosity adjustment to reduce the variability when molding a secondary feedstock.Highlights Pressure‐controlled injection molding of recycled polypropylene. Automated closed‐loop adaptive process control methodology. Methodology resulted in a reduction in pressure variation during molding. Changes in mechanical properties and in‐mold viscosity were investigated. Results show the potential of pressure‐controlled molding at reducing variation.

Utilization of Programmable Logic Controller (PLC) with System Control Lights On Large Buildings

Enhancement need for energy electricity in buildings or large buildings​​ will increase waste energy and improve the expenditure of funds. For That need given solution How method saves electricity with cheap and efficient equipment.​ The PLC ( Programmable Logic Controller ) program is A tool operating electronics​ digitally for​ replace Suite a row of relays in a conventional process control system. To carry out its function then the PLC has sensor elements, controllers, and output devices so that capable do task control sequential, control sophisticated, and control supervision. Research results This shows that the application of PLC in buildings or big buildings​ will increase high efficiency​ by utilizing: a) elements of the system control light involving appropriate sensors, controllers (servers), and actuators; b) put sensor devices with appropriate; c) count wide room with lighting appropriate; and d) combine usage halogen lamp as replacement ray sun and TL lamps as lighting normal.

Flow-through moisture meter for measuring grain moisture as part of an automated grain moisture control system

The methods of increasing the accuracy and efficiency of the production process, as well as ensuring high quality of final products in the grain processing industry, are investigated. It is shown that to solve the problem of insufficient quality control of grain materials, an automated system for monitoring the properties and characteristics of bulk granular materials is necessary. The features of the construction of automatic and automated systems for monitoring the properties and characteristics of bulk granular materials are considered. Measurement methods and control devices of the main technological parameters used in the management of grain processing facilities are briefly described. It is proposed to include a flow moisture meter in the automated grain moisture control system. The physical properties of grain and grain materials, measurement conditions and instrumentation for grain moisture control are analyzed. The use of devices based on the dielkometric method in the subsystem of an automated process control system is discussed. The application of intelligent sensors of a measuring system with a complex multilevel hierarchy is described. The structure of the interconnection of measuring devices for intellectual support of humidification processes and quality control of the studied materials is given. A functional diagram and metrological characteristics of a prototype grain moisture monitoring device, a flow moisture meter, are presented. The metrological characteristics of this device meet the requirements of the grain processing industry and allow it to be used as part of a humidity control system

Signal Decomposition for Monitoring Systems of Processes

This article is devoted to the problem of signal decomposition into periodic and aperiodic components. According to the proposed approach, there is no need to evaluate the aperiodic component as a difference between the total signal of its periodic components. This research aims to create a general analytical approach that combines the Fourier and Maclaurin series methodologies into a single comprehensive series. As a result, analytical expressions for determining deposition coefficients were established for an aperiodic signal with a monoharmonic overlay. Recurrence relations were established to determine the coefficients of this series. These relations allow direct integrations of the obtained values of integrals to be avoided. The evaluated numerical values of the coefficients are also presented graphically and tabulated. It was proven that the values of these coefficients are universal numbers since they do not depend on the period/frequency of oscillations. The reliability of the proposed approach was confirmed by the fact that the evaluated coefficients are equal to the Fourier series coefficients in the case of a periodic signal. Also, for an aperiodic signal, these coefficients were reduced to the coefficients of the Maclaurin series. The usability of the proposed generalized analytical approach for signal decomposition is for control and monitoring systems of processes.

Including validation of process control systems’ engineering into the technical debt classification

The Technical Debt (TD) concept depicts a situation in which a technical compromise is selected despite a better solution available. The associated risks to TD may be critical if TD is overlooked or not fixed properly. For instance, the product might not be used safely (in the healthcare supplies industry) or be contaminated (in the food & beverage sector) due to a design fault not adequately addressed. This work extends the TD classification for process automation systems that need to undergo a validation process according to Good Automated Manufacturing Practice (GAMP), which is required for pharmaceutical production or food processing, for example. The approach analysed industrial engineering documents to identify such TD types and sub-types. Three selected TD use cases confirmed by industry experts are reported. The presented meta-analysis approach on engineering documents can be employed as a TD identification method for such process control systems. The TD classification for process automation was thereby enlarged for an especially critical type of machine that may harm the health of many humans.

Technology for Effective Control and Intellectualization of Multifunctional Automated Thermal Process Control Systems

Technology for Effective Control and Intellectualization of Multifunctional Automated Thermal Process Control Systems

Technology of Intellectualization of Automated Process Control Systems Based on a Software and Hardware Complex

Technology of Intellectualization of Automated Process Control Systems Based on a Software and Hardware Complex

Преимущества интеграции автоматизированных систем управления технологическим процессом угольных шахт с системами определения местоположения

Coal mining companies, especially those involved in underground operations, are currently at different stages on their way to digitalization and face a number of challenges, which are described in the article. One group of such problems is the difficulties concerned with the coal mine dispatching control. The paper shows how a properly selected approach, i.e. the integration of various automated process control systems with positioning systems, provides a solution to these problems and offers significant advantages both regarding the industrial safety and maximizing the economic effect. Examples of such integration are given for the conveyor transport control system, for the air and mine gas control systems as well as a CCTV systems with positioning systems within the Smart Mine® complex. An assessment of the current technical basis for the implementation of this approach is given, and the advantages of using a single platform for subsystems of the multi-functional safety system and production management systems are shown.

Preparation and properties of micro-arc oxidation ceramic coatings using machine vision technology

In this paper, a machine vision system is combined with non-immersion micro-arc oxidation (MAO) technology, using color as a visual feature, and automatically determining the MAO process through a self-developed color image segmentation program for HSV channel. The robotic arm accurately regulates the machining position and duration. Dense ceramic oxide coatings of similar quality to the artificially prepared coatings were successfully prepared on aluminum (Al) surface. The surface morphology and elemental composition of the samples were characterized using scanning electron microscopy (SEM), energy dispersive spectrometry (EDS) and X-ray diffraction (XRD). The performance of the coatings was tested through thickness tests, hardness tests, and roughness tests. The tribological properties were tested by friction experiments, and its corrosion resistance was tested by electrochemical corrosion tests. The results confirm the effectiveness of a machine vision system for MAO process control, which is capable of preparing high-quality coatings comparable to manual operations. This not only solves the need for precise film formation in different application scenarios, but also provides a more efficient, controllable and innovative solution for the MAO process.

Research on Multi-System Coupling Vibration of a Hot Tandem Mill

Vibration in hot tandem rolling mills has been a problem in the iron and steel industry mainly due to its unpredictability. In this work, vibration data of the second finishing mill (F2) stand of a hot tandem rolling mill are collected and analyzed, and a mathematical model based on the coupling of a non-uniform deformation process, mill structure and hydraulic control system is constructed. The influence of different inlet thickness fluctuation forms, structural parameters and control parameters on the vibration behavior is analyzed. It is concluded that the low-frequency thickness fluctuation with additional skewness can cause the resonance of each subsystem of the rolling mill. The deviation angle of the roll system influences the vibration harmonic output of the rolling mill under a single low-frequency thickness fluctuation excitation. The compensation parameter in the thickness control system affects the natural frequency of the vertical system.

Considerations about the evolution of steam formation in discontinuous evaporating crystallizers by utilizing a camera

Steam formation in discontinuous evaporating crystallizers experiences several transitions throughout the progress of a strike due to the applied processing methods. A microscope detects steam bubbles 0.3 m above the calandria at the wall of a typical batch evaporating crystallizer. The optical results of 15 strikes are analyzed and evaluated in the respective process control system data context. Excessive amounts of bubbles are only detected during the early stages of a strike, which agrees with the general assessment of the evaporation within the evaporating crystallizer regarding an upwards-moving steam formation front. Vapor contents close to PCS data estimations and literature reports are determined incidentally. The suitable utilization of cameras can offer more comprehensive information about the state of the process than is currently available.

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.