Production Process Control System Research Articles

Development of a Powder Analysis Procedure Based on Imaging Techniques for Examining Aggregation and Segregation Phenomena.

In this manuscript, a method that utilizes classical image techniques to assess particle aggregation and segregation, with the primary goal of validating particle size distribution determined by conventional methods, is presented. This approach can represent a supplementary tool in quality control systems for powder production processes in industries such as manufacturing and pharmaceuticals. The methodology involves the acquisition of high-resolution images, followed by their fractal and textural analysis. Fractal analysis plays a crucial role by quantitatively measuring the complexity and self-similarity of particle structures. This approach allows for the numerical evaluation of aggregation and segregation phenomena, providing valuable insights into the underlying mechanisms at play. Textural analysis contributes to the characterization of patterns and spatial correlations observed in particle images. The examination of textural features offers an additional understanding of particle arrangement and organization. Consequently, it aids in validating the accuracy of particle size distribution measurements. To this end, by incorporating fractal and structural analysis, a methodology that enhances the reliability and accuracy of particle size distribution validation is obtained. It enables the identification of irregularities, anomalies, and subtle variations in particle arrangements that might not be detected by traditional measurement techniques alone.

Analysis of experience in optimizing the operation of an automated production line for folding cardboard boxes

The object of research is an automated system for controlling the bending mechanisms of the folding-gluing line for cardboard packaging products. In the work, the ways of optimization and the development of an automated control system for the bending mechanisms of the folding and gluing line, which makes it possible to fold various structures and standard sizes of cardboard boxes using modern automation tools based on programmable logic controllers, were carried out in the work. A mathematical model has been proposed to describe operations on the folding-gluing line. Based on the model, a methodology has been developed for calculating the parameters of the automated control system for the box folding production line, depending on the technical parameters of the line and the parameters of the boxes to be bent. This will make it possible to choose optimal technological modes of the production process and obtain high quality parameters of cardboard packaging products. To verify the mathematical model of the production line, software has been developed in the Delphi development environment, which was applied with the developed automated production process control system based on a programmable logic controller (PLC) and an operator panel. This produced a number of results, in particular, controlling the speed of the hook bend in proportion to the speed of the line. And also provided an opportunity to increase line speed and, accordingly, production productivity. It has been possible to change the mutual location of system elements, which made it possible to reduce the distance between workpieces and increase the capacity of the line tape by 30 %. The obtained research results were implemented at the production enterprise of typographic products «Dinas» (Zaporizhzhia, Ukraine), which contributed to the improvement and optimization of production processes. Conducting further research will provide an opportunity to expand the proposed methodology for use on all types of folding and gluing lines.

Automated evaluation models and algorithms for optimizing exercise assessments in food production training complexes

The article is devoted to the development of models and algorithms of intelligent training complexes for training engineering specialists in the food industry. A method has been developed for comprehensive assessment of the quality of performing exercises on optimization problems in virtual environment. The method differs from the known ones in many parameters that determine the structure and specificity of these problems. It is formalized based on of fuzzy sets that describe incomplete knowledge when comparing the mathematical model of the problem created by the student with the reference one. The use of intelligent training complexes, in the software of which the presented method is implemented, will allow for ongoing monitoring and self-monitoring of students’ knowledge and skills when studying disciplines in the field of developing software for automated control systems for production processes. The use of intelligent training complexes ensures the collection and analysis of data on the dynamics in the formation of professional knowledge and skills among students in the development of mathematical software for automated control systems. Accordingly, the time for conducting control activities for the teacher is reduced, and the accuracy of the results of monitoring the formation of knowledge and skills among students is increased.

Improvement of the mathematical model for obtaining finely dispersed material to create an automated production process control system

Improvement of the mathematical model for obtaining finely dispersed material to create an automated production process control system

Механизмы принятия управленческих решений в области цифровизации производственных процессов промышленного предприятия

Introduction. The relevance of studying the industrial enterprise digitalization processes and developing a methodology for implementing production process control systems is due to the fact that digital technologies introduced into the manufacturing sector are important drivers for improving production management processes, improving labor productivity indicators, reducing the labor intensity of manufacturing products, reducing the cost of products and increasing quality. Theoretical analysis. The information systems and products most commonly used in modern practice of industrial enterprises in aviation industries are analyzed. Empirical analysis. The analysis of options for making managerial decisions to create an ERP complex that automates the processes of production’s technological preparation was carried out using the methods of analyzing advantages and disadvantages, paired comparisons and Kepner – Trego. A mechanism for making informed management decisions on the analysis of alternatives is presented, as well as the evaluation and selection of options for digitalization of the technological preparation processes based on the use of the principles of developing a management decision. Results. The choice of the Global ERP system for managing production preparation processes at industrial enterprises in the aircraft industry is justified, since it most closely matches the selected evaluation criteria.

Application of mathematical modelling methods in oil production management

Purpose. To assess the effectiveness of the practical application of mathematical modelling methods of the operation principles of oil production management systems in a fuzzy environment and the main aspects of their application in oil production. Methodology. The basis of the methodological approach in this study is a combination of methods of quantitative and qualitative analysis of the basic principles of the development of mathematical models for managing oil production processes in a fuzzy environment. Findings. The authors investigated the available methods of mathematical modeling in order to select the optimal possibilities for creating mathematical models. A qualitative assessment of the effectiveness of the practical application of methods of mathematical modeling of the principles of operation of oil production management systems in a fuzzy environment was formulated. The main aspects of application of methods of mathematical modeling directly in the process of oil production were established. Originality. A fuzzy approach is proposed for solving the problem of multi-criteria optimization in the development of a field and oil production, in which the task is set and solved in a fuzzy environment without previously converting them to equivalent clear tasks. This ensures the correctness and efficiency of the solution by increasing the adequacy of the description of the problem in a fuzzy environment. Practical value. The results obtained and the conclusions formulated on their basis are of considerable practical importance for employees of research institutes of the oil industry responsible for the development of effective methods of mathematical modelling of oil production process control systems and for employees of oil companies whose professional duties include the introduction of the mentioned mathematical models in oil fields.

Improving the Quality of Palm Oil NPK Fertilizer Products at PT.XYZ Using Statistical Process Control Methods and Taguchi Experiment

Quality palm oil NPK fertilizer products are fertilizer products that meet the quality requirements specified in SNI Standard 2801: 2010 and SIRIM Standards. This research was conducted with the aim to improve the quality of oil palm NPK fertilizer products at PT. XYZ. To maintain the stability of nutrients, the production process must be strictly considered with the aim of minimizing product variations. To achieve these objectives the production process control system is designed using Statistical Process Control. Then a process is designed to produce a robust product using the Taguchi experiment. Taguchi experiment obtained the results of the optimization of the process parameter level settings in combination as follows: raw material intake 27 mt / hour; water usage 1100 m3 / hour; gas usage 100 MMBtu; material temperature granulator 52°C; dryer material temperature 52°C; cooler material temperature of 44°C; finish product temperature 39°C; process environment temperature of 31°C. From the results of ANOVA for each nutrient showed that the highest levels of nutrient N were obtained from the finish product temperature 38°C; the highest P2O5 nutrient content is obtained from the variable water usage of 1000 m3 / hour; the highest K2O nutrient content is obtained from the variable water usage of 1100 m3 / hour; the highest MgO nutrient content is obtained from the variable gas usage of 90 MMBtu; The highest levels of B2O3 nutrients are obtained from the variable water usage of 1100 m3/hour and the best physical size of the granules is obtained from the variable cooler material temperature of 42oC. The results of this study can reduce as much as possible complaints from customers because the product meets the quality standard specifications required.

THEORETICAL AND METHODOLOGICAL STUDY OF THE METROLOGICAL SUPPORT SYSTEM

The system of metrological support is the basis of product quality management at a machine-building enterprise. The most important element of metrological support is the real quality parameters. It was studied that the administrative management system does not create conditions for the implementation of objective technical management and, as a result, for the optimization of the management structure, reduction of production costs and quality assurance. This problem can be solved only through the development of appropriate mathematical models of metrological support systems and production process control. However, in order to build mathematical models of metrological support and production process control systems, it is necessary to establish functional and structural diagrams of the technological process and form a process for obtaining graphic models using product reliability parameters. A model is a simplified system that reflects individual elements and more important aspects of the process under study. The same process can be described by different models, and one model can describe different processes. One of the most important and difficult issues in modeling is the definition of key indicators of the system, which should more fully reflect the quality of the product. These parameters include failure, durability, time spent on product development and commissioning, etc. Thus, the problem of modeling a metrological assurance system can be formulated as follows: it is necessary to find a system that meets the aggregate requirements of the initial data, and in this case the quality indicators should have the best values in accordance with a previously selected higher criterion.

Features of the Digital Transformation of the Industrial Enterprise Management System in the Modern Conditions of Economic Development

The article examines the prerequisites for using the elements of digital transformation to improve the efficiency of industrial enterprises in the modern conditions of economic development. The authors identify and formulate the distinctive features of the transformation of the production process control system under the influence of digital transformation. The main provisions of the methodological substantiation of the transformation of the production and organizational structures of an industrial enterprise, involving the use of a system for allocating structural units into separate centers of financial and production responsibility, interacting with each other through “smart contracts” are revealed. The authors prove the relevance of the use of “smart contracts”, which allows self-regulation of production and management business processes of business entities. The stages of digital transformation of industrial enterprises are proposed, including: identification of the level of digital maturity of the enterprise; identification and development of the instrumental apparatus for the implementation of the digital transformation of the enterprise; assessment of the effectiveness of transformative actions aimed at the digital transformation of an economic entity. In the course of the proposed study, the conceptual foundations of the digital transformation of the enterprise management system are developed with the division into digital responsibility centers, and recommendations are formulated and proposed for the formation and development of the “digital field” of the enterprise.

Separation process control system in the cement production facility

The article developed a system for controlling the process of cement separation using neural networks. The control object is a separator. The task is to improve the cement production process control system by installing a frequency converter and an electric air damper. In order for the current frequency and the degree of opening of the damper to be set automatically, a neural network was developed for the separation process, which has two input and two output parameters. The neural network is able to adjust the rotor speed of the separator, relying on sensors that control the speed of the separator rotor and the size of the cement particles. If the speed of rotation of the rotor of the separator becomes low, artificial intelligence will adjust the fineness of grinding, changing the degree of opening of the damper for air supply to the separator. If the speed of rotation of the separator rotor approaches the maximum, and the grinding fineness has not reached the specified values, then the grinding fineness is controlled by changing the degree of opening of the damper for air supply to the separator.

Совершенствование цифровых технологий формирования мелиоративного режима агроэкосистем

The relevance of research is due to the increasing role of digital technologies for managing agricultural production on reclaimed lands in ensuring sustainable growth of agricultural production efficiency. The object of research is precision (precise) management of agricultural production. The subject is advanced technologies for the rapid formation and regulation of the reclamation regime of agroecosystems that meet the requirements of sustainable development of the crop production system of the domestic agro-industrial complex. The purpose of this work is to improve methodological and technological approaches to digitalization of technologies for managing the reclamation regime of the agroecosystem. the Scientific novelty of the work is to substantiate the functional orientation and list of priority tasks solved by the created digital systems, which required studying the specifics of applied technologies for managing agricultural production; determining the effective direction of improving automated management. The research was based on the analysis of normative-methodological and legal documents, literary sources, as well as personal developments of the author on the subject under consideration. Methods of comparative and system analysis and expert assessments were used in the work. Factors of competitiveness of economic entities implementing support of management decisions by digital systems are identified. Uncovered causes that reduce the effectiveness of the implementation of the digital control systems of agricultural production on reclaimed lands in the Russian agricultural sector Shows the priority approaches to the structure of control system of technological processes of agricultural production, emerging based on the integration of access to information for business processes of enterprise management. A list of priority tasks of automation of technological processes of reclamation agriculture has been developed. Priority requirements for improving digital technologies for managing the reclamation regime of agroecosystems in terms of information, technology and software are formulated. The proposed transformation of approaches to the creation and use of automated production process control systems (APCS) and General approaches to enterprise management (APCS) meets the requirements of the «Internet of things (IOT)», one of the newest trends in the evolution of modern Internet technologies. The technological process of precision management of agricultural production based on digital systems Maxim built into the management procedures of the hydroreclamation system, rationalized, with significantly increased efficiency transforms the interaction of producers and consumers, bringing them flexibility, organizing the exchange of information via the Internet.

Identification of sustainable control and digital dimension errors in business organizations

In recent years, the technique of centralized control of complex production processes has moved from the stage of development and experimentation to widespread industrial implementation. Centralized control equipment is used in large, complex objects, and the control systems themselves are so complex that they cannot be calculated or reasonably selected using the methods used for conventional control and measuring equipment. The work undertaken recently in order to create various calculation methods for centralized control systems, at best, solved individual particular problems, often from different initial positions, and, apparently, there was a need for generalizing work that would give the system designers centralized control is an efficient settlement tool. Of the technical characteristics of centralized control systems, the most essential and most fully reflecting the effectiveness of their operation is accuracy, especially if this concept is broadly approached, including any deviation from the required system behavior in the error. Centralized control systems are used in various fields: to control production processes, for scientific research, including space objects, for testing and researching technical structures, for monitoring the health of complex equipment. These applications have a number of similarities and, however, differ in the number of requirements put forward by individual applications. When writing the article, the main attention was paid to centralized control systems for continuous production processes, which, in contrast to a number of testing and research systems, are characterized by the duration of action, since the production processes themselves in most cases run continuously for many hours, days or even months.

Key technologies for energy saving and emission reduction of heating furnaces in petrochemical plants

The safety instrumented system is a system that is independent of the petrochemical production process control system and can independently complete the safety interlock protection function. It can avoid significant hazards to production equipment caused by process production failures, field instrument failures, system power supply failures, etc., and ensure safe operation of production equipment. In petrochemical plants, it is imperative to configure a safe, reliable, and timely safety instrumented system. Combined with applying the burner management system of the heating furnace in a refinery, the paper focuses on the technical realization of the hardware structure, system configuration, logic programming, man-machine interface configuration system debugging of the TRICON system. Practical application shows that TRICON?s safety instrumented system is a set of safety instrumented systems with comprehensive functions, safety and reliability, and easy to learn.

The basic stages of improving the power grid complex functioning of the Chechen Republic

The article considers the state of the electric power industry functioning of the Chechen Republic. Comparative data on the reception in the network and useful electricity supply of the Chechen Republic in recent years are presented. The total transformer capacity structure of all substations, as well as the power lines total length of Chechenenergo JSC, is considered. The main electric power industry problems of the Chechen power system, which are the lack of own generating capacities, the transformer capacities shortage of substations 110 and 35 kV and the main production assets high level wear of the electric grid economy, are studied. The tasks to reduce the Chechen energy system electric energy losses are considered. The values and causes of the electric energy losses in different district electric networks (RES) of JSC "Chechenenergo" are determined. A comparative analysis of the electrical energy losses in recent years has been performed. Issues related to reactive power in electrical networks are considered. An analysis was carried out to determine the reactive power values in different district electric networks of Chechenenergo JSC. Measures are proposed that contribute to the reactive power normalization and the improvement of technical and economic indicators in electric networks. The networks electrical circuits improvement analysis was carried out to ensure the power supply stability and reliability to consumers in the republic. The production process control system and diagnostics is proposed, which will allow to regulate and coordinate the activities to manage the technical condition, as well as the power system reliability.

Risk management of oil and gas transportation facilities based on reliability indicators monitoring

The paper considers the methodological aspects of the analysis of technical risk based on real data on the reliability of objects. Today, there is a problem of assessing the probability of technological events of various types based on statistical data of events at various facilities; however, the current state of automatic control systems for production processes allows preventing an accident, transferring it to the category of incidents. In this case, there is a real distortion of information on statistics of dangerous situations. In modern control systems, information for forecasting and preventing accidents is the most valuable. The paper presents a systematic approach to the creation of new generation technical risk management systems.

Synthesis Algorithms for Adaptive Process Control Systems Based on Associative Memory Technology

The results of the regular synthesis algorithms development for adaptive process control systems based on the associative memory technology are presented in the article. The single-step and multi-step, deterministic and stochastic algorithms used for solving control and tracking problems are considered. The relative simplicity of these algorithms makes possible to recommend them for managing complex objects in conditions of uncertainty using concepts and associative memory technology. Based on the technology of associative memory, synthesis algorithms for adaptive production process control systems are proposed to function under unpredictable uncertainties and ensure the rate of the structure adapting process of the main system circuit, commensurate with the rate of transients in the technological control object operating under stochastic independent disturbances.

ANALYSIS OF DATA FROM MEASURING SENSORS FOR PREDICTION IN PRODUCTION PROCESS CONTROL SYSTEMS

The article presents a solution based on a cyber-physical system in which data collected from measuring sensors was analysed for prediction in the production process control system. The presented technology was based on intelligent sensors as part of the solution for Industry 4.0. The main purpose of the work is to reduce data and select the appropriate covariate to optimise modelling of defects using the Cox model for a specific mechanical system. The reliability of machines and devices in the production process is a condition for ensuring continuity of production. Predicting damage, especially its movement, gives the ability to monitor the current state of the machine. In a broader perspective, this enables streamlining the production process, service planning or control. This ensures production continuity and optimal performance. The presented model is a regressive survival analysis model that allows you to calculate the probability of failure occurring over a given period of time.

A Scalable Automation System for the Auxiliary and DC Power Supply Switchgear of Power Plants and Substations

The principles of implementing a scalable microprocessor system for automation of auxiliary and d.c. power supply switchgear at power plants and substations are described taking as an example the demonstration model of the cabinet with self-contained switchgears for shutoff and control valves (of the KRUZA P type). The computerized subsystem constructed on the basis of a communication programmable logic controller is described. The controller serves for supporting digital data exchange according to the standard protocols used in the electric power industry (Modbus, IEC 61850, and IEC 60870-101/104). The field-level digital networks transmit data exchanged with distributed signal input/output modules and panel-mounted instruments. The upper-level network transmits these data to the process instrumentation and control system (process I&C). Approaches to elaborating application software that allows scalable automation system configurations to be developed are considered. Embodiment versions in the form of a self-contained automation system, process I&C subsystem, or a remote-control subsystem are given. The use of standard modules in cabinet designs and in control algorithms helps enhance the reliability in designing production process control systems.

Production Planning, Scheduling, and Process Control System in Microalgae and Biogas Supply Chain

Biomass feedstock is a potential solution to the future source of biofuels and fine chemicals. A major challenge of its availability to meet energy demands extends the scope of production planning ...

MANUFACTURING PLANNING AND CONTROL SYSTEM USING TOMOGRAPHIC SENSORS

The article presents an idea of a production process control system. Advanced automation and control of production processes play a key role in maintaining competitiveness. The proposed solution consists of sensor networks for measurement process parameters, production resources and equipment state. The system uses wired and wireless communication, which gives possibility to acquisition data from existing in enterprise sensors and systems as well as acquisition data from new systems and sensors used to measure all processes, starting from production preparation to the final product. The solution contains process tomography sensors based on electrical capacitance tomography, electrical impedance tomography and ultrasound tomography. The use of tomographic methods enables to manage the intelligent structure of the companies in terms of processes and products. Industrial tomography enables observation of physical and chemical phenomena without the need to penetrate inside. It will enable the optimization and auto-optimization of design processes and production. Such solutions can operate autonomously, monitor and control measurements. All sensors return to the system continuous data about state of processes in some technologically closed objects like fermenters. Process tomography can also be used to acquisition data about a flow of liquids and loose ingredients in pipeline based on transport systems. Data acquired from sensors are collected in data warehouses in order to future processing and building the knowledge base. The results of the data analysis are showed in user control panels and are used directly in the control of the production process to increase the efficiency and quality of the products. Control methods cover issues related to the processing of data obtained from various sensors located at nodes. Monitoring takes place within the scope of acquired and processed data and parameter automation.