Control System Software Research Articles

Evaluation of Image Segmentation Methods for In Situ Quality Assessment in Additive Manufacturing

Additive manufacturing (AM), or 3D printing, has revolutionized the fabrication of complex parts, but assessing their quality remains a challenge. Quality assessment, especially for the interior part geometry, relies on post-print inspection techniques unsuitable for real-time in situ analysis. Vision-based approaches could be employed to capture images of any layer during fabrication, and then segmentation methods could be used to identify in-layer features in order to establish dimensional conformity and detect defects for in situ evaluation of the overall part quality. This research evaluated five image segmentation methods (simple thresholding, adaptive thresholding, Sobel edge detector, Canny edge detector, and watershed transform) on the same platform for their effectiveness in isolating and identifying features in 3D-printed layers under different contrast conditions for in situ quality assessment. The performance metrics used are accuracy, precision, recall, and the Jaccard index. The experimental set-up is based on an open-frame fused filament fabrication printer augmented with a vision system. The control system software for printing and imaging (acquisition and processing) was custom developed in Python running on a Raspberry Pi. Most of the segmentation methods reliably segmented the external geometry and high-contrast internal features. The simple thresholding, Canny edge detector, and watershed transform methods did not perform well with low-contrast parts and could not reliably segment internal features when the previous layer was visible. The adaptive thresholding and Sobel edge detector methods segmented high- and low-contrast features. However, the segmentation outputs were heavily affected by textural and image noise. The research identified factors affecting the performance and limitations of these segmentation methods and contributing to the broader effort of improving in situ quality assessment in AM, such as automatic dimensional analysis of internal and external features and the overall geometry.

INVESTIGATION OF THE EFFICIENCY AND EFFECTIVENESS OF THE ALGORITHM FOR CONTROLLING THE ACCELERATION AND DECELERATION OF A WHEELED VEHICLE BY MEANS OF A STROKE PEDAL IN CONDITIONS OF MAINLINE TRAFFIC

Justification. Modern battery-powered vehicles still do not meet the needs of consumers in terms of autonomous mileage. Therefore, the task of increasing energy efficiency in order to reduce energy consumption for movement is acutely relevant. One of the directions, along with the use of more efficient units and systems, can be the creation of control algorithms that minimize these costs, which allow you to control movement using only the stroke pedal. The purpose of the work. The study of the operability and effectiveness of the algorithm for controlling a vehicle only with the help of a stroke pedal using simulated virtual motion modeling and further practical implementation of the algorithm in the control system. Materials and methods. The study was performed using the Matlab Simulink software package. Results. The article describes the functioning of the single-pedal control algorithm using the example of a passenger vehicle with an individual traction electric drive, the results of virtual simulation modeling proving its operability and energy efficiency for the case of traffic in the main cycle. Conclusion. The practical value of the research lies in the proven efficiency and energy efficiency and the possibility of using the algorithm to develop software for vehicle traffic control systems.

Research on the key techniques of composite processing of EDM and vibration ultrasonic drilling

PurposeUtilizing electrical discharge machining (EDM) to process micro-holes in superalloys may lead to the formation of remelting layers and micro-cracks on the machined surface. This work proposes a method of composite processing of EDM and ultrasonic vibration drilling for machining precision micro-holes in complex positions of superalloys.Design/methodology/approachA six-axis computer numerical control (CNC) machine tool was developed, whose software control system adopted a real-time control architecture that integrates electrical discharge and ultrasonic vibration drilling. Among them, the CNC system software was developed based on Windows + RTX architecture, which could process the real-time processing state received by the hardware terminal and adjust the processing state. Based on the SoC (System on Chip) technology, an architecture for a pulse generator was developed. The circuit of the pulse generator was designed and implemented. Additionally, a composite mechanical system was engineered for both drilling and EDM. Two sets of control boards were designed for the hardware terminal. One set was the EDM discharge control board, which detected the discharge state and provided the pulse waveform for turning on the transistor. The other was a relay control card based on STM32, which could meet the switch between EDM and ultrasonic vibration, and used the Modbus protocol to communicate with the machining control software. FindingsThe mechanical structure of the designed composite machine tool can effectively avoid interference between the EDM spindle and the drilling spindle. The removal rate of the remelting layer on 1.5 mm single crystal superalloys after composite processing can reach over 90%. The average processing time per millimeter was 55 s, and the measured inner surface roughness of the hole was less than 1.6 µm, which realized the micro-hole machining without remelting layer, heat affected zone and micro-cracks in the single crystal superalloy.Originality/valueThe test results proved that the key techniques developed in this paper were suite for micro-hole machining of special materials.

Synthesis of hardware and software for adaptive discrete high-order control systems based on a model of the desired transient process with a guaranteed degree of stability

In this work, analytical expressions for the connection between optimization criteria andsettings parameters of the adaptive PI-PID controller with variable parameters of the object andadaptive filter have been removed. A method for synthesizing a model of discrete controllersbased on given dynamic characteristics has been developed. A method has been developed forsynthesizing a model of a discrete PID controller based on given dynamic characteristics basedon the criterion of the transient process of a guaranteed level of stability. 3 figures, 0 tables, 32formulas, 19 bibliographic sources..Analytical expressions have been removed to link the optimization criteria andadjustment parameters of the adaptive PI-PID controller with the variable parameters of theobject and adaptive filter.A method for synthesizing a model of discrete controllers from specified dynamiccharacteristics has been developed. The average warehouse of output pulses at the output of anonlinear channel, which is formed at the output of such a regulator and is seen as an inertialinduced uninterrupted part, changes according to the law, which is designated as a reversetransmission the function of the lanyard of the new molded filter model at the collar of the non-linear element.A method has been developed for synthesizing a model of a discrete PID controller fromspecified dynamic characteristics based on the criterion of the required transient process of aguaranteed stability level.The modeling showed that while the parameters of the object and the adaptive filter willchange during the ASC operation, then, obviously, the optimal parameters for adjusting theadaptive PID controller will immediately change.

Design and application of portable eddy current inspection device for thimble tubes of nuclear power plant

Abstract The Thimble tube is an important piece of equipment in the nuclear power plant; its role is to provide a neutron flux detector with a channel for the reactor fuel assembly. Eddy current detection is the main way to evaluate and track the wear of the thimble tube. In order to conduct more efficient detection of the thimble tube, this paper has carried out a series of studies on the mechanical device of the eddy current detection of the thimble tube and the software control system. The inspection system is compact, portable, and does not require an external power supply or gas source, making it easy to carry and operate. It is well-suited for promotion in various nuclear power plants.

Implementation of Integrated Development Environment for Machine Vision-Based IEC 61131-3

IEC 61131-3 is an international standard for developing standardized software for automation and control systems. Machine vision systems are a prominent technology in the field of computer vision and are widely used in various industries, such as manufacturing, robotics, healthcare, and automotive, and are often combined with AI technologies. In industrial automation systems, software developed for defect detection or product classification typically involves separate systems for automation and machine vision programs, leading to increased system complexity and unnecessary resource wastage. To address these limitations, this study proposes an IEC 61131-3-based integrated development environment for programmable machine vision. We selected 11 APIs commonly used in machine vision systems, evaluated their functions in an IEC 61131-3 compliant development environment, and measured the performance of representative machine vision applications. This approach demonstrates the feasibility of developing PLC and machine vision programs within a single-controller system. We investigated the impact of controller performance on function execution.

Використання засобів комп’ютерного моделювання з метою підвищення інтересу учнів до вивчення фізики

The article analyzes scientific research on the problem of the development of cognitive interest: the essence of the concept of "cognitive interest" is considered, the features of the formation of students' cognitive interest in physics classes are described. The directions of the introduction of information technologies into the educational process are characterized, which include the development and practical use of scientific and practical support, the high-quality and effective use of software, computer training and knowledge control systems, the systematic integration of these technologies into existing educational processes and organizational structures. It has been found that conducting experiments that are difficult or impossible to reproduce in a real experiment can be effectively implemented based on the use of multimedia models. Possibilities of using computer modeling during the study of physics are offered. It has been confirmed that the use of computer simulation elements is appropriate and justified during the study of educational material, for which conducting various kinds of educational physical experiments is limited. This is the study of the basic concepts of quantum physics. The peculiarities of the study of the "Quantum optics" section are described, in which special attention is paid to the study of the phenomenon of the photoeffect. Examples of interactive computer models are given, the use of which makes it possible to increase the interest of students in studying this material in physics, to stimulate the formation and development of cognitive activity and creative thinking, to form in students an idea of the phenomena of the microcosm, their regularities, and the modern physical picture of the world.

Development of multi-channel magnetic flux leakage testing system for bridge cables

Magnetic flux leakage (MFL) is one of the most popular techniques for detecting broken wire in bridge cables. MFL sensor array has attracted a lot of attention in recent years due to its capacity to measure the spatial distribution of the magnetic field of bridge cable. More sensors in the array lead to increased useful information extraction from the MFL field, allowing for more precise quantitative evaluation of bridge cable damage. This study reports the development of a cable MFL testing system capable of synchronous acquiring up to 512 channels of MFL sensors signal. Radial sensor arrays (RSA) composed of vertically placed magnetic sensors spaced at equal intervals are developed to be arranged around the bridge cable. They record the spatial distribution of the magnetic leakage field of the broken wire by collecting the MFL signal at various lift-offs. To solve the problem of multi- channel MFL signal synchronous acquisition, this study develops a MFL signal acquisition card based on multiplexing technology, capable of synchronous acquisition of up to 512 channels of MFL signal. Multiplexers are used to switch sensor channels, followed by multi-channel A/D conversion chips to convert the transmitted data. The converted data are temporally stored in the First-In-First-Out (FIFO) buffer of the Field Programmable Gate Array (FPGA) and transferred to the computer through the network port for display, storage, and signal processing. Finally, the motion control circuit, mechanical structure, and control software of the bridge cable MFL testing system are fully customized. Experiment results reveal that the system can be used in multi-channel MFL testing, laying the foundation for further multi-channel signal processing and bridge cable health evaluation.

Research on a Real-Time Control System for Discrete Factories Based on Digital Twin Technology

Gear factories are most typical discrete manufacturing factories. Many gear factories are striving to explore how to achieve intelligent manufacturing in order to improve efficiency and reduce costs. Digital twin technology is currently one of the most reliable ways to achieve intelligent manufacturing. This article aims to establish a real-time control system in order to promote intelligent manufacturing for discrete manufacturing factories. Firstly, a model for a digital twin gear factory is put forward based on the characteristics of gear factories, and the composition of a real-time control system for gear factories is clarified. Then, a human–computer interaction architecture for the real-time control system is proposed. The real-time control system consists of three parts as follows: a monitoring module, a virtualizing module, and a controlling module. At work, it appears as a kind of human–machine interaction form with the three following interfaces: a monitoring window, a virtualizing window, and a controlling window. Finally, a gear factory, which is specialized in manufacturing the intermediate shaft dual gear of a new energy vehicle gearbox, develops a set of software for the real-time control system. The prototype software is obtained through some development activities such as 3D MAX and WebGL virtualization modeling and OPC UA and REST communication design.

Extra-articular screw placement strategy in Stoppa approach based on three-dimensional reconstruction model

The study aimed to explore an extra-articular screw placement strategy in Stoppa approach. Radiographic data of patients who underwent pelvic computed tomography from January 2016 to June 2017 were imported into Materiaise’s interactive medical image control system software for three-dimensional reconstruction. Superior and lower margins of acetabulum and ipsilateral pelvic brim could be observed simultaneously through inlet-obturator view. A horizontal line from superior acetabular margin intersected pelvic brim at point “A” and another vertical line from lower margin intersected pelvic brim at point “B” were drawn, respectively. Lengths form sacroiliac joint to “A” (a), “A” to “B” (b), and “B” to pubic symphysis (c) were measured. Patients were divided into four groups depending on gender and side difference of measured hemi-pelvis: male left, male right, female left, and female right. Lengths of adjacent holes (d) and spanning different holes (e) of different plates were also measured. Mean lengths of a, b, c in four groups were 40.94 ± 1.85 mm, 40.09 ± 1.93 mm, 41.78 ± 3.62 mm, and 39.77 ± 2.23 mm (P = 0.078); 40.65 ± 1.58 mm, 41.48 ± 1.64 mm, 40.40 ± 1.96 mm, and 40.66 ± 1.70 mm (P = 0.265); 57.03 ± 3.41 mm, 57.51 ± 3.71 mm, 57.84 ± 4.40 mm, and 59.84 ± 4.35 mm (P = 0.165), respectively. Mean d length of different plates was 12.23 mm. Average lengths spanning 1, 2, 3 and 4 holes were 19.33 mm, 31.58 mm, 43.80 mm, and 55.93 mm. Our data showed that zones a and c could be safely inserted three and four screws. Penetration into hip joint could be avoided when vacant 3-hole drilling was conducted in zone b. Fracture line in zone b could serve as a landmark for screw placement.

Different radius of curvature at the talus trochlea from northern Chinese population measured using 3D model

BackgroundTo analyze the curvature characteristics of the talus trochlea in people from northern China in different sex and age groups.MethodsComputed tomography scanning data of talus from 61 specimens were collected and constructed as a three-dimensional model by Materialise’s Interactive Medical Image Control System(MIMICS) software, anteromedial(AM), posteromedial(PM), anterolateral(AL), and posterolateral(PL) edge, anterior edge of medial trochlea, posterior edge of medial trochlea and anterior edge of lateral trochlea were defined according to the anatomical landmarks on trochlear surface. The curvature radii for different areas were measured using the fitting radius and measure module.ResultsThere were significant differences among the talus curvatures in the six areas (F = 54.905, P = 0.000), and more trends in the analytical results were as follows: PM > PL > MP > AL > MA > AM. The average PL radius from specimens aged > 38 years old was larger than that from specimens aged < = 38 years (t=-2.303, P = 0.038). The talus curvature of the AM for males was significantly larger than that for females (t = 4.25, P = 0.000), and the curvature of the AL for males was larger than that for females (t = 2.629, P = 0.010). For observers aged < = 38 years, the AM curvature of the right talus in the male group was significantly larger than that in the female group (P < 0.01). In age < = 38years group, the MA curvature of right talus in male was significantly larger than in female group(P < 0.01), fitting radius of talus for male (21.90 ± 1.97 mm) was significantly greater than female of this(19.57 ± 1.26 mm)(t = 6.894, P = 000). The average radius of the talus in the male population was larger than that in the female population.ConclusionThere was no significant relationship between age and talus curvature for males and females. The radius of curvature in the posterior area was significantly larger than that in the anterior area. We recommend that this characteristic of the talus trochlea should be considered when designing the talus component in total ankle replacement (TAR).

Research on Detection System of Intelligent Computer Optimization Algorithm for Concrete Mix Ratio Based on Big Data

PLC is used to complete the control function of the concrete proportioning system. The MCGS (Configuration Software Monitor and Control System) is used to realize the real-time monitoring, data management and fault warning of the whole monitoring system. The material feed and PLC control process in the feed system are emphatically introduced. A concrete proportioning design method based on multiple parameters is proposed. The nonlinear multi-objective optimization model of concrete mix ratio was established by stepwise regression analysis and complex optimization method. The problems of narrow range of variables and single form of objective and constraint in traditional linear optimization methods are solved, which makes the selection of optimal index simpler and more flexible. Through the calculation of examples, it is clear that this method can obtain the mixture that meets the use conditions, and can greatly save the experimental work and construction cost.

Shallow trochlear groove and narrow medial trochlear width at the proximal trochlea in patients with trochlear dysplasia: Athree-dimensional computed tomography analysis.

Although the Dejour classification is the primary classification system for evaluating trochlear dysplasia, concerns have been raised about its reliability owing to its qualitative criteria and challenges associated with obtaining accurate radiographs. This study aimed to quantify trochlear dysplasia using three-dimensional (3D) computed tomography (CT) reconstruction with novel parameters related to the transepicondylar axis (TEA). Sixty patients were enrolled, including 20 with trochlear dysplasia and 40 healthy controls. The 3D CT model was generated using the Materialise Interactive Medical Image Control System software. The following six parameters were measured in eight consecutive planes at 15° intervals (planes 0-105): the distance from the TEA to the most cortical point of the lateral condyle ('LP-TEA', where LP stands for lateral peak), medial condyle ('MP-TEA', MP for medial peak)and deepest point of the trochlea ('TG-TEA', TG for trochlear groove). The distances from the medial epicondyle (MEC) to the corresponding TEA points were measured ('LP-MEC', 'MP-MEC'and 'TG-MEC'). In the dysplasia group, TG-TEA (planes 0, 15and 30) and MP-MEC (planes 0, 15and 30) were significantly greater than those in the control group (all p < 0.05 for planes of TG-TEA and MP-MEC). For type A dysplasia, LP-MEC (plane 0) was greater than that in the control group. For type B dysplasia, the MP-MEC (planes 0 and 15) and TG-TEA (planes 0 and 15) were greater than those of the control group. For type D dysplasia, MP-MEC (planes 0, 15and 30) and TG-TEA (planes 0 and 15) were elevated. The 3D CT reconstruction analysis established a reproducible method for quantifying osseous trochlear morphology. Patients with trochlear dysplasia had a shallow TG and narrow medial trochlear width at tracking angles of 0°-30°. This finding corroborates the clinical manifestations of recurrent patellar instability that occur during early flexion. Level III.

Design and implementation of control software for radar antenna performance index test system

According to the actual requirements of radar antenna performance testing, focusing on the design of the instrument control software of the test system, in this paper, the functional requirement of the instrument control software of the system is analyzed, the basic framework of the software design is put forward, and the design ideas and implementation methods of the instrument and equipment management as well as the specific design methods of the instrument and equipment control are given. Practical applications have shown that the control software has advantages such as an intuitive interface, convenient operation, and good interactivity. Combined with system hardware, it can achieve fast and accurate measurement of radar antenna performance and has high practical value.

Research on online intelligent welding system based on resistance spot welding of aluminum galvanized steel

The article follows a resistance spot welding system, which integrates a six-axis industrial robot, power supply, pneumatic actuator, welder, cooler, trimmer, software control system, welding analyzer, force feedback sensor and welding fixture to realize monitoring of welding quality and real-time adjustment of welding parameters. Taking the resistance spot welding of 6 series aluminum alloy and DC06 galvanized steel as a study, four groups of electrode combinations, 16-6/16-6, 16-10/16-10, 16-7/16-10, and 16-5/16-16 (steel side/aluminum side), are selected for simulation and analysis, and the electrodes are optimized with the simulation results. By selecting the optimal electrode combination to carry out experiments and analyzing the influence of welding current and welding time on the joint performance, the average pulling shear force of the aluminum alloy steel resistance spot weld head is finally realized to exceed the average pulling shear force of the aluminum alloy aluminum resistance spot weld head, and the fracture is all started from the parent material of the alloy side to achieve the failure of the button, and ultimately a good welding effect is achieved.

Study of Stability Criteria of Automatic Control Systems By Multiparametric Aviation Objects

ABSTRACT This paper considers the comparative analysis of the physical and mathematical methods of the optimal operation of aviation objects’ automatic control systems, which is an urgent scientific and technical task. The paper also represents the corresponding stability criteria, depending on the operating conditions, and the influence of external factors that allows ensuring the automatic control systems’ reliable operation not only in normal circumstances, but also in the presence of probable disagreements. The scientific novelty of the research lies in developing new stability criteria by means of synthesising the influence of different factors and also the ability to ensure optimal functioning of the automatic control systems. Corresponding mathematical and computer models have been developed. The use of these models allows to determine the optimal stability criteria for control systems with parameters of a different physical nature and ensure reliable operation of electromechanical systems for general and special applications based on the current analysis. The research results are illustrated by corresponding mathematical models, engineering calculations and modelling of the optimal control limits depending on the influence of various factors. The simulation results coincide with the theoretical calculations, which indicates the consistency between the microprocessor-based and software of automatic control systems.

Information technology of synthesis of liquid dosing process control

Problem. Currently, different solutions are available on the global market for liquid dosing. There is no universal technology, as the same substances can be dosed using different types of equipment. Therefore, manufacturers face the complex task of determining the most optimal kind of equipment to achieve their goals. These issues are a complex multi-criteria scientific problem, and to effectively address them, it is necessary to develop a technology for synthesizing a liquid dosing control system using multi-criteria optimization methods in different conditions of information determinacy. Goal. The paper aims to increase the efficiency of liquid dosing control by developing information technology for the control system synthesizing. The object of the paper is the process of information technology development for synthesizing the liquid dosing control system. The subject of the paper is the models for the selection of hardware and software for the liquid dosing control system. Methodology. The study analyses and provides a classification of liquid dosing technology and analyses existing liquid dosing control systems. A structural model of information technology for synthesising a liquid dosing control system is developed, and criteria for selecting the elements of the liquid dosing control system are justified. A model for selecting PLC and SCADA systems for synthesising the liquid dosing control system is also developed using hierarchical analysis methods and multi-criteria evaluation and optimisation. Results. The paper resulted in the following: analysis and classification of liquid dosing technology; analysis of existing liquid dosing control systems; development of a structural model of the information technology of synthesising a liquid dosing control system; justification of criteria for selecting the elements of the liquid dosing control system, and the development of a model for selecting PLC and SCADA systems for the synthesis of the liquid dosing control system using hierarchical analysis methods and multi-criteria evaluation and optimisation. Originality. Further development of the methods of hierarchy analysis and multi-criteria assessment and optimization has been achieved by applying them to a specific field – the development of models for selecting hardware and software for the liquid dosing process control system. Practical value. The proposed information technology of synthesising a liquid dosing control system, as well as the mathematical models for selecting hardware and software for the liquid dosing process control system, will reduce the time and cost required to develop such a system.

Analysis of Performance Parameters of Engines with Spark Ignition with Variable Regulations of the Fuel-Injection System, Powered by E100 Fuel

Emission limits imposed on gas-powered vehicles, which have gradually been introduced by the European Commission, as well as the exhaustibility of the planet’s natural resources involve the need to search for alternative solutions and restore renewable fuel markets. In terms of ecology, using biofuels for powering spark-ignition engines has a positive impact on the natural environment. This kind of fuel, however, has a negative effect on the drive unit performance parameters, such as power and torque. This study presents test results of performance parameters of a spark-ignition engine fueled by E100 (pure ethanol). Parameters that have been analyzed are power, torque, exhaust emission components (oxygen, carbon dioxide, hydrocarbons), solid particles included in exhaust gases and emission of noise generated by the drive unit. The vehicle control system software adjustments have also been tested. Twelve regulations have been tested to evaluate performance parameters of a spark-ignition engine powered by E100 fuel. An analysis of the test results has confirmed the advisability of the introduction of control system software regulation. The aim of the work was to develop a model that will help select the appropriate software adjustment for an engine powered by E100 fuel. Due to the introduced emission restrictions, there is an important issue that concerns users of combustion vehicles. The research presented in the manuscript concerns a joint analysis of the engine’s fueling with alternative fuel and the introduction of changes to its software in order to reduce emissions.

Virtual Shake Robot: Simulating Dynamics of Precariously Balanced Rocks for Overturning and Large-displacement Processes

Understanding the dynamics of precariously balanced rocks (PBRs) is important for seismic hazard analysis and rockfall prediction. Utilizing a physics engine and robotic tools, we develop a virtual shake robot (VSR) to simulate the dynamics of PBRs during overturning and large-displacement processes. We present the background of physics engines and technical details of the VSR, including software architecture, mechanical structure, control system, and implementation procedures. Validation experiments show the median fragility contour from VSR simulation is within the 95% prediction intervals from previous physical experiments, when PGV/PGA is greater than 0.08 s. Using a physical mini shake robot, we validate the qualitative consistency of fragility anisotropy between the VSR and physical experiments. By overturning cuboids on flat terrain, the VSR reveals the relationship between fragility and geometric dimensions (e.g., aspect and scaling ratios). The ground motion orientation and lateral pedestal support affect PBR fragility. Large-displacement experiments estimate rock trajectories for different ground motions, which is useful for understanding the fate of toppled PBRs. Ground motions positively correlate with large displacement statistics such as mean trajectory length, mean largest velocity, and mean terminal distance. The overturning and large displacement processes of PBRs provide complementary methods of ground motion estimation.

Study efficiency of single-pedal control algorithm

The paper describes the methodology for conducting experimental studies, as well as the results confirming the operability and effectiveness of the algorithm for controlling a vehicle only with the help of a pedal in conditions close to operational ones. The study was carried out by conducting a full-scale experiment on an electric bus of a large class of the M3 category. The practical value of the research lies in the confirmed operability and energy efficiency of the algorithm in conditions close to operational ones, which makes it possible to use the algorithm to develop software for vehicle traffic control systems. Keywords energy efficiency, single-pedal control, traction mode, recovery mode, rolling motion, mathematical modeling, pedal stroke, specific energy consumption, experimental studies, operating condition