Control Systems Of Technological Processes Research Articles

Greenhouse microclimate control

Extensive data have been accumulated indicating that for the regions of the Far North, the most effective are opaque greenhouses with enclosing structures of sufficiently high resistance to heat transfer, providing for the cultivation of plants under artificial or joint (semi-opaque greenhouses) lighting. From 1 m of such structures, you can get 140 … 300 kg of vegetables per year. To maintain a certain air temperature in greenhouses, mainly two heating systems are used: water and air. Extensive data have been accumulated indicating that for the regions of the Far North, the most effective are opaque greenhouses with enclosing structures of sufficiently high resistance to heat transfer, providing for the cultivation of plants under artificial or joint (semi-opaque greenhouses) lighting. From 1 m of such facilities, you can get 140 … 300 kg of vegetables per year. When growing plants in cultivation rooms in winter and spring, it is necessary to artificially maintain climatic factors affecting the growth and development of plants. In this regard, the automatic regulation of these factors in accordance with the requirements of agricultural technology is of great importance. To automatically maintain the temperature in greenhouses, a two-position control system is used. Large-scale greenhouse production is currently developing along the path of introducing technologies for intensive cultivation of vegetable crops and the use of automated control systems for technological processes based on micro- and mini-computers. One of the important technological processes is watering and feeding plants with mineral fertilizers. The need to automate this process is associated with the laboriousness of the process of preparing solutions, accurately maintaining a given concentration of substances in them, timely supply and uniform dosing over the entire area of the greenhouse under various disturbances of the external environment.

Scientific Problems in Creating Intelligent Control Systems for Technological Processes in Pyrometallurgy Based on Industry 4.0 Concept

This article discusses the main application fields of the Industry 4.0 concept at the Magnitogorsk Iron and Steel Company (MMK); this concept enables creating a unified information foundation for implementing a set of measures to optimize and improve the efficiency of individual units, workshops, industries, and the overall enterprise. For the blast furnace iron-making process, this concept involves the intellectualization of the process personnel’s tasks, provision of solutions to modeling problems, process flow optimization, and implementation of decision-making support systems in production processes automation and control. Using the methodology of system research, the Ural Federal University (UrFU) and Magnitogorsk Iron and Steel Works (MMK) improved the model of the blast furnace process and significantly expanded its practical capabilities; they accomplished such an improvement by considering the thermal mode, gas-dynamic mode, blasting mode, slag mode, available information on the blast furnace operation, and the uneven distribution of materials and gases. Software development using contemporary digital technologies has resulted in the creation of an automated system for analyzing and forecasting blast furnace production situations in the MMK, and this enables solving a set of technological problems for the management of blast furnace smelting.

An Automated System for Control of Refrigerant Parameters in a Fractionating Plant

Introduction of automatic control systems for technological processes is an urgent task. For maintaining the fractionating plant refrigerant parameters, an automated monitoring and control system based on Russia-made programmable logic controllers (PLC) using a software developed in the freely available CoDeSys environment is proposed. The probability of use of shutoff-control valves with an electric drive and a stepper motor for controlling refrigerant flow rate and maintaining pressure in the fractionating column condenser is examined. Application of the control system enables reduction of refrigerant consumption in the fractionating plant operation process and maintenance of the key process parameters, which facilitates production of high-purity gases.

Modernization of Test Benches of UDMW

The article analyzes the reasons for the downtime of test stands, reveals the shortcomings of the automated control system, and suggests ways to solve the problems.
 Keywords: automation of control systems of technological processes, modernization.

Energy efficiency control systems of technological processes and the ways to improve them

Purpose. To identify the disadvantages of the existing systems of energy efficiency control of production processes and the reasons for their occurrence, to analyze requirements for modern control systems.Methodology. Analyzing disadvantages of the existing control systems, comparing and determining their capabilities in a market economy, generalizing the received results.Findings. The functionalities of the existing energy efficiency control systems do not correspond to the current conditions of production processes, that create problems for determining the content and implementation of energy saving measures. Low efficiency of the control systems is caused by the limited capabilities of the existing methods of calculating the normalized values of energy consumption, the lack of prompt assessment of the factors affecting the final result of energy efficiency, as well as the significant cost of modern energy metering. The limitation of the information component of control is that there is a difficulty in identifying from the set of factors influencing the achieved level of energy efficiency component, which is associated with the activity of service personnel in the implementation of energy saving measures. There is a need to improve the accuracy of calculating the normalized values of energy consumption. The ways to eliminate existing problems are to determine the patterns of formation of normalized values of energy consumption in terms of operational control, application of new approaches to assessing the effectiveness of impact factors, justification of errors in calculating normalized values of energy efficiency, creating and determining criteria for energy consumption in the periods related to the reporting of the enterprise. The implementation of these actions involves a significant change in views on the organization of the control procedure, technical and information support for its implementation.Originality. For the first time, a comprehensive improvement of the existing energy efficiency control systems, basing on increasing their efficiency, information content and the reliability of data, are proposed. For the first time, the causes and demonstration of the disadvantages of the existing control systems in modern production are analyzed.Practical value. Certain areas of research are identified, their implementation will expand the functionality of energy efficiency control in modern conditions and will increase the efficiency of production process management.

DEVELOPMENT OF A UNIVERSAL AUTOMATIC CONTROL SYSTEM FOR TECHNOLOGICAL PROCESS OF HOLE PROCESSING WITH A MULTI-TOOL

The industry serially produces hydraulic power heads, tables designed for drilling, countersinking and boring holes. The disadvantage of these power heads is that they are not universal in terms of the impossibility of rapid changeover from the drilling operation to the reamer. At the same time, two methods of processing holes with multi-blade tools are implemented. The first one is drilling holes in solid metal with a drill, in which the cutting tool experiences heavy loads, leading to premature wear and breakage. The second one is boring of the obtained holes after technological operations of drilling and countersinking, which leads to increased energy costs and labor of operators. The existing fleet of drilling machines, as a rule, is not equipped with automatic control systems of technological processes, allowing to ensure the quality of hole processing at high productivity. The article presents the original universal two-circuit scheme of automatic control of technological processes of drilling and reaming holes. The system controls the technological processes of drilling holes by switching the appropriate taps in the application of hydraulic power heads and improves the quality of processing and tool life. With the help of General transfer functions and according to the Raus - Hurwitz criterion, its stable operation is achieved both during drilling and deployment. The derived mathematical models make it possible to perform calculations to determine the mass-geometric and regime parameters necessary for the design and creation of automatic systems for controlling the modes of operation of hydraulic power heads.

Концептуальные подходы и тенденции развития систем прецизионного управления мелиоративным режимом агроэкосистемы

Formation of conceptual approaches, development and implementation of the systems of precision control of reclamation mode in the practice of agricultural production within the agroecosystems – the key issue of the evolution of the process of automation in the field of land reclamation that meet theoretical and practice requirements of innovative technologies of agriculture in the Russian Federation nowadays. According to the results of the study as well as theoretical and practice generalization of informational digital control system application in the reclamation activities recognized the need for digitalization and automation of technological processes of agricultural production in reclaimed lands was recognized. At the same time, productivity growth in agro-phyto-cenoses guarantees to exceed the effects of mechanization, fertilizers application, the use of the tractors, herbicides, genetically modified seeds, etc. It is shown that the development of high-precision control of the process of the reclamation mode formation is based on the wide use of computers, digital systems, indicators of remote active and passive sensing, robotics, specialized means of mechanization. The basic principles and requirements of the formation of the automated control systems of technological processes to regulate reclamation mode in the agroecosystem, which save the best achievements of the theory in the field of effective and sustainable agricultural production in reclaimed lands are tested in practice. The features of automation at management, operational, tactical and strategic levels of decision – making for micro-, meso- and macrolevels of the hierarchy of the managed area are characterized. The priority directions to improve high-precision management of meliorative mode in agroecosystems regarding to spatial and temporal variability of soil fertility and other conditions within agro-phyto-cenosis differ in the methods of monitoring and specific indicators’ evaluation; determination of the agro-ecologically similar contours of the field/crop rotation; creation of the targeted, object – oriented recommendations, differentiated to each economy, site, culture and biodiversity.

Модели и алгоритмы автоматизации поддержки управления проведением поисково-спасательных работ

Introduction. The efficiency of search and rescue operations (PSR) due to the elimination of emergencies and fires indicates the need to create a structure for an automated control system (ACS) for technological decision-making processes at natural and industrial sites in Vietnam based on a software and hardware complex (PAC) for conducting the PSR in the Socialist Republic of Vietnam (SRV). The relevance of the research is due to the need to implement modern models and algorithms for automating the management support of the PSR and the development of automated control systems for technological processes of management decision-making at natural and industrial sites in Vietnam based on the PAC management system. Goals and objectives. The aim of the work is to reduce the response time of search and rescue units using models and algorithms to support the management of search and rescue operations using an automated control system for natural objects and industrial facilities in Vietnam based on a software and hardware complex. The practicality of the work is that the use of the recommended mathematical models, algorithms and the development of an automated system for the management of technological decision-making processes in natural and industrial sites in Vietnam, based on the software and hardware set for search and rescue operations reduce the time spent in the process. Methods. Systems analysis, statistical analysis, mathematical statistics, etc., are used to solve the problems of the study. Results and discussion thereof. The results are represented by the developed models and algorithms for supporting the management of the PSR using automated control systems at natural and industrial sites in Vietnam based on the PAC for the PSR. Conclusions. The functional structure of the automated control system for technological processes of management decision-making at natural and industrial sites in Vietnam based on a software and hardware complex for search and rescue operations, which allows you to visualize the location of victims in open areas in conditions of smoke, fog, rain. Key words: models, algorithms, automation, control support, search and rescue.

Automated Control System of Technological Process of Applying Wear-Resistant Coating by Ion-Plasma Method

An increase in labor productivity is realized due to a sharp increase in cutting speed and requirements for operability of the tool used. This requires fundamentally new solutions in design of machine tools and cutting tools, the use of more efficient tool materials, etc. One of the ways to increase the service characteristics of the tools used is to apply wear-resistant coating with special properties to their working surfaces. The use of wear-resistant coatings is of particular importance in conditions of modern production intensification. There are a lot of methods that can significantly improve operational characteristics of cutting tool. The ion-plasma method is a special case among them because it is implemented on vacuum installations equipped with electric arc evaporators of the metal which is the basis of coating. Coating a tool by this method is quite common also due to a number of positive properties: the purity of the coating composition (due to work in vacuum); nontoxicity of the method, the possibility of using the coating as a decorative one. This article considers the problem of improving the quality and efficiency of the automated control system for the installation of ion-plasma coating on metal cutting tools. Existing installations use fairly outdated and imperfect control tools. In addition the existing control systems model only certain stages of the coating process. Most often consideration is given to the distribution problem of heat fluxes in static in a tool to be heated without solving the problem of radial distribution of the temperature field. This paper proposed to apply Butkovsky method to simplify the solution of control problem of a tool heating process. It also proposed the general mathematical model of dynamics of all technology components (tool cleaning, coating and tool cooling). Based on mathematical models, processes control systems were created.

AUTOMATIC CONTROL OF THE CROSS-WEDGE ROLLING SYSTEM BY PROGRAMMABLE LOGIC CONTROLLER ON THE BASE OF ARDUINO APPARATUS AND SOFTWARE PLATFORM

One of the main basic automation tools in modern industrial enterprises is programmable logic controllers. Programmable logic controllers (PLCs) are microprocessor or microcontroller devices intended for the implementation of automated control systems for technological processes at enterprises [1]. The principle of PLC's work is to collect and process data on the user's application program with control signals generation to the operating devices. The modular concept of constructive execution of the PLC, allowed composing the programmed logic control devices in accordance with the peculiarities of the tasks solved by the customer. The range of application of PLC extends from devices of local control of working bodies of machines and technological units to multi-level control systems of complex technological objects. PLCs control machine tools, automatic production lines, robotic technological complexes, and also control the safety of equipment operation.There are thousands of different PLC models on the market today, which differ not only in technical characteristics (memory size, computing block power, input / output channels), but also functional capabilities. PLCs are available in a wide range of foreign companies such as Siemens, Schneider Electric, Mitsubishi Electric, Rockwell Automation, etc.The research has confirmed the choice of alternative to an expensive PLC based on the use of the Arduino hardware and software platform. A similar approach, and even schematic and software solutions, can be used in the design of the LLA for other small automation objects. The automation of the PLC process significantly reduces the cost of production, increases productivity and reduces the cost of metal compared with turning parts on the automatic lathes.The acquired development skills can be recommended for use in teaching students how to work with modern microcontrollers and building rather simple programmable logic controllers.

Разработка Scada-модели компрессорной станции магистрального газопровода

Nowadays, at all levels of created automated control systems for technological processes, programmable technical means are used that require specific software within framework of necessary functional tasks. This software should include a set of software tools that communicate with technical devices and organize «human-machine interface» (HMI) in the form of application software for AWPs with assigned communication tasks for persons, responsible for management decision-making: operators, dispatchers, managers. However, hardware architecture is unique for each particular case, so it is necessary to refine or create a new control system. This is a rather laborious process. To simplify creation of such systems SCADA-systems are used.Article is devoted to development of SCADA-component for trunk gas pipeline's compressor workshop. Developed component allows tracking the characteristics of gas transportation process selected by operator. Development is based on «Windows» operating system and integrated environment TRACE MODE (SCADA/HMI).

РАЗРАБОТКА ЕРС - МОДЕЛЕЙ УГРОЗ НАРУШЕНИЯ ИНФОРМАЦИОННОЙ БЕЗОПАСНОСТИ АВТОМАТИЗИРОВАННОЙ СИСТЕМЫ УПРАВЛЕНИЯ ТЕХНОЛОГИЧЕСКИМИ ПРОЦЕССАМИ.

The purpose of this study is to develop threat models specific to the object of protection-automated process control systems. When developing the threat models, we propose a method of constructing graphical notations of events (Event-driven Process Chain), the main elements of which are events and functions associated with logical operations. We present the results of the analysis of threats of violation of information security of automated control systems of technological processes. The EPC-models of threats of information security violation of modern information and control systems of industrial enterprises are presented. The EPC-models allow to describe in detail ways of realization of the threats that, in turn, gives the chance to the experts working in the field of information security to design systems of information protection matched to potential threats and taking into account specifics of production. Modeling threats of violation of information security allows the specialist for data protection obtaining sufficient arguments about the feasibility of a violator of the threats to specific automated control systems of technological processes, which contributes to the financing of the project. This paper is not limited to the consideration of only business process models as the only means of creating threat models in the field of information security, and offer EPC-modeling as one of the methods of building information security threats for automated control systems. The EPC models allow to describe ways of realization of the threats actual for modern automated control systems and to estimate probabilities of their realization.

The problems of intelligence improving of power plants process control system

Trends in the development of modern control systems of technological processes (ACS TP) on the basis of program and technical complexes (PTC) are aimed at creating a unified control system of the power unit in all modes of its operation, capable in addition to directly controlling the power unit, blocking operator errors, using intelligent control strategies. At the same time, improving the quality of technological processes based on new hardware and software and the achievements of the modern theory of automatic control occurs mainly at the level of power unit equipment and to a much lesser extent – at the level of the power plant. It is obvious that the level of intelligence of ACS TP should correspond to the technical level of promising high-efficiency power plants. Under these conditions, the problem of increasing the degree of intelligence of energy production management systems in power plants through the development and implementation of new innovative technologies, algorithms and systems for optimal control of the operation of equipment of power plants and power plants in general is extremely urgent. At the same time, a set of technical solutions and technologies should provide, in addition to high efficiency, such “sparing” modes of operation, which allow to reduce the rate of exhaustion of the resource characteristics of the equipment and thereby prolong its service life. This shows the necessity and expediency of developing intelligent high-performance control systems for the entire cycle of energy production in power plants, by expanding the functionality of the PTC in terms of optimal control of technological and production processes of the block and station levels.

System of process control for associated concentrate nanostructures production

The article presents developed automated process control system of the associated concentrate nanostructure production and the technical and system software, which includes a local process control system and software and hardware that are shared by the technological purpose. The main technological parameters controlled and managed by the APCS are reflected. The article presents the composition of lower-level control system of the plant for production line nanomaterial products, software and hardware complex heat-exchanger and coagulator. The requirements to the functioning modes of the APCS ACNP are presented. It is shown that the developed automated control system of technological process of associated concentrates nanostructures provides the opportunity for the system structure development, including the increase in the number of measurement points using a margin of 10% on signals of input/output. While software and information support of automated control systems CNAA involves changing the configuration of the system and possibility of its expansion through modernization and the introduction of new tasks (complexes of tasks and algorithms).

Comparison of Requirements of Regulators of the Russian Federation and the United States of America to Automatic Control Systems of Technological Processes of Critical Objects

There are requirements for AMS TP CO based on federal laws, the presidential decree, the FSTEC decree and documents, other information security conceptions, state standards in the Russian Federation and requirements for ICS based on other security strategies, the FISMA Act, NIST, IEEE, GAO documents and others in the Unitet States of America. The main FSTEC document for information security AMS TP CO is the decree of March 14, 2014 no. 31. The main FIPS document for information security ICS is Special Publication 800-82 Rev 2. The FIPS document Special Publication 800-82 Rev 2 is more detailed than the FSTEC document in realization control levels, components, objects of ICS protection. The Special Publication includes base operations in ICS main components and enterprises network, ICS system review, USA critical object feature description. Special Publication 800-82 Rev 2 shows more quality performance than the FSTEC document. It has more pages, system descriptions, recommendation for the life cycle security system of ICS, a lot of network contents.

Применение модели нечёткой логики для оценки качества передачи данных в сетях индустриального интернета вещей

Fuzzy logic by its main characteristic of simulation of human reasoning, it is classified among the techniques of artificial intelligence. This technique can be used to model and then replace the monitoring and control expertise of the process from the designer or user. Fuzzy logic has contributed to the development of several areas. In industrial maintenance, fuzzy logic is used to solve diagnostic problems by automatically classifying vibration signals corresponding to different modes of operation of machines. In this article, a comparative analysis of the methods of automated control system of technological processes (ACS TP) in modern industrial fields is carried out,  the preferential analysis of applying fuzzy logic methods in modern process control systems, as well as an example of using a fuzzy model in assessing the quality of data transmission in IIoT net-works.&nbsp

Information security of automated control systems of technological processes

Information security of automated control systems of technological processes

Метод эффективной организации специализированного информационного обеспечения для системы автоматизированного управления технологическими процессами

Метод эффективной организации специализированного информационного обеспечения для системы автоматизированного управления технологическими процессами

ЭНЕРГОЭФФЕКТИВНОЕ УПРАВЛЕНИЕ ВЫСОКОЧАСТОТНОЙ ОБРАБОТКОЙ ПОЛИМЕРНЫХ МАТЕРИАЛОВ

The article deals with the formation of general approaches for energy efficiency provision and improvement of the performance of technological processes of polymer high-frequency electrothermy. The research was carried out on the basis of physics and chemistry of polymer materials, thermodynamics, electrical engineering and fundamentals of automated system design. Experimental studies involved the use of the control methods of heat deformations and fields. A functional diagram of automated control systems of technological processes of high-frequency electrothermy is presented. The tasks are identified that are solved at control implementation by individual technological processes of high frequency electrothermy (drying and welding of polymer parts). Control process cyclograms are specified. The principles and general approaches to the control organization of high-frequency heating of polymers are determined. They have been formed on the basis of the need to build a universal automated control system of technological processes and provision of energy efficiency, high performance of technological processes of high-frequency processing of polymers. According to the discussed approaches, it is shown that the transition to processing in the area of the maximum possible voltages of the operating capacitor of the electrothermal equipment U p provides the possibility to save up to 30-40% of energy costs and 70% of processing time.

Аналіз динаміки функціонування багаторівневих систем з використанням моделей на підстаі ієрархічних мереж петрі

Проаналізовано сучасні підходи до організації ефективного управління сучасними підприємствами. Отримані результати аналізу дають змогу стверджувати, що розвиток енергетичної галузі України, як і інших галузей, неможливий без впровадження принципів технології "Industry 4.0" та розроблення систем управління підприємством має відбуватися з урахуванням міжнародних стандартів: ANSI/ISA-95 і IEC 62264–1. Побудова власної ієрархічної системи управління під конкретне підприємство має ґрунтуватися на використанні вже існуючих базових програмно-апаратних складових, що дасть змогу істотно зменшити її вартість. Відповідно, виникає задача узгодження роботи сумісного функціонування базових програмно-апаратних складових, а саме: дослідження динаміки функціонування ієрархічної системи. Для аналізу функціонування таких систем запропоновано моделі, які ґрунтуються на теорії ієрархічних та простих мереж Петрі, які дають змогу дослідити динаміку функціонування розроблювальної системи. Окрім цього, модель з використанням ієрархічних мереж Петрі надає можливість дослідити інформаційні потоки між ієрархічними рівнями та їх взаємний вплив. Наведено результати апробації побудованих моделей, а саме: приклад аналізу функціонування багаторівневої ієрархічної системи управління технологічними процесами підприємства. Отримані результати дають змогу стверджувати, що розроблена багаторівнева ієрархічна система управління технологічними процесами підприємства функціонує правильно, усі стани досяжні, а тупики відсутні.