Abstract: This paper describes a two-stage methodology derived from IMC (Internal Model Control) for tuning a PID (Proportional-Integral-Derivative) controller for levels or other integrating processes in an industrial environment. Focus is ease of use and implementation speed which are critical for an industrial application. Tuning can be done with minimum effort and without the need of time-consuming open-loop step tests on the plant. The first stage of the method applies to levels only: the vessel residence time is calculated from equipment dimensions and used to derive a set of preliminary PI (Proportional-Integral) settings with IMC. The second stage, re-tuning in closed-loop, applies to levels as well as other integrating processes: a tuning correction mechanism has been developed based on a series of closed-loop simulations with model errors. The tuning correction is done from a simple closed-loop step test and application of a generic correlation between observed overshoot and integral time correction. A spin-off of the method is that an estimate of the vessel residence time (levels) or open-loop process gain (other integrating process) is obtained from the closed-loop data.
Abstract: Biosensors play a significant role in the healthcare
sectors, scientific and technological progress. Developing electrodes
that are easy to manufacture and deliver better electrochemical
performance is advantageous for diagnostics and biosensing. They
can be implemented extensively in various analytical tasks such as
drug discovery, food safety, medical diagnostics, process controls,
security and defence, in addition to environmental monitoring.
Development of biosensors aims to create high-performance
electrochemical electrodes for diagnostics and biosensing. A
biosensor is a device that inspects the biological and chemical
reactions generated by the biological sample. A biosensor carries
out biological detection via a linked transducer and transmits the
biological response into an electrical signal; stability, selectivity,
and sensitivity are the dynamic and static characteristics that affect
and dictate the quality and performance of biosensors. In this
research, a developed experimental study for laser scribing technique
for graphene oxide inside a vacuum chamber for processing of
graphene oxide is presented. The processing of graphene oxide (GO)
was achieved using the laser scribing technique. The effect of the
laser scribing on the reduction of GO was investigated under two
conditions: atmosphere and vacuum. GO solvent was coated onto a
LightScribe DVD. The laser scribing technique was applied to reduce
GO layers to generate rGO. The micro-details for the morphological
structures of rGO and GO were visualised using scanning electron
microscopy (SEM) and Raman spectroscopy so that they could
be examined. The first electrode was a traditional graphene-based
electrode model, made under normal atmospheric conditions, whereas
the second model was a developed graphene electrode fabricated
under a vacuum state using a vacuum chamber. The purpose was
to control the vacuum conditions, such as the air pressure and the
temperature during the fabrication process. The parameters to be
assessed include the layer thickness and the continuous environment.
Results presented show high accuracy and repeatability achieving low
cost productivity.
Abstract: Society demands more reliable manufacturing processes
capable of producing high quality products in shorter production
cycles. New control algorithms have been studied to satisfy this
paradigm, in which Fault-Tolerant Control (FTC) plays a significant
role. It is suitable to detect, isolate and adapt a system when a harmful
or faulty situation appears. In this paper, a general overview about
FTC characteristics are exposed; highlighting the properties a system
must ensure to be considered faultless. In addition, a research to
identify which are the main FTC techniques and a classification
based on their characteristics is presented in two main groups:
Active Fault-Tolerant Controllers (AFTCs) and Passive Fault-Tolerant
Controllers (PFTCs). AFTC encompasses the techniques capable of
re-configuring the process control algorithm after the fault has been
detected, while PFTC comprehends the algorithms robust enough
to bypass the fault without further modifications. The mentioned
re-configuration requires two stages, one focused on detection,
isolation and identification of the fault source and the other one in
charge of re-designing the control algorithm by two approaches: fault
accommodation and control re-design. From the algorithms studied,
one has been selected and applied to a case study based on an
industrial hydraulic-press. The developed model has been embedded
under a real-time validation platform, which allows testing the FTC
algorithms and analyse how the system will respond when a fault
arises in similar conditions as a machine will have on factory. One
AFTC approach has been picked up as the methodology the system
will follow in the fault recovery process. In a first instance, the fault
will be detected, isolated and identified by means of a neural network.
In a second instance, the control algorithm will be re-configured to
overcome the fault and continue working without human interaction.
Abstract: Recently, crystal growth technologies have made
progress by the requirement for the high quality of crystal materials.
To control the crystal growth dynamics actively by external forces
is useuful for reducing composition non-uniformity. In this study,
a control method based on model predictive control using thermal
inputs is proposed for crystal growth dynamics of semiconductor
materials. The control system of crystal growth dynamics considered
here is governed by the continuity, momentum, energy, and mass
transport equations. To establish the control method for such thermal
fluid systems, we adopt model predictive control known as a kind
of optimal feedback control in which the control performance over
a finite future is optimized with a performance index that has a
moving initial time and terminal time. The objective of this study
is to establish a model predictive control method for crystal growth
dynamics of semiconductor materials.
Abstract: Quality measurement and reporting systems are used in healthcare internationally. In Australia, the Australian Council on Healthcare Standards records and reports hundreds of clinical indicators (CIs) nationally across the healthcare system. These CIs are measures of performance in the clinical setting, and are used as a screening tool to help assess whether a standard of care is being met. Existing analysis and reporting of these CIs incorporate Bayesian methods to address sampling variation; however, such assessments are retrospective in nature, reporting upon the previous six or twelve months of data. The use of Bayesian methods within statistical process control for monitoring systems is an important pursuit to support more timely decision-making. Our research has developed and assessed a new graphical monitoring tool, similar to a control chart, based on the beta-binomial posterior predictive (BBPP) distribution to facilitate the real-time assessment of health care organizational performance via CIs. The BBPP charts have been compared with the traditional Bernoulli CUSUM (BC) chart by simulation. The more traditional “central” and “highest posterior density” (HPD) interval approaches were each considered to define the limits, and the multiple charts were compared via in-control and out-of-control average run lengths (ARLs), assuming that the parameter representing the underlying CI rate (proportion of cases with an event of interest) required estimation. Preliminary results have identified that the BBPP chart with HPD-based control limits provides better out-of-control run length performance than the central interval-based and BC charts. Further, the BC chart’s performance may be improved by using Bayesian parameter estimation of the underlying CI rate.
Abstract: Industry accounts for one-third of global final energy demand. Crossover technologies (e.g. motors, pumps, process heat, and air conditioning) play an important role in improving energy efficiency. These technologies are used in many applications independent of the production branch. Especially electrical power is used by drives, pumps, compressors, and lightning. The paper demonstrates the algorithm of the energy analysis by some selected case studies for typical industrial processes. The energy analysis represents an essential part of energy management systems (EMS). Generally, process control system (PCS) can support EMS. They provide information about the production process, and they organize the maintenance actions. Combining these tools into an integrated process allows the development of an energy critical equipment strategy. Thus, asset and energy management can use the same common data to improve the energy efficiency.
Abstract: Water supply and sanitation in Saudi Arabia is portrayed by difficulties and accomplishments. One of the fundamental difficulties is water shortage. With a specific end goal to beat water shortage, significant ventures have been attempted in sea water desalination, water circulation, sewerage, and wastewater treatment. The motivation behind Statistical Process Control (SPC) is to decide whether the execution of a procedure is keeping up an acceptable quality level [AQL]. SPC is an analytical decision-making method. A fundamental apparatus in the SPC is the Control Charts, which follow the inconstancy in the estimations of the item quality attributes. By utilizing the suitable outline, administration can decide whether changes should be made with a specific end goal to keep the procedure in charge. The two most important quality factors in the distilled water which were taken into consideration were pH (Potential of Hydrogen) and TDS (Total Dissolved Solids). There were three stages at which the quality checks were done. The stages were as follows: (1) Water at the source, (2) water after chemical treatment & (3) water which is sent for packing. The upper specification limit, central limit and lower specification limit are taken as per Saudi water standards. The procedure capacity to accomplish the particulars set for the quality attributes of Berain water Factory chose to be focused by the proposed SPC system.
Abstract: In accordance with the industry 4.0 concept, manufacturing process steps as well as the materials themselves are going to be more and more digitalized within the next years. The “digital twin” representing the simulated and measured dataset of the (semi-finished) product can be used to control and optimize the individual processing steps and help to reduce costs and expenditure of time in product development, manufacturing, and recycling. In the present work, two material characterization methods based on Lamb waves were evaluated and compared. For demonstration purpose, both methods were shown at a standard industrial product - copper ribbons, often used in photovoltaic modules as well as in high-current microelectronic devices. By numerical approximation of the Rayleigh-Lamb dispersion model on measured phase velocities second order elastic constants (Young’s modulus, Poisson’s ratio) were determined. Furthermore, the effective third order elastic constants were evaluated by applying elastic, “non-destructive”, mechanical stress on the samples. In this way, small microstructural variations due to mechanical preconditioning could be detected for the first time. Both methods were compared with respect to precision and inline application capabilities. Microstructure of the samples was systematically varied by mechanical loading and annealing. Changes in the elastic ultrasound transport properties were correlated with results from microstructural analysis and mechanical testing. In summary, monitoring the elastic material properties of plate-like structures using Lamb waves is valuable for inline and non-destructive material characterization and manufacturing process control. Second order elastic constants analysis is robust over wide environmental and sample conditions, whereas the effective third order elastic constants highly increase the sensitivity with respect to small microstructural changes. Both Lamb wave based characterization methods are fitting perfectly into the industry 4.0 concept.
Abstract: This paper deals with the design of an intelligent control structure for a bioprocess of Hansenula polymorpha yeast cultivation. The objective of the process control is to produce biomass in a desired physiological state. The work demonstrates that the designed Hybrid Control Techniques (HCT) are able to recognize specific evolution bioprocess trajectories using neural networks trained specifically for this purpose, in order to estimate the model parameters and to adjust the overall bioprocess evolution through an expert system and a fuzzy structure. The design of the control algorithm as well as its tuning through realistic simulations is presented. Taking into consideration the synergism of different paradigms like fuzzy logic, neural network, and symbolic artificial intelligence (AI), in this paper we present a real and fulfilled intelligent control architecture with application in bioprocess control.
Abstract: This paper presents a contribution to the design of a multi-agent for the energy management system in a hybrid energy system (SEH). The multi-agent-based energy-coordination management system (MA-ECMS) is based mainly on coordination between agents. The agents share the tasks and exchange information through communications protocols to achieve the main goal. This intelligent system can fully manage the consumption and production or simply to make proposals for action he thinks is best. The initial step is to give a presentation for the system that we want to model in order to understand all the details as much as possible. In our case, it is to implement a system for simulating a process control of energy management.
Abstract: Although gun barrel steels are an important variety from defense view point, available literatures are very limited. In the present work, an IF grade Ni-Cr-Mo-V high strength low alloy steel is produced in Electric Earth Furnace-ESR Route. Ingot was hot forged to desired dimension with a reduction ratio of 70-75% followed by homogenization, hardening and tempering treatment. Sample chemistry, NMIR, macro and micro structural analyses were done. Mechanical properties which include tensile, impact, and fracture toughness were studied. Ultrasonic testing was done to identify internal flaws. The existing high strength low alloy Ni-Cr-Mo-V steel shows improved properties in modified processing route and heat treatment schedule in comparison to properties noted earlier for manufacturing of gun barrels. The improvement in properties seems to withstand higher explosive loads with the same amount of steel in gun barrel application.
Abstract: To improve the manufacturing efficiency of biologics, such as antibody drugs, a quality engineering framework was designed. Within this framework, critical steps and parameters in the manufacturing process were studied. Identification of these critical steps and critical parameters allows a deeper understanding of manufacturing capabilities, and suggests to process development department process control standards based on actual manufacturing capabilities as part of a PDCA (plan-do-check-act) cycle. This cycle can be applied to each manufacturing process so that it can be standardized, reducing the time needed to establish each new process.
Abstract: Fault diagnosis of Linear Parameter-Varying (LPV)
system using an adaptive Kalman filter is proposed. The LPV model
is comprised of scheduling parameters, and the emulator parameters.
The scheduling parameters are chosen such that they are capable of
tracking variations in the system model as a result of changes in the
operating regimes. The emulator parameters, on the other hand,
simulate variations in the subsystems during the identification phase
and have negligible effect during the operational phase. The nominal
model and the influence vectors, which are the gradient of the feature
vector respect to the emulator parameters, are identified off-line from
a number of emulator parameter perturbed experiments. A Kalman
filter is designed using the identified nominal model. As the system
varies, the Kalman filter model is adapted using the scheduling
variables. The residual is employed for fault diagnosis. The
proposed scheme is successfully evaluated on simulated system as
well as on a physical process control system.
Abstract: The garment manufacturing industry involves
sequential processes that are subjected to uncontrollable variations.
The industry depends on the skill of labour in handling the varieties
of fabrics and accessories, machines, as well as complicated sewing
operation. Due to these reasons, garment manufacturers have created
systems to monitor and to control the quality of the products on a
regular basis by conducting quality approaches to minimize variation.
With that, the aim of this research has been to ascertain the quality
approaches deployed by Malaysian garment manufacturers in three
key areas - quality systems and tools; quality control and types of
inspection; as well as sampling procedures chosen for garment
inspection. Besides, the focus of this research was to distinguish the
quality approaches adopted by companies that supplied finished
garments to both domestic and international markets. Feedback from
each company representative has been obtained via online survey,
which comprised of five sections and 44 questions on the
organizational profile and the quality approaches employed in the
garment industry. As a result, the response rate was 31%. The results
revealed that almost all companies have established their own
mechanism of process control by conducting a series of quality
inspections for daily production, either it was formally set up or
otherwise. In addition, quality inspection has been the predominant
quality control activity in the garment manufacturing, while the level
of complexity of these activities was substantially dictated by the
customers. Moreover, AQL-based sampling was utilized by
companies dealing with exports, whilst almost all the companies that
only concentrated on the domestic market were comfortable using
their own sampling procedures for garment inspection. Hence, this
research has provided insights into the implementation of a number
of quality approaches that were perceived as important and useful in
the garment manufacturing sector, which is truly labour-intensive.
Abstract: Different terms of the Statistical Process Control (SPC)
has sketch in the fuzzy environment. However, Measurement System
Analysis (MSA), as a main branch of the SPC, is rarely investigated
in fuzzy area. This procedure assesses the suitability of the data to be
used in later stages or decisions of the SPC. Therefore, this research
focuses on some important measures of MSA and through a new
method introduces the measures in fuzzy environment. In this
method, which works based on Buckley approach, imprecision and
vagueness nature of the real world measurement are considered
simultaneously. To do so, fuzzy version of the gauge capability (Cg
and Cgk) are introduced. The method is also explained through
example clearly.
Abstract: The work aims to develop a robot in the form of
autonomous vehicle to detect, inspection and mapping of
underground pipelines through the ATmega328 Arduino platform.
Hardware prototyping is very similar to C / C ++ language that
facilitates its use in robotics open source, resembles PLC used in
large industrial processes. The robot will traverse the surface
independently of direct human action, in order to automate the
process of detecting buried pipes, guided by electromagnetic
induction. The induction comes from coils that send the signal to the
Arduino microcontroller contained in that will make the difference in
intensity and the treatment of the information, and then this
determines actions to electrical components such as relays and
motors, allowing the prototype to move on the surface and getting the
necessary information. This change of direction is performed by a
stepper motor with a servo motor. The robot was developed by
electrical and electronic assemblies that allowed test your application.
The assembly is made up of metal detector coils, circuit boards and
microprocessor, which interconnected circuits previously developed
can determine, process control and mechanical actions for a robot
(autonomous car) that will make the detection and mapping of buried
pipelines plates. This type of prototype can prevent and identifies
possible landslides and they can prevent the buried pipelines suffer an
external pressure on the walls with the possibility of oil leakage and
thus pollute the environment.
Abstract: Quality control helps industries in improvements of its
product quality and productivity. Statistical Process Control (SPC) is
one of the tools to control the quality of products that turning practice
in bringing a department of industrial engineering process under
control. In this research, the process control of a turning
manufactured at workshops machines. The varying measurements
have been recorded for a number of samples of a rice polished
cylinder obtained from a number of trials with the turning practice.
SPC technique has been adopted by the process is finally brought
under control and process capability is improved.
Abstract: In this paper the intelligent control of full automatic car wash using a programmable logic controller (PLC) has been investigated and designed to do all steps of carwashing. The Intelligent control of full automatic carwash has the ability to identify and profile the geometrical dimensions of the vehicle chassis. Vehicle dimension identification is an important point in this control system to adjust the washing brushes position and time duration. The study also tries to design a control set for simulating and building the automatic carwash. The main purpose of the simulation is to develop criteria for designing and building this type of carwash in actual size to overcome challenges of automation. The results of this research indicate that the proposed method in process control not only increases productivity, speed, accuracy and safety but also reduce the time and cost of washing based on dynamic model of the vehicle. A laboratory prototype based on an advanced intelligent control has been built to study the validity of the design and simulation which it’s appropriate performance confirms the validity of this study.
Abstract: The paper gives the results of the project that was oriented on the usage of knowledge discoveries from production systems for needs of the hierarchical process control. One of the main project goals was the proposal of knowledge discovery model for process control. Specifics data mining methods and techniques was used for defined problems of the process control. The gained knowledge was used on the real production system thus the proposed solution has been verified. The paper documents how is possible to apply the new discovery knowledge to use in the real hierarchical process control. There are specified the opportunities for application of the proposed knowledge discovery model for hierarchical process control.
Abstract: A numerical simulation of optimization all of electrospinning processing parameters to obtain smallest nanofiber diameter have been performed by employing genetic algorithm (GA). Fitness function in genetic algorithm methods, which was different for each parameter, was determined by simulation approach based on the Reneker’s model. Moreover, others genetic algorithm parameter, namely length of population, crossover and mutation were applied to get the optimum electrospinning processing parameters. In addition, minimum fiber diameter, 32 nm, was achieved from a simulation by applied the optimum parameters of electrospinning. This finding may be useful for process control and prediction of electrospun fiber production. In this paper, it is also compared between predicted parameters with some experimental results.