Abstract: The industrial automation is dependent upon pneumatic control systems. The industrial units are now controlled with digital control systems to tackle the process variables like Temperature, Pressure, Flow rates and Composition.
This research work produces an evaluation of the response time fluctuations for proportional mode, proportional integral and proportional integral derivative modes of automated chemical process control. The controller output is measured for different values of gain with respect to time in three modes (P, PI and PID). In case of P-mode for different values of gain the controller output has negligible change. When the controller output of PI-mode is checked for constant gain, it can be seen that by decreasing the integral time the controller output has showed more fluctuations. The PID mode results have found to be more interesting in a way that when rate minute has changed, the controller output has also showed fluctuations with respect to time. The controller output for integral mode and derivative mode are observed with lesser steady state error, minimum offset and larger response time to control the process variable. The tuning parameters in case of P-mode are only steady state gain with greater errors with respect to controller output. The integral mode showed controller outputs with intermediate responses during integral gain (ki). By increasing the rate minute the derivative gain (kd) also increased which showed the controlled oscillations in case of PID mode and lesser overshoot.
Abstract: In the highly competitive and rapidly changing global
marketplace, independent organizations and enterprises often come
together and form a temporary alignment of virtual enterprise in a
supply chain to better provide products or service. As firms adopt the
systems approach implicit in supply chain management, they must
manage the quality from both internal process control and external
control of supplier quality and customer requirements. How to
incorporate quality management of upstream and downstream supply
chain partners into their own quality management system has recently
received a great deal of attention from both academic and practice.
This paper investigate the collaborative feature and the entities-
relationship in a supply chain, and presents an ontology of
collaborative supply chain from an approach of aligning
service-oriented framework with service-dominant logic. This
perspective facilitates the segregation of material flow management
from manufacturing capability management, which provides a
foundation for the coordination and integration of the business process
to measure, analyze, and continually improve the quality of products,
services, and process. Further, this approach characterizes the different
interests of supply chain partners, providing an innovative approach to
analyze the collaborative features of supply chain. Furthermore, this
ontology is the foundation to develop quality management system
which internalizes the quality management in upstream and
downstream supply chain partners and manages the quality in supply
chain systematically.
Abstract: Bioprocesses are appreciated as difficult to control because their dynamic behavior is highly nonlinear and time varying, in particular, when they are operating in fed batch mode. The research objective of this study was to develop an appropriate control method for a complex bioprocess and to implement it on a laboratory plant. Hence, an intelligent control structure has been designed in order to produce biomass and to maximize the specific growth rate.
Abstract: Modeling of complex dynamic systems, which are
very complicated to establish mathematical models, requires new and
modern methodologies that will exploit the existing expert
knowledge, human experience and historical data. Fuzzy cognitive
maps are very suitable, simple, and powerful tools for simulation and
analysis of these kinds of dynamic systems. However, human experts
are subjective and can handle only relatively simple fuzzy cognitive
maps; therefore, there is a need of developing new approaches for an
automated generation of fuzzy cognitive maps using historical data.
In this study, a new learning algorithm, which is called Big Bang-Big
Crunch, is proposed for the first time in literature for an automated
generation of fuzzy cognitive maps from data. Two real-world
examples; namely a process control system and radiation therapy
process, and one synthetic model are used to emphasize the
effectiveness and usefulness of the proposed methodology.
Abstract: Monitoring and control of cane sugar crystallization
processes depend on the stability of the supersaturation (σ ) state.
The most widely used information to represent σ is the electrical
conductivity κ of the solutions. Nevertheless, previous studies point
out the shortcomings of this approach: κ may be regarded as
inappropriate to guarantee an accurate estimation of σ in impure
solutions. To improve the process control efficiency, additional
information is necessary. The mass of crystals in the solution ( c m )
and the solubility (mass ratio of sugar to water / s w m m ) are relevant
to complete information. Indeed, c m inherently contains information
about the mass balance and / s w m m contains information about the
supersaturation state of the solution. The main problem is that c m
and / s w m m are not available on-line. In this paper, a model based
soft-sensor is presented for a final crystallization stage (C sugar).
Simulation results obtained on industrial data show the reliability of
this approach, c m and the crystal content ( cc ) being estimated with
a sufficient accuracy for achieving on-line monitoring in industry
Abstract: recurrent neural network (RNN) is an efficient tool for
modeling production control process as well as modeling services. In
this paper one RNN was combined with regression model and were
employed in order to be checked whether the obtained data by the
model in comparison with actual data, are valid for variable process
control chart. Therefore, one maintenance process in workshop of
Esfahan Oil Refining Co. (EORC) was taken for illustration of
models. First, the regression was made for predicting the response
time of process based upon determined factors, and then the error
between actual and predicted response time as output and also the
same factors as input were used in RNN. Finally, according to
predicted data from combined model, it is scrutinized for test values
in statistical process control whether forecasting efficiency is
acceptable. Meanwhile, in training process of RNN, design of
experiments was set so as to optimize the RNN.
Abstract: When an assignable cause(s) manifests itself to a multivariate process and the process shifts to an out-of-control condition, a root-cause analysis should be initiated by quality engineers to identify and eliminate the assignable cause(s) affected the process. A root-cause analysis in a multivariate process is more complex compared to a univariate process. In the case of a process involved several correlated variables an effective root-cause analysis can be only experienced when it is possible to identify the required knowledge including the out-of-control condition, the change point, and the variable(s) responsible to the out-of-control condition, all simultaneously. Although literature addresses different schemes to monitor multivariate processes, one can find few scientific reports focused on all the required knowledge. To the best of the author’s knowledge this is the first time that a multi task model based on artificial neural network (ANN) is reported to monitor all the required knowledge at the same time for a multivariate process with more than two correlated quality characteristics. The performance of the proposed scheme is evaluated numerically when different step shifts affect the mean vector. Average run length is used to investigate the performance of the proposed multi task model. The simulated results indicate the multi task scheme performs all the required knowledge effectively.
Abstract: The most common type of controller being used in
the industry is PI(D) controller which has been used since 1945 and
is still being widely used due to its efficiency and simplicity. In
most cases, the PI(D) controller was tuned without taking into
consideration of the effect of actuator saturation. In real processes,
the most common actuator which is valve will act as constraint and
restrict the controller output. Since the controller is not designed to
encounter saturation, the process may windup and consequently
resulted in large oscillation or may become unstable. Usually, an
antiwindup compensator is added to the feedback control loop to
reduce the deterioration effect of integral windup. This research
aims to specifically control processes with constraints. The
proposed method was applied to two different types of food
processes, which are blending and spray drying. Simulations were
done using MATLAB and the performances of the proposed
method were compared with other conventional methods. The
proposed technique was able to control the processes and avoid
saturation such that no anti windup compensator is needed.
Abstract: This paper presents an alternate approach that uses
artificial neural network to simulate the flood level dynamics in a
river basin. The algorithm was developed in a decision support
system environment in order to enable users to process the data. The
decision support system is found to be useful due to its interactive
nature, flexibility in approach and evolving graphical feature and can
be adopted for any similar situation to predict the flood level. The
main data processing includes the gauging station selection, input
generation, lead-time selection/generation, and length of prediction.
This program enables users to process the flood level data, to
train/test the model using various inputs and to visualize results. The
program code consists of a set of files, which can as well be modified
to match other purposes. This program may also serve as a tool for
real-time flood monitoring and process control. The running results
indicate that the decision support system applied to the flood level
seems to have reached encouraging results for the river basin under
examination. The comparison of the model predictions with the
observed data was satisfactory, where the model is able to forecast
the flood level up to 5 hours in advance with reasonable prediction
accuracy. Finally, this program may also serve as a tool for real-time
flood monitoring and process control.
Abstract: Process measurement is the task of empirically and objectively assigning numbers to the properties of business processes in such a way as to describe them. Desirable attributes to study and measure include complexity, cost, maintainability, and reliability. In our work we will focus on investigating process complexity. We define process complexity as the degree to which a business process is difficult to analyze, understand or explain. One way to analyze a process- complexity is to use a process control-flow complexity measure. In this paper, an attempt has been made to evaluate the control-flow complexity measure in terms of Weyuker-s properties. Weyuker-s properties must be satisfied by any complexity measure to qualify as a good and comprehensive one.
Abstract: Usually, the solid-fuel flow of an iron ore sinter plant
consists of different types of the solid-fuels, which differ from each
other. Information about the composition of the solid-fuel flow
usually comes every 8-24 hours. It can be clearly seen that this
information cannot be used to control the sintering process in real
time. Due to this, we propose an expert system which uses indirect
measurements from the process in order to obtain the composition of
the solid-fuel flow by solving an optimization task. Then this
information can be used to control the sintering process. The
proposed technique can be successfully used to improve sinter
quality and reduce the amount of solid-fuel used by the process.
Abstract: Efforts to secure supervisory control and data acquisition
(SCADA) systems must be supported under the guidance of
sound security policies and mechanisms to enforce them. Critical
elements of the policy must be systematically translated into a format
that can be used by policy enforcement components. Ideally, the
goal is to ensure that the enforced policy is a close reflection of
the specified policy. However, security controls commonly used to
enforce policies in the IT environment were not designed to satisfy
the specific needs of the SCADA environment. This paper presents
a language, based on the well-known XACML framework, for the
expression of authorization policies for SCADA systems.
Abstract: In process control applications, above 90% of the
controllers are of PID type. This paper proposed a robust PI
controller with fractional-order integrator. The PI parameters were
obtained using classical Ziegler-Nichols rules but enhanced with the
application of error filter cascaded to the fractional-order PI. The
controller was applied on steam temperature process that was
described by FOPDT transfer function. The process can be classified
as lag dominating process with very small relative dead-time. The
proposed control scheme was compared with other PI controller
tuned using Ziegler-Nichols and AMIGO rules. Other PI controller
with fractional-order integrator known as F-MIGO was also
considered. All the controllers were subjected to set point change and
load disturbance tests. The performance was measured using Integral
of Squared Error (ISE) and Integral of Control Signal (ICO). The
proposed controller produced best performance for all the tests with
the least ISE index.
Abstract: One of the most basic functions of control engineers is
tuning of controllers. There are always several process loops in the
plant necessitate of tuning. The auto tuned Proportional Integral
Derivative (PID) Controllers are designed for applications where
large load changes are expected or the need for extreme accuracy and
fast response time exists. The algorithm presented in this paper is
used for the tuning PID controller to obtain its parameters with a
minimum computing complexity. It requires continuous analysis of
variation in few parameters, and let the program to do the plant test
and calculate the controller parameters to adjust and optimize the
variables for the best performance. The algorithm developed needs
less time as compared to a normal step response test for continuous
tuning of the PID through gain scheduling.
Abstract: This paper deals with the application of Principal Component Analysis (PCA) and the Hotelling-s T2 Chart, using data collected from a drinking water treatment process. PCA is applied primarily for the dimensional reduction of the collected data. The Hotelling-s T2 control chart was used for the fault detection of the process. The data was taken from a United Utilities Multistage Water Treatment Works downloaded from an Integrated Program Management (IPM) dashboard system. The analysis of the results show that Multivariate Statistical Process Control (MSPC) techniques such as PCA, and control charts such as Hotelling-s T2, can be effectively applied for the early fault detection of continuous multivariable processes such as Drinking Water Treatment. The software package SIMCA-P was used to develop the MSPC models and Hotelling-s T2 Chart from the collected data.
Abstract: For the electrical metrics that describe photovoltaic
cell performance are inherently multivariate in nature, use of a
univariate, or one variable, statistical process control chart can have
important limitations. Development of a comprehensive process
control strategy is known to be significantly beneficial to reducing
process variability that ultimately drives up the manufacturing cost
photovoltaic cells. The multivariate moving average or MMA chart,
is applied to the electrical metrics of photovoltaic cells to illustrate
the improved sensitivity on process variability this method of control
charting offers. The result show the ability of the MMA chart to
expand to as any variables as needed, suggests an application
with multiple photovoltaic electrical metrics being used in
concert to determine the processes state of control.
Abstract: Process control and energy conservation are the two
primary reasons for using an adjustable speed drive. However,
voltage sags are the most important power quality problems facing
many commercial and industrial customers. The development of
boost converters has raised much excitement and speculation
throughout the electric industry. Now utilities are looking to these
devices for performance improvement and reliability in a variety of
areas. Examples of these include sags, spikes, or transients in supply
voltage as well as unbalanced voltages, poor electrical system
grounding, and harmonics. In this paper, simulations results are
presented for the verification of the proposed boost converter
topology. Boost converter provides ride through capability during
sag and swell. Further, input currents are near sinusoidal. This
eliminates the need of braking resistor also.
Abstract: In manufacturing industries, development of measurement leads to increase the number of monitoring variables and eventually the importance of multivariate control comes to the fore. Statistical process control (SPC) is one of the most widely used as multivariate control chart. Nevertheless, SPC is restricted to apply in processes because its assumption of data as following specific distribution. Unfortunately, process data are composed by the mixture of several processes and it is hard to estimate as one certain distribution. To alternative conventional SPC, therefore, nonparametric control chart come into the picture because of the strength of nonparametric control chart, the absence of parameter estimation. SVDD based control chart is one of the nonparametric control charts having the advantage of flexible control boundary. However,basic concept of SVDD has been an oversight to the important of data characteristic, density distribution. Therefore, we proposed DW-SVDD (Density Weighted SVDD) to cover up the weakness of conventional SVDD. DW-SVDD makes a new attempt to consider dense of data as introducing the notion of density Weight. We extend as control chart using new proposed SVDD and a simulation study of various distributional data is conducted to demonstrate the improvement of performance.
Abstract: This paper presents an advance in monitoring and
process control of surface roughness in CNC machine for the turning
and milling processes. An integration of the in-process monitoring
and process control of the surface roughness is proposed and
developed during the machining process by using the cutting force
ratio. The previously developed surface roughness models for turning
and milling processes of the author are adopted to predict the inprocess
surface roughness, which consist of the cutting speed, the
feed rate, the tool nose radius, the depth of cut, the rake angle, and
the cutting force ratio. The cutting force ratios obtained from the
turning and the milling are utilized to estimate the in-process surface
roughness. The dynamometers are installed on the tool turret of CNC
turning machine and the table of 5-axis machining center to monitor
the cutting forces. The in-process control of the surface roughness
has been developed and proposed to control the predicted surface
roughness. It has been proved by the cutting tests that the proposed
integration system of the in-process monitoring and the process
control can be used to check the surface roughness during the cutting
by utilizing the cutting force ratio.
Abstract: Development of intelligent assembly cell conception includes new solution kind of how to create structures of automated and flexible assembly system. The current trend of the final product quality increasing is affected by time analysis of the entire manufacturing process. The primary requirement of manufacturing is to produce as many products as soon as possible, at the lowest possible cost, but of course with the highest quality. Such requirements may be satisfied only if all the elements entering and affecting the production cycle are in a fully functional condition. These elements consist of sensory equipment and intelligent control elements that are essential for building intelligent manufacturing systems. Intelligent behavior of the system as the control system will repose on monitoring of important parameters of the system in the real time. Intelligent manufacturing system itself should be a system that can flexibly respond to changes in entering and exiting the process in interaction with the surroundings.