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: 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: 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: 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: 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: 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: 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: Traditional multivariate control charts assume that measurement from manufacturing processes follows a multivariate normal distribution. However, this assumption may not hold or may be difficult to verify because not all the measurement from manufacturing processes are normal distributed in practice. This study develops a new multivariate control chart for monitoring the processes with non-normal data. We propose a mechanism based on integrating the one-class classification method and the adaptive technique. The adaptive technique is used to improve the sensitivity to small shift on one-class classification in statistical process control. In addition, this design provides an easy way to allocate the value of type I error so it is easier to be implemented. Finally, the simulation study and the real data from industry are used to demonstrate the effectiveness of the propose control charts.
Abstract: The Programmable Logic Controller (PLC) plays a
vital role in automation and process control. Grafcet is used for
representing the control logic, and traditional programming
languages are used for describing the pure algorithms. Grafcet is used
for dividing the process to be automated in elementary sequences that
can be easily implemented. Each sequence represent a step that has
associated actions programmed using textual or graphical languages
after case. The programming task is simplified by using a set of
subroutines that are used in several steps. The paper presents an
example of implementation for a punching machine for sheets and
plates. The use the graphical languages the programming of a
complex sequential process is a necessary solution. The state of
Grafcet can be used for debugging and malfunction determination.
The use of the method combined with a set of knowledge acquisition
for process application reduces the downtime of the machine and
improve the productivity.
Abstract: In the semiconductor manufacturing process, large
amounts of data are collected from various sensors of multiple
facilities. The collected data from sensors have several different characteristics
due to variables such as types of products, former processes
and recipes. In general, Statistical Quality Control (SQC) methods
assume the normality of the data to detect out-of-control states of
processes. Although the collected data have different characteristics,
using the data as inputs of SQC will increase variations of data,
require wide control limits, and decrease performance to detect outof-
control. Therefore, it is necessary to separate similar data groups
from mixed data for more accurate process control. In the paper,
we propose a regression tree using split algorithm based on Pearson
distribution to handle non-normal distribution in parametric method.
The regression tree finds similar properties of data from different
variables. The experiments using real semiconductor manufacturing
process data show improved performance in fault detecting ability.
Abstract: Control chart pattern recognition is one of the most important tools to identify the process state in statistical process control. The abnormal process state could be classified by the recognition of unnatural patterns that arise from assignable causes. In this study, a wavelet based neural network approach is proposed for the recognition of control chart patterns that have various characteristics. The procedure of proposed control chart pattern recognizer comprises three stages. First, multi-resolution wavelet analysis is used to generate time-shape and time-frequency coefficients that have detail information about the patterns. Second, distance based features are extracted by a bi-directional Kohonen network to make reduced and robust information. Third, a back-propagation network classifier is trained by these features. The accuracy of the proposed method is shown by the performance evaluation with numerical results.