Principles of Constructing a HIL Simulation Stand for Debugging Automated Process Control Systems based on the Baget PLC

Current development of power engineering in Russia is characterized by deployment of power units with distributed multifunctional automatic process control systems (APCS) based on software and hardware systems (I&C) complex with hierarchical network structure. I&C is the backbone of this structure and APCS creates common information and technological environment of the power unit. Key issues of the multifunctional APCS are associated with lack of the technical efficiency of the I&C, usage of unproven control algorithms and immaturity of the system development technology. Overcoming the identified key issues in the development of the technology of creating I&C and APCS as a whole is associated with the formation of special functionality developed by I&C, their capabilities to use mathematical models of control objects and processes in real time (RT), assessing the information properties of controlled and uncontrolled parameters and generated signals. Performance paradigm (price/quality) of the APCS which answers on these questions can be received only after putting system in the operation and caring additional work on the assessment and optimization of information-functional and technical structures of APCS. The report discusses some new results in solving the indicated issues as part of improving the technology of modern APCS and prospects for their development as the main scientific direction of the Department of Automatic control Systems of ISPU.

The purpose of this study is to develop a new conceptual approach to the modernization of existing industrial operated automated process control systems (IOAP CS) in order to integrate them into the technology of building digital twins and digital factories with minimal expenditure of computing resources and reducing the amount of processed data. To solve this problem, it is proposed to modify existing automated process control systems (IOAP CS) sequentially by automation levels so that the volume of redundant information is reduced in the structures of the levels, as well as predicting the values of technological parameters based on the properties of control objects using artificial intelligence in order to use identical values in automated process control systems (IOAP CS) and in their models of digital twins. To obtain information about technological processes with a low degree of automation, it is proposed to use organizational and technical structures based on the theory of graphs with a finite vertex, reflecting the volume and quality of the products obtained using algorithms based on artificial intelligence tools, which make it possible to predict the result of subsequent ones based on the results of the previous stage, taking into account the accumulated experience, this will enable an expert assessment of the correctness of the technological process to achieve the required product properties and performance of the technological unit. The proposed concept of modification of automated control systems (IOAP CS) for technological processes in operation will make it possible to ensure the transition to building digital counterparts of technological processes with minimal time using available computing resources with minimal loss of the volume of products.

Within industry today, advancements in process and control technologies have given way to differing control systems in the form of programmable logic controllers (PLC) and distributed control systems (DCS). Over the past decade, PLCs have now been able to bridge certain gaps within process and control systems that were capabilities only typically found within DCS environments. This paper will provide an overview of various control system strategies and design considerations with regard to both PLC and DCS schemes within petrochemical applications.

For modern high-speed rolling mills, stable and efficient operation is possible only with the use of automatic process control systems. Such systems involve the use of certain process models, both for control and technology development. Therefore, research aimed at improving existing models of the process of rolling rods and developing new ones remains relevant.
 The aim is to improve the model of the process of rolling rods of round cross-section using a system of passes "oval-round", suitable for the development of technology (determining the size of pass and power parameters) and as software for automatic process control systems.
 A characteristic difference of the proposed improved model is the application of the condition of volume constancy to determine not only the speed but also the deformation parameters of rolling. Features of the model also include the appointment of the ratio of the axes of oval passes and the use of the rate of mismatch in the interstand spaces to control and minimize tension.The sequence of calculations in the model includes an iterative procedure with three mandatory approximations, which involves adjusting the coefficients of elongation using the condition of constant volume, and adjusting the size of the workpieces using speed mismatch as a factor characterizing the corresponding tension or compressive.
 The model uses known expression and geometric relationships, the combination and sequence of which provides the definition of technological parameters and sizes of roll passes with the required accuracy. The program can be implemented in various forms depending on the needs, from the most common applications to environments of professional computer systems. The model can be used as a basis for the development of systems for automatic control of the rolling process for the conditions of the existing mills.

Modern automated process control systems that use programmable logic controllers use software controllers based on the proportional integral-differential control law, the PID controller. In most cases, this regulator is sufficient for conducting the technological process. It has high performance with configurable and sufficient quality of regulation. However, using a PID controller for non-linear, poorly defined, multi-connected objects with a long delay time can lead to unstable control quality indicators, accumulation of errors, and ultimately to a deterioration in product quality. One of the most promising methods of control is Model Predictive Control - MPC. The method base on predictive models of control objects. The quality of the controller's control depends on how well the system dynamics described by the model used to design the controller. In most cases, MPC-based control use to handle optimal control problems on the Manufacturing Execution System-MES. However, thanks to the development of microprocessors and increased CPU performance, it becomes possible to apply the principles of control with a predictive model at a lower level, and perform real-time operational control in optimal modes. The work presents the algorithm of MPC controller. The control object is a SISO object with a nonlinear characteristic and a long transition process. Studies of the developed MPC regulator showed that the quality of regulation, compared to the PID regulator, increased by more than 20%, the time to get to set point decreased, and there was almost no over-regulation. The most effective application of the MPC controller is seen in processes with long transitions and with a significant delay time.

The gasoline blending station is a key unit at an oil refinery, ensuring the production of finished products compliant with modern technical specifications. The purpose of this study is a comprehensive analysis of the technological process and layout of a gasoline blending station operating at an oil refinery in Uzbekistan. The investigation covers the feedstock base, equipment, sequence of operations, automated process control system, and features of enhanced fuel production. The process is based on the compounding of three components-light naphtha, reformate, and butane fraction-followed by the addition of specialized detergent additives to produce QuWatt-branded fuel. A critical factor ensuring consistent product quality is the adjustment of the blending recipe based on real-time laboratory data on the properties of the feedstock components. The analysis confirms a high level of reliability and safety of the unit, achieved through a multi-level system of alarms, interlocks, and automatic regulation, enabling effective control of the complex technological process and the production of gasoline grades strictly in accordance with national standards.

The paper analyzes the tasks of producing high-quality iron ore concentrates suitable for nonblast-furnace metallurgy and the challenges of processing magnetite ores with the current technological level of dressing equipment and technologies. One of the best methods to improve the quality and the grade of iron ore raw materials is the use of magnetic gravity separation in the technological process, which allows selective separation of the liberated magnetite particles from their aggregates in processing of undersize products of fine vibrating screening. This trend is implemented in the innovative magnetite ore processing technology that uses the principle of the staged output of finished concentrate. The technology makes it possible to produce a high-quality concentrate after the first grinding stage. The magnetic gravity separation has undergone industrial validation, has proven its efficiency in practice, and has become widespread at mining and processing plants not only in Russia, but also in the CIS countries. Over 180 MGS-2.0 magnetic gravity separators produced by Russian manufacturers have already been or are being implemented at various Russian and CIS companies. Industrial separators are equipped with modern automation systems providing high technological separation performance, have no rotating parts and are simple in design. The authors continue R&D works on creation of automated control systems for the magnetic gravity separation process based on designing digital models adapted for introduction into the plant’s automated process control systems.

A centralized graphical user interface has been added to the DIII-D neutral beam (NB) control systems for status monitoring and remote control applications. This user interface provides for automatic data acquisition, alarm detection and supervisory control of the four NB programmable logic controllers (PLC) as well as the mode control PLC. These PLCs are used for interlocking, control and status of the NB vacuum pumping, gas delivery, and water cooling systems as well as beam mode status and control. The system allows for both a friendly user interface as well as a safe and convenient method of communicating with remote hardware that formerly required interruption of machine operations to access. In the future, to enable high level of control of PLC subsystems, complete procedures can be written and executed at the touch of a screen control panel button. The system consists of an IBM compatible 486 computer running the FIX DMACS for Windows data acquisition and control operator interface software, a Texas Instruments/Siemens communication card and Phoenix Digital optical communications modules. Communication is achieved via the TIWAY (Texas Instruments) protocol link utilizing both fiber optic communications and a copper local area network (LAN). Hardware and software capabilities will be reviewed. Data and alarm reporting, extended monitoring and control capabilities will also be discussed.

The article presents the results of the analysis of business processes of pasta production. According to the concept of lean production, types of losses during the production of pasta products were identified. Among the causes of losses are a high proportion of unregulated interruptions, cases of incomplete production in a shift, the presence of downtime due to technological equipment failures, and the laboriousness of manual operations. Taking into account the high importance of optimization of production business processes, emphasis is placed on the expediency of using lean production tools to eliminate losses. The standard SCADA system ‒ TRACE MODE with pre-developed functional schemes for processing grain into flour in the cross-platform Ramus system using CASE technologies was used to develop an automatic process control system. The description of the developed automatic control system for the technological process of flour disinfection using the energy of ultra-high frequency electromagnetic radiation is given. The proposed automatic technological process control system using a disinfectant will speed up and, accordingly, reduce the cost of production. a promising method of drying is proposed - with an infrared energy supply, which ensures obtaining a final product with high quality characteristics, reducing energy consumption and shortening the duration of the drying process. The use of silent heating elements will reduce the noise level at the enterprise; Modernization of technological equipment made it possible to ensure: the possibility of producing pasta products of higher quality; compaction of the structure of the semi-finished product and reduction of its fragility, while simultaneously increasing the strength limit of finished products by 20-25%; improvement of consumer properties, as well as sanitary and hygienic indicators of pasta products due to its pasteurization; decrease in moisture absorption and loss of nutritional value during storage.

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.

The numerous benefits of automatic application code generation are widely accepted within the software engineering community. A few of these benefits include raising the abstraction level of application programming, shorter product development time, lower maintenance costs, and increased code quality and consistency. Surprisingly, code generation concepts have not yet found wide acceptance and use in the field of programmable logic controller (PLC) software development. Software engineers at the NASA Kennedy Space Center (KSC) recognized the need for PLC code generation while developing their new ground checkout and launch processing system. They developed a process and a prototype software tool that automatically translates a high-level representation or specification of safety critical application software into ladder logic that executes on a PLC. This process and tool are expected to increase the reliability of the PLC code over that which is written manually, and may even lower life-cycle costs and shorten the development schedule of the new control system at KSC. This paper examines the problem domain and discusses the process and software tool that were prototyped by the KSC software engineers.

The issues of automation of technological processes in metalworking are considered. A program for the implementation of a drilling machine automatic control based on a programmable logic controller (PLC) is given. Keywords automation in mechanical engineering, technological process, programmable logic controller, visualization, emulation

The study reports the results of a comparative analysis of advanced high-accuracy Stewart-lift platform along with a comparative study of dynamic control. A control system powered by a programmable logic controller (PLC) was used. The properties of the system were described using a dynamic model using the Lagrange method. The real object was verified by performing several tests and comparing them using quality indicators. The results of verification tests conclusively demonstrate the system suitability for applications within industrial automation and robotics systems.

The analysis of publications revealed a lack of research on assessing economic indicators when introducing artificial intelligence into technological and production processes. In this regard, the authors aim to find and analyze published methods for assessing the economic effectiveness of automation of production processes using AI. It is rather difficult to evaluate the cost-effectiveness of AI introduced into production for the purpose of automation. Artificial intelligence in automated process control systems is a competitor to deductible means that are the basis of such systems. AI allows improving the quality of a number of functions performed by these means, for example, enhancing the quality of regulation. This, in turn, leads to a rise in the quality of products. However, it is challenging to assess in advance how this event will affect the profitability from the sale of these products. The article developed a methodology for assessing the economic effectiveness of the AI introduction.

The Proportional-Integral-Derivative (PID) controller, already known for its stability, is widely used in industrial applications and integrated into many Programmable Logic Controllers (PLCs). However, most PLCs do not support the self-tuning mechanism for PID controller parameters. Therefore, users must manually adjust several times to achieve the desired outcomes. This manual adjustment is time-consuming and must be repeated as control object parameters change over time. This study proposed a fine-tuning mechanism for the PID controller’s parameters based on a fuzzy-PD controller. The mechanism was designed and simulated using MATLAB/Simulink on an identified plant, then converted into a Structured Control Language (SCL) code for implementation on the PLC programs.Experimental results on the Siemens S7-1200 PLC demonstrated the proposed mechanism’s effectiveness in stabilizing the thermal plant by adjusting the initial parameters of the integrated PID controller. The system response was more stable, and the overshoot was minimized in comparison with the built-in auto-tuning feature on the S7-1200. Specifically, overshoot decreased to 0.79% from 0.94%, and the setting error declined to 0.1 °C from 0.45 °C. The above results indicate the effectiveness of the proposed self-tuning mechanism when used to improve the quality of PID controllers in PLCs. In addition, due to its ability to self-tuning parameters, it helps users reduce the time required to design PID controllers.