Real Time Automation and Ratio Control Using PLC&SCADA in Industry 4.0

Industrial Control Systems(ICS)and SCADA(Supervisory Control and Data Acquisition)systems play a critical role in the management and regulation of critical infrastructure.SCADA systems brings us closer to the real-time application world.All process and equipment control capability is typically provided by a Distributed Control System(DCS)in industries such as power stations,agricultural systems,chemical and water treatment plants.Instead of control through DCS,this paper proposes a SCADA and PLC(Programmable Logic Controller)system to control the ratio control division and the assembly line division inside the chemical plant.A specific design and implementation method for development of SCADA/PLC based real time ratio control and automated assembly line system in a chemical plant is introduced.The assembly line division is further divided into sorting stage,filling stage and the auxiliary stage,which includes the capping unit,labelling unit and then the storage.In the ratio control division,we have defined the levels inside the mixer and ratio of the raw materials through human machine interface(HMI)panel.The ratio of raw materials is kept constant on the basis of flow rates of wild stream and manipulated stream.There is a flexibility in defining new levels and the ratios of the raw materials inside the mixer.But here we taken the predefined levels(low,medium,high)and ratios(3:4,2:1,2:5).Control valves are used for regulating the flow of the compositions.In the assembly line division,the containers are sorted on the basis of size and type of material used i.e.,big sized metallic containers and small sized non-metallic containers by inductive and capacitive proximity sensors.All the processes are facilitated with laser beam type or reflective type sensors on the conveyor system.Building a highly stable and dependable PLC/SCADA system instead of Distributed Control System is required to achieve automatic management and control of chemical industry processes to reduce waste manpower and physical resources,as well as to improve worker safety.

Adaptive Air-Fuel Ratio Control with MLP Network

This paper presents an application of adaptive neural network model-based predictive control (MPC) to the air-fuel ratio of an engine simulation. A multi-layer perceptron (MLP) neural network is trained using two on-line training algorithms: a back propagation algorithm and a recursive least squares (RLS) algorithm. It is used to model parameter uncertainties in the nonlinear dynamics of internal combustion (IC) engines. Based on the adaptive model, an MPC strategy for controlling air-fuel ratio is realized, and its control performance compared with that of a traditional PI controller. A reduced Hessian method, a newly developed sequential quadratic programming (SQP) method for solving nonlinear programming (NLP) problems, is implemented to speed up nonlinear optimization in the MPC. Keywords Air-fuel ratio control - IC engine - adaptive neural networks - nonlinear programming - model predictive control Shi-Wei Wang PhD student, Liverpool John Moores University; MSc in Control Systems, University of Sheffield, 2003; BEng in Automatic Technology, Jilin University, 2000; Current research interests automotive engine control, model predictive control, sliding mode control, neural networks.Ding-Li Yu obtained B.Eng from Harbin Civil Engineering College, Harbin, China in 1981, M.Sc from Jilin University of Technology, Changchun, China in 1986 and PhD from Coventry University, U.K. in 1995, all in control engineering. He is currently a Reader in Process Control at Liverpool John Moores University, U.K. His current research interests are in process control, engine control, fault detection and adaptive neural nets. He is a member of SAFEPROCESS TC in IFAC and an associate editor of the IJMIC and the IJISS.

EXPERIMENT STUDY ON SPEED RATIO CONTROL OF METAL V-BELT TYPE CVT

Based on the control scheme of force and position, the controlling andtesting system of metal V-belt type CVT is developed. Having taken account of the complex nonlinearcharacteristics of the CVT shift dynamics and the saturation and nonlinear characteristics of thespeed ratio control valve, the speed ratio fuzzy controller based on the speed ratio feedback isdesigned. The experiment results show that the developed speed ratio control system is practical andfeasible.

Transient Air-Fuel Ratio Control in a CNG Engine Using Fuzzy Neural Networks

The fuzzy neural networks has been used as means of precisely controlling the air-fuel ratio of a lean-burn compressed natural gas (CNG) engine. A control algorithm, without based on engine model, has been (utilized) to construct a feedforward/feedback control scheme to regulate the air-fuel ratio. Using fuzzy neural networks, a fuzzy neural hybrid controller is obtained based on PI controller. The new controller, which can adjust parameters online, has been tested in transient air-fuel ratio control of a CNG engine.

Variable Gear Ratio Control Using Vehicle Body Slip Angle

Vehicles with variable steering characteristics have long been studied and compared with those having typical fixed gear ratio steering, and the variable gear ratio properties are reported to have improved maneuverability and stability in high-speed lane changes and on slippery low-friction road surfaces. However, it is not clear how gear ratios should be set for individual vehicle characteristics. Therefore, the present study has investigated a variable steering gear system using body slip angle feedback for the purpose of improved maneuverability and stability in the critical cornering range and upwards, in excess of the critical limit, and into the countersteer range. The results of a driving simulator experiment show that the steering effect improves and maneuverability and stability increase in the critical cornering range and upwards, in excess of the critical limit, and into the countersteer range by applying linear-variable control to the steering ratio from a body slip angle of 5?. This result is seen both in double lane changes, such as in hazard avoidance, and in J-turns with long drifting. Moreover, it shows an improvement in drift controllability through prompt countersteering. Overall, the present system can enhance the driver’s hazard avoidance capability.

Water medium retarders for heavy-duty vehicles:Computational fluid dynamics and experimental analysis of filling ratio control method

The water medium（WM） retarder is an auxiliary braking device that could convert the kinetic energy of the vehicle to the thermal energy of the coolant, and it is used instead of the service brake under non-emergency braking conditions. This paper analyzes the flow distribution based on a mathematical model and analyzes the key factors that could affect the filling ratio and the braking torque of the WM retarder. Computational fluid dynamics（CFD） simulations are conducted to compute the braking torque, and theresults are verified by experiments. It is shown that the filling ratio and the braking torque can be expressed by the mathematical model proposed in this paper. Compared with the Reynolds averaged Navier-Stokes（RANS） turbulent model, the shear stress transport（SST） turbulent model can more accurately simulate the braking torque. Finally, the flow distribution and the flow character in the WM retarders are analyzed.

Research on the novel discretized ratio control strategies and hardware-in-the-loop test for continuous variable transmission system

Based on traditional continuous control strategy for Continuously Variable Transmission(CVT)ratio,according to the principles of shift control strategy for stepped automatic transmission,the influences of throttle opening and external resistance or vehicle speed on CVT ratio control are analyzed on bumpy road.Under the same variation of external resistance condition,the differences between optimal economic control strategy and optimal dynamic control strategy are discussed.Then,the traditional continuous optimal dynamic and economic control lines are divided into multi-step upshift points.Meanwhile,the corresponding downshift points are set to avoid the interference near shift points.After that,the novel discretized ratio control methods for CVT system are proposed.By respectively discretizing throttle opening and vehicle speed,the discretized ratio control strategy for throttle opening,and the integrated discretized ratio control strategy for throttle opening and vehicle speed are further proposed and simulated.Furthermore,the hardware-in-the-loop(HIL)test system is built to further verify the feasibility and accuracy of discretized ratio control strategies.Both simulation and HIL test results show that the sensitivity of throttle opening and vehicle speed to ratio control is reduced dramatically,the fluctuation of ratio is decreased considerably,the transmission efficiency is increased significantly,and the jerk is declined moderately.

Air-fuel ratio control with stochastic L_2 disturbance attenuation in gasoline engines

In this paper, the problem of stochastic L2 disturbance attenuation of the air-fuel ratio is investigated with consideration of cyclic variation of the residual gas fraction （RGF）. A stochastic robust controller is designed based on a discrete-time dynamic model in which the RGF is modeled as a stochastic process with Markovian property. Finally, the sampling process-based statistical analysis for the RGF and the validation of the proposed control law are presented through the experiments conducted on a gasoline engine test bench.

Air flow control based on optimal oxygen excess ratio in fuel cells for vehicles

Air flow control is one of the most important control methods for maintaining the stability and reliability of a fuel cell system, which can avoid oxygen starvation or oxygen saturation. The oxygen excess ratio （OER） is often used to indicate the air flow condition. Based on a fuel cell system model for vehicles, OER performance was analyzed for different stack currents and temperatures in this paper, and the results show that the optimal OER was affected weakly by the stack temperature. In order to ensure the system working in optimal OER, a control scheme that includes an optimal OER regulator and a fuzzy control was proposed. According to the stack current, a reference value of air flow rate was obtained with the optimal OER regulator and then the air compressor motor voltage was controlled with the fuzzy controller to adjust the air flow rate provided by the air compressor. Simulation results show that the control method has good dynamic and static characteristics.

Optimizing the Aspect Ratio of Cephalexin in Reactive Crystallization by Controlling Supersaturation and Seeding Policy

Batch crystallization in acidic aqueous solution of cephalexin was conducted by reactive crystallization with or without seeding. Supersaturation was generated by mixing ammonia and acidic aqueous solution of cephalexin and controlled by solution feeding rate and seeding conditions. UV and Morphologi G3 were used to measure supersaturation and aspect ratio. Experimental results demonstrated that burst nucleation occurred and the products were needle-like at high supersaturation;meanwhile, the products were plate-like and had high aspect ratio at low supersaturation. Analysis of the measured supersaturation profi les and corresponding aspect ratio explained the mechanisms governing the aspect ratio. The optimized operating parameters were also proposed (seeding supersaturation is equal to 1.3, seed mass ratio 8% and feeding rate 368 μL/min).

Variable Tension Control for Discontinuous Tape Winding of Composites Based on Constant Extension Ratio

Discontinuous tape winding, which has obvious advantages in large extension ratio winding, is widely used in the molding of composites. Therefore, the research on technological parameters becomes the focus of many scholars. However, how to accomplish the variable tension control is usually not fully considered. Accordingly, the constant extension ratio and the smoothness of winding process cannot be ensured. Aiming at the problem of tension control, this paper first gives a comparatively deep research on the control method and the interaction mechanism of tension, extension ratio, automatic lap and automatic rectification. Then, according to the winding process features, the mechanical device and the mathematical model of tension control system are established respectively. With regard to the characteristics of PID controller and fuzzy controller, the fuzzy self-tuning PID controller is designed. As a result, the variable tension control is realized during the winding and lapping process, and the constant extension ratio is guaranteed. Finally, a sample application is presented for demonstration. By presenting the variable tension control techniques for discontinuous tape winding, the constant extension ratio of tapes is achieved, the consecution and the automation degree of winding process is improved as well. Thus, the quality of wound products is guaranteed.

Simple adaptive air-fuel ratio control of a port injection SI engine with a cylinder pressure sensor

The problem of air-fuel ratio(AFR) control of the port injection spark ignition(SI) engine is still of considerable importance because of stringent demands on emission control. In this paper, the static AFR calculation model based on in-cylinder pressure data and on the adaptive AFR control strategy is presented. The model utilises the intake manifold pressure, engine speed, total heat release, and the rapid burn angle, as input variables for the AFR computation. The combustion parameters, total heat release,and rapid burn angle, are calculated from in-cylinder pressure data. This proposed AFR model can be applied to the virtual lambda sensor for the feedback control system. In practical applications, simple adaptive control(SAC) is applied in conjunction with the AFR model for port-injected fuel control. The experimental results show that the proposed model can estimate the AFR, and the accuracy of the estimated value is applicable to the feedback control system. Additionally, the adaptive controller with the AFR model can be applied to regulate the AFR of the port injection SI engine.

Design of flying vehicle control system by signal to noise ratio

Presents the new concept of ″Desired to be small″ based on the basic function of vehicle flight control system for an optimal design of flying vehicle control system, and the definition of S/N ratio and calculation formula for ″Desired to be small″ dynamic characteristics, and the S/N ratio method established for design of velicle flight control systems, by which, an orthogrnal table is used to arrange test schemes, and error facters are used to simulate various interferences, and the use of S/N ratio as a design criterion to synthesise the design of dynamic and static characteristics for definition of an optimal scheme, the application of S/N ratio method to the design of a type of vehicle control system and the single run success abtained in design of control system, technical evaluation test and design finalization flight test.

串并联混合动力变速箱挡位对整车性能的影响

针对串并联混合动力车辆变速箱选型匹配问题,采用试验设计(DOE)方法选取变速箱最优速比并分析挡位对整车性能的影响。建立了整车仿真模型和控制策略并进行了台架验证,分析了该混合动力系统3种变速箱挡位配置对车辆的加速性能、爬坡性能和整车油耗的影响。仿真结果表明,挡位的增多可以提高整车动力性,降低整车对电池放电功率及电池容量的需求,但是对整车油耗改善较小。进一步仿真结果表明,即使改善发动机低转速中高负荷区域的燃油消耗率,变速箱挡位数对整车油耗的影响也不大。

悬索桥竖弯涡振MTMD减振控制效果和参数优化研究

为研究多重调谐质量阻尼器(Multiple Tuned Mass Damper,MTMD)抑制桥梁单阶涡振的性能,建立桥梁结构-MTMD系统竖弯涡振广义单自由度动力方程,以某大跨度悬索桥为背景进行MTMD减振控制效果和参数优化分析。采用数值方法求解动力方程,获得系统在简谐涡激力下达到稳态谐振时结构的动力放大系数和MTMD对结构的附加模态阻尼比,并与单一频率调谐质量阻尼器(Single Tuned Mass Damper,STMD)的减振控制效果进行对比,然后以附加模态阻尼比为目标对MTMD进行参数优化。结果表明:MTMD比最优参数STMD拥有更宽的控制频带和更好的减振效果,经优化后的MTMD减振性能优于最优参数STMD。实际应用MTMD时,应选择较大广义质量、5~7种频率规格,并根据二者找到无量纲频率范围和各TMD阻尼比的惟一最优取值。

Nonlinear General Integral Control Design via Equal Ratio Gain Technique

This paper proposes two kinds of nonlinear general integral controllers, that is, one is generic and another is practical, for a class of uncertain nonlinear system. By extending equal ratio gain technique to a canonical interval system matrix and using Lyapunov method, theorems to ensure regionally as well as semi-globally asymptotic stability are established in terms of some bounded information. Moreover, for the practical nonlinear integral controller, a real time method to evaluate the equal ratio coefficient is proposed such that its value can be chosen moderately. Theoretical analysis and simulation results demonstrated that not only nonlinear general integral control can effectively deal with the uncertain nonlinear system but also equal ratio gain technique is a powerful and practical tool to solve the control design problem of dynamics with the nonlinear and uncertain actions.

IGSA-PID算法的双带式全电调节CVT速比优化控制

双带式全电调节无级变速器(Double-Belt Electro-Mechanical Continuously Variable Transmission,简称DEMCVT)具有两组带传动装置,能够有效提升CVT的承载能力;DEM-CVT具有单带与双带两种工作模式,通过设计基于效率最优的模式切换策略,能够有效提高燃油经济性;采用直流电机调节主从动轮工作半径从而实现速比变化调节,针对DEM-CVT速比控制,设计了针对不同工况的速比控制策略,以PID算法为基础,提出了一种改进算法IGSA对PID算法进行参数优化,并通过建模仿真得到仿真结果,验证了提出的速比控制策略和控制方法的有效性。

Equal Ratio Gain Technique and Its Application in Linear General Integral Control

In conjunction with linear general integral control, this paper proposes a fire-new control design technique, named Equal ratio gain technique, and then develops two kinds of control design methods, that is, Decomposition and Synthetic methods, for a class of uncertain nonlinear system. By Routh’s stability criterion, we demonstrate that a canonical system matrix can be designed to be always Hurwitz as any row controller gains, or controller and its integrator gains increase with the same ratio. By solving Lyapunov equation, we demonstrate that as any row controller gains, or controller and its integrator gains of a canonical system matrix tend to infinity with the same ratio, if it is always Hurwitz, and then the same row solutions of Lyapunov equation all tend to zero. By Equal ratio gain technique and Lyapunov method, theorems to ensure semi-globally asymptotic stability are established in terms of some bounded information. Moreover, the striking robustness of linear general integral control and PID control is clearly illustrated by Equal ratio gain technique. Theoretical analysis, design example and simulation results showed that Equal ratio gain technique is a powerful tool to solve the control design problem of uncertain nonlinear system.

Power Ratio Gain Technique and General Integral Control

In conjunction with general integral control, and synthesizing Singular perturbation and Equal ratio gain techniques, this paper proposes a new control design technique, named Power ratio gain technique, and then by Lyapunov method, theorem to ensure regionally as well as semi-globally asymptotic stability is established in terms of some bounded information. The highlight point is that it not only inherits all the essences of Singular perturbation and Equal ratio gain techniques but also makes up for their shortcomings, and then the conservatism of control input can be improved by compromising the Power ratio coefficients. Theoretical analysis, design example and simulation results show that Power ratio gain technique is a simple, practical and powerful tool to deal with the uncertain nonlinear system.

神经网络阻尼比模型及工业机器人导纳控制

在工业机器人打磨过程中,环境刚度随未知环境的变化,将对力控制精度产生不利的影响,针对环境刚度变化的问题,该文提出一种基于神经网络阻尼比模型的自适应导纳控制方法。在导纳控制设计中,根据力误差与系统阻尼比之间的机理关系,设计激励函数,构造神经网络阻尼比模型;通过该模型使阻尼比在线调整,适应末端环境的刚度变化,实现力到位置自适应转换的导纳控制。与常规导纳控制进行仿真比较,结果表明所提出的力控制策略力误差更小,响应速度更快,能适应变刚度的未知打磨环境。