A HybridManufacturing ProcessMonitoringMethod Using Stacked Gated Recurrent Unit and Random Forest

This study proposed a new real-time manufacturing process monitoring method to monitor and detect process shifts in manufacturing operations.Since real-time production process monitoring is critical in today’s smart manufacturing.The more robust the monitoring model,the more reliable a process is to be under control.In the past,many researchers have developed real-time monitoring methods to detect process shifts early.However,thesemethods have limitations in detecting process shifts as quickly as possible and handling various data volumes and varieties.In this paper,a robust monitoring model combining Gated Recurrent Unit(GRU)and Random Forest(RF)with Real-Time Contrast(RTC)called GRU-RF-RTC was proposed to detect process shifts rapidly.The effectiveness of the proposed GRU-RF-RTC model is first evaluated using multivariate normal and nonnormal distribution datasets.Then,to prove the applicability of the proposed model in a realmanufacturing setting,the model was evaluated using real-world normal and non-normal problems.The results demonstrate that the proposed GRU-RF-RTC outperforms other methods in detecting process shifts quickly with the lowest average out-of-control run length(ARL1)in all synthesis and real-world problems under normal and non-normal cases.The experiment results on real-world problems highlight the significance of the proposed GRU-RF-RTC model in modern manufacturing process monitoring applications.The result reveals that the proposed method improves the shift detection capability by 42.14%in normal and 43.64%in gamma distribution problems.

MULTIPLE ELECTRONIC CONTROL UNITS CALIBRATION SYSTEM BASED ON EXPLICIT CALIBRATION PROTOCOL AND J1939 PROTOCOL

The rising number of electronic control units （ECUs） in vehicles and the decreasing time to market have led to the need for advanced methods of calibration. A multi-ECU calibration system was developed based on the explicit calibration protocol （XCP） and J1939 communication protocol to satisfy the need of calibrating multiple ECUs simultaneously. The messages in the controller area network （CAN） are defined in the J1939 protocol. Each CAN node can get its own calibration messages and information from other ECUs, and block other messages by qualifying the CAN messages with priority, source or destination address. The data field of the calibration message is designed with the XCP, with CAN acting as the transport layer. The calibration sessions are setup with the event-triggered XCP driver in the master node and the responding XCP driver in the slave nodes. Mirroring calibration variables from ROM to RAM enables the user to calibrate ECUs online. The application example shows that the multi-ECU calibration system can calibrate multiple ECUs simultaneously, and the main program can also accomplish its calculation and send commands to the actuators in time. By the multi-ECU calibration system, the calibration effort and time can be reduced and the variables in ECU can get a better match with the variables of other ECUs.

Incremental multivariable predictive functional control and its application in a gas fractionation unit

The control of gas fractionation unit(GFU) in petroleum industry is very difficult due to multivariable characteristics and a large time delay.PID controllers are still applied in most industry processes.However,the traditional PID control has been proven not sufficient and capable for this particular petro-chemical process.In this work,an incremental multivariable predictive functional control(IMPFC) algorithm was proposed with less online computation,great precision and fast response.An incremental transfer function matrix model was set up through the step-response data,and predictive outputs were deduced with the theory of single-value optimization.The results show that the method can optimize the incremental control variable and reject the constraint of the incremental control variable with the positional predictive functional control algorithm,and thereby making the control variable smoother.The predictive output error and future set-point were approximated by a polynomial,which can overcome the problem under the model mismatch and make the predictive outputs track the reference trajectory.Then,the design of incremental multivariable predictive functional control was studied.Simulation and application results show that the proposed control strategy is effective and feasible to improve control performance and robustness of process.

Consensus intuitionistic fuzzy group decision-making method for aircraft cockpit display and control system evaluation

A novel group decision-making （GDM） method based on intuitionistic fuzzy sets （IFSs） is developed to evaluate the ergonomics of aircraft cockpit display and control system （ACDCS）. The GDM process with four steps is discussed. Firstly, approaches are proposed to transform four types of common judgement representations into a unified expression by the form of the IFS, and the features of unifications are analyzed. Then, the aggregation operator called the IFSs weighted averaging （IFSWA） operator is taken to synthesize decision-makers’ （DMs’） preferences by the form of the IFS. In this operator, the DM’s reliability weights factors are determined based on the distance measure between their preferences. Finally, an improved score function is used to rank alternatives and to get the best one. An illustrative example proves the proposed method is effective to valuate the ergonomics of the ACDCS.

Force Control Compensation Method with Variable Load Stiffness and Damping of the Hydraulic Drive Unit Force Control System

Each joint of hydraulic drive quadruped robot is driven by the hydraulic drive unit（HDU）, and the contacting between the robot foot end and the ground is complex and variable, which increases the difficulty of force control inevitably. In the recent years, although many scholars researched some control methods such as disturbance rejection control, parameter self-adaptive control, impedance control and so on, to improve the force control performance of HDU, the robustness of the force control still needs improving. Therefore, how to simulate the complex and variable load characteristics of the environment structure and how to ensure HDU having excellent force control performance with the complex and variable load characteristics are key issues to be solved in this paper. The force control system mathematic model of HDU is established by the mechanism modeling method, and the theoretical models of a novel force control compensation method and a load characteristics simulation method under different environment structures are derived, considering the dynamic characteristics of the load stiffness and the load damping under different environment structures. Then, simulation effects of the variable load stiffness and load damping under the step and sinusoidal load force are analyzed experimentally on the HDU force control performance test platform, which provides the foundation for the force control compensation experiment research. In addition, the optimized PID control parameters are designed to make the HDU have better force control performance with suitable load stiffness and load damping, under which the force control compensation method is introduced, and the robustness of the force control system with several constant load characteristics and the variable load characteristics respectively are comparatively analyzed by experiment. The research results indicate that if the load characteristics are known, the force control compensation method presented in this paper has positive compensation effects on the load characteristics variation, i.e., this method decreases the effects of the load characteristics variation on the force control performance and enhances the force control system robustness with the constant PID parameters, thereby, the online PID parameters tuning control method which is complex needs not be adopted. All the above research provides theoretical and experimental foundation for the force control method of the quadruped robot joints with high robustness.

MicroGrid Designer:user-friendly design,operation and control assist tools for resilient microgrid and autonomous community

During this decade,many countries have experienced natural and accidental disasters,such as typhoons,floods,earthquakes,and nuclear plant accidents,causing catastrophic damage to infrastructures.Since the end of 2019,all countries of the world are struggling with the COVID-19 and pursuing countermeasures,including inoculation of vaccine,and changes in our lifestyle and social structures.All these experiences have made the residents in the affected regions keenly aware of the need for new infrastructures that are resilient and autonomous,so that vital lifelines are secured during calamities.A paradigm shift has been taking place toward reorganizing the energy social service management in many countries,including Japan,by effective use of sustainable energy and new supply schemes.However,such new power sources and supply schemes would affect the power grid through intermittency of power output and the deterioration of power quality and service.Therefore,new social infrastructures and novel management systems to supply energy and social service will be required.In this paper,user-friendly design,operation and control assist tools for resilient microgrids and autonomous communities are proposed and applied to the standard microgrid to verify its effectiveness and performance.

基于Unity3D的油田抽油机三维可视化监控系统设计

针对抽油机监测形式单一、三维可视化程度低和联动性差的缺陷,引入信息―物理实时映射思想,开发了油田抽油机三维可视化监控系统。设计了抽油机数字空间,搭建虚实交互层设计架构;搭建三维可视化系统数据组成及关系框架;结合逆运动学,构建数学模型,基于五维模型和Unity 3D平台设计抽油机三维可视化系统总体架构;以游梁式抽油机为对象进行实验验证,实现了实时动态监测、虚实混合控制、运动轨迹追踪和在线预警等服务功能。为三维可视化监控在石油机械领域的落地应用和数字孪生系统的开发提供借鉴。

Type selection and maintenance of the control system of large-scale air separation units

Based on the practice of Baosteel＇ s 60000 m3/h air separation unit （ASU） ,which is the first domestically- integrated unit of such a scale, this paper studies the principles of type selection of the distribution control system （DCS）. It discusses the design of the unit＇s control system,which involves a compressor system,a purification system （molecular sieving）, a turbo expansion system and an air separation system. The final part of the paper discusses the maintenance and future development of the ASU control system at Baosteel.

A gated recurrent unit model to predict Poisson’s ratio using deep learning

Static Poisson’s ratio(vs)is crucial for determining geomechanical properties in petroleum applications,namely sand production.Some models have been used to predict vs;however,the published models were limited to specific data ranges with an average absolute percentage relative error(AAPRE)of more than 10%.The published gated recurrent unit(GRU)models do not consider trend analysis to show physical behaviors.In this study,we aim to develop a GRU model using trend analysis and three inputs for predicting n s based on a broad range of data,n s(value of 0.1627-0.4492),bulk formation density(RHOB)(0.315-2.994 g/mL),compressional time(DTc)(44.43-186.9 μs/ft),and shear time(DTs)(72.9-341.2μ s/ft).The GRU model was evaluated using different approaches,including statistical error an-alyses.The GRU model showed the proper trends,and the model data ranges were wider than previous ones.The GRU model has the largest correlation coefficient(R)of 0.967 and the lowest AAPRE,average percent relative error(APRE),root mean square error(RMSE),and standard deviation(SD)of 3.228%,1.054%,4.389,and 0.013,respectively,compared to other models.The GRU model has a high accuracy for the different datasets:training,validation,testing,and the whole datasets with R and AAPRE values were 0.981 and 2.601%,0.966 and 3.274%,0.967 and 3.228%,and 0.977 and 2.861%,respectively.The group error analyses of all inputs show that the GRU model has less than 5% AAPRE for all input ranges,which is superior to other models that have different AAPRE values of more than 10% at various ranges of inputs.

Digital Instrumentation and Control System for Unit 5 ＆ 6 of YangJiang NPP

The article describes the digital instrumentation and control system for unit 5 ＆ 6 of YangJiang NPP, involving the overall I ＆ C （instrumentation and control） structure, the basic requirements and independent verification and validation. Advanced I ＆ C systems for YangJiang NPPs have to meet increasing demands for safety and availability. Additionally, the specific requirements coming from the nuclear qualification have to be fulfilled.

Research on the Application of Evidence-Based Quality Control Circle to Improve the Implementation Rate of Airway Management Measures in Adult Critically Ill Patients

Objective: To explore the effect of evidence-based quality control circle (QCC) in improving the implementation rate of airway management measures in adult critically ill patients. Methods: Based on the Joanna Briggs Institute (JBI) evidence-based health care model, the best evidence of airway management in adult critically ill patients was obtained and applied to the clinic. Results: The total implementation rate of airway management measures in adult critically ill patients increased from 23.62% before the implementation of quality control circle to 88.82%, and the pulmonary infection rate in critically ill patients decreased from 42.31% to 21.74%, with statistical significance between the two groups (P 0.05). Conclusion: Evidence-based quality control circle activities can standardize the practice standards of airway management in critically ill patients, reduce the occurrence of patients’ airway related complications, and improve clinical outcomes.

有效避免ABB UNITROL 6800励磁系统故障导致机组跳闸的方案

ABB UNITROL 6800拥有多重冗余和多CPU配置,通道最大可达三通道。整个控制系统配有两套恒机端电压控制(AVR)、两套恒励磁电流控制(FCR)和一套备用恒励磁电流控制(BFCR),高冗余度的设计和彼此间的合理切换大大地提高了机组运行的安全性和可靠性,但ABB UNITROL 6800励磁系统测量板(CCM)本身存在一个概率极小的故障,且动作权限最高,一旦发生,将直接导致机组跳闸。介绍了一种有效避免因CCM板故障导致机组跳闸的优化方案。

Multi-model Predictive Control of Ultra-supercritical Coal-fired Power Unit

The control of ultra-supercritical(USC) power unit is a difficult issue for its characteristic of the nonlinearity, large dead time and coupling of the unit. In this paper, model predictive control(MPC) based on multi-model and double layered optimization is introduced for coordinated control of USC unit. The linear programming(LP) combined with quadratic programming(QP) is used in steady optimization for computation of the ideal value of dynamic optimization. Three inputs(i.e. valve opening, coal flow and feedwater flow) are employed to control three outputs(i.e. load, main steam temperature and main steam pressure). The step response models for the dynamic matrix control(DMC) are constructed using the three inputs and the three outputs. Piecewise models are built at selected operation points. Double-layered multi-model predictive controller is implemented in simulation with satisfactory performance.

Nonlinear inversion-based output tracking control of a boiler-turbine unit

The capability to perform fast load-following has been an important issue in the power industry. An output tracking control system of a boiler-turbine unit is developed. The system is composed of stable inversion and feedback controller. The stable inversion is implemented as a feedforward controller to improve the load-following capability, and the feedback controller is utilized to guarantee the stability and robustness of the whole system. Loop-shaping H∞ method is used to design the feedback controller and the final controller is reduced to a multivariable PI form. The output tracking control system takes account of the multivariable, nonlinear and coupling behavior of boiler-turbine system, and the simulation tests show that the control system works well and can be widely applied.

ESO-based decoupling control with multi-objective optimization for boiler-turbine unit

A model-assistant extended state observer(MESO)-based decoupling control strategy is proposed for boiler-turbine units in the presence of unknown external disturbance and model-plant mismatch. For ease of implementation, the decoupling compensator is reduced to the proportion integration(PI) decoupler with the frequency domain analysis, where the decoupling error in collusion of uncertainties and disturbances can be estimated by the proposed MESO and then compensated. To decrease the sensitivity of the dynamic error for the decoupling control and fulfill various requirements of constraints, such as safety operation, energy conservation, emission reduction, etc., the plant is transmitted through a scheduled steady state region which is achieved from the optimized reference governor in advance. Simulation results show that the proposed control strategy can well suppress various disturbances including a decoupling error, and multi-objective optimization can meet multiple requirements with the premise of safety production.

Pressure control strategy for pump motor energy transfer unit

Multi-level pressure source system is a novel hydraulic system with distinct advantage of energy saving. In order to balance each pressure level of the multi-level pressure source system, a pump motor energy transfer unit is usually equipped. However, the pump motor energy transfer has the characteristics of poor starting and low response, which cause long time of pressure adjustment and large pressure jitter when the transformer is switched to system suddenly and the motor-side pressure has pressure impact when rail of the pump-side is switched. To address these problems, this paper proposes a compound control strategy of feedforward compensation control with Fuzzy-PID to improve the controllability of the multi-level pressure source system. A test rig of the pump motor energy transfer unit is built and the controllability of compound controller and PID controller are compared. The experiment results show that, compared with the traditional PID, the adjustment time and the pressure impact are reduced by 20% and 25% with the proposed compound control strategy. Therefore, the presented compound control strategy can be used to improve starting performance and robustness of the pump motor energy transfer unit control system.

IMPROVE THE KINETIC PERFORMANCE OF THE PUMP CONTROLLED CLAMPING UNIT IN PLASTIC INJECTION MOLDING MACHINE WITH ADAPTIVE CONTROL STRATEGY

The kinetic characteristics of the clamping unit of plastic injection molding machine that is controlled by close loop with newly developed double speed variable pump unit are investigated. Considering the wide variation of the cylinder equivalent mass caused by the transmission ratio of clamping unit and the severe instantaneous impact force acted on the cylinder during the mold closing and opening process, an adaptive control principle of parameter and structure is proposed to improve its kinetic performance. The adaptive correlation between the acceleration feedback gain and the variable mass is derived. The pressure differential feedback is introduced to improve the dynamic performance in the case of small inertia and heavy impact load. The adaptation of sum pressure to load is used to reduce the energy loss of the system. The research results are verified by the simulation and experiment, The investigation method and the conclusions are also suitable for the differential cylinder system controlled by the traditional servo pump unit.

Coordinated Controller Tuning of a Boiler Turbine Unit with New Binary Particle Swarm Optimization Algorithm

Coordinated controller tuning of the boiler turbine unit is a challenging task due to the nonlinear and coupling characteristics of the system.In this paper,a new variant of binary particle swarm optimization （PSO） algorithm,called probability based binary PSO （PBPSO）,is presented to tune the parameters of a coordinated controller.The simulation results show that PBPSO can effectively optimize the control parameters and achieves better control performance than those based on standard discrete binary PSO,modified binary PSO,and standard continuous PSO.

Hardware-in-the-Loop Research on the Electronic Control Unit for Diesel Engines

A hardware-in-the-loop simulating platform is developed to avoid designing defects caused by the complicated logical structure and multiple-functional buildup of the dectronic control unit（ECU）in modem diesel engines, and to diminish potential damages on components or human exposure to dangers in R＆D en- deavor. This plat-form consists of a computer installed with software Matlab/Simulink/RTW and dSPACE/ ControlDesk; a diesel engine ECU, and a dSPACE autobox which runs a real-time diesel engine model. A typical model of diesel engine with turbocharger and intercooler is presented. Based on this model our research is carried out with a real ECU to test its software control strategies. Results show that by using the diesel engine model downloaded inside, the hardware-in-the-loop platform can simulate diesel engine＇s working conditions and generate all kinds of sensor signals which ECU needs on a real-time basis. So the ECU control strategies can be validated and relevant parameters roughly calibrated.

Design of 32 kbit one-time programmable memory for microcontroller units

A 32 kbit OTP(one-time programmable)memory for MCUs(micro-controller units)used in remote controllers was designed.This OTP memory is used for program and data storage.It is required to apply 5.5V to BL(bit-line)and 11V to WL(word-line)for a OTP cell of 0.35μm ETOX(EEPROM tunnel oxide)type by MagnaChip.We use 5V transistors on column data paths to reduce the area of column data paths since they require small areas.In addition,we secure device reliability by using HV(high-voltage)transistors in the WL driver.Furthermore,we change from a static logic to a dynamic logic used for the WL driver in the core circuit.Also,we optimize the WD(write data)switch circuit.Thus,we can implement them with a small-area design.In addition,we implement the address predecoder with a small-area logic circuit.The area of the designed 32 kbit OTP with 5V and HV devices is 674.725μm×258.75μm(=0.1745mm2)and is 56.3% smaller than that using 3.3V devices.