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.

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.

Experimental Study on Wire Melting Control Ability of Twin-Body Plasma Arc

The twin-body plasma arc has the decoupling control ability of heat transfer and mass transfer,which is beneficial to shape and property control in wire arc additive manufacturing.In this paper,with the wire feeding speed as a characteristic quantity,the wire melting control ability of twin-body plasma arc was studied by adjusting the current separation ratio(under the condition of a constant total current),the wire current/main current and the position of the wire in the arc axial direction.The results showed that under the premise that the total current remains unchanged(100 A),as the current separation ratio increased,the middle and minimum melting amounts increased approximately synchronously under the effect of anode effect power,the first melting mass range remained constant;the maximum melting amount increased twice as fast as the middle melting amount under the effect of the wire feeding speed,and the second melting mass range was expanded.When the wire current increased,the anode effect power and the plasma arc power were both factors causing the increase in the wire melting amount;however,when the main current increased,the plasma arc power was the only factor causing the increase in the wire melting amount.The average wire melting increment caused by the anode effect power was approximately 2.7 times that caused by the plasma arc power.The minimum melting amount was not affected by the wire-torch distance under any current separation ratio tested.When the current separation ratio increased and reached a threshold,the middle melting amount remained constant with increasing wire-torch distance.When the current separation ratio continued to increase and reached the next threshold,the maximum melting amount remained constant with the increasing wire-torch distance.The effect of the wire-torch distance on the wire melting amount reduced with the increase in the current separation ratio.Through this study,the decoupling mechanism and ability of this innovative arc heat source is more clearly.

Base Pressure Control with Semi-Circular Ribs at Critical Mach Number

When better fuel-air mixing in the combustion chamber or a reduction in base drag are required in vehicles,rockets,and aeroplanes,the base pressure control is activated.Controlling the base pressure and drag is necessary in both scenarios.In this work,semi-circular ribs with varying diameters(2,4,and 6 mm)positioned at six distinct positions(0.5D,1D,1.5D,2D,3D,and 4D)inside a square duct with a side of 15 mm are proposed as an efficient way to apply the passive control technique.In-depth research is done on optimising rib size for various rib sites.According to this study,the base pressure rises as rib height increases.Furthermore,the optimal location for the semi-circular ribs with a diameter of 2 mm is at 0.5D.The 1D location appears to be optimal for the 4 mm size as well.For the 6 mm size,however,the 4D position fills this function.

Hybrid Multi-Infeed Interaction Factor Calculation Method Considering Voltage Regulation Control Characteristics of Voltage Source Converter

Voltage source converter based high voltage direct current(VSC-HVDC)can participate in voltage regulation by flexible control to help maintain the voltage stability of the power grid.In order to quantitatively evaluate its influence on the voltage interaction between VSC-HVDC and line commutated converter based high voltage direct current(LCC-HVDC),this paper proposes a hybrid multi-infeed interaction factor(HMIIF)calculation method considering the voltage regulation control characteristics of VSC-HVDC.Firstly,for a hybrid multi-infeed high voltage direct current system,an additional equivalent operating admittance matrix is constructed to characterize HVDC equipment characteristics under small disturbance.Secondly,based on the characteristic curve between the reactive power and the voltage of a certain VSC-HVDC project,the additional equivalent operating admittance of VSC-HVDC is derived.The additional equivalent operating admittance matrix calculation method is proposed.Thirdly,the equivalent bus impedance matrix is obtained by modifying the alternating current(AC)system admittance matrix with the additional equivalent operating admittance matrix.On this basis,the HMIIF calculation method based on the equivalent bus impedance ratio is proposed.Finally,the effectiveness of the proposed method is verified in a hybrid dual-infeed high voltage direct current system constructed in Power Systems Computer Aided Design(PSCAD),and the influence of voltage regulation control on HMIIF is analyzed.

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.

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.

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.

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).

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.

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.

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.

Crude oil cracking in deep reservoirs:A review of the controlling factors and estimation methods

The natural cracking of crude oils in deep reservoirs has gained great interest due to continuously increasing depth of petroleum exploration and exploitation.Complex oil compositions and surroundings as well as complicated geological evolutions make oil cracking in nature much more complex than industrial pyrolysis.So far,numerous studies,focused on this topic,have made considerable progress although there still exist some drawbacks.However,a comprehensive review on crude oil cracking is yet to be conducted.This article systematically reviews the controlling factors of oil cracking from six aspects,namely,oil compositions,temperature and time,pressure,water,minerals and solid organic matter.We compare previous experimental and modelling results and present new field cases.In the following,we evaluate the prevailing estimation methods for the extent of oil cracking,and elucidate other factors that may interfere with the application of these estimation methods.This review will be helpful for further investigations of crude oil cracking and provides a guide for estimation of the cracking extent of crude oils.

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.

A 155 Mbps laser diode driver with automatic power and extinction ratio control

An integrated laser diode driver(LDD) driving an edge-emitting laser diode was designed and fabricated by 0.35 μm BiCMOS technology. This paper proposes a scheme which combines the automatic power control loop and temperature com-pensation for modulation current in order to maintain constant extinction ratio and average optical power. To implement tem-perature compensation for modulation current,a novel circuit which generates a PTAT current by using the injecting base current of a bipolar transistor in saturation region,and alternates the amplifier feedback loop(closed or not) to control the state of the current path is presented. Simulation results showed that programmed by choice of external resistors,the IC can provide modu-lation current from 5 mA to 85 mA with temperature compensation adjustments and independent bias current from 4 mA to 100 mA. Optical test results showed that clear eye-diagrams can be obtained at 155 Mbps,with the output optical power being nearly constant,and the variation of extinction ratio being lower than 0.7 dB.

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.

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.

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.

Study on the Environmental Quality Guarantee Ratio on the Basis of Total Air Pollutant Emission Amount Control

The hourly and daily air quality concentration in the total air pollutant emission amount control zone is not sure to be continuously up to national ambient air quality standard, even though the total annual air pollutant emission is permitted under the total air pollutant emission amount control (TAPEAC) on the basis of A-value method. So the concept of the environmental quality guarantee ratio (EQGR) for TAPEAC is advanced in this paper and its quantitative formula is figured out for both hourly and daily EQGR. It is concluded that the EQGR is related with the yearly arrangement of A-value besides the pollutant type. According to the meteorological data in a lower area along Yangtze River in 2000, the yearly A-value trend is analyzed. Based on the data, the hourly EQGR of SO 2 and NO 2 is respectively 97.4% and 90.2%, and daily EQGR respectively 90.2% and 79.5%.

DOUBLE LOOP ACTIVE VIBRATION CONTROL OF PNEUMATIC ISOLATOR WITH TWO SEPARATE CHAMBERS

A newly designed pneumatic spring with two separate chambers is promoted and double-loop active control is introduced to overcome the following drawbacks of passive pneumatic isolation： ① The low frequency resonances introduced into the system; ② Conflict between lower isolation frequency and stiffness high enough to limit quasi-static stroke;③ Inconsistent isolation level with different force load. The design of two separate chambers is for the purpose of tuning support frequency and force independently and each chamber is controlled by a different valve. The inner one of double-loop structure is pressure control, and in order to obtain good performance, nonlinearities compensation and motion flow rate compensation （MFRC） are added besides the basic cascade compensation, and the influence of tube length is studied. The outer loop has two functions： one is to eliminate the resonance caused by isolation support and to broaden the isolation frequency band by payload velocity feedback and base velocity feed forward, and the other is to tune support force and support stiffness simultaneously and independently, which means the support force will have no effect on support stiffness. Theoretical analysis and experiment results show that the three drawbacks are overcome simultaneously.