Hybrid modeling and dynamic simulation of automated batch plants

A proposal is presented for the hybrid modeling and dynamic simulation of automated batch processing plants with dominant discrete-event behavior. The proposal encompasses current techniques for modeling continuous-time/discrete-event processes, synthesizing discrete-event controllers as well as the use of industrial standards for batch control. The result is a hierarchical-modular model of a plant in which process and control tasks are clearly differentiated. Implementation rules are established for a specific dynamic simulator capable of handling hybrid systems. The approach is demonstrated by building and verifying a complete model for an automated milk pasteurization plant. Results show that handling problems of realistic complexity is feasible using state-of-the-art technology.     

INDUSTRIAL ENGINEERING AND VISUALISATION-A PRODUCT DEVELOPMENT PERSPECTIVE

Taking the actual project of teaching and researching process for example, the relationship between the industrial engineering and product development is discussed. And use the novel visualization technology to support the industrial engineering and product development. How to use the new computer modeling and simulating technologies to support the product development and industrial engineering, is introduced especially. The support includes both domestic products and industrial systems. The visualization and computer technologies take a very important role in some system or multi-direction modeling, those technologies mentioned above can help the industrial engineers study the effect of design on the whole life circle, including the producing steps. So the engineers can avoid making the wrong decision which may cause bad effects on the whole industrial engineering.     

A new approach to PLC software design

This paper presents a model-based approach to PLC software development. The essence of this approach is the introduction of a new procedural modeling language called ProcGraph. In contrast to commonly used methods, ProcGraph deals with the procedural aspect of the control system and allows software specification at a higher level of abstraction. The modeling language has been supported with the development of a software tool which facilitates graphical model design and automatic code generation. The specification notation has been tested in the development of software for industrial applications. The supporting tool has been tested in a laboratory environment.     

现代产品几何量技术规范(GPS)国际标准体系

现代产品几何量技术规范(GPS)是国际标准化组织“尺寸与几何技术委员会(ISO/TC213)”基于新一代GPS语言提出的新的国际标准体系,它以计量数学为基础,给出产品功能、技术规范、制造与计量之间的量值传递的数学方法,为产品设计、制造及计量测试人员提供了一个无歧义的信息交流平台。详细研究了新体系的框架、概念及运作方法,给出它的科学基础,提出实际应用的方法。     

On the aspect of implementing solutions for information support of industrial plant control systems

The authors of this paper look at the aspect of engineering information systems for planning and scheduling operations of an industrial plant. The authors propose to introduce new steps to the engineering process which include functional modelling, elaboration of an initial request for proposal (or RFP) for a functional model, development of functional models and algorithms, and elaboration of a software specification. The engineering step-by-step process is presented as an entity set model. The authors introduce a system functionality design formula which includes business rules, business logic, project roles, and visualization. An example of a machining shop with repeated machining operations is used to demonstrate the effect of introduction of new design stages. The simulation software AnyLogic was chosen as a visualization tool to demonstrate all the functionalities of the new system. AnyLogic enabled to implement all the roles of the information system. Elaboration of the functional model took place along with development of an RFP for implementation of an information system as part of an automation package of an industrial plant. As a result of the functional model demonstration, certain drawbacks were identified in the project, and recommendations were provided on how to eliminate them.     

An unambiguous expression method of the surface texture

The current specification and verification of surface texture in international standards are considered to be too theoretical, complex and over-elaborate for industry. A functional approach that completely expresses the complicated surface texture knowledge for designers and engineers is often nonexistent on the shop floor. Based on Geometrical Product Specification (GPS) philosophy, this paper proposes an unambiguous expression schema of surface texture. The surface texture knowledge in design, manufacture and measurement is based on the general GPS matrix and structured by a categorical object model. Explicit specification and verification processes and the mapping between them are presented. The ultimate goal is to improve the collaboration and bridge the knowledge gap between design, manufacture and measurement of surface texture to reduce product development lead time and improve product quality and performance.     

Flexible tools for specifying design variation

This paper describes flexible tools for specifying design variations that are based on non-uniform profile tolerance definitions. These tools specify bounds of design performance that can be used for negotiation among engineers in a collaborative design process. These specification methods allow for the capture of many different design functions that are not easily described with current tool designs. In addition, these specification methods lend themselves to efficient verification methods. Profile tolerance definitions provide the most general variation controls for complex mechanical surfaces. Common design practices and engineering standards for profile tolerances exhibit many weaknesses and limitations. We present a rationale for a complete specification approach using B-splines [1, 2] for profile tolerances, and illustrate the approach with examples. B-splines can be used to specify both uniform and non-uniform profile tolerance boundaries. Subsequently, algorithms for the evaluation of actual feature deviations and reporting methodologies for such tolerance zones are presented.     

An innovative cost modelling system to support lean product and process development

This paper presents a cost modelling system for lean product and process development to support proactive decision making and mistake elimination at the design stage. The foundations of the system are based upon three lean product and process development enablers, namely: Set-based concurrent engineering, knowledge-based engineering, and mistake proofing (Poka-yoke). The development commenced with an industrial field study of eleven leading European industries from the aerospace, automotive, telecommunication, medical and domestic appliance sectors. Based on the requirements of industrial collaborators, the developed system comprises six modules: value identification, manufacturing process/machines selection, material selection, geometric features specification, geometric features and manufacturability assessment, and manufacturing time and cost estimation. The work involved the development of a feature-based cost estimation method for the resistance spot welding process. The developed system was finally validated using an industrial case study. The developed system has the capability to provide estimates related to product cost and associated values concurrently, facilitate decision making, eliminate mistakes during the design stage, and incorporate ‘customer voice’ during a critical decision making stage.     

基于GPS的线性尺寸计量认证技术研究

基于对新一代GPS（dimensional geometrical product specification and verification）线性尺寸规范及其数字化理论基础的分析,揭示并阐明新一代GPS线性尺寸规范以产品功能特征为中心、以“规范设计”与“计量认证”统一为原则、以计量数学为基础的规范思路及内在规律性;基于计量学和操作技术,给出线性尺寸计量认证中、实现实体计量系统与虚拟计量技术互补的思路与方法,并进一步建立其线性尺寸数字化计量认证的关键操作——拟合的数学描述及线性规划模型,开发出线性尺寸数字化计量认证（软件工具）系统;并在此基础上,进一步给出基于GPS数字化技术的虚拟综合量规设计与应用方法,以满足产品特定的功能要求;并通过实例说明其工程价值及技术经济意义。     

Quality assurance —Have we specified it the wrong way round?

There is a considerable drive in both engineering and technology to develop and improve the systems of quality assurance and quality management during the manufacturing process. This drive has led to the development of international (CEN, ISO) and European national standards (BS, ON, DIN, AFNOR) to assist engineers, metrologists and designers in the specification of products to achieve this objective. The main problem with the developments so far is that although they clearly contribute to the quality of products and their components, the quality assured may have little relevance to the function performance of the product.This paper examines as a model the functional quality assurance system that inherently exists within a human being to see if an analogy can be drawn to the differences between the human quality assurance system and what is really required in a manufacturing environment.As a result of this assessment and comparison with the human quality assurance system, proposals are made for a way forward in developing quality assurance protocols for engineering manufacture, an alternative philosophy that may lead to an approach that stems from developing a comprehensive functional specification for both manufactured parts and products. Such a new basis would meet the aims of the quality assurance community and could lead to the provision of more reliable functional product design.     

FPGA based chip emulation system for test development of analog and mixed signal circuits: A case study of DC–DC buck converter

Prototyping on FPGA has become a main stream verification methodology for hardware design, test development, software co-design, etc. in the area of digital VLSI. In the case of test development, FPGA serves as a virtual DUT (Design Under Test) and test patters are applied from automatic test equipment (ATE). This verifies not only the chip with design for test (DFT) circuitry and test program but also the entire test setup involving virtual DUT, load board, interconnections with ATE, etc. Although, FPGA based platform is used widely for test program verification of digital ICs, this technique is not used for analog/mixed signal (AMS) circuits because of the difficulty in implementing AMS circuits in FPGAs. This work is concerned with the development of a test emulation platform, termed as hand-in-hand test flow, of AMS circuits based on FPGA. The proposed methodology exploits fixed-point modeling and DSP implementation techniques facilitated by latest FPGAs to model the AMS circuits. The proposed hand-in-hand test flow for AMS circuits will help the test engineers to start their test plan concurrently with the design engineers and validate them much prior to the first silicon. We have illustrated the proposed scheme using the case study of a current programmed buck type switching converter on Xilinx® Virtex™-5 FPGA. The FPGA emulation measurement results show that performance of the emulated DC–DC buck converter (e.g., duty ratio test, line transient, load step) matches well with that of SPICE simulation.     

ISA S88标准模块在医药生产控制中的应用

医药是典型的批处理工艺应用行业,程序代码质量在很大程度上决定了控制系统的质量。本文根据ISA S88标准,设计出适用于医药生产的分布式PLC控制系统,并对其中的反应釜温度控制功能进行了模块化编程的研究,使程序结构清晰明朗,具备可扩展性和柔性,缩短项目时间,确保项目质量,具有工程意义。     

面向大型吊装的三维仿真系统

移动式起重机被广泛地应用在快速发展的桥梁建设、核电、风电、海洋工程、石油化工等行业的建设项目中.事实上,吊装工程师是基于需求、紧急程度和优先级程度来管理和使用移动式起重机,移动式起重机必须要在某个地方,在指定时间内完成它的工作任务.因此,为了降低风险、节约成本、缩短项目周期,这就要求吊装工程师制定一个安全、高效、经济的吊装方案.但是传统的手工迭代式做法非常低效,难以满足当前复杂而大型的吊装工程要求.为此,研发了一款面向大型吊装的三维仿真系统,该系统包含吊装设备及作业环境建模模块、吊索具计算模块、起重机选型模块、起重机参数化建模模块、吊装仿真模块、计算书和CAD图输出模块以及数据库管理模块.最后以石化的一个实际案例验证系统的有效性并展示其主要特点.     

工艺危险性分析（PHA）仪表设计的探讨

首先介绍工艺危险性分析的基本概念和美国知名工程公司执行化工项目所采用的分析方法,然后通过国内某大型多晶硅项目PHA设计,阐述仪表及控制系统在安全完整性方面的设计准备、执行及跟进。     

OPC技术在工业过程控制中的应用研究

OPC规范是由OPC基金会制定的一个工业标准，它规范了过程控制和自动化软件与工业现场设备之间的接口。简要介绍了OPC技术的产生，OPC标准的技术规范以及采用OPC规范设计系统的益处并概述了它在国内外的主要应用领域，对OPC技术在应用中的主要作用也有相应的分析。OPC代表了今后一段时间内过程控制系统通信标准的发展方向。     

基于ACIS和HOOPS平台的数控磨削加工仿真系统的开发

介绍了一个小型的磨削加工仿真系统,该系统基于ACIS支持的B—rep精确模型建模所有参与磨削加工的实体,然后由HOOPS平台转化为对应的HOOPS图元进行显示;数控代码的验证仿真采用基于设计模型的验证方法。     

SP88 — The painkiller in validation

The process of establishing a pharmaceutical plant requires a well controlled engineering process, where the requirements to be met are clearly spelt out — and the design and the actual plant is tested against these requirements. In the context of batch processes — with the added complexity of time variance and some degree of flexibility — this becomes anything but trivial.

The approach described in this paper is an attempt to combine a consistent engineering approach for pharmaceutical plants with the models presented by SP88. The SP88 batch control standard provides an excellent platform for structuring this problem - not only from a control perspective, but from the perspective of the multi-disciplinary, complete specification and test of a plant. The following life-cycle models and terminology are therefore in no way control-specific, but cover the complete installation - including mechanical equipment and installations and manual functions.     

Material flow and control sequence specification of flexible production systems using coloured Petri nets

Starting with the specification of each resource and the whole structure of a flexible production system, in this approach a special kind of coloured Petri nets is used for performing the modelling and the validation of the coordination control structure of the systems. In a second phase, it is proposed to modify the first models to synchronised Petri net schemas to facilitate the supervision and the interaction of the coordination model with the physical components of the system as well as the development and maintainability of the discrete-event control structures. The final result is a formal specification of coloured Petri net based coordination control of resources of the system, and logic control structures for control sequencing based on the use of synchronised subPetri net structures derived from the first one by refining transitions, i.e., their occurrence. Based on the proposed approach, the coordination control model of resources and a first skeleton of the logic control structures of a flexible assembly cell located at the Institute of Manufacturing Automation and Production Systems at the University of Erlangen-Nuremberg, Germany is elaborated and then the correctness of the obtained models with regard to material flow and control sequence specifications is validated by means of the structural analysis of the coloured Petri net-based models.     

工业工程师培养模式的初探

工业工程是一门“技术＋管理＋系统”的科学。国内工业工程推广与应用的关键是工业工程师的培养。阐述了工业工程师的职业特征,结合企业ＩＥ应用的实践,探讨了工业工程师六种培养模式及其提高ＩＥ应用人员素质的途径。     

Function block applications in control systems based on IEC 61804

A variety of fieldbus technologies and digital fieldbus devices have been introduced within the process industries over the last ten years. There has been a gradual acceptance of the fact that a variety of communication technologies are needed to fully address the application requirements of a manufacturing facility. However, engineers responsible for the specification, engineering, and implementation of control systems require that a common interface and functionality be provided in the control system. This capability should be independent of the underlying fieldbus technology or manufacturer of the fieldbus device. The draft IEC 61804 standard defines how a control system can be structured to provide this flexibility in the utilization of fieldbus technology. In this paper, we discuss how a consistent function block capability may be provided for all fieldbus technology utilized in a control system. Examples will be given of how this standard has been applied in modern control systems to give a consistent interface to Foundation Fieldbus and PROFIBUS. Some detail will be presented on the standard means that is defined for manufacturers to describe function block capability of a field device. An analysis is given of the impact and benefit that the IEC 61804 standard will have on the process industry and on manufacturers of control systems.