Orientador: Ana Maria Frattini Fileti / Dissertação (mestrado) - Universidade Estadual de Campinas, Faculdade de Engenharia Química / Made available in DSpace on 2018-08-18T19:16:53Z (GMT). No. of bitstreams: 1 Santos_BrunnoFerreirados_M.pdf: 1390100 bytes, checksum: 6d2b1c02098b1bb57ec404e3263f61a6 (MD5) Previous issue date: 2011 / Resumo: Indústrias de polimerização, em geral, utilizam diferentes sistemas reacionais para obter polímeros com diferentes características. Os processos de polimerização de estireno em batelada podem a apresentar um perfil de temperatura transiente, por causa de efeitos de viscosidade no meio reacional, são chamados de efeitos difusionais. Com a finalidade de controlar a temperatura destes tipos de sistema, engenheiros têm se voltado à busca de modelos que descrevam com fidelidade os processos nãolineares. Controle preditivo baseado em um modelo (MPC) de Redes Neurais Artificiais (RNAs) é uma opção para estes casos. Neste trabalho foram implementadas as equações algébricas e os parâmetros ajustados no treinamento de um modelo neural em uma planilha do Microsoft Excel. A atualização das variáveis do modelo se deu através da comunicação entre o Indusoft Web Studio (IWS) e a planilha via driver DDE (Dynamics Data Exchange). O treinamento do modelo neural aconteceu com algoritmo de Levenberg-Marquardt com regularização bayesiana utilizando o toolbox do MATLAB (comando trainbr). A validação do modelo foi realizada online, para garantir o uso do mesmo. Num primeiro momento, foram estudadas as condições para aplicação de controle fixando a proporção da mistura reacional em 50-50% em volume para monômero e solvente (estireno e tolueno, respectivamente) e a modelagem com RNA mostrou bons resultados. Em outro momento, realizou-se um controle em cascata da temperatura do reator manipulando a potência da resistência (variável manipulada) através da passagem de um fluido pela camisa do reator. Foi utilizado o simulink do MATLAB para fazer a malha de controle em cascata, através de um diagrama de blocos e sua atualização aconteceu via protocolo OPC (OLE for Process Control) de dados do Indusoft. Em paralelo, um modelo fenomenológico validado para processos poliméricos, envolvendo equações e parâmetros relacionados à polimerização de estireno, foi utilizado para estimar valores de conversão, massa molar média numérica (Mn) e massa molar média ponderal (Mw). Observou-se o sucesso da aplicação da estratégia de controle cascata adotada para a planta real, permitindo assim estabelecer uma comparação com as predições do modelo. Para o funcionamento do MPC, foram enviadas, a cada 5 segundos, as informações das variáveis de entrada (temperatura do reator, temperatura do fluido e a variação de potência) para o modelo neural na planilha, calculando automaticamente a temperatura do reator em um instante de amostragem à frente usando-a na função-objetivo do Solver no Excel (minimizar erro quadrático). O valor do Solver foi, então, mandado para o processo através de uma programação em VBA (Visual Basic Applications). Foram analisados os desempenhos dos controladores através do oveshoot, tempo de acomodação, IAE e ITAE. E realizou-se a utilização do controlador Híbrido (controle em cascata e MPC) o que melhorou a performance do sistema / Abstract: Chemical processes are included in several types of industries and demand precise control to reach the final product with quality. Because of the viscosity effects of reactor bulk (diffusional effects), the batch styrene polymerization processes present transient temperature behavior. Aiming at controlling the temperature of these systems, rigorous first principles models that describe nonlinearities precisely have been developed by engineers. The model predictive control (MPC) based on neural network modeling is one of the most approppriate techniques for these processes. In this work, the algebraic equations of a neural network and its adjusted parameters from the training step were implemented in an electronic worksheet (Excel software). The communication from the supervisory software (Indusoft Web Studio - IWS) and the worksheet were done through driver DDE (Dynamics Data Exchange), allowing the update of measured variables. The Bayesian Regularization Levenberg-Marquardt algorithm (trainbr function in the software MATLAB) was employed in network training. The model validation was on line performed in order to prove its suitability to the actual process. Initially, a 50/50 % volume ratio of solvent (Toluene) and monomer (styrene) was used for the control application studies, obtaining precise results using the neural network. Afterwards, a temperature cascade control loop was implemented by manipulating the resistance power inverter of the heating thermal fluid tank. This fluid circulates at the reactor jacket. The cascade control diagram was developed in the Simulink/MATLAB software. Updating measurements occurred by means of the OLE for Process Control protocol (OPC). A validated first principles model, using parameters related to the polymerization of styrene, was used to estimate conversion rates, number average molecular weight (Mn) and weight average molecular weight (Mw). The successful application of the control strategy allowed the comparison to the rigorous model predictions. The neural model input variables (reactor temperature, thermal fluid temperature and power inverter position) were captured from sensors every 5 seconds. At this time, the model in the worksheet calculated automatically the one-step-ahead temperature value, using this prediction in the objective function (squared error minimization) implemented in the solver of the Excel software. Using VBA (Visual Basic Applications) programming, the manipulated variable action was calculated and then sent to the process. The overshoot, settling time, IAE and ITAE were used as controller performance indexes. A hybrid controller (cascade feedback and MPC) was also tested, improving the performance of the system / Mestrado / Sistemas de Processos Quimicos e Informatica / Mestre em Engenharia Química

Nos últimos anos diversas áreas do setor produtivo vêm experimentando acelerados avanços tecnológicos e, desta forma, exigindo ferramentas cada vez mais específicas para monitorar e avaliar estes processos. Melhorias significativas nos processos de medições das características de qualidade têm sido observadas. Em relação ao controle de processo, em 1924, Walter Shewhart desenvolveu o conceito estatístico das cartas de controle para processos cujos dados sejam independentes e normalmente distribuídos, suposição esta que deve ser atendida para a construção das cartas de controle. Este artigo tem como objetivo mostrar a aplicação das cartas de controle estatístico de processo, no setor de pintura da Empresa Metasa, Rio Grande do Sul, Brasil, cuja característica do processo de pintura industrial analisada foi à espessura da camada de tinta. Os dados foram coletados levando em consideração, as seqüências que constituem o processo da aplicação da tinta (demãos de pintura), procurando-se oferecer uma melhoria sensível nos níveis de qualidade desse setor, com o objetivo de reduzir custos de produção. Os resultados encontrados são de grande importância para a empresa, pois foram estabelecidos os limites de controle que permitirão monitorar os processos. Para os casos onde a análise, entretanto, diagnosticou a permanência do processo fora de controle, se fez necessário o estudo das causas da variabilidade do mesmo. / In the last years many areas in the productive section have experienced fast technologic progress and, this way, demanding even more specific tools to control and assess these processes. Significant improvement in the processes of quality characteristics measurements has been noted. Regarding the process control, in 1924, Walter Shewhart (1931) developed the statistic concept of control letters to processes which data are independent and normally distributed, supposition that must be understood to control letters construction. This article has the goal to show the process statistic control letters, in the painting sector of the Company Metasa, Rio Grande do Sul, Brazil, which process characteristic of industrial painting analyzed was the paint coat thickness. The data were collected taking into consideration, the sequences that form the paint application process (painting coating), searching to offer a sensible improvement in the quality levels of this sector, with the objective of reducing production costs. The results found are of great importance to the company, since limits of control were established that will allow monitor the processes. For the cases where the analysis, otherwise, diagnosed the process permanence out of control, the study of their variability causes was necessary.

Orientadores: Flávio Vasconcelos da Silva, Jones Erni Schmitz / Dissertação (mestrado) - Universidade Estadual de Campinas, Faculdade de Engenharia Química / Made available in DSpace on 2018-08-27T17:33:20Z (GMT). No. of bitstreams: 1 Silva_BrunoFirminoda_M.pdf: 5897961 bytes, checksum: ac5990dc3d98f600c8592ed2ea843e04 (MD5) Previous issue date: 2015 / Resumo: Os processos químicos apresentam dinâmicas complexas devido a presença de reciclos, integrações energéticas e diversas operações unitárias interconectadas, gerando problemas de interação entre as variáveis e dificultando um efetivo controle do processo. Metodologias de controle global ou plantwide buscam estabelecer sistemas de controle contemplando a planta química como um todo, porém, geram mais de uma solução de controle. Este trabalho propõe avaliar diferentes estruturas de controle global para uma mesma planta química através do uso de indicadores chave de desempenho (KPI ¿ Key Performance Indicator) para o processo, determinando assim qual sistema de controle melhor atende aos objetivos estratégicos da indústria. Como caso de estudo simulou-se uma planta típica para a produção de biodiesel através dos softwares Aspen Plus e Aspen Plus Dynamics. O processo implementado busca representar a produção do biocombustível obtido na transesterificação do óleo de soja com metanol, por meio da rota de catálise alcalina e homogênea. Para simulação dinâmica do processo, utilizaram-se dois conjuntos de controladores obtidos da metodologia de controle global heurística, configurando-se duas propostas de controle para o processo. Para avaliação das propostas de controle, utilizaram-se indicadores chave de desempenho representativos do processo global. O indicador DDS (Dynamic Disturbance Sensitivity), o qual relaciona o acúmulo molar total dos componentes ao longo do tempo, e um indicador que relaciona os custos de matérias-primas foram utilizados. Ambos indicadores, permitiram uma visualização do desempenho dos controladores de modo global e a auxiliaram na escolha do melhor conjunto de malhas de controle para o processo / Abstract: Chemical process have complex dynamics behaviors due to the presence of recycle streams, heat integration and several unit operations interconnected, leading to interaction problems among variables and making difficult to do an effective process control. Plantwide control methodologies aim to establish controls systems for entire chemical plants; however, it is possible to obtain different control solutions. This work proposes an evaluation of different Plantwide control structures for a specific process using Key Performance Indicators (KPI) and determinate which structure best meets the industry strategic goals. As a case study, it was implemented a simulation of a typical biodiesel process in Aspen Plus and Aspen Plus Dynamics. The process implemented intended to represent the production of biofuel obtained from the transesterification of soybean oil with methanol and homogeneous alkaline catalysis as chemical route. For dynamic simulation of the process, two sets of controllers obtained using global control heuristic methodology were used to control the process, setting up two proposals of control for biodiesel production. Key performance indicators of the overall process were used to evaluate the control proposals, such as the DDS indicator (Dynamic Disturbance Sensitivity), which presents the total molar accumulation over time, and an indicator that presents the raw material costs also over time. Both indicators allowed a view of the controllers global performance and aided in choose the best set of control loops for the process / Mestrado / Sistemas de Processos Quimicos e Informatica / Mestre em Engenharia Química

Buffer tanks are widely used within the process industry to prevent flow variations from being directly propagated throughout a plant. The capacity of the tank is used to smoothly transfer inlet flow upsets to the outlet. Ideally, the tank thus works as a low pass filter where the available tank capacity limits the achievable flow smoothing. For infrequently occurring upsets, where the system has time to reach steady state between flow changes, the averaging level control problem has been extensively studied. After an inlet flow change, flow filtering has traditionally been obtained by letting the tank level deviate from its nominal value while slowly adapting the outlet to cancel out the flow imbalance and eventually bringing back the level to its set-point. The system is then again in steady state and ready to surge the next upset. By ensuring that the single largest upset can be handled without violating the level constraints, satisfactory flow smoothing is obtained. In this thesis, the smoothing of frequently changing inlet flows is addressed. In this case, standard level controllers struggle to obtain acceptable flow smoothing since the system rarely is in steady state and flow upsets can thus not be treated as separate events. To obtain a control law that achieves optimal filtering while directly accounting for future upsets, the averaging level control problem was approached using robust model predictive control (MPC). The robust MPC differs in the way it obtains flow smoothing by not returning the tank level to a fixed set-point. Instead, it lets the steady state tank level depend on the current value of the inlet flow. This insight was then used to propose a linear control structure, designed to filter frequent upsets optimally. Analyses and simulation results indicate that the proposed linear and robust MPC controller obtain flow smoothing comparable to the standard optimal averaging level controllers for infrequent upsets while handling frequent upsets considerably better.

Orientador: Carlos Eduardo Angeli Furlani / Coorientador: Rouverson Pereira da Silva / Banca: Carlos Alessandro Chioderoli / Banca: Paulo Roberto Arbex Silva / Resumo: O Brasil é o maior produtor mundial de cana-de-açúcar, devido a expansão de áreas cultivadas, a adubação mecanizada torna-se muito importante para o aumento do desempenho operacional nesta cultura, porém esta adubação pode demonstrar alguns problemas na distribuição de fertilizantes, como a não realização da caracterização dos fertilizantes por meio do ângulo de repouso, granulometria e densidade dos nutrientes, entre outros. Dessa forma, torna-se necessário o desenvolvimento de novas tecnologias que possibilitem uma melhora na aplicação de fertilizantes na cultura da cana-de-açúcar. À vista disso, um novo conceito de adubadora está em desenvolvimento considerada como protótipo, pois esta realiza aplicação individualizada de nitrogênio, fósforo e potássio proporcionando maior eficiência na distribuição destes em relação às outras adubadoras. Com este trabalho o objetivo foi avaliar aplicação mecanizada de N-P-K individualizada na cultura da cana-de-açúcar. O experimento foi desenvolvido no município de Matão em área de cana-de-açúcar pertencente à Fazenda Cascavel, possuindo 1,66 ha aproximadamente de área experimental. O delineamento experimental foi Inteiramente Casualizado (DIC), com três tratamentos e trinta repetições por tratamento. Este delineamento foi estabelecido conforme os critérios do controle de qualidade, sendo o monitoramento das variáveis realizado durante a operação de adubação. Ao final do período de avaliação foram coletados 90 pontos amostrais no total, sendo 30 pontos por tratamento. Os tratamentos foram: 1- Adubação mecanizada, sem aplicação de herbicida; 2- Operação conjugada (aplicação simultânea de herbicida e adubação); e 3- Duas operações (aplicação separada de herbicida e adubo). Concluiu-se que a melhor qualidade operacional por meio das cartas de controle foi o tratamento 3, sendo duas operações (aplicação separada de herbicida e adubo)... / Abstract: The Brazil is the largest producer of sugarcane, due to expansion of cultivated areas, mechanized fertilizer becomes very important for the increase in operating performance in this culture, but this fertilization may show some problems in the distribution of fertilizers, so that when not performing the characterization of fertilizers through the angle of repose, particle size and density of nutrients, among other. Thus, it becomes necessary to develop new technologies that enable an improvement in the application of fertilizers in the cultivation of sugarcane. In view of this, a new concept of fertilizer in development considered as a prototype because this performs individualized application of nitrogen, phosphorus and potassium, providing greater efficiency in the distribution of these over other fertilizer machine. With this work the objective was to evaluate the mechanical application of NPK individualized culture of sugarcane. The experiment was conducted in the Matão municipality in the area of sugarcane belonging to the Fazenda Cascavel, possessing approximately 1.66 ha experimental area. The experimental design was completely randomized (DIC), with three treatments and thirty replications for treatment. This design was established according to the criteria of quality control, and monitoring of variables held during fertilization operation. At the end of the evaluation period were collected 90 sample points in total, with 30 points per treatment. The treatments were: 1- mechanized fertilized, without herbicide; 2- Operation combined (simultaneous application of herbicide and fertilizer); and 3- Two operations (separate application of herbicide and fertilizer). It was concluded that the best operational quality through control charts was the third treatment, two operations (separate application of herbicide and fertilizer) for presenting less variability. The right side of fertilizer machine was the best for having applied ... / Mestre

The study investigates potential of promising combination of Lean principles and Industry 4.0 tools in order to find a solution for control of manufacturing process. Firstly, each of the buzzwords is defined and their relation is explained. Then, rules which will facilitate implementation of I4.0 tools into Lean production are enumerated. Afterwards, situation at the shopfloor is observed and statistical analysis of production data is done to analyze current manufacturing process. Deep investigation revealed strong potential for improvement, which was the motive to elaborate a proposal for Lean automated process control.

This master‘s thesis deals with using surface texture parameters for conformity assessment and process control. The aim of the thesis was to create an overview of surface texture parameters, an overview of procedures for conformity assessment and process control using surface texture parameters, practical application on an industrial product and practical recommendations. The thesis includes an overview of profile and areal surface texture parameters, including an original translation of terms of the areal method. Methods of conformity assessment and process control in connection with the surface texture parameters are also described. Statistical analysis was performed based on 7200 values of surface parameters and 1843200 values of profile parameters which were measured on parts from serial production. The last chapter includes practical recommendations.

The master’s thesis is focused on the reduction of rejection rate in production of plastic bowls with the use of statistic methods. The theoretical part of this thesis describes among others Statistical Process Control, Process capability and types regulatory diagrams. The basis for the practical part is data collection over a certain period of production, from which the percentage of the rejection rate is evaluated. Experiments and corrective actions are designed to improve the process and thereby reduce scrap.

Master’s thesis describes statistical process control as a support for company management. Statistical process control methods and tools are introduced. Requirements for automotive industry are stated specifically for IATF 16949 standard and VDA 6.3 process audit method. Thesis presents current state in company Sanmina-SCI Czech Republic s.r.o regarding statistical regulation. Applies statistical process controls into the new process considering automotive requirements. It is all happening together with a new business introduction of automotive customer.

The master’s thesis is focused on process monitoring using statistical process control SPC tools. It is designed as a guide for the implementation and use of control charts in the manufacturing process of the base plates, which would ultimately be conducive to improving and stabilizing the process. The theoretical parts are the basic attitudes and practices methodology of SPC, especially classical Shewhart control charts. The next section describes the current status in Strojírny Třinec, a.s. and the manufacturing process of the base plates. Followed by application of control charts for a given quality features and analysis using statistical software. Based on the evaluation are findings and recommendations for long-term monitoring of the defined quality features.