Este trabalho apresenta uma proposta de metodologia de desenvolvimento de sistemas de Informática Industrial para fábrica de celulose. Inicialmente foi elaborado um estudo sobre a automação na industria de celulose nos seus diversos aspectos a fim de estabelecer uma referência sobre a natureza dos sistemas a serem desenvolvidos e de diretrizes na condução de um projeto deste tipo. Após este levantamento é apresentada a metodologia de projeto propriamente dita a qual se baseia numa descrição formal do processo a fim de que possamos levantar suas principais características. Esta descrição é a base do projeto do sistema de controle de processos. / This work deals with the development of industrial control system. First is present a survey on process control for pulp and paper industry in such a way to give a direction for the proposal. The main aspects of system are present and their impact in the economics of this industrial field. Secondly the methodology it self is presented. It departs from the formal description of the process and its characteristics as the base for the process control system.

Este trabalho apresenta uma proposta de metodologia de desenvolvimento de sistemas de Informática Industrial para fábrica de celulose. Inicialmente foi elaborado um estudo sobre a automação na industria de celulose nos seus diversos aspectos a fim de estabelecer uma referência sobre a natureza dos sistemas a serem desenvolvidos e de diretrizes na condução de um projeto deste tipo. Após este levantamento é apresentada a metodologia de projeto propriamente dita a qual se baseia numa descrição formal do processo a fim de que possamos levantar suas principais características. Esta descrição é a base do projeto do sistema de controle de processos. / This work deals with the development of industrial control system. First is present a survey on process control for pulp and paper industry in such a way to give a direction for the proposal. The main aspects of system are present and their impact in the economics of this industrial field. Secondly the methodology it self is presented. It departs from the formal description of the process and its characteristics as the base for the process control system.

The present work is concerned with the advancement of the knowledge of structural optimization in engineering design while focusing on efficient and easy to use ways of setting-up the required automated processes as well as the problems arising from it. Three industry examples are considered. In the first example a software tool that serves as a hands-on decision guidance for many occurring design situations for structured wall PE pipes is developed. In order to avoid licensing fees only public domain software or in-house code are used. It offers the efficient and automated simulation of the ringstiffness test as well as the most common pipe installation scenarios. In addition, an optimization feature is implemented for the design of optimum pipe profiles with regards to the ringstiffness test. In the second example a framework for the optimum design of carbon fibre mountain bike frames is developed. An extensively parameterized and automated simulation model is created that allows for varying tube shapes, paths and laminate ply thicknesses as well as joint locations. For improved efficiency a decomposition approach has been employed that decomposes the original optimization problem into a size optimization sub problem and a shape optimization top level problem. The former is solved by the built-in optimization tool in OptiStruct and the latter by means of surrogate based optimization where each experiment in the DoE is a full size optimization. The third example is concerned with the optimum design of a blade for a novel vertical axis wind turbine. A design approach similar to those with horizontal axes is chosen. The altered design requirements are accounted for by creating a parameterized simulation model and performing size optimization runs for 32 models with different material settings and shear web locations where the model creation process has been automated.

Thesis (MTech (Electrical Engineering))--Peninsula Technikon, Cape Town, 2002 / Fermentation is the process that results in the formation of alcohol or organic acids on the basis of growth of bacteria, moulds or fungi on different nutritional media (Ahmed et al., 1982). Fermentation process have three modes of operation i.e. batch, fed-batch and continuous mode ofoperation. The process that interests a lot of control engineers is the fed-batch fe=entation process (Johnson, 1989). The Fed-batch process for the production ofyeast is considered in the study. The considered yeast in the study is the Saccharomyces cerevisiae. It grows in both aerobic and anaerobic environmental conditions with maximum product in the aerobic conditions, also at high concentration of glucose (Njodzi, 2001). Complexity of fedbatch fe=entation process, non-linearity, time varying characteristics, application of conventional analogue controllers provides poor control due to problems in tuning individual loops and the process characteristics. The problem for control of the fedbatch process for the production of yeast is further complicated by the lack of on-line sensors, lack of adequate models as a result of poorly understood dynamics. The lack of on-line sensors results in the impossibility of tuning the analogue controllers in real time. The process for propagation of yeast in aerobic conditions is considered in the dissertation. The experiments are conducted at the University of Cape Town (VCT), Department of Chemical Engineering with a bioreactor and bio-controller are combined in a Biostat ® C lab scale plant (B. Braun Biotech International, 1996). The bio-controller has built in PID controller loops for control variables, with the ability to adjust the controller parameters i.e. P, D and I through the serial interface (Seidler, 1996).

Thesis (MTech (Electrical Engineering))--Cape Peninsula University of Technology, 2005 / Fennentation is the process that results in the fonnation ofalcohol or organic acids on the basis of growth of bacteria, moulds or fungi on different nutritional media (Ahmed et al., 1982). Fennentation process have three modes of operation i.e. batch, fed-batch and continuous ones. The process that interests a lot of control engineers is the fed-batch fennentation process (Johnson, 1989). The Fed-batch process for the production ofyeast is considered in the study. The fennentation is based on the Saccharomyces cerevisiae yeast. It grows in both aerobic and anaerobic environmental conditions with maximum product in the aerobic conditions, also at high concentration of glucose (Njodzi, 200I). Complexity of fed-batch fennentation process, non-linearity, time varying characteristics, application of conventional analogue controllers provides poor control due to problems in tuning individual loops and the process characteristics. The problem for control of the fed-batch process for the production of yeast is further complicated by the lack of on-line sensors, lack ofadequate models as a result ofpoorly understood dynamics. The lack of on-line sensors results in the impossibility oftuning the analogue controllers in real time. The process for propagation of yeast in aerobic conditions is considered in the dissertation. The experiments are conducted at the University of Cape Town (DCT), Department of Chemical Engineering with a bioreactor and bio-controller combined in a Biostat ® C lab scale plant (H. Braun Biotech International, 1996). The bio-controller has built in Pill controller loops for control variables, with the ability to adjust the controller parameters i.e. P, D and I through the serial interface (SeidIer, 1996).

Submitted in fulfillment ofthe requirement for Masters degree oftechnology (Mtech): Electrical engineering, 2002 / Fermentation is the process that results in the formation of alcohol or organic acids on the basis of growth of bacteria, moulds or fungi on different nutritional media (Ahmed et al., 1982). Fermentation process have three modes of operation i.e. batch, fed-batch and continuous mode ofoperation. The process that interests a lot of control engineers is the fed-batch fe=entation process (Johnson, 1989). The Fed-batch process for the production ofyeast is considered in the study. The considered yeast in the study is the Saccharomyces cerevisiae. It grows in both aerobic and anaerobic environmental conditions with maximum product in the aerobic conditions, also at high concentration of glucose (Njodzi, 2001). Complexity of fedbatch fe=entation process, non-linearity, time varying characteristics, application of conventional analogue controllers provides poor control due to problems in tuning individual loops and the process characteristics. The problem for control of the fedbatch process for the production of yeast is further complicated by the lack of on-line sensors, lack of adequate models as a result of poorly understood dynamics. The lack of on-line sensors results in the impossibility of tuning the analogue controllers in real time. The process for propagation of yeast in aerobic conditions is considered in the dissertation. The experiments are conducted at the University of Cape Town (VCT), Department of Chemical Engineering with a bioreactor and bio-controller are combined in a Biostat ® C lab scale plant (B. Braun Biotech International, 1996). The bio-controller has built in PID controller loops for control variables, with the ability to adjust the controller parameters i.e. P, D and I through the serial interface (Seidler, 1996). Even though the used lab scale bio-controller has the ability to monitor certain variables, the automation of the industrial bioreactors is still developing slowly (Dochan and Bastin, 1990) with major problems experienced in modelling and measuring important control variables on-line. This existing situation is due to the characteristics of the fermentation processes as an object of control with highly non-linear, non-stationary, slow dynamics and complex relationships between variables. The existing control strategies on industry are based only of local PID control of some easy for measuring variables. No computer systems for monitoring and optimisation of the process (Morari and Stephanopoulos, 1980). The dissertation is overcoming the mentioned above drawbacks by developing methods, algorithms and programmes for building of a two layer system for optimal control of the Biostat ® C pilot plant with the following subsystems: ~ Data acquisition, ~ Modelling and simulation, ~ Model parameter estimation, ~ Process optimisation, ~ PlO controller parameter tuning, ~ Real time control implementation The system is based on LabVIEW™ and serial communication protocol. The interface between the Bio-start and the host computer is through a standard communication serial port. The development in the dissertation are described as follows: Chapter 1 describes the necessity of the research discussed in the dissertation and highlights comparison between the different approaches for modelling and control of fed-batch processes for the production of yeast, (Johansson, 1993). The aim and the objectives ofthe dissertation are stated and explained. Chapter 2 describes the process as an object of control looking precisely at the influence of the physiochemical variables on the biological variables. The relationship is identified through the enzymes. The results from previous experiments are discussed to illustrate the constraints associated with the control of the process under study Chapter 3 describes the different types of models as applicable to the dissertation. The comparison between different types is highlighted. The derivation of the developed yeast model using mass balance equations and rate laws is discussed and presented in the chapter. The problem for simulation of the model is solved using Matlab and LabVIEW™ programs. Chapter 4 describes the formulation of the problem for estimation of the fed-batch model coefficients and the method, algorithm and programme developed to solve this problem. In chapter 5 the optimal control problem is formulated and solved using optimal control theory, the approach of the functional of Lagrange is used. The optimisation layer problems are determined and based on the solutions of the previous upper layer i.e. the model parameters from the adaptation layer. The optimal operation of the process or yield of the yeast is based on some criteria for the production of biomass, and some constraints over minimal and maximal values of the variables. Decomposition method to solve the optimal control problem is developed on the bases of an augmented functional of Lagrange and decomposition in time domain. Algorithm of the method and program in Matlab are developed. Tuning of PID parameters for the controllers in Biostat ® C is described based on the optimal trajectories for the physiochemical variables obtained from the optimal control problem solution. Chapter 6 presents algorithms and programmes for monitoring and real time control of fed-batch fermentation process for the production of yeast, using Personal Computer, B Braun Biostat ® C Lab scale fermentation unit and LabVIEW™ as driver software. Hardware and software parts of the control systems are described and discussed. LabVIEW™ code is described. Chapter 7 presents the users manual. The mam functionality of the developed application and programmes is described and discussed. The source code ofthe developed programmes is presented in chapter 8. Chapter 9 presents the conclusion highlighting the developments in the dissertation as well as the future work on the topic and the possible application of the developed work in industry on the bigger scale fermentors. The positive characteristics of the developed methods algorithms and programmes are: -7 The developed model incorporates the physiochemical variables in the biological mass balance equations. In this way: the influence of the enzymes over the biological variables is utilised and possibilities for process optimisation is created. The process can be optimised m both physiochemical and biological variables. The physiochemical variables can be used as control inputs to reach the process optimisation. Data acquisition system gIves good possibilities for analysis and simulation ofthe process. The optimal control of the process is achieved without using expensive online sensors for measurement of the biological variables. This is why the developed system is applicable to the existing hardware and software control and measurement systems in industry. The control system automates the operation of the lab scale fermentation unit. It is safe, stable and operational.

Este trabalho apresenta uma proposta de metodologia de desenvolvimento de sistemas de Informática Industrial para fábrica de celulose. Inicialmente foi elaborado um estudo sobre a automação na industria de celulose nos seus diversos aspectos a fim de estabelecer uma referência sobre a natureza dos sistemas a serem desenvolvidos e de diretrizes na condução de um projeto deste tipo. Após este levantamento é apresentada a metodologia de projeto propriamente dita a qual se baseia numa descrição formal do processo a fim de que possamos levantar suas principais características. Esta descrição é a base do projeto do sistema de controle de processos. / This work deals with the development of industrial control system. First is present a survey on process control for pulp and paper industry in such a way to give a direction for the proposal. The main aspects of system are present and their impact in the economics of this industrial field. Secondly the methodology it self is presented. It departs from the formal description of the process and its characteristics as the base for the process control system.

Orientadores: Flávio Vasconcelos da Silva, Rubens Gedraite / Dissertação (mestrado) - Universidade Estaual de Campinas, Faculdade de Engenharia Química / Made available in DSpace on 2018-08-21T17:13:53Z (GMT). No. of bitstreams: 1 Sislian_Rodrigo_M.pdf: 5208613 bytes, checksum: 98e7f9c71ee28be7ab6cc618b41ea7bd (MD5) Previous issue date: 2012 / Resumo: A presença de resíduos em superfícies mal higienizadas pode aumentar a incidência de microrganismos e ocasionar problemas operacionais nos equipamentos de processo. A identificação da dinâmica do processo pode contribuir para a melhoria da sua eficiência, racionalizando o uso de água e energia empregada nas operações de enxágue. Atualmente, a maioria dos processos de limpeza CIP é conduzida com base em procedimentos padronizados considerando a experiência dos operadores de processo no que tange ao tempo de funcionamento do ciclo. Este trabalho aborda, em um primeiro momento, a implantação da instrumentação e do sistema de controle necessários para monitorar e controlar o processo e, na sequência, o levantamento experimental do comportamento do sistema a estímulos na vazão e/ou temperatura de operação do processo. Para tal foi utilizado um trocador de calor instalado em planta piloto com o objetivo de relacionar, ao longo do tempo, a variação da alcalinidade (pH) da água empregada para remoção do detergente alcalino utilizado no processo de limpeza com a temperatura e vazão da mesma. Neste trabalho a planta utilizada possui dimensões de uma planta semi-industrial típica; tal característica possibilita que se considerem as dinâmicas e fenômenos encontrados em plantas reais, obtendo-se resultados de grande interesse prático. Os equipamentos utilizados (sensores, interfaces e atuadores) são padrão de mercado, adequadamente combinados e instalados de maneira a permitir o estudo de vários aspectos relacionados às etapas de um processo CIP. Testes foram realizados na planta partindo dos parâmetros de sintonia calculados pelo método ITAE por Rovira para o controle de vazão do fluido de processo. Os valores finais dos parâmetros PID que apresentaram o melhor resultado e foram utilizados na planta foram: Kp= 2,68 e Ti= 0,101 s. Devido à diferença na dinâmica para aumento e redução da temperatura para o controle de temperatura do fluido de processo, partiu-se dos parâmetros de sintonia calculados pelo Método CHR sem sobre valor. Os valores finais dos parâmetros PID que apresentaram o melhor resultado nos testes e foram utilizados na planta foram: para o aumento da temperatura Kp = 6,394, Ti = 3,640 s e Td=0,621 s, e para a diminuição da temperatura, foi utilizado o controlador proporcional com o parâmetro Kp = 0,08. A cinética da remoção foi avaliada a partir da variação do pH medido. Foram identificadas as dinâmicas da planta para diferentes condições operacionais que mostram que os parâmetros dinâmicos do sistema são fortemente influenciados pelas vazões e pouco afetados pelas temperaturas utilizadas, com maior contribuição para valores mais elevados de vazão (16 L.min-1), onde há menor consumo de água. Apesar de a identificação aproximada apresentar um modelo (com erro) que representa a resposta do processo, motivou-se o uso de uma metodologia de identificação mais refinada com o objetivo de comparação. Esta foi obtida através de modelos baseados no sistema de Inferência Fuzzy Neuro-Adaptativo (ANFIS) através do aplicativo Simulink/MATLAB'MARCA REGISTRADA'. Os resultados obtidos com os modelos foram validados por comparação com os dados experimentais. Para este processo duas entradas (a saída atrasada em uma amostragem - pH [k-1] - e a vazão atual - F[k]) e uma saída (o pH atual - pH[k]) para o treinamento da rede, mostraram ser mais adequadas para modelar a resposta da dinâmica do pH na etapa de enxague estudada. O erro médio foi de 0,011 quando comparados os dados experimentais coletados com o modelo obtido (tanto com o uso do algoritmo Grid partition quanto com o algoritmo Subtractive Clustering e com o uso de 3 ou 5 funções de pertinência do tipo triangular) / Abstract: The presence of residues in poorly cleaned surfaces may increase the micro-organisms incidence and cause operational problems in process equipments. The process dynamics identification can contribute to improve efficiency, rationalizing the energy and water used in rinsing operations. Nowadays, most of CIP cleaning process is conducted based on standard procedures considering the process operators' experience regarding the operating time cycle. This paper discusses, at first, the instrumentation and control system implementation required to monitor and control the process and, after that, the experimental tests to analyze the system behavior to stimuli in flow and/or process operating temperature. For that it was used a heat exchanger installed in a pilot plant in order to relate, over time, the water alkalinity (pH) variation used to remove alkaline detergent used in the cleaning process with the temperature and flow rate of the same. The plant used in this study has the typical dimensions of a semi-industrial plant; this characteristic makes it possible to consider the dynamic and phenomena found in real plants, obtaining results of great practical interest. It was used industry standard equipments (sensors, actuators and interfaces) properly combined and installed so as to allow the study of various aspects related to the CIP process stages. Tests were done in the plant starting with the tuning parameters calculated by the ITAE by Rovira method to control the process fluid flow. The final PID parameters values that presented the best results and were used in the plant were: Kp = 2.68 and Ti = 0.101 s. Due to the difference in dynamics for increasing and decreasing temperature to control the process fluid temperature, It was started from the tuning parameters calculated by the CHR method without over value. The final PID parameter values that had the best results in the plant and were used were: for the temperature increase Kp = 6,394, Ti = 3,640 s and Td=0,621 s, and for decreasing temperature it was used a proportional controller with the parameter Kp = 0.08. The kinetics removal was evaluated starting from the measured pH variation. The plant dynamics were identified for different operating conditions which shows that the system's dynamic parameters are strongly influenced by the flow and little affected by the temperatures used, with a greater contribution for higher flow levels (16 L.min-1), where there is less water consumption. Although the approximate identification provide a suitable model (with error) that represents the process response, there was a motivation for the use of a more refined identification methodology with the objective of comparing. It was obtained by Adaptive Neuro-Fuzzy Inference System (ANFIS) model-based via Simulink/MATLAB'TRADE MARK' software. The results obtained with those models were validated by comparison with the experimental data. For this process two inputs (the output delayed by one sample - pH [k-1] - and the current flow - F[k]) and one output (the current pH - pH [k]) to the network training, revealed to be more appropriate to model the pH dynamics response in the rinse step studied. The average error was 0,011 when comparing the experimental collected data with the obtained model (either using the Grid Partition algorithm and the Subtractive Clustering algorithm and using 3 or 5 triangular membership functions) / Mestrado / Sistemas de Processos Quimicos e Informatica / Mestre em Engenharia Química

This Thesis is concerned with model-based control, where models of linear nonminimal state-space (NMSS) and nonlinear state-dependent parameter (SDP) form are considered. In particular, the focus is on model-based predictive control (MPC) in conjunction with the linear NMSS model and on proportional-integralplus (PIP) pole-assignment control in conjunction with the SDP model. The SDP-PIP pole-assignment controller is based on a nonlinear SDP model, however, the approach uses a linear pole-assignment controller design technique. This ‘potential paradox’ is addressed in this Thesis. A conceptual approach to realising the SDP-PIP pole-assignment control is proposed, where an additional conceptual time-shift operator is introduced. This allows the SDPPIP, at each sampling time instance, to be considered as an equivalent linear controller, while operating, in fact, in a nonlinear overall context. Additionally, an attempt to realise SDP-PIP control, where the SDP model exhibits equivalent linear system numerator zeros, is proposed. Regarding the NMSS MPC, emphasis is on square, i.e. equal number of inputs and outputs, multi-input multi-output (MIMO) modelled systems, which exhibit system output cross-coupling effects. Moreover, the NMSS MPC in incremental input form and making use of an integral-of-errors state variable, is considered. A strategy is proposed, that allows decoupling of the system outputs by diagonalising the closed-loop system model via an input transformation. A modification to the NMSS MPC in incremental input form is proposed such that the transformed system input - system output pairs can be considered individually, which allows the control and prediction horizons to be assigned to the individual pairs separately. This modification allows imposed constraints to be accommodated such that the cross-coupling effects do not re-emerge. A practical example is presented, namely, a DC-DC boost converter operating in discontinuous conduction mode (DCM), for which a SDP model is developed. This model is based on measured input-output data rather than on physical relationships. The model incorporates the output current so that the requirements for the load, driven by the converter, is constrained to remain within a predefined output current range. The proposed SDP model is compared to an alternative nonlinear Hammerstein-bilinear structured (HBS) model. The HBS model is, in a similar manner to the SDP model, also based on measured input-output data. Moreover, the differences as well as the similarities of the SDP and HBS model are elaborated. Furthermore, SDP-PIP pole-assignment control, based on the developed SDP model, is applied to the converter and the performance is compared to baseline linear PIP control schemes.

James Womack and his colleagues Daniel Jones and Daniel Roos changed the way western civilization approached manufacturing. In 1990, they published a book called ‘The Machine That Changed the World: The Story of Lean Production’. It was a concept that had slowly filtered from the east but had not made its mark on the manufacturing sector. The concept of lean, born out of the Japanese Toyota Manufacturing System, was first thought to be impossible to duplicate outside of Japan. Since Womack and company popularised this “new” way of producing goods and delivering services it spread across industries finding popularity in the medical, engineering, accounting and especially the manufacturing industries. Over the last few decades lean practices has been synonymous with efficiency, cost reduction, supply chain optimisation and innovative problem solving (Anvari Norzima, Rosnah, Hojjati and Ismail, 2010; Pieterse et al., 2010; Womack et al., 1990). Lean process implementation has been researched in abundance, as has failed attempts at lean implementation. The purpose of this study was to identify and assess enablers of lean sustainability in organisations where lean processes are already being implemented. The literature study found Organisational Culture, Leadership, Employee Engagement and Trade Unions participation as factors that contributed to successful lean implementations. The author developed a model to test Organisational Culture, Leadership, Employee Engagement and Trade Unions as enablers to sustain lean practices in organisations in South Africa’s manufacturing industries. The results proved that Organisational Culture, Leadership and Employee Engagement were considered enablers for lean sustainability. These three enablers have an interlinked relationship and together help sustainability. Lacking just one factor would surely result in unsustainable lean practices. The study was conducted in the quantitative paradigm, as the hypothesised relationship was statistically tested. The data was collected from a homogenous group via an email sent with a link to the questionnaire. The data was statistically analysed with Statistica software and Microsoft Excel.