Os sistemas produtivos (SPs) podem utilizar controladores programáveis (CPs) como dispositivos de realização do controle. Neste contexto, programas de controle executados por estes CPs podem ser desenvolvidos de forma que não estejam em conformidade com as especificações de projeto, o que poderá provocar o surgimento de erros funcionais associados à execução de tais programas de controle, erros estes que podem levar os SPs sob controle a um estado que poderá implicar em acidentes envolvendo equipamentos, pessoas e o meio-ambiente. Esta questão tem motivado o surgimento de diversas abordagens para identificar a existência de erros em programas de controle de CPs, de forma a permitir a correção destes erros e garantir, conseqüentemente, maior confiabilidade operacional. O presente trabalho tem por objetivo identificar a existência de erros em programas de controle baseados em LD (Ladder Diagram). Para isto, propõe-se um procedimento de desenvolvimento de modelos baseados em máquinas de estados finitos estendidas (MEFEs), que são gerados a partir do mapeamento de cada um dos rungs contidos no programa de controle que se deseja identificar erros. Uma vez desenvolvidos os modelos em MEFEs, torna-se possível a utilização de uma ferramenta computacional de verificação, própria para estabelecer se os modelos verificados satisfazem determinadas proposições estabelecidas em lógica temporal. Uma proposição em lógica temporal está relacionada a um estado específico do programa de controle modelado, sendo que o objetivo da verificação é o de estabelecer se a proposição estipulada é atendida ou não. Se um determinado estado específico for, por exemplo, um estado indesejado do programa de controle modelado, e este estado for possível de ser alcançado como resultado do processo de verificação realizado, isto impactará na não conformidade do programa de controle com as especificações comportamentais estipuladas na forma de proposição em lógica temporal, indicando haver, portanto, um erro neste programa de controle modelado. Palavras-chave: Controladores programáveis. Linguagem de programação LD. Modelagem e verificação de máquinas de estados finitos estendidas (MEFEs). / Productive systems (PS) can use programmable logic controllers (PLCs) as the devices of accomplishment of the control. In this context, control programs executed by these PLCs can be developed in a way so that they can be in non-conformity with the project specifications, and this fact may result in functional errors related to the control programs execution. These errors can take the PS under control to a state which can lead into accidents involving equipment, people and the environment. This fact has motivated the appearance of different approaches so as to identify the existence of these errors in PLC control programs so that they can be corrected and assure a greater operational reliability. This work aims at identifying the existence of errors in control programs based on Ladder Diagram (LD). In order to accomplish that, a modeling procedure that generates extended finite state machines (EFSMs) is proposed from the mapping of each one of the rungs in the control program whose errors are to be identified. Once the models based on EFSMs are developed it becomes possible to use a computational verification tool, specifically designed to determine if the verified models fulfill determined propositions established in temporal logic. A proposition in temporal logic is related to a specific state of the modeled control program and the objective of the verification is to establish whether the proposition is fulfilled or not. If a determined specific state, for example, is an unwanted state of the modeled control program and if this state is reachable as a result of the verification process, this will impact in the non-conformity of the control program with the behavior specifications established in a temporal logic proposition, indicating an error in this modeled control program.

Κύριος στόχος της παρούσας διατριβής ήταν να συμβάλλει στην συστηματοποίηση του έργου του Ηλεκτρολόγου Μηχανικού όταν αναλύει, μοντελοποιεί και σχεδιάζει τον έλεγχο ενός βιομηχανικού συστήματος. Για την μοντελοποίηση βιομηχανικών συστημάτων έχουν προταθεί διάφορες μέθοδοι, όπως τα δίκτυα Petri και όλες οι μορφές αυτομάτων ελέγχου. Τα αυτόματα αποτέλεσαν την βάση για την δημιουργία μιας νέας μεθόδου μοντελοποίησης στα πλαίσια της παρούσας διατριβής. Τα Γενικευμένα Αυτόματα (Global Automata), όπως ονομάστηκε η νέα μέθοδος, δανείζονται χαρακτηριστικά από τις διάφορες προϋπάρχουσες μορφές αυτομάτων, ενώ εισαγάγουν νέες παραμέτρους μοντελοποίησης ώστε να καλύψουν τις όποιες ανάγκες των σύγχρονων βιομηχανικών συστημάτων. Βάσει της μεθόδου αναπτύχθηκαν διάφορα εργαλεία με στόχο την αύξηση της δύναμης μοντελοποίησης της. Το πρώτο εργαλείο περιλαμβάνει μια συστηματοποιημένη τεχνική συγχώνευσης καταστάσεων ενός μοντέλου και αποσκοπεί στον περιορισμό της υπέρμετρης αύξησης του γράφου καταστάσεων, ο οποίος σε περιπτώσεις μεγάλων συστημάτων μπορεί να φτάσει τις δεκάδες χιλιάδες καταστάσεις. Το δεύτερο εργαλείο που αναπτύχθηκε, αποτελεί την σύνθεση αυτομάτων με στόχο την δημιουργία ενός νέου αυτομάτου που έχει την ίδια ακριβώς συμπεριφορά με τα αρχικά. Η σύνθεση επιτρέπει την δημιουργία μοντέλου ακόμα και ενός συστήματος υψηλής πολυπλοκότητας, μέσω σύνθεσης των μοντέλων όλων των υποσυστημάτων του. Τέλος, τα γενικευμένα αυτόματα επιτρέπουν την δημιουργία ιεραρχικών μοντέλων που αποτελούνται από πλήθος αυτομάτων ιεραρχικά δομημένων. Σε αυτή την περίπτωση το αυτόματο του ανωτέρου επιπέδου έχει τον ρόλο του επόπτη-συντονιστή και τροφοδοτεί τα αυτόματα του κατώτερου επιπέδου με δεδομένα, τιμές αναφοράς κτλ. Αναφορικά με τον προγραμματισμό των βιομηχανικών ελεγκτών που θα επωμιστούν τον έλεγχο της διεργασίας παρουσιάζονται δύο εργαλεία παραγωγής κώδικα από ένα γενικευμένο αυτόματο. Το πρώτο εργαλείο παρουσιάζει συστηματικά τα βήματα μετατροπής ενός αυτομάτου σε εκτελέσιμο κώδικα μιας γλώσσας προγραμματισμού υψηλού επιπέδου. Η χρησιμότητα είναι σημαντική κατά την διάρκεια εξομοίωσης ενός μοντέλου και επαλήθευσης της ορθής λειτουργίας του ελεγκτή, αλλά όχι μόνο. Οι σύγχρονες βιομηχανίες είναι εξοπλισμένες με Σταθμούς Εποπτικού Έλεγχου και Συλλογής Πληροφοριών (SCADA) οι οποίοι στην πλειονότητά τους φέρουν ενσωματωμένη δυνατότητα εκτέλεσης κώδικα σε μια γλώσσα υψηλού επιπέδου. Με εκτέλεση του παραγόμενου, από το εργαλείο, κώδικα σε λογισμικό SCADA, μπορεί να επιτευχθεί και έλεγχος του συστήματος. Βέβαια, ο επικρατέστερος τύπος ελεγκτή παραμένει το Προγραμματιζόμενος Λογικός Ελεγκτής, λόγω των ιδιαίτερων χαρακτηριστικών που διαθέτει και υπερισχύει συγκριτικά με τις εναλλακτικές προσεγγίσεις. Η υλοποίηση των γενικευμένων αυτομάτων σε PLC επιτυγχάνεται μέσω του δεύτερου εργαλείου, το οποίο δημιουργήθηκε με βάση το διεθνές πρότυπο IEC 61131-3 και περιγράφει όλα τα συστηματικά βήματα που πρέπει να ακολουθήσει ο μηχανικός για να υλοποιήσει την στρατηγική ελέγχου, που εμπεριέχει ένα γενικευμένο αυτόματα, σε ένα PLC. Το πρότυπο IEC 61131-3 περιλαμβάνει ένα σύνολο πέντε γλωσσών και το εργαλείο σύνθεσης τις περιλαμβάνει όλες δίνοντας κατάλληλες κατευθύνσεις υλοποίησης με βάση τα ιδιαίτερα χαρακτηριστικά της καθεμιάς. Η παρουσίαση των γενικευμένων αυτομάτων και των εργαλείων που αναπτύχθηκαν ολοκληρώνεται μέσω παραδειγμάτων χρήσης. Οι παρουσιαζόμενες εφαρμογές αποτελούν είτε θεωρητικά συστήματα για επεξήγηση, είτε πραγματικές εφαρμογές υλοποιημένες ως εργαστηριακές διατάξεις ή ως πραγματικά συστήματα παραγωγής. / In this work Global Automata are introduced as a new method offering the convenience of modelling various types of industrial systems without any restrictions on systems properties. Their structure has common characteristics with several types of automata, such as the control graph with a finite set of states and transitions between those states. Global automata can be used for modelling hybrid systems handling both discrete and real valued variables combining flow, invariant and guard conditions from hybrid automata, with clock constraints and delayed inputs from timed and PLC automata. In addition, new modelling parameters as reset table at each transition and hierarchical classification of executable events at each state are introduced. Application independence derives from the fact that they are a super-set of every other type of automata and hence are less application depended compared to any of them. Based on Global Automata some tools were developed in order to increase their modelling power. First tool is the ability of state aggregation which generally means the merging of two or more states in order to produce a new super-state. State aggregation is a powerful tool to avoid state space expansion. The second developed tool is automata composition and is mainly used in cases where ad-hoc modelling is not a practical solution, since it allows the construction of large system model using simple models of all system’s components. Finally, global automata allow the development of hierarchical models, consisting of two or more automata. In such case, the automaton of the higher level has the role of supervisor feeding the automata of lower level with data, reference values etc. Two implementation tools for programming industrial controllers are also presented. The first tool is a synthesis tool for translating a global automaton into executable code of a programming language (i.e. C, Matlab). Tool usage is important for simulation and verification but is not limited on this. Contemporary industrial systems are equipped with Supervisory Control and Data Acquisition Systems (SCADA), which have embedded functions of running code. Consequently, an industrial system modelled as a global automaton can be controlled by the executable code running in a SCADA station. But, in industry the dominant controller is the Programmable Logic Controller, which is a special aim computer suitably built for the application control tasks. The IEC 61131-3 Programming Norm describes all the well-known languages for programming PLCs and the second tool is a synthesis tool for implementing global automata in PLCs based on this programming norm. Global automata as a modelling method and all the above mentioned tools are illustrated through representative examples. The presented examples are either theoretical or real systems implemented in the laboratory or even real production systems.

Made available in DSpace on 2016-12-12T17:38:37Z (GMT). No. of bitstreams: 1 Moacyr Carlos Possan Junior.pdf: 1940795 bytes, checksum: 58824c0ca3ed2180f9e245d34118e117 (MD5) Previous issue date: 2009-12-15 / Coordenação de Aperfeiçoamento de Pessoal de Nível Superior / This work presents a new methodology for the modeling of supervisory control systems based on state machines with outputs, obtained from the automata which represent the supervisors found with the usage of the Supervisory Control Theory (SCT) of Discrete Event Systems (DES). Procedures like that are useful to create the documentation which represents the control logic for large scale systems and for the code generation, as well as allows that the documentation and program code updates be easier when new requirements to change the control logic in flexible systems appear. Besides, it makes way for the generation of more reliable solutions and also for the possibility of automatic code generation. The proposed technique consists on the obtaining of finite state machines with outputs using as input information the automata of the supervisors obtained by the SCT and the control actions of the system, where the control logic redundancies existing in the model of the automata are eliminated. Methodologies based on either monolithic or local modular approach are proposed, where the obtained machines are further simplified in order to have simpler models which are used as templates for the implementation in Programmable Logic Controller (PLC) using Ladder language. The methodology is shown using a simple manufacturing system as example to help on its understanding. Besides, this work deals with the difficulties found in the migration from the event based theory in the TCS to the signal based practice for the CLPs. After the presentation of this methodology, it is performed the modeling and implementation for a larger system, a manufacturing cell where a comparison with another existing methodology which also has the SCT as base is performed in order to verify the advantages and disadvantages of such methodology. / Este trabalho apresenta uma nova metodologia para a modelagem de sistemas de controle supervisório baseados em máquinas de estados com saídas, obtidas a partir dos autômatos que representam os supervisores encontrados com o uso da Teoria de Controle Supervisório (TCS) de Sistemas a Eventos Discretos (SEDs). Procedimentos como este são úteis para criar a documentação relativa à especificações de sistemas de grande porte e à geração de código, assim como permitem que a atualização da documentação e do código seja facilitada quando surgem novos requisitos para variação da lógica de controle em sistemas flexíveis. Além disso, isso abre espaço para a geração de soluções mais confiáveis e também para a possibilidade de geração automática de código. A técnica proposta consiste em obter máquinas de estados finitos com saídas usando como informação os autômatos dos supervisores obtidos por intermédio da TCS e as ações de controle do sistema, onde redundâncias da lógica de controle presentes no modelo do autômato são eliminadas. São propostas abordagens tanto no contexto monolítico quanto no contexto modular local, onde as máquinas obtidas são reduzidas posteriormente com o intuito de obter modelos mais simples, que servem como referência para a implementação em Controlador Lógico Programável (CLP) usando linguagem Ladder. A metodologia é demonstrada usando um sistema de manufatura simples como exemplo a fim de facilitar sua compreensão. Além disso, este trabalho trata das dificuldades encontradas na migração da teoria baseada em eventos da TCS na prática baseada em sinais dos CLPs. Após a apresentação da metodologia, é feita a modelagem e implementação para um sistema de maior porte, uma célula de manufatura onde é efetuada uma comparação com uma metodologia já existente que também têm como base a TCS, com o intuito de verificar as vantagens e desvantagens dessa metodologia

Made available in DSpace on 2014-12-17T14:08:47Z (GMT). No. of bitstreams: 1 TiagoSB_DISSERT.pdf: 2511631 bytes, checksum: 6bc0111c2afb2c48acf040134ddb6f46 (MD5) Previous issue date: 2011-07-22 / From their early days, Electrical Submergible Pumping (ESP) units have excelled in lifting much greater liquid rates than most of the other types of artificial lift and developed by good performance in wells with high BSW, in onshore and offshore environments. For all artificial lift system, the lifetime and frequency of interventions are of paramount importance, given the high costs of rigs and equipment, plus the losses coming from a halt in production. In search of a better life of the system comes the need to work with the same efficiency and security within the limits of their equipment, this implies the need for periodic adjustments, monitoring and control. How is increasing the prospect of minimizing direct human actions, these adjustments should be made increasingly via automation. The automated system not only provides a longer life, but also greater control over the production of the well. The controller is the brain of most automation systems, it is inserted the logic and strategies in the work process in order to get you to work efficiently. So great is the importance of controlling for any automation system is expected that, with better understanding of ESP system and the development of research, many controllers will be proposed for this method of artificial lift. Once a controller is proposed, it must be tested and validated before they take it as efficient and functional. The use of a producing well or a test well could favor the completion of testing, but with the serious risk that flaws in the design of the controller were to cause damage to oil well equipment, many of them expensive. Given this reality, the main objective of the present work is to present an environment for evaluation of fuzzy controllers for wells equipped with ESP system, using a computer simulator representing a virtual oil well, a software design fuzzy controllers and a PLC. The use of the proposed environment will enable a reduction in time required for testing and adjustments to the controller and evaluated a rapid diagnosis of their efficiency and effectiveness. The control algorithms are implemented in both high-level language, through the controller design software, such as specific language for programming PLCs, Ladder Diagram language. / Desde a sua concep??o, as unidades de Bombeio Centr?fugo Submerso (BCS) destacaram- se pelas altas vaz?es desenvolvidas e pelo bom desempenho em po?os com alto BSW, tanto em ambientes onshore como offshore. Em qualquer sistema de eleva??o, sua vida ?til e a frequ?ncia das interven??es s?o de fundamental import?ncia, em virtude dos elevados custos das sondas e dos equipamentos, al?m dos prejuizos oriundos de uma parada na produ??o. Na busca por uma maior vida ?til do sistema, surge a necessidade de que o mesmo trabalhe com efici?ncia e dentro dos limites de seguran?a de seus equipamentos, isso implica na necessidade de peri?dicos ajustes, monitoramento e controle. Como ? crescente a perspectiva de se minimizar as a??es humanas diretas, esses ajustes dever?o ser feitos cada vez mais via automa??o. A automa??o do sistema n?o s? possibilita uma maior vida ?til, mas tamb?m um maior controle sobre a produ??o do po?o. O controlador ? o c?rebro da maioria dos sistemas de automa??o, concentrando l?gica e estrat?gias necess?rias a atua??o no processo de maneira a lev?-lo a trabalhar com efici?ncia. Tal ? a import?ncia do controle para qualquer sistema de automa??o que se espera que, com o desenvolver das pesquisas e melhor conhecimento do BCS, muitos controladores venham a ser propostos para este m?todo de eleva??o. Depois que um controlador ? proposto, o mesmo deve ser testado e validado antes de se tom?-lo como eficiente e funcional. O uso de um po?o produtor ou de um po?o de teste poderia viabilizar a realiza??o de testes, mas com o s?rio risco de que falhas no projeto do controlador viessem a ocasionar danos aos equipamentos do po?o, muitos deles de custo elevado. Diante dessa realidade, o objetivo deste trabalho ? apresentar um ambiente para avalia??o de controladores fuzzy para po?os equipados com o m?todo BCS, utilizando-se de um simulador computacional representando um po?o virtual, de um software de projeto de controladores fuzzy e de um CLP comercial. O uso do ambiente proposto possibilitar? uma redu??o no tempo requerido para a realiza??o dos testes e ajustes necess?rios ao controlador avaliado e um diagn?stico r?pido de sua efici?ncia e efic?cia. Os algoritmos de controle s?o implementados tanto em linguagem de alto n?vel, atrav?s do software de projeto de controladores, como em linguagem espec?fica para programa??o de CLPs, a linguagem de Diagramas Ladder.