- process control science and engineering
- computer science and software engineering
- signal processing engineering
- measurement science
- process engineering
- manufacturing
![Manufacturing Process Control Manufacturing Process Control](/uploads/1/2/3/6/123687800/897918520.jpg)
- Variability and quality. Advanced sensors and process controls are necessary to monitor process variations so that high-quality operations can be maintained at lower cost.
- Environmental constraints. Innovative, robust sensory devices, including innovative sensor materials and coating technologies, are necessary to monitor process parameters and provide information in extreme high-temperature and chemically corrosive environments.
- Service. Process controllers are necessary to provide proactive maintenance capabilities, such as measurements of performance degradation, fault recovery, self-maintenance, and remote diagnostics.
STRATEGY FOR A PROCESS CONTROLS INITIATIVE
- measuring temperature profiles in harsh processing environments
- measuring chemical composition/stoichiometry in harsh processing environments
- measuring physical attributes at high line speeds and high temperatures
- monitoring combustion processes
- methodologies that enable in-situ-level process control
- hybrid process models
- plantwide or enterprise-level optimization
- tools for open-architecture applications
- adaptive control systems
- methods and diagnostic tools for condition-based maintenance of process equipment
- the development of sensor materials (including materials for the entire sensor system, which consists of sensor elements, packaging, leads, interconnects, and actuators) with significantly improved thermal and chemical resistance
- the compilation of a comprehensive database of candidate sensor material properties, including mechanical and physical properties; high-temperature properties; reactivity in chemical environments; and methods for deposition, formation, and patterning processing to accelerate the design and development cycle for the fabrication of new sensor systems
- the development of methods to measure temperatures accurately and reliably, including techniques, such as Johnson-noise thermometry, Raman-based thermal measurements, phosphor thermography, and self-verifying temperature sensors
- the development of low-cost, miniaturized, integrated analytical instruments that can provide direct, easy measurements of process chemistries for a wide range of process flow streams and conditions; techniques to be considered for process measurement and control include near-infrared spectroscopy, Raman spectroscopy, mass spectrometry, infrared spectroscopy, UV-visible spectroscopy, electrochemical spectroscopy, and acoustic spectroscopy
- the application of new processing science for fabricating and packaging integrated sensor/signal processing/actuation modules
- the development of measurement technologies that can rapidly characterize and evaluate physical properties for wide-sheet processes or web processes
- the application of wireless telecommunications technology to the development of advanced wireless sensors; areas for development include reliable wireless networks for process monitoring and control, remote power systems for wireless devices, and standardization of communication protocols, interfaces, and software
- the development of process control methodologies that can facilitate the transition from environmental-level to in-situ-level control methods; areas of interest include the effective use of process measurements, intelligent control algorithms, and the development of reliable process models
- the development of techniques that can integrate disparate process models
- plantwide optimization and controls, including automated data analysis techniques to identify key process variables, integration of control with maintenance operations, process control approaches to minimize energy consumption and environmental impact, large-scale nonlinear optimization algorithms, methods to deal with process model uncertainties, and dynamic data reconciliation for large-scale models
- the evaluation of open-architecture control systems for large-batch and continuous processes typical of IOF industries
- the development and implementation of learning and adaptive controls; particular topics for research include distributed adaptive/learning system architectures that are feasible for implementation by process industries, operator interfaces in semi-autonomous control systems, and system stability and safety
- potential for reducing the consumption of energy and raw materials and for reducing waste
- consistency with the technology road maps of the IOF industries
- potential benefits for more than one industrial sector
- potential for commercial application
- the development of road maps to identify technology needs and implementation plans
- participation in interactions with cross-cutting technology programs (e.g., technical workshops and progress reviews)
- the development and validation of process models related to specific key processes
- improved process models that can facilitate the transition from environment-level control schemes to in-situ-level controls
- the optimization of process control systems, especially supervisory controls and plantwide integration
- the validation and implementation of improved sensor technologies and process control systems for large-scale processes
- National Institute for Standards and Technology program to develop standards for open-architecture systems; IOF industries should evaluate and validate system standards for large-batch and continuous operations
- National Science Foundation programs to improve process sensing and process modeling capabilities (e.g., the Measurement and Control Engineering Center at the University of Tennessee-Knoxville; the Center for Process Analytical Chemistry at the University of Washington; and the Center for Industrial Sensors and Measurements at Ohio State University); IOF industries should coordinate the implementation and application of process modeling and advanced sensor technologies
- U.S. Department of Defense research, especially at DARPA, to develop MEMS devices, fabrication processes, and applications; IOF industries should evaluate these devices for sensing/control of industrial processes
- U.S. Department of Defense (especially Army, Navy, and DARPA) programs to develop condition-based maintenance approaches; IOF industries should evaluate sensors and diagnostics developed to monitor processing equipment and machinery
Basics of Process Control Systems
In a manufacturing setup, there will be different parameters for critical processes that have to be monitored. The real time values of these parameters will be fed to a central control system. These values are compared with the preset set-points through feedback systems and the necessary alerts are output on the display system, so that corrective action can be taken.
Representative process control system is one in which, a laser diode acts as the measuring device for detection of liquid/gas present in a given industrial environment.
The frequency signature of concerned material (liquid/gas) is then passed on to the receiver. It is then converted in digital form and picked by the processor.
The cost-performance trade off is to be balanced to implement application-specific peripherals for achieving the desired core performance.
Once the core is optimized for working with the desired peripherals, and speed, the rest of the system may be designed as per budget considerations.
PLC and DCS: The Heart of Process Controls
The primary devices that are used in a process control system are Programmable Logic Controllers better known as PLCs in short. PLCs are the best bets for controlling machines with several discrete devices such as motor starters, limit switches, and the likes of them, which are often involved in automation process like material handling, state machines, sequencing, status reports etc.
Distributed Control Systems, commonly abbreviated as DCS, are central control systems, which are good at controlling analog devices; thereby aiding in process control.
In a manufacturing setup, feedback from different sensors tendering to many processes are given to a bank of PLCs. Each process has a separate set of PLCs and the output of these which contain information regarding the status at the shop floor is given to the DCS. PLC is just a controller and DCS is a central controller with a MMI [Man Machine Interface]. Corrective controls are input to the DCS, which is given to the PLC and thereafter sent to the individual control devices.
Modern PLCs & DCSs have enormous capability in a plant automation setting. There is good deal of difference in the capabilities of DCS as well as PLCs. DCS offers an integrated development environment which provides more powerful remote process control computers. DCS also functions as a supervising control which maintains quality at the desired level intended for the product.
Process Control Systems for Small Systems
For small systems a PLC+PC based system is perhaps the best possible solution, which may even supersede the goods delivered by a DCS.