Self-Playing Labyrinth Game Using Camera and Industrial Control System

In this master’s thesis, an industrial control system together with a network camera and servo motors were used to automate a ball and plate labyrinth system. The two servo motors, each with its own servo drive, were connected by joint arms to the plate resting on two interconnected gimbal frames, one for each axis. A background subtraction-based ball position tracking algorithm was developed to measure the ball-position using the camera. The camera acted as a sensor node in a control network with a programmable logical controller used together with the servo drives to implement a cascaded PID control loop to control the ball position. The ball reference position could either be controlled with user input from a tablet device, or automatically to make the labyrinth self-playing. The resulting system was able to control the ball position through the labyrinth using the camera for position feedback

The design and evaluation of a PLC-based model predictive controller for application in industrial food processes

Model Predictive Control (MPC) is a viable control strategy for industrial processes that display relatively large variations in the process variable, have complex process variable interactions, or display a large amount of process deadtime. The objective of using MPC in manufacturing is to reduce overall process variability, the result being an increase in process accuracy, precision and efficiency. This study focused on the implementation of model predictive control techniques on an industrial sugar cooking process. The goal was to implement a successful MPC solution directly on a programmable logic controller (PLC) rather than on a personal computer (PC). Although there are many commercially available MPC controllers for implementation on a stand-alone PC, to date there are no control packages for realizing model-based control techniques directly on the ubiquitous PLC. This study implemented and evaluated three PC-based, commercial MPC technologies for the sugar cooking process, and a new model state feedback (MSF) MPC implementation directly on Rockwell Automation\u27s Allen-Bradley ControlLogix ® PLC. A standard proportional-integral-derivative (PID) control implementation was used as a baseline for comparing the MPC strategies. There were three main areas on which the overall comparative analysis focused. These comparison areas were the dynamic response of each strategy at startup, including both temperature rise time and overshoot, and the steady-state disturbance rejection capabilities of each strategy. The test results showed that the MPC strategies controlled the sugar cooking process better than the traditional PID control method in regards to temperature rise time, temperature overshoot, and disturbance rejection based on feed rate disturbances. It was seen that the differences between the various MPC strategies was not significant relative to temperature overshoot and disturbance rejection. The PLC-based MPC strategy was comparable, but not superior, to the PC-based commercial MPC applications. However, this strategy has several benefits such as requiring no external hardware, software, and communications protocols, which may result in a less expensive implementation than the commercial MPC strategies. The PLC-based strategy is also easier and cheaper to maintain because it is developed on the existing, well-known control platform with existing tools

A Transformative Process Control Solution

Knowing that a technology invented almost hundred years ago (PID controller) is still dominating industrial process control, a historical review was done to understand how the control field evolved. Model dependency and high level of mathematics appear as the main reasons that prevent other technologies from penetrating the engineering practice. A relatively novel methodology introduced by J. Han in 1998 called Active Disturbance Rejection Control (ADRC) came with characteristics that matches process control needs and restrictions on model dependency. This study will present a transformative solution for process control based on that. The control algorithm is designed and discretized for digital implementation in PLC or DSC. The tuning process is explained in a logical and intuitive way based on time and frequency domain characteristics. The idea was to use the language familiar to industry practitioners. To show its applicability, a case study was done for server’s temperature control; and the results show energy savings of 30% when compared to PID controllers. This solution is not yet optimal, since it is generally applicable for a wide range of processes, but it aims to be a step further in process control

A Transformative Process Control Solution

Knowing that a technology invented almost hundred years ago (PID controller) is still dominating industrial process control, a historical review was done to understand how the control field evolved. Model dependency and high level of mathematics appear as the main reasons that prevent other technologies from penetrating the engineering practice. A relatively novel methodology introduced by J. Han in 1998 called Active Disturbance Rejection Control (ADRC) came with characteristics that matches process control needs and restrictions on model dependency. This study will present a transformative solution for process control based on that. The control algorithm is designed and discretized for digital implementation in PLC or DSC. The tuning process is explained in a logical and intuitive way based on time and frequency domain characteristics. The idea was to use the language familiar to industry practitioners. To show its applicability, a case study was done for server’s temperature control; and the results show energy savings of 30% when compared to PID controllers. This solution is not yet optimal, since it is generally applicable for a wide range of processes, but it aims to be a step further in process control

Deterministic Artificial Intelligence

Kirchhoff’s laws give a mathematical description of electromechanics. Similarly, translational motion mechanics obey Newton’s laws, while rotational motion mechanics comply with Euler’s moment equations, a set of three nonlinear, coupled differential equations. Nonlinearities complicate the mathematical treatment of the seemingly simple action of rotating, and these complications lead to a robust lineage of research culminating here with a text on the ability to make rigid bodies in rotation become self-aware, and even learn. This book is meant for basic scientifically inclined readers commencing with a first chapter on the basics of stochastic artificial intelligence to bridge readers to very advanced topics of deterministic artificial intelligence, espoused in the book with applications to both electromechanics (e.g. the forced van der Pol equation) and also motion mechanics (i.e. Euler’s moment equations). The reader will learn how to bestow self-awareness and express optimal learning methods for the self-aware object (e.g. robot) that require no tuning and no interaction with humans for autonomous operation. The topics learned from reading this text will prepare students and faculty to investigate interesting problems of mechanics. It is the fondest hope of the editor and authors that readers enjoy the book

Towards narrowing the reality gap in electromechanical systems: error modeling in virtual commissioning

Digital factories and smart manufacturing systems have been increasingly researched and multiple concepts were developed to cope with prevailing ever-shortening life-cycles. The ubiquitous digital twin, despite many definitions, is often praised for accurate virtual models. One key idea to improve manufacturing through such virtual models is $\textit{virtual commissioning}$ (VC), aiming at early machine code validation. VC and its virtual models are still lacking behind their real counterparts. This gap between reality and its virtual model, commonly termed $\textit{reality gap}$, increases the complexity of creating cyber-physical systems. An especially stark contrast is visible between the idealized virtual model and a real machine encountering errors. While error simulations exist in other fields of research, a thorough investigation in VC is missing. Thus, this paper addresses the task of narrowing the reality gap in VC based on two steps. First, a comprehensive body of research of possible errors encountered in virtual commissioning is analyzed. Secondly, the feasibility of error implementation is discussed. This paper lays the foundation for narrowing the reality gap and enabling test automation and digital twin-based control

Design and Development of an Optical Chip Interferometer For High Precision On-Line Surface Measurement

Advances in manufacturing and with the demand of achieving faster throughput at a lower cost in any industrial setting have put forward the need for embedded metrology. Embedded metrology is the provision of metrology on the manufacturing platform, enabling measurement without the removal of the workpiece. Providing closer integration of metrology upon the manufacturing platform will improve material processing and reliability of manufacture for high added value products in ultra-high-precision engineering. Currently, almost all available metrology instrumentation is either too bulky, slow, destructive in terms of damaging the surfaces with a contacting stylus or is carried out off-line. One technology that holds promise for improving the current state-of-the-art in the online measurement of surfaces is hybrid photonic integration. This technique provides for the integration of individual optoelectronic components onto silicon daughter boards which are then incorporated on a silica motherboard containing waveguides to produce a complete photonic circuit. This thesis presents first of its kind a novel chip interferometer sensor based on hybrid integration technology for online surface and dimensional metrology applications. The complete metrology sensor system is structured into two parts; hybrid photonic chip and optical probe. The hybrid photonic chip interferometer is based on a silica-on-silicon etched integrated-optic motherboard containing waveguide structures and evanescent couplers. Upon the motherboard, electro-optic components such as photodiodes and a semiconductor gain block are mounted and bonded to provide the required functionality. Optical probe is a separate entity attached to the integrated optic module which serves as optical stylus for surface scanning in two measurement modes a) A single-point for measuring distance and thus form/surface topography through movement of the device or workpiece, b) Profiling (lateral scanning where assessment of 2D surface parameters may be determined in a single shot. Wavelength scanning and phase shifting inteferometry implemented for the retrival of phase information eventually providing the surface height measurement. The signal analysis methodology for the two measurement modes is described as well as a theoretical and experimental appraisal of the metrology capabilities in terms of range and resolution. The incremetal development of various hybrid photonic modules such as wavelength encoder unit, signal detection unit etc. of the chip interferometer are presented. Initial measurement results from various componets of metrology sensor and the surface measurement results in two measurement modes validate the applicability of the described sensor system as a potential metrology tool for online surface measurement applications

A METHODOLOGY FOR AUTONOMOUS ROOF BOLT INSTALLATION USING INDUSTRIAL ROBOTICS

The mining sector is currently in the stage of adopting more automation, and with it, robotics. Autonomous bolting in underground environments remains a hot topic for the mining industry. Roof bolter operators are exposed to hazardous conditions due to their proximity to the unsupported roof, loose bolts, and heavy spinning mass. Prolonged exposure to the risk inevitably leads to accidents and injuries. The current thesis presents the development of a robotic assembly capable of carrying out the entire sequence of roof bolting operations in full and partial autonomous sensor-driven rock bolting operations to achieve a high-impact health and safety intervention for equipment operators. The automation of a complete cycle of drill steel positioning, drilling, bolt orientation and placement, resin placement, and bolt securing is discussed using an anthropomorphic robotic arm.A human-computer interface is developed to enable the interaction of the operators with the machines. Collision detection techniques will have to be implemented to minimize the impact after an unexpected collision has occurred. A robust failure-detection protocol is developed to check the vital parameters of robot operations continuously. This unique approach to automation of small materials handling is described with lessons learned. A user-centered GUI has been developed that allows for a human user to control and monitor the autonomous roof bolter. Preliminary tests have been conducted in a mock mine to evaluate the developed system\u27s performance. In addition, a number of different scenarios simulating typical missions that a roof bolter needs to undertake in an underground coal mine were tested