An optimization-based control strategy for energy efficiency of discrete manufacturing systems

In order to reduce the global energy consumption and avoid highest power peaks during operation of manufacturing systems, an optimization-based controller for selective switching on/off of peripheral devices in a test bench that emulates the energy consumption of a periodic system is proposed. First, energy consumption models for the test-bench devices are obtained based on data and subspace identification methods. Next, a control strategy is designed based on both optimization and receding horizon approach, considering the energy consumption models, operating constraints, and the real processes performed by peripheral devices. Thus, a control policy based on dynamical models of peripheral devices is proposed to reduce the energy consumption of the manufacturing systems without sacrificing the productivity. Afterward, the proposed strategy is validated in the test bench and comparing to a typical rule-based control scheme commonly used for these manufacturing systems. Based on the obtained results, reductions near 7% could be achieved allowing improvements in energy efficiency via minimization of the energy costs related to nominal power purchased.Peer ReviewedPostprint (author's final draft

Energy efficiency in discrete-manufacturing systems: insights, trends, and control strategies

Since the depletion of fossil energy sources, rising energy prices, and governmental regulation restrictions, the current manufacturing industry is shifting towards more efficient and sustainable systems. This transformation has promoted the identification of energy saving opportunities and the development of new technologies and strategies oriented to improve the energy efficiency of such systems. This paper outlines and discusses most of the research reported during the last decade regarding energy efficiency in manufacturing systems, the current technologies and strategies to improve that efficiency, identifying and remarking those related to the design of management/control strategies. Based on this fact, this paper aims to provide a review of strategies for reducing energy consumption and optimizing the use of resources within a plant into the context of discrete manufacturing. The review performed concerning the current context of manufacturing systems, control systems implemented, and their transformation towards Industry 4.0 might be useful in both the academic and industrial dimension to identify trends and critical points and suggest further research lines.Peer ReviewedPreprin

The role of learning on industrial simulation design and analysis

The capability of modeling real-world system operations has turned simulation into an indispensable problemsolving methodology for business system design and analysis. Today, simulation supports decisions ranging from sourcing to operations to finance, starting at the strategic level and proceeding towards tactical and operational levels of decision-making. In such a dynamic setting, the practice of simulation goes beyond being a static problem-solving exercise and requires integration with learning. This article discusses the role of learning in simulation design and analysis motivated by the needs of industrial problems and describes how selected tools of statistical learning can be utilized for this purpose

Closed-loop Identification of an Industrial Extrusion Process

This paper deals with the challenging problem of closed-loop identification for multivariable chemical processes and particularly the estimation of an open-loop plant model for a lab-scale industrial twin-screw extruder used in a powder coatings manufacturing line. The aim is to produce a low order efficient model in order to assist the scaling-up and the model-based control design of the manufacturing process. To achieve this goal, a two-stage indirect approach has been deployed which relies on the a-priori knowledge of the controller parameters in order to extract good estimates of the open-loop dynamics of the underlying process. As input excitation signals we have used multiple single variable step tests at various operating conditions (current industrial practice) carried out manually in order to generate the data-set which captures the dynamics of the extrusion process. In order to increase the efforts for obtaining a suitable plant model, we have employed various identification techniques, such as Prediction Error Methods (PEM) and Subspace Identification Methods (SIM) in order to generate candidate closed-loop models that fit to the original input-output process data. Then, a comparison of the estimated models was performed by means of the mean square error and data fitting criteria in order to select the model that best describes the dynamic behaviour of the extrusion process. Model validation based on closed-loop step responses also used as verification of the results

On the Identification of Agents in the Design of Production Control Systems

This paper describes a methodology that is being developed for designing and building agent-based systems for the domain of production control. In particular, this paper deals with the steps that are involved in identifying the agents and in specifying their responsibilities. The methodology aims to be usable by engineers who have a background in production control but who have no prior experience in agent technology. For this reason, the methodology needs to be very prescriptive with respect to the agent-related aspects of design

Energy efficiency improvement through MPC-based peripherals management for an industrial process test-bench

High energy costs evince the growing need for energy efficiency in industrial companies. This paper presents a solution at the industrial machine level to obtain efficient energy consumption. Therefore, a controller inspired by the well-known model predictive control (MPC) strategy was developed for the management of peripheral devices. The validation of the control requires a test-bench to emulate the energy consumption of a manufacturing machine. The test-bench has four devices, two used to emulate the periodic and fixed energy consumption of the manufacturing process and two as peripherals, subject to rules associated with the process. Consequently, a subspace identification (SI) was employed to identify energy models to simulate the behavior of the device. As a final step, a performance comparison between a rule-based control (RBC) and the proposed predictive-like controller revealed the remarkable energy savings. The MPC results show an energy saving of around 3% with respect to RBC as well as an instant maximum energy consumption reduction of 8%, approximately.Peer ReviewedPostprint (published version

VR-PMS: a new approach for performance measurement and management of industrial systems

A new performance measurement and management framework based on value and risk is proposed. The proposed framework is applied to the modelling and evaluation of the a priori performance evaluation of manufacturing processes and to deciding on their alternatives. For this reason, it consistently integrates concepts relevant to objectives, activity, and risk in a single framework comprising a conceptual value/risk model, and it conceptualises the idea of value- and risk based performance management in a process context. In addition, a methodological framework is developed to provide guidelines for the decision-makers or performance evaluators of the processes. To facilitate the performance measurement and management process, this latter framework is organized in four phases: context establishment, performance modelling, performance assessment, and decision-making. Each phase of the framework is then instrumented with state of-the-art quantitative analysis tools and methods. For process design and evaluation, the deliverable of the value- and risk-based performance measurement and management system (VR-PMS) is a set of ranked solutions (i.e. alternative business processes) evaluated against the developed value and risk indicators. The proposed VR-PMS is illustrated with a case study from discrete parts manufacturing but is indeed applicable to a wide range of processes or systems

Task analysis of discrete and continuous skills: a dual methodology approach to human skills capture for automation

There is a growing requirement within the field of intelligent automation for a formal methodology to capture and classify explicit and tacit skills deployed by operators during complex task performance. This paper describes the development of a dual methodology approach which recognises the inherent differences between continuous tasks and discrete tasks and which proposes separate methodologies for each. Both methodologies emphasise capturing operators’ physical, perceptual, and cognitive skills, however, they fundamentally differ in their approach. The continuous task analysis recognises the non-arbitrary nature of operation ordering and that identifying suitable cues for subtask is a vital component of the skill. Discrete task analysis is a more traditional, chronologically ordered methodology and is intended to increase the resolution of skill classification and be practical for assessing complex tasks involving multiple unique subtasks through the use of taxonomy of generic actions for physical, perceptual, and cognitive actions