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A Complete Programming Framework for Process Control Education

This paper discusses a programming framework for process control education, focusing on interactive design of controllers, textual and graphical programming, data acquisition and controller implementation, real-time control, and case studies. The framework addresses the challenges faced in acquiring good data for model-based control and implementing digital controllers.

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A Complete Programming Framework for Process Control Education

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  1. A Complete Programming Framework for Process Control Education Ricardo Dunia and Thomas Edgar Chemical Engineering Department University of Texas at Austin Finn Haugen Department of Technology Telemark University College, Norway IEEE Multi-conference on Systems and Control September 4, 2008

  2. Outline • Introduction • Useful Software Features for Practical Control Education • 1) Interactive Framework • 2)Textual and Graphical Programming • Multi-* • 3) Data Acquisition and Controller Implementation • Real time and Jittering • Case Study and Conclusions

  3. Introduction Motivation • Process control courses need to educate students regarding tools used in industry.These tools not only refer to methods and basic rules, but also software features (interactive control design) and hardware (data acquisition and control implementation). • Many industry control challenges are in the implementation. (Process-Hardware-Software- Hardware- Process).

  4. Introduction (cont.) Some Challenges • How to acquire good data for model based control?

  5. Introduction (cont.) Some Challenges • How to acquire good data for model based control? • How to implement digital controllers?

  6. Introduction (cont.) Some Challenges • How to acquire good data for model based control? • How to implement digital controllers? • What is the effect of different parameters in the open and closed loop response (interactive design)?

  7. Introduction (cont.) Some Challenges • How to acquire good data for model based control? • How to implement digital controllers? • What is the effect of different parameters in the open and closed loop response (interactive design)? • Effect of using the same/different hardware interface for data acquisition and controller implementation.

  8. Introduction (cont.) Some Challenges • How to acquire good data for model based control? • How to implement digital controllers? • What is the effect of different parameters in the open and closed loop response (interactive design)? • Effect of using the same/different hardware interface for data acquisition and controller implementation. There is a need for academic software to address these issues

  9. Useful Features Academic Software Features Sought • Interactive Design of Controller • Graphical as well as textual programming. • Friendly Software-Hardware data exchange. • Affordable price and scalable hardware. • Reusable programming code. • Graphical process simulation with process equipment and debugging tools needed.

  10. Example

  11. Useful Features Academic Software Features Sought • Interactive Design of Controller • Graphical as well as textual programming. • Friendly Software-Hardware data exchange. • Affordable price and scalable hardware. • Reusable programming code. • Graphical process simulation with process equipment and debugging tools needed.

  12. Interactive Framework Step Response

  13. Interactive Framework (cont.) Root Locus

  14. Interactive Framework (cont.) Rendering

  15. Interactive Framework (cont) Interactive Tool Chain

  16. Textual and Graphical Multi-framework: Hybrid graphical/textual programming

  17. Textual and Graphical (cont.) Re-use of existent textual code

  18. Textual and Graphical (cont.) Formula node inside simulation subsystem

  19. Textual and Graphical (cont.) Multi-platform Software

  20. Textual and Graphical (cont.) Multi-rate: toallow different execution rates Slow Execution Fast Execution

  21. Textual and Graphical (cont.) Multi-hardware: Assign different code to run on different machines communicated by a network. controller estimator validation

  22. Textual and Graphical (cont.) Multi-core: Assign different code to run on different processors using the timed-loop.

  23. Data Acquisition and Controller Implementation

  24. Data Acquisition and Controller Implementation

  25. Data Acquisition and Controller Implementation (cont.) What is Real-Time? • A real-time (RT) control application repeatedly performs user-defined tasks with a specified elapsed time between the operations • RT parameters • Control loop cycle time • Determinism • Jitter • Determinism measures the consistency of the specified time interval between the user-defined tasks

  26. Data Acquisition and Controller Implementation (cont.)

  27. Data Acquisition and Controller Implementation (cont.) Jitter and Determinism • Jitter measures the amount of time (error) that the loop cycle time varies from the desired time • The RT operating system (RTOS) guarantees operation within a time-bounded amount of jitter • If the jitter is not time-bound, the control system may suffer from instability as the control algorithm is typically calculated assuming a predetermined fixed time interval

  28. Data Acquisition and Controller Implementation (cont.) Multi-core/hardware/rate in RT: Assign different a portion of code to run on different processors/equipment/time-loops

  29. Case Study Air Heater

  30. Case Study (cont.) Equipment Description NI USB 6009/6008. Allows 4-AI and 2-AO (and 16 discrete signals). AC/DC converter (110AC to 24V) ‘U’ shape Air Pipe. Two thermistors (CVs) Fan (DV) Electric Heater (MV) Pulse Width Modulator (PWM) Laptop or PC

  31. Case Study (cont.) Modeling and Measurements

  32. Case Study (cont.) • First Principle Models

  33. Case Study (cont.) • Open Loop Response

  34. Case Study (cont.) • Closed Loop Response (MPC) • MPC vs. PID.Moving ahead of the SP change is important. • MPC moves ahead • of the SP change

  35. Case Study (cont.) • Determinism and Jittering

  36. Conclusions Academic software programming features like: • Interactive controller tuning • Friendly hardware/software configuration and communication. • Multi-* • Real time control will give better insight into industrial control challenges.

  37. Conclusions Academic software programming features like: • Interactive controller tuning • Friendly hardware/software configuration and communication. • Multi-* • Real time control will give better insight into industrial control challenges. The use of classroom experiments is required to illustrate 3 out of 4 of these features.

  38. Questions? • ?

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