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Automation of Gas Heated Furnace Using Ethernet Based Analog Input

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					  Automation of Gas Heated
Furnace Using Ethernet Based
 Analog Input and Controller
          Modules

   Attila Kovács M.Sc. Student
 Gusztáv Szecső Dr. El. Eng. PhD.
  The Theoretical Structure of
Control System of the Gas Heated
             Furnace
• The Block Diagram of
  the Control System
• System Models:                      K e  s s /   1
                          G p s  
  Process Dynamic –                  T2 s  1T3 s  1

  The Resultant Dynamic                      Ka
                               G a s  
    of the Actuator and                   T1 s  1
    Flow Systems (Gas
    and Air) -
                   Controllers
• General Controller                      y ( z ) A  Bz 1  Cz 2  
                                  Dz          
  Algorithm:                              x z  1  Pz 1  Qz  2  
• Design Methods:
  - Dead-beat Controller –     Dz  
                                       yz 
                                             
                                                          
                                                q0  A z 1
                                                                 G p z  
                                                                            Bz   d
                                                         
                                       xz  1  q0 B z 1 z  d            Az 
                                                                                  z

                                                        y 0 d  d
                                              1                   T
                               q0 
                                      b1  b2    bm            Ts
  - PID-controller (velocity
                                                   q0  q1 z 1  q2 z 2
    algorithm) –                           Dz  
                                                         1  z 1
  - Feed-forward
    Controller                  Gs  z  
                                              
                                           H z 1 h0  h1 z 1  ... hl z l
                                                  
                                              
                                           F z 1
                                                    1  f 1 z 1  ... f l z l
 Designing PID- and Feed-forward
           Controllers
• Used Design Method: General Parameter Optimization
  Method Implemented in PIDCAD-software developed by
  G. Szecso
• Designing Steps:
   – Finding Starting Points of the Optimization
   – Building up Database for the Optimization
   – Choosing Optimization Methods and Achieving
     Refinement
   – Algorithm Realization or Parameters Transformation
     for Real-time Applications (GENI or Intelligent PID-
     module)
   – Simulation and Real-time Testing
     Real-time Implementation of
       Controllers Algorithms
• Implementing Dead-beat and Feed-forward
  Algorithms in GENI Basic-Script
  – Function Declaration
  public Function ztran(ube as single, a() as single, b() as
    single, be() as single, ki() as single) as single
  – PID-parameters Transformation to Industrial
    Standard Velocity Algorithm’s Parameters

                          
             q0 q1 q2   K p    AI    Td   
System Realization I. Using by
 DAS-board Type Interfaces
                              Without Feedforward Compensation blue: GeniDAQ red: MATLAB
    1.4

    1.2

      1

    0.8

    0.6

    0.4

    0.2

      0

    -0.2
           0   50   100    150         200         250        300         350           400   450   500
                                                  t s


                          Applying Feedforward Compensation blue: GeniDAQ red: MATLAB
    1.2

      1

    0.8

    0.6

    0.4

    0.2

      0

    -0.2
           0   50   100    150         200         250        300         350           400   450   500
                                                  t s
   System Realization II. Using
Double-bus Type Intelligent Modules
Results of Double-bus Control
           Structure
Single-bus Control System
        Structure
Results of Single-bus Control
     System Structure
                     Conclusions
Two computer languages were used to program the system, Basic
Script for the programming of the GENI and C++ for the function
library. A new series of problems emerged at this development stage.
The documentations of the modules were inaccurate [4] or erroneous
and the vendor provided function library is not able to make more than
one TCP/IP connection at one time, which is a very serious limitation in
this circumstances, moreover it was even a bigger problem because
the system was not always able to build up the connections with its
modules in time. Many of the ASCII commands [3], which purpose
were to provide easier data acquisition and processing, were simply
not working. Although to modernize the system with Ethernet based
modules looked promising, the final result was much less satisfactory
than we presumed. The inaccurate and nondescript documentation
and the lack of help from the Advantech Technical Support made the
development much harder than it was expected. The design of their
function library seems to be flawed but we didn’t test the modules OPC
capabilities. The system is properly working now, fulfilling the
requirements set forward to it.

				
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