China has abundance of mineral resources such as
magnesite, hematite and bauxite, which constitute a key component of its economy. The relatively low grade, and the widely varying and complex compositions of the raw extracts, however, pose difficult processing challenges including specialized equipment with excessive energy demands. The energy intensive furnaces together with widely uncertain features of the extracts form hybrid complexities of the system, where the existing modeling, optimization and control methods have met only limited success.
Currently, the mineral processing plants generally employ manual control and are known to impose greater demands on the energy, while yielding unreasonable waste and poor operational efficiency. The recently developed Cyber-Physical System (CPS) provides a new key for us to address these challenges. The idea is to make the control system of energy intensive equipment into a CPS, which will lead to a CPS driven control system.
This talk presents the syntheses and implementation of a CPS driven control system for energy-intensive equipment under the framework of CPS. The proposed CPS driven control system consists of four main functions: (I) setpoint control; (II) tracking control; (III) self-optimized tuning; and (IV) remote and mobile monitoring for operating condition. The key in realizing the above functions is the integrated optimal operational control methods to implement setpoint control, tracking control and self-optimized tuning together seamlessly. This talk introduces the integrated optimal operational control methods we proposed.
Hardware and software platform of CPS driven control system for energy-intensive equipment is then briefly introduced, which adopts embedded control system, wireless network and industrial cloud. It not only realizes the functions of computer control system using DCS (PLS), optimization computer and computer for abnormal condition identification and self-optimized tuning, but also achieves the functions of mobile and remote monitoring for industrial process.
Then, using fused magnesium furnace as an example, a hybrid simulation system for CPS driven control system for energy-intensive equipment developed by our team is introduced. The results of simulation experiments show the effectiveness of the proposed method that integrates the setpoint control, tracking control,self-optimized tuning and remote and mobile monitoring for operating condition in the framework of CPS.
The industrial application of the proposed CPS driven control system is also discussed. It has been successfully applied to the largest magnesia production enterprise in China, resulting in great returns. Finally, future research on the CPS driven control system is outlined.
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