S&C FY02 ANNUAL REVIEW MEETING Integrated Intelligent Industrial - - PowerPoint PPT Presentation

S&C FY02

Integrated Intelligent Industrial Process Sensing and Control Applied to and Demonstrated on Cupola Furnaces PI: Mohamed Abdelrahman Tennessee Technological University

Presented by

• D. E. Clark, INEEL

S&C FY02 ANNUAL REVIEW MEETING

S&C FY02

Project Description

Collaborative effort that aims at the development of generic technology for improving operation of industrial processes through the integration of process sensing and control. This is achieved through the following

– Development of a generic object oriented architecture for integration of various system components – Development of algorithms for Multi Modal Sensor Fusion, or MMSF – Integration of MMSF and intelligent control – Application of developed technology to cupola furnaces

S&C FY02

Collaborations

DOE Albany Research Center

Demonstration

• P. L. King

Industrial Oversight

AFS

• J. A. Santner

Advisory Board

Mark Bauer, GM Mike Barstow, US Pipe Sy Katz, Katz Associates

Tennessee Tech

Technical Development

• M. Abdelrahman
• J. Frolik
• M. Haggard
• W. Mahmoud

Utah State

• K. L. Moore

INEEL

• D. E. Clark
• E. D. Larsen

S&C FY02

Foundry Operation Goals Foundry Operation Goals Planner Planner AFS Model Based Expert System AFS Model Based Expert System MMSF MMSF Database Database Offline Analysis Offline Analysis Technical Services

Overall System Vision

Cupola Operational Parameters Cupola Operational Parameters Intelligent Controller Intelligent Controller Cupola

S&C FY02

Project Objectives/Goal

IOF need(s) addressed by this technology

– Improved sensing and control technology is an issue of importance to most IOF industries. – Direct Application to : Metal Casting

Objectives

– Develop Generic Technology for Improved Process Sensing – Technology for Integration of Sensing and Control – Demonstration of Technology on Cupola Furnaces

Overall goal

– Improved process monitoring and control by utilizing all available multi-modal sources of information.

S&C FY02

System Architecture

Run Time Planner Run Time Planner Plant Controller Plant Controller Model Interrogator Model Interrogator Expert System Expert System MMSF Module Multi Modal Sensor Fusion MMSF Module Multi Modal Sensor Fusion Setup Information (Standard grammar file) Setup Information (Standard grammar file)

Data Structure Data Structure Plant Plant

Sensors DAQ

S&C FY02

MMSF Module Architecture

Graphical User Interface LabVIEW Graphical User Interface LabVIEW Setup files Setup files Setup Fusion Groups Setup Fusion Groups Create Sensor Self-validation Files Create Sensor Self-validation Files Fusion Group File Fusion Group File MMSF Algorithm MMSF Algorithm Fuzzy Fis Files Fuzzy Fis Files

Multi-modal Sensor fusion Multi-modal Sensor fusion

S&C FY02

Technical Risks/Innovation

• Technical risks

– Cupola furnace sensing and control practices have remained generally untouched for a long time – Sensors for measuring cupola furnace parameters such as melt-rate are not well developed

• Innovation

– New Algorithms for sensor fusion (Basic Research) – New Algorithms for integration of intelligent control and sensor fusion based on confidence in measurements – Generic architecture that allows for easy integration of new components and adaptation of the developed system to new industrial applications

• Advancement of state-of-the-art over competition

– Control has been limited to control of input parameters such as blast rate – Control of process variables such as iron composition is more desirable, and is the goal of the current project

S&C FY02

Task Performance

Past Technical Milestones

Still Going due to recent tragic events Delay of 9 Months Third Year Demonstration Plans Delayed due to recent tragic events Delay of 6 Months Third Year Implementation on Albany Cupola Proof of concept Hardware Implementation Improvements continue On Time Second Year Generic Architecture On Time Third Year Intelligent Control On Time First Year Sensor Fusion Comments Completion Date Due Date Milestone

S&C FY02

Progress Toward Performance Goals

– Innovative sensor fusion algorithms based on a new concept has been developed, implemented and tested. Allow for the fusion of quasi-redundant sensors data Produce a best estimate and a parameter indicating the degree of confidence in the measurement – The preliminary algorithms were presented in 4 refereed articles American Control Conference (ACC) proceedings IEEE Transactions on Instrumentation and Measurements. – Complete Algorithms under preparation for publication and patenting

• 4
• 2

2 4 6 8 10 12 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 Sensor Readings Multiple Sensor Fusion Correct Sensors Self Confidence = 1 Noisy Sensor Self Confidence= 0.5 Centroid Estimate Integration Limits * Sensor Data

S&C FY02

Progress Toward Performance Goals

– An algorithm for Integration of Sensor Fusion and Intelligent Control developed, implemented and tested – Results presented: Refereed conference paper in the ACC 2002 Will appear in 2002 in Transactions of Instrumentation Society

• f America

Plant Redundant Sensors Self - Validation (On each sensor Data) Multiple Sensor Fusion Input

• +

Error Control Input Output Redundant Data Self Confidence Confidence Estimate Kh Kl WA Controller WA - Weighted Avg. Kh and Kl - Controller Defined Before

Speed of response depends on confidence In measurements

S&C FY02

Progress Toward Performance Goals

– An adaptation of the generic algorithms for the cupola furnace was developed, implemented and tested. – A fuzzy logic-based controller that controls %C, %Si, melt rate, and temperature by adjusting coke-to-metal ratio, charge composition, blast rate, and Oxygen – Results presented at the AFS congress in 2002 and will appear in the Transactions

S&C FY02

Progress Toward Performance Goals

– A Generic package was developed in LabVIEW A leading instrumentation software package Integrates the developed system components into a working system that can be easily modified Can be considered a Beta version for a commercial implementation of the developed algorithms – Current Modules include: Plant Interface Monitoring System Sensor Fusion Module Virtual Sensors Module Controller Module Planner Module

S&C FY02

Progress Toward Performance Goals

– FPGA (Floating Point Gate Array) implementations of a subset of developed sensor fusion algorithms have been developed, implemented and tested – Developed system interfaced with the cupola furnace at the DOE Albany Research Center, Oregon, and successfully tested – Several demonstration runs have been performed and data collected Results illustrate system’s flexibility and potential to improve cupola furnace operation.

• In Summary, the project has achieved all the technical
• bjectives. The remaining demonstration plans will be used to

further illustrate the capabilities of the developed system.

S&C FY02

Publications Supported by Project

Refereed Journal Publications

• 1. “A methodology for self-validation, fusion and reconstruction of quasi-redundant sensors," IEEE Transaction on Instrumentation

and Measurement. , Vol. 50, No. 6, December 2001.

• 2. “Integration Of Multiple Sensor Fusion In Controller Design,” Accepted for Publication in the Transactions of Instrumentation Society of

America, 2002.

• 3. “Fuzzy Control Of A Cupola Iron Melting Furnace,” To Appear in Transactions of American Foundry Society, 2003.

Refereed Conferences 4. “INTEGRATION OF MULTIPLE SENSOR FUSION IN CONTROLLER DESIGN,” in proceedings of the the American Control Conference, Anchorage, AK, May 2002. 5. “Fuzzy Control Of A Cupola Iron Melting Furnace,” AFS Congress, Kansas City, MO, May 2002. 6. ”Wavelet-Based Sensor Fusion for Data with Different Sampling Rates,” ," in Proceedings of American Control Conference, Washington D.C., June 2001. 7. "A Methodology For Fusion Of Redundant Sensors," in Proceedings of American Control Conference, Chicago, IL, June 2000. 8. "Synthesis of quasi-redundant sensor data: a probabilistic approach," ," in Proceedings of American Control Conference, Chicago, IL, June 2000. 9. "Fuzzy rules for automated sensor self-validation and confidence measure," in Proceedings of American Control Conference, Chicago, IL, June 2000. 10. "A convenient methodology for the hardware implementation of fusion of quasi-redundant sensors," Proceedings of 32nd SSST Conference, Tallahassee, FL, Mar 2000, pp. 349-353. 11. "A Methodology for Integrating Multiple Sensor Fusion in the Controller Design," in Proceedings Of 32nd SSST conference, Tallahassee, FL, March 2000, pp. 115 -118. 12. “Intelligent Control of Cupola Furnaces,” in Proceedings of the 34th SSST conference, Huntsville, AL, March 2002, pp. 435-440.

S&C FY02

MS Theses Supported by Project

• Tennessee Technological University

– Confidence-based Integration Of Multiple Sensor Fusion Into Controller Design, Param. Kanadasamy, 2000 – Wavelet Based Sensor Fusion For Multiple Sampling Rate Data, Min Luo, 2001 – A Methodology for Multi-Modal Sensor Fusion, Vipin Vijayakumar, 2001 – Hardware/Software Codesign – Efficient Algorithms for Hardware Synthesis from C to VHDL, S. Sankaran 2001 – Comparison of Cordic Algorithms Implementation on FPGA Families, Srikala Vadlamani 2002 – (Work in Progress) Jie Chen, 12/2002

• Utah State University

– Multi-dimensional Data Structure for Cupola Information Processing, Avinash Seegehalli, 2000 – (Work in Progress) Spencer Anderson, 2002

S&C FY02

Input/Output Cupola Control Parameters

Cupola Furnace

Blast rate % O2 C/Metal ratio Steel/Iron ratio Si C Fluxes Melt rate Temperature %C % Si Slag Properties

Demonstration On Cupola Furnace

S&C FY02

Demonstration

Experimental Cupola, DOE Albany Research Center, Oregon 18-inch diameter Fully instrumented Analytical capabilities

S&C FY02

Demonstration Results

Insert graphic here Insert graphic here

Monitoring of Tap hole from Albany Cupola Furnace

Tap Hole Temperatures

2400 2500 2600 2700 2800 2900 3000 1000 2000 3000 4000 time, seconds Temperature, F

Spout Temperature Pyrometer 1 Pyrometer 2 Fused Temperature Kalman T

S&C FY02

Demonstration Results

Monitoring System detects Bridging by Monitoring Exit Temperature and Cupola Pressure

Insert graphic here Insert graphic here

Exit Temperature

200 400 600 800 1000 1200 1400 1600 1800 1 1 1 9 2 8 3 7 4 6 5 5 6 4 7 3 8 2 9 1 1 1 9 1 1 8 1 2 7 1 3 6 1 4 5 1 5 4 1 6 3 1 7 2 1 8 1 1 9 1 9 9 2 8 2 1 7 2 2 6 2 3 5 2 4 4

Cupola_Press.

• 1
• 0.5

0.5 1 1.5 2 2.5 3 3.5 4 4.5 1 9 1 7 2 5 3 3 4 1 4 9 5 7 6 5 7 3 8 1 8 9 9 7 1 5 1 1 3 1 2 1 1 2 9 1 3 7 1 4 5 1 5 3 1 6 1 1 6 9 1 7 7 1 8 5 1 9 3 2 1 2 9 2 1 7 2 2 5 2 3 3 2 4 1

Bridging Detected

S&C FY02

Confidence in MR Estimate

Melt Rate

1000 2000 3000 4000 1000 2000 3000 4000 5000

pounds/hour MR Fusion Melt Rate from Radar Kalman MR Manual MR

Confidence

0.5 1 1000 2000 3000 4000 5000 time, seconds

S&C FY02

Automatic Control of Steel/Cast Iron

10 20 30 40 50 60 70 9:36:00 AM 10:48:00 AM 12:00:00 PM 1:12:00 PM 2:24:00 PM 3:36:00 PM Steel Pig Iron

Pig Iron Disturbance

S&C FY02

Control of Carbon

%C 2 2.2 2.4 2.6 2.8 3 3.2 3.4 9:36:00 AM 10:48:00 AM 12:00:00 PM 1:12:00 PM 2:24:00 PM 3:36:00 PM

Start Control Disturbance in Composition

Expected new level if Disturbance is not rejected

S&C FY02

Commercialization

Proposed plant tests/deployments, and planned use in IOF manufacturing plant(s)

– As set forth in the proposal, the technology is being demonstrated

• n a research cupola facility in Albany Oregon

Commercialization path & partners

– The generic part of the results of the research are published in refereed journals and presented at AFS congress – Several presentations to AFS cupola committee regarding research results have been made to seek industrial partners – The project has industrial advisory boards from manufacturing facilities such as US Pipe and GM that are interested in improving cupola melting technology – Funding for implementation of the developed technology in a foundry is currently sought from DOE programs with such focus.

S&C FY02

Performance Merits

Improving energy efficiency

– How will energy be saved? Better control over cupola parameters such as %C and metal temperature would produce less return scrap Monitoring and detection of operational problems such as bridging early can reduce the impact of such problems over the quality of molten metal – What are the energy savings (per installed unit and nationwide)? A 10% improvement in the efficiency of cupola operation would result in savings of Quads/Year

S&C FY02

Performance Merits

Improving product quality

– How will product quality be improved? Metal casting products are affected by variations in the chemical composition of the molten iron as well as the iron temperature. The developed technology would give better control over these parameters and hence a more consistent produce would be expected – How will this improvement be quantified? This could be judged by the percentage reduction in the amount of returns

S&C FY02

Path Forward

Future Technical Milestones

Extension Requested Sep.30,2002 June 30, 2002 Final Report July 31,2002 Sep 30,2001 Finish Demonstration Plans Comments Completion Date Due Date Milestone