Engineering Commons^™

Process Control Experiment: Automated Titration System, Marc Shuflit, Nathan Martin, Noelle Miller, Benjamin Tavares

Scholar Week 2016 - present

A titration experiment has been designed using a chemical reaction tank and implementing all the basic components found in automatic control systems. This system has been constructed using basic fluid flow hardware, control sensors and actuators, along with ladder logic programing for the Programmable Logic Controller (PLC) to automate an acid-base chemical titration. This system will be used in Olivet Nazarene University’s engineering labs to provide hands-on learning of state-of-the-art process technology.

Addition Of Process Control Experiment To Unit Operations Ii Laboratory., Bradley Esselman

Electronic Theses and Dissertations

Process control is an essential aspect of manufacturing, contributing to improved process safety, efficiency, product consistency, and energy optimization. Chemical engineers are often responsible for ensuring the safe, efficient, and cost-effective operation of industrial processes, and process control plays a pivotal role in accomplishing this.

Chemical engineering students at the University of Louisville complete the course, Elements of Process Control, during the second semester of their fourth year. This lecture-based course offers limited hands-on, practical experience. To supplement the lack of hands-on experience in the classroom, a new process control experiment was designed and implemented into the Unit Operations …

Operation And Process Control Development For A Pilot-Scale Leaching And Solvent Extraction Circuit Recovering Rare Earth Elements From Coal-Based Sources, Douglas Kweku Addo

Theses and Dissertations--Mining Engineering

The US Department of Energy in 2010 has identified several rare earth elements as critical materials to enable clean technologies. As part of ongoing research in REEs (rare earth elements) recovery from coal sources, the University of Kentucky has designed, developed and is demonstrating a ¼ ton/hour pilot-scale processing plant to produce high-grade REEs from coal sources. Due to the need to control critical variables (e.g. pH, tank level, etc.), process control is required. To ensure adequate process control, a study was conducted on leaching and solvent extraction control to evaluate the potential of achieving low-cost REE recovery in addition …

A Transformative Process Control Solution, Simone Castanho Nobrega De Almedia Soares

ETD Archive

Knowing that a technology invented almost hundred years ago (PID controller) is still dominating industrial process control, a historical review was done to understand how the control field evolved. Model dependency and high level of mathematics appear as the main reasons that prevent other technologies from penetrating the engineering practice. A relatively novel methodology introduced by J. Han in 1998 called Active Disturbance Rejection Control (ADRC) came with characteristics that matches process control needs and restrictions on model dependency. This study will present a transformative solution for process control based on that. The control algorithm is designed and discretized for …

Control Of Single- And Dual-Probe Atomic Force Microscopy, Muthukumaran Loganathan

Doctoral Dissertations

“Atomic force microscope (AFM) is one of the important and versatile tools available in the field of nanotechnology. It is a type of probe-based microscopy wherein an atomically sharp tip, mounted on the free end of a microcantilever, probes the surface of interest to generate 3D topographical images with nanoscale resolution. An integral part of the AFM is the feedback controller that regulates the probe deflection in the presence of surface height changes, enabling the control action to be used for generating topographical image of the sample. Besides sensing, the probe can also be used as a mechanical actuator to …

Use Of An Automated, Integrated Laboratory Environment To Enable Predictive Modeling Approaches For Identifying Critical Process Parameters And Controlling Key Quality Attributes, Brandon Downey, John Schmitt, Jeffrey Breit, Brian Russell, Justin Beller, Liz Herman, Anthony Quach, David Lyon

Cell Culture Engineering XV

An essential part of ensuring a high quality medicine is being able to reliably control Critical Quality Attributes (CQA’s). In the cell culture process, bioreactor conditions, feeds, cell state are some of the many variables that affect CQA’s. Out of this very large set of possible variables, the small subset of these (i.e., critical process parameters, or CPP’s) that have a large effect on the CQA’s must be identified and understood such that those CPP’s can be controlled to ensure quality product. Here, we demonstrate the use of predictive modeling techniques to supplement experimental bioreactor studies when defining critical process …

Evolution Of An Integrated Continuous Antibody Manufacturing Process, Christopher Kistler

Cell Culture Engineering XV

Efforts continue to reduce the timeline and cost of progressing biologics from discovery through preclinical development to product launch. Integrated processes, those that link upstream and downstream processing with control of product quality are an attractive way to achieve meaningful reductions in the overall cost of ownership of a biologics manufacturing process.

To start along this path, an integrated continuous processing laboratory, the PROLab (Protein Refinery Operations Lab) was built to pilot the concepts of an integrated continuous antibody manufacturing process under automated control. A perfusion process was developed capable of operating for >30 days using either TFF (Spectrum KrosFlo® …

Application Of Secondary Analyses On Industrial Data Sets, Luis G. Perez

Open Access Theses & Dissertations

Secondary analysis on quantitative data sets is the in-depth analysis of relationships, trends, patterns or behaviors that are not obvious from a superficial examination of data but that can be very germane in the application of that data. The present work presents a framework for investigators to use in applying secondary analysis on big data that correlates to the research topic. The framework can facilitate the illumination of possible data behaviors or patterns that could be useful in arriving at an answer to a question. Behavior of monitored equipment (analyzers, meters, etc.) can easily be depicted and can be used …

Protein Refinery Operations Lab (Pro Lab): A Sandbox For Continuous Protein Production & Advanced Process Control, Mark Brower, David Pollard, Finn Hung

Integrated Continuous Biomanufacturing II

Significant strides towards implementation of continuous bioprocessing are being made at an ever increasing rate. Advances in technology for traditional unit operations such as cell-retention devices in perfusion cell culture, continuous multi-column chromatography (CMCC) and single-pass tangential flow filtration have led to demonstrations of both semi-continuous and fully-continuous protein production processes operating at periodic steady states at the pilot-scale. Previous proof of concept work at Merck & Co., Inc. has shown an automated (DeltaV) and single-use monoclonal antibody (mAb) purification scheme through Protein A CMCC and pH viral inactivation with minimal human interaction for 30 days fed from a perfusion …

Flow Behavior Modeling And Process Control Of Electrically-Assisted Forming (Eaf) For Sheet Metals In Uniaxial Tension, Joshua Jones

All Dissertations

This work studies the influence of an applied electrical current on magnesium sheet metal and introduces models which are successful in predicting the deformation behavior (i.e. material flow stress, local material strain, and thermal response). Also, this work examined the theory of electroplasticity by studying prior proposed theories and by quantifying the prior theories potential for improved dislocation mobility. From this analysis, a single dominant mechanism is determined and the theory of electroplasticity is explained using this single mechanism. The theory discussed in this work is supported by experimental testing and microstructure analysis.
In addition to studying the exact electroplastic …

Fault Detection In Process Control Plants Using Principal Component Analysis, Vamshi Krishna Kandula

LSU Master's Theses

The aim of this thesis is to use a statistical method (principal component analysis) to detect a fault in a system. PCA is a dimensionality reduction technique that is used here. First the PCA algorithm was implemented on a simple two dimensional random data to reduce its dimensionality. Then the algorithm was implemented on a three dimensional data from a linear first order process and introduce some white noise later on and compare the results with that under normal operating conditions, thus determining the presence of a fault. Then data from a real time plant is considered for testing. This …

End Point Detection Of Plasma Etching Using Optical Methods, Jeff M. Czebiniak

Journal of the Microelectronic Engineering Conference

The objective of this experiment is to obtain an endpoint detection unit that can be used on all plasma etch tools in the Semiconductor and Microsystems Fabrication Laboratory (SMFL). This investigation examined one of the most common methods for end point detection in plasma etching; optical emission spectroscopy. Optical emission spectroscopy involves monitoring the wavelength emission intensity of the plasma of different species within the etchant plasma. From all of the data collected in this experiment it was shown that the Ocean Optics Spectrometer can be utilized for end point detection on any toolset in the SMFL.

Hierarchical Optimal Force-Position-Contour Control Of Machining Processes. Part I. Controller Methodology, Yan Tang, Robert G. Landers, S. N. Balakrishnan

Mechanical and Aerospace Engineering Faculty Research & Creative Works

There has been a tremendous amount of research in machine tool servomechanism control, contour control, and machining force control; however, to date these technologies have not been tightly integrated. This paper develops a hierarchical optimal control methodology for the simultaneous regulation of servomechanism positions, contour error, and machining forces. The contour error and machining force process reside in the top level of the hierarchy where the goals are to 1) drive the contour error to zero to maximize quality and 2) maintain a constant cutting force to maximize productivity. These goals are systematically propagated to the bottom level, via aggregation …

Hierarchical Optimal Force-Position-Contour Control Of Machining Processes. Part Ii. Illustrative Example, Yan Tang, Robert G. Landers, S. N. Balakrishnan

Mechanical and Aerospace Engineering Faculty Research & Creative Works

There has been a tremendous amount of research in machine tool servomechanism control, contour control, and machining force control; however, to date these technologies have not been tightly integrated. This paper develops a hierarchical optimal control methodology for the simultaneous regulation of servomechanism positions, contour error, and machining forces. The contour error and machining force process reside in the top level of the hierarchy where the goals are to 1) drive the contour error to zero to maximize quality and 2) maintain a constant cutting force to maximize productivity. These goals are systematically propagated to the bottom level, via aggregation …

Trends In Process Control Systems Security, Ann K. Miller

Electrical and Computer Engineering Faculty Research & Creative Works

The protection of critical infrastructure systems is a hotly debated topic. The very label "critical infrastructure" implies that these systems are important, and they are: they support our everyday lives, from the water and food in our homes to our physical and financial welfare. This article explores the recent evolution of programmable logic controllers (PCSs) and their environments, explains the need for improved security in these systems, and describes some of the emerging research areas that offer promise in PCS security.

Hierarchical Optimal Force-Position Control Of A Turning Process, B. Pandurangan, Robert G. Landers, S. N. Balakrishnan

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Machining process control technologies are currently not well integrated into machine tool controllers and, thus, servomechanism dynamics are often ignored when designing and implementing process controllers. In this brief, a hierarchical controller is developed that simultaneously regulates the servomechanism motions and cutting forces in a turning operation. The force process and servomechanism system are separated into high and low levels, respectively, in the hierarchy. The high-level goal is to maintain a constant cutting force to maximize productivity while not violating a spindle power constraint. This goal is systematically propagated to the lower level and combined with the low-level goal to …

Approximate Dynamic Programming Based Optimal Neurocontrol Synthesis Of A Chemical Reactor Process Using Proper Orthogonal Decomposition, Radhakant Padhi, S. N. Balakrishnan

Mechanical and Aerospace Engineering Faculty Research & Creative Works

The concept of approximate dynamic programming and adaptive critic neural network based optimal controller is extended in this study to include systems governed by partial differential equations. An optimal controller is synthesized for a dispersion type tubular chemical reactor, which is governed by two coupled nonlinear partial differential equations. It consists of three steps: First, empirical basis functions are designed using the "Proper Orthogonal Decomposition" technique and a low-order lumped parameter system to represent the infinite-dimensional system is obtained by carrying out a Galerkin projection. Second, approximate dynamic programming technique is applied in a discrete time framework, followed by the …

Hierarchical Optimal Control Of A Turning Process - Linearization Approach, Anand Dasgupta, B. Pandurangan, Robert G. Landers, S. N. Balakrishnan

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Machining process control technologies are currently not well integrated into machine tool controllers and, thus, servomechanism dynamics are often ignored when designing and implementing process controllers. In this paper, a hierarchical controller is developed that simultaneously regulates the servomechanism positions and cutting forces in a lathing operation. The force process and servomechanism system are separated into high and low levels, respectively, in the hierarchy. The high level goal is to maintain a constant cutting force to maximize productivity while not violating a spindle power constraint. This goal is systematically propagated to the lower level and combined with the low level …

Output Feedback Force Control For A Parallel Turning Operation, Raghusimha Sudhakara, Robert G. Landers

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Parallel machine tools (i.e., machine tools capable of cutting a part with multiple tools simultaneously but independently) are being utilized more and more to increase operation productivity, decrease setups, and reduce floor space. Process control is the utilization of real-time process sensor information to automatically adjust process parameters (e.g., feed, spindle speed) to increase operation productivity and quality. To date, however, these two technologies have not been combined. This paper describes the design of an output feedback controller for a parallel turning operation that accounts for the inherent nonlinearities in the force process. An analysis of the process equilibriums explains …

Dynamic Re-Optimization Of A Fed-Batch Fermentor Using Adaptive Critic Designs, Donald C. Wunsch, M. S. Iyer

Electrical and Computer Engineering Faculty Research & Creative Works

Traditionally, fed-batch biochemical process optimization and control uses complicated off-line optimizers, with no online model adaptation or re-optimization. This study demonstrates the applicability of a class of adaptive critic designs for online re-optimization and control of an aerobic fed-batch fermentor. Specifically, the performance of an entire class of adaptive critic designs, viz., heuristic dynamic programming, dual heuristic programming and generalized dual heuristic programming, was demonstrated to be superior to that of a heuristic random optimizer, on optimization of a fed-batch fermentor operation producing monoclonal antibodies

Fed-Batch Dynamic Optimization Using Generalized Dual Heuristic Programming, Donald C. Wunsch, M. S. Iyer

Electrical and Computer Engineering Faculty Research & Creative Works

Traditionally fed-batch biochemical process optimization and control uses complicated theoretical off-line optimizers, with no online model adaptation or re-optimization. This study demonstrates the applicability, effectiveness, and economic potential of a simple phenomenological model for modeling, and an adaptive critic design, generalized dual heuristic programming, for online re-optimization and control of an aerobic fed-batch fermentor. The results are compared with those obtained using a heuristic random optimizer

Dynamic Re-Optimization Of A Fed-Batch Fermentor Using Heuristic Dynamic Programming, Donald C. Wunsch, M. S. Iyer

Electrical and Computer Engineering Faculty Research & Creative Works

Traditionally, fed-batch biochemical process optimization and control uses complicated theoretical off-line optimizers, with no online model adaptation or re-optimization. This study demonstrates the applicability, effectiveness, and economic potential of a simple phenomenological model for modeling, and an adaptive critic design, heuristic dynamic programming, for online re-optimization and control of an aerobic fed-batch fermentor. The results are compared with those obtained using a heuristic random optimizer

Distributed Control Takes New Shapes Under Pc Pressure, Elizabeth C. Scheyder

Elizabeth C Scheyder

PCs are making inroads in process control, but DCSs still rule in many applications. Here is why engineers go the DCS route, and what DCS makers are doing to keep it that way.