#10 2020

CONTENTS №10

Buryak Yu.I.  Automated technology for fast diagnosis of intricate-profile cutting tools

The paper offers new approaches to the organization of the diagnosis of intricate profile cutting tools based on extensive application of automatically identified barcodes with laser engraving, mobile devices controlled per setpoints, and electronic workflow, combined together by appropriate software components. Automated technology for data acquisition and state monitoring in real time is developed. A hard-/software system comprising both static and moving parts is developed. It ensures the reliability and efficiency of intricate-profile cutting tool state monitoring in the real-time.

Keywords: tracing, technical state parameters, broaching tool, automated identification, mobile computing devices.

Discussing a Topic…

Automation of Scientific Research and Full-Scale Test

Kyrenkov V.S., Chushkin A.V., Tsakanyan V.N.  Automated system for adhesive strength measuring at high-energy material tearing-off from antiadhesion coating

The paper discusses the development of an automated system for investigating the adhesive strength of high-energy materials. The drawbacks of the existing test bench are outlined. The system includes state-of-the-art precision mechanisms and instrumentation enabling maximum automation of testing process, exclude the influence of human factor in improve labor productivity. System advantages are shown.

Keywords: high-energy materials, adhesive strength, antiadhesion coating, automated system, test bench, measuring instrument, test data.

Kurashkin S.O., Tynchenko V.S., Rogova D.V.  Automation of electron beam application in thin-walled structure welding

The automation of electron beam injection in electron-beam welding (EBW) is discussed. The paper describes the algorithms for electron beam injection control and injection mode optimization, which underlie the automated EBW control system. System operability was tested in the trial EBW of 1.2 mm article made of VT14 titanium alloy.

Keywords: electron-beam welding, mathematical modeling, thermal processes, process parameters optimization, electron beam application.

Solovyov S.Yu., Serov V.S., Kondrashkin A.A.  SIMATIC WinCC Open Architecture platform as a framework for state-of-the-art scientific test benches and complexes

The paper reviews SIMATIC WinCC Open Architecture (WinCC OA) as a framework for test benches, investigation units, development and testing rigs for innovative technologies and new products. Example projects from scientific research automation and the development of dedicated units on the basis of WinCC OA platform are cited.

Keywords: scientific test benches, automation, scientific research, experimental development complexes, digitization.

Potapov A.I., Shikhov A.I., Dunaeva E.N.  Measuring dynamic deformation properties of frozen soils during their defrosting

The development of new mineral deposits in frozen soil zone requires the deployment of appropriate infrastructure and the construction of buildings. Monitoring of permanently frozen soils in such areas is quite a challenge. The paper shows the possibility of applying active acoustic method for permanently frozen soil state monitoring. The technique is based on the change of soil’s dynamic deformation properties during defrosting.

Keywords: elastic modulus, cryolithozone, acoustic monitoring methods, monitoring of permanently frozen soils.

Unified digital platform improves the efficiency and intelligence of underlying assets

The development of digital technologies, strong competition, and the aspiration for costs reduction and production efficiency resulting in higher business profitability are key incentives for the pacesetters of oil and gas industry to further digitization. Digital data are an important element of this process including their acquisition, storage, processing, and communication. The new digital platform developed by Energoavtomatizatsiya Scientific and Production Center (Ufa, Russia) implements all these functions.

Keywords: digital technologies, data acquisition, processing, and communication, unified digital platform, integration.

Yevdoshenko O.I.  Automation of the classification of the techniques for improving performance characteristics of technical devices at the conceptual design stage

The classification of the techniques for improving performance characteristics of technical devices consists of two basic processes: keywords database development for each generalized group and the determination of the generalized acceptance group. The paper describes the algorithm for determining the acceptance group; it comprises graphematic morphological, and frequency analysis of acceptance. Analysis results are illustrated with the methods for improving the performance characteristics of bimorph elements. The architecture and functionality of the developed system for automatic acceptance group selection are described.

Keywords: acceptance, generic group, keyword, graphematic analysis, morphological analysis, frequency analysis, web application, functional module, information system.

Discussing a Topic…

Monitoring and Technical Diagnostics in Industry

Alexandrov A.I., Kvaratskhelia N.G.  State monitoring and prediction of electric motors

The predictive diagnostics system for the technical state of electric motors is offered, its composition and structure are described, the factors affecting the accuracy of the system’s forecasts are analyzed, the results of system testing on real-life data presented. Organizational and technical actions are proposed that may help industrial enterprises to improve the operation safety and efficiency of complex equipment, which includes electric motors.

Keywords: predictive maintenance, condition-based maintenance, maintenance system, data analysis, big data, mathematical modeling.

Antonenko I.N.  On reliability-centered maintenance

Reference document and technical guidelines do not provide a single definition of reliability-centered maintenance (RCM) that misleads the users. The paper formulates the key RCM concepts, discusses and disputes common mistakes and myths known from consulting practice.

Keywords: reliability-centered maintenance, fault management, maintenance and repair system.

Reshetnikov I.S., Churanov S.A.  NC machinery monitoring in operating efficiency context

The paper examines the evolutionary approach to the design of equipment monitoring system for a modern engineering plant. The functionality of a standard monitoring system is discussed with reference to NC machinery. Recommendations on monitoring systems deployment dependent on the plant readiness level are made.

Keywords: production management, MES, NC machinery, monitoring systems, evolution.

Maltsev V.A., Murzagulov D.A., Zamyatin A.V.  Detection of anomalies in process signals with the help of autoencoder-type neural network architecture

Anomalies detection in process signals are investigated. The paper presents an approach to anomalies detection based on a neural network with autoencoder architecture which allows for the context of signal changes. It shows that the autoencoder architecture overcomes the challenge of long-term relationships in the signal owing to the long short-term memory mechanism. Formal description of the autoencoder-based approach is presented, a numerical example is included. Based on the analysis of experimental data, a learning threshold selection procedure is developed that enables the operation in adaptive mode without any a priori information about either anomalies or the signal itself.

Keywords: anomaly, process signal, neural network, process control system, predictive analytics, equipment monitoring.

Journal’s Club

How to surmount the barriers and achieve success in digital transformations

A series of round tables was organized in June 2020 within the DIGITAL MANUFACTURING CONF: digital processes online conference to discuss the pressing issues of industry digitization. The participants of the round table How to Surmount the Barriers and Achieve Success in Digital Transformations talk about the initiators of digitization projects, discuss approaches to project implementation, the role of IT service and its interaction with business departments, the transformation of IT service into competence centers.

Keywords: digitization, IT service, competence center, business process transformation.

Ershov V.E., Serdobintsev S.P., Golubev A.V.  Optimization of power plant equipment operation with the help of genetic algorithm

Combined-cycle power units are extensively used in Russia due to their higher efficiency as against other generation types. However, a gas turbine unit is strongly affected by the changes of ambient conditions. Maintaining the optimal operation mode of a combined-cycle unit poses both scientific and engineering challenges that can be overcome by developing an automated optimization system to help the operator. The paper discusses the implementation of an optimization loop based on a genetic algorithm, describes its structural diagram and the interaction with the plant and the existing base-level controls. The power unit efficiency improvement is shown. The results obtained can be used as a framework for developing an optimization system as a part of a real-life power plant’s process controls.

Keywords: genetic algorithm, mathematical modeling, process control system of a power plant, gas turbine unit.