#12 2025

CONTENTS №12

Zharko E.F., Chernyshov K.R., Abdulova E.A.  Hybrid intelligent decision support system for A-plant operators: design concepts, architecture, and data module

The operator of a nuclear power unit is a key element of its safe and effective operation. Against the backdrop of the increasing process complexity and tougher requirements to reliability and traceability, the paper proposes an approach to the design of a hybrid intelligent system for A-plant operator support. The system ensures the required accuracy and stability levels, improved explainability and manageable integration with process controls that underlies the future solution scalability and certifiability.

Keywords: operator support system, A-plant, expert systems, dynamic models, digital twin, diagnosis, prediction, cybersecurity.

Skryabin A.V., Veresnikov G.S., Goncharenko V.I., Avkhimenko G.M., Bazhenov S.G., Fedenyuk V.A., Yerofeev E.V., Timofeeva A.D.  Automated system for conducting quick life tests of electromechanical actuators

The paper discusses the development of an automated system for conducting quick life tests of electromechanical actuators aimed at the organization of condition-based maintenance of robotic vehicles. It describes the developed methods for reproducing test scenarios of operation in autonomous and semi-natural operating modes for the generation of data related to the actuator’s static and dynamic characteristics in various technical states. Methods for ensuring accelerated consumption of operational resources during the reproduction of periodic signals under mechanical load are proposed and investigated. The developed automated system includes, in particular, subsystems for passive loading, experiment control, and data acquisition. Test results for four identical electromechanical actuators with failures with various consequences are presented. The processes of automated control of life tests, measurement, and data acquisition using general-purpose controllers and sensors were investigated. The obtained data related to progressive degradations are considered: positional, mechanical, electrical, vibroacoustic, and thermal.

Keywords: electromechanical drive, life tests, automated diagnosis, degradation, reducer, big data, machine learning.

Pleshivykh A.S.  Application of adaptive observer in control algorithms for the automatic control system of an aircraft engine

The paper presents the application results of the Yazvinsky filter-basd adaptive observer in the algorithms implemented in the electronic control and monitoring system of a dual-circuit turbojet engine (DCTE). It describes the mathematical model of the adaptive observer and its integration into the mathematical model of a fifth-generation middle-class engine with a thrust of 14 tf. A method for generating information redundancy is presented. It includes the algorithm for identifying the coefficients of a mathematical model of DCTE’s automatic control system (ACS), the optimal observer, which generates the ACS output vector’s parameter estimates subject to the criterion of minimum variance of filtering estimates (useful signal enhancement against noisy background), and the algorithms for detecting measuring channel failures with the help of statistical methods. The parameters of the output vector of the ACS, estimated using the adaptive observer, are as follows: the rotation speed of the low- and high-pressure compressor rotor, the air pressure downstream of the high-pressure compressor, and the gas temperature downstream of the low-pressure turbine.

Keywords: aircraft engine, demonstrator engine, electronic engine governor, algorithmic redundancy, mathematic model, fault-tolerance, optimal observer, Kalman filter, Yazvinsky filter.

Plekhanov A.A., Chistyakova T.B.  Optimal scheduling system for multigrade distributed polymer production

The paper presents a computer system for optimal scheduling of multi-product distributed production of polymeric materials. The scheduling problem is formalized as an NP-hard problem on parallel heterogeneous aggregates with sequentially dependent reconfigurations and process constraints. For its solution, a genetic algorithm was adapted with hybrid crossover and mutation operations, allowing for spatial distribution of production sites, product slate variability, and equipment reconfiguration procedures. The software system is implemented in client/server architecture and uses C#/.NET (server), React/TypeScript (client), PostgreSQL (database) и OpenStreetMap (GIS). It supports two objective functions: the minimization of maximum lead time or of total costs, and ensures transparent visualization as Gantt diagram, geographical production and supply map, and a solution tree. Testing and implementation at polymer production facilities in Russia and Germany have shown that the system finds the global optimum faster than a complete search and reduces equipment downtime and reconfiguration costs by ca. 1% in less calculation time as against other known production planning methods. The proposed approach is applicable in other industries with multi-product spatially distributed production such as in metallurgy, pulp and paper, and food industries, provided that the orders, aggregates, and reconfiguration rules are formalized according to the proposed model.

Keywords: optimal scheduling, software system, multi-product production, distributed production, polymer materials, genetic algorithm, geospatial data, client/server architecture.

Gun’kov S.A., Sergeev A.I.  Simulation modeling software for a production cell

Foreign simulation modeling software is currently unavailable in Russia because of sanctions restrictions. As a promising alternative, the paper offers a cloud SAAS solution enabling the assessment of design solutions during the development or modernization of a production cell. The simulation of the operation of the selected production cell with the help the created SAAS.

Keywords: simulation modeling, design, production cells.

Metreveli I.S., Leventsov V.A., Pavlova E.I., Nasevich P.E.  AI-based production process modeling methodology for product quality management

The problem of product quality management at continuous food production is formulated. A step-by-step algorithm for constructing and training information models using the random forest decision method is presented. The resulting model implements a two-stage data processing architecture. At the first step, the initial time series of process variables are transformed to a feature space by means of FPCA techniques. At the second stage, the decision tree ensemble predicts the target quality indicator. The proposed approach was tested at an oil extraction plant, the results are presented.
Keywords: modeling, production process, product quality, random forest, artificial intelligence, quality indicators, production indices, forecast.

Zakirzyanov R.M., Latypov A.R., Shpilyov A.I.  Import substitution experience in chemical process control

Under sanction restrictions and the need for ensuring technological sovereignty, the modernization of process controls is becoming an important task for chemical industry. Import substitution of foreign solutions with Russian analogues is becoming especially relevant. Against this background, the paper describes the experience of replacing the process control system at a chemical enterprise with a domestic one, which eliminates the architectural flaws of the previous system and improves the overall plant performance.

Keywords: process control system, PLC, SCADA, import substitution, continuous production, modernization.

TexX-monitor: an integrated system for digital control of business processes at industrial enterprises

The paper briefly reviews the architecture and functionality TexX-monitor platform, a complex solution which can automatically acquire and unify information from various corporate systems and protocols and ensure its accuracy and availability for further analysis. The platform is furnished with analytics tools based on present-day BI technologies, machine learning and statistical analysis techniques. This enables not only the visualization of information but also pattern detection and risk forecasting.

Keywords: integration, open interfaces, protocols, visualization, forecasting, analytics, risks, business processes.

Pal’chunov A.A., Meshchaninov E.V., Pal’chunov N.V.  Methods for analyzing the efficiency of drilling operations and their software implementations

The paper discusses modern methods for analyzing and improving the efficiency of drilling operations, based on detailed processing of data from measuring stations and telemetry systems that support continuous navigation of drilling objects, monitoring of drilling tools and operating parameters. Information technologies enable fast (almost real-time) and justified management decision-making during well construction. High risks of underground borehole operations and their service organization at the drilling site require the development and implementation of novel methods, models, and web-based software using international industry standards for information gathering and storing. The paper overviews dedicated software suites based on business process modeling, which were successfully tested at various drilling sites in Russia, Belarus, and Uzbekistan, and are compatible with Western counterparts.

Keywords: drilling process, modeling, business process, hidden unproductive time, digitalization, drilling production management.

Buynevich M.V., Izrailov K.E.  The challenges of synthesizing the organizational security structure of a ship’s information system for NSTC navigation

Cyber security of ship systems is studied. The ship is considered as a complex automation object operating in extreme conditions. The problems of Informational provision. The problems of comprehensive security of ship navigation in Nothern Sea Transport Corridor under digital transformation conditions are discussed. The first problem is associated with the organization of the trusted cyber environment, the second one refers to simultaneous operation of ship’s security systems within the integrated protection system. The paper examines rational ways for solving these problems based on the authors’ knowledge-intensive innovative evolution approaches in respect of the synthesis of the organizational security structure for ship’s information system.

Keywords: Northern Sea Transport Corridor, information system, comprehensive security, trusted cyber environment, organizational structure, integrated protection, unified protocol.

Journal’s Club

Ghinsberg K.S.  To the 120th anniversary of Academician V.A. Trapeznikov

Menn A.A.  Two episodes from the life of Academician V.A. Trapeznikov (to the 120th anniversary)