Logic Control / Steuerungstechnik SoSe 2018

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Fakultät Bio- und Chemieingenieurwesen Lehrstuhl für Systemdynamik und Prozessführung Logic Control / Steuerungstechnik SoSe 2018 Mandatory course for: Master Program Automation and Robotics (Process

1 Fakultät Bio- und Chemieingenieurwesen Lehrstuhl für Systemdynamik und Prozessführung Logic Control / Steuerungstechnik SoSe 2018 Mandatory course for: Master Program Automation and Robotics (Process Automation) Elective course for: iplom/master Bio / Chemieingenieurwesen Master Program Process Systems Engineering Master Program Automation and Robotics (other specializations)... and for anyone else interested!

Course Organization (1) Contact Info: A.

de (Room: BCI-G2-509) T. Ebrahim, S. Subramanian, S.

thangavel@tu-dortmund.de (Room: BCI-G2-526) afaq.

2 Course Organization (1) Contact Info: A. Tatulea-Codrean (Room: BCI-G2-509) T. Ebrahim, S. Subramanian, S. Thangavel, A. Ahmad (Room: BCI-G2-330) (Room: BCI-G2-332) (Room: BCI-G2-526) (Room: BCI-G2-510) Consultation hours: by appointment (see web page) 2

3 Course Organization (2) Course page: Moodle Course name: Logic Control SoSe 2018 Password: LCSS18 Registration: 11 th April 1 st May Consult for: Schedule Lecture slides Tutorial problems Latest information 3

4 Course Organization (3) Lectures: Wednesday, 14:15-15:45 Room: C/HS2 (chemistry / lecture hall 2) Tutorials: Wednesday, 16:00-17:30 Rooms: PC-Pools I + II or C/HS2 Credits: any changes will be announced on our website distribution to PC pools will be done in the first tutorial 6 (ECTS), 4 SWS (2 VV + 2 VÜ) Assignment (June 20 July 11) check Moodle! Written examination: 1 st attempt : 30, 31 July or 3, 6 August 2 nd attempt : September (tba) Final grade : 0.75*Exam[%] *Assignment[%] For passing the course: >= 35% 4

5 Literature (1) R.W. Lewis: Programming Industrial Control Systems using IEC IEE Control Engineering Series, o. 50, IEE, London, International Electrotechnical Commission: International Standard Programmable Controllers; in particular: Part 3 - Programming Languages. International Standards Organization: International Standard Process measurement control functions and instrumentation. C.G. Cassandras, S. Lafortune: Introduction to iscrete Event Systems. Kluwer Academic Publishers, J.E. Hopcroft, J.. Ullman: Introduction to Automata Theory, Languages, and Computation. Addison Wesley,

6 Literature (2) J. Lunze: Automatisierungstechnik. Oldenbourg Verlag, 2003 [in German]. G. Olsson, G. Piani: Steuern, Regeln, Automatisieren. Hanser Verlag, 1993 [in German]. H. Fasol: Binäre Steuerungstechnik. Springer, 1988 [in German]. K.-H. John, M. Tiegelkamp: SPS-Programmierung mit IEC Springer, 1995 [in German]. W. Jakoby: Automatisierungstechnik Algorithmen und Programme. Springer, 1996 [in German]. 6

7 Tentative Schedule ate Wednesday 14:15 15:45 Lecture Wednesday 16:00-17:30 ate Wednesday 14:15 15:45 Lecture Wednesday 16:00-17:30 Tutorial Lecture Tutorial Lecture Tutorial Lecture Tutorial Lecture Tutorial Lecture Tutorial Tutorial Lecture Tutorial Tutorial Lecture Lecture Tutorial Tutorial Assignment / Consultation hour Lecture Tutorial Lecture Tutorial 7

Computer Programming (German) Control and Automation Lab M.Sc.

Automation and Robotics (English program) Control Theory and Applications (compulsory) Logic Control (also elective for Chem.E.) Process Control Lab Electives for all programs: Safe and Optimal Process Operations (r.

8 Courses Offered B. Sc. Chemical Engineering/ Biochemical Engineering Process ynamics and Control (English) Process Automation (Prozessautomatisierung, German) Computer Programming (German) Control and Automation Lab M.Sc. Chemical Engineering / Biochemical Engineering / PSE Process Performance Optimization (with r. Guido ünnebier, BTS) M. Sc. Automation and Robotics (English program) Control Theory and Applications (compulsory) Logic Control (also elective for Chem.E.) Process Control Lab Electives for all programs: Safe and Optimal Process Operations (r. Kuschnerus, in German) ynamic Models / ata-based ynamic Modelling ynamic Simulation Process Optimization Controller esign Fundamentals / Multivariable Control Advanced Process Control Batch Process Operation (r. Krämer, IEOS) Logistics of Chemical Production Processes 8

Process Control Methods and Applications Economics optimizing control Multistage robust MPC Iterative optimization using gradient

distillation, ERC Advanced Investigator Grant MOBOCO Research Process Management Market-like mechanisms for the coordination of coupled

systems emand-side management Control of biotechnological production processes Modeling and control of yeast fermentations Modeling and

chains Production Scheduling Planning and scheduling under uncertainty Timed automata based scheduling Reactive scheduling Process esign.

9 Process Control Methods and Applications Economics optimizing control Multistage robust MPC Iterative optimization using gradient modifiers Guaranteed parameter estimation and dual control Applications: polymerization processes, chromatographic separations, reactive distillation, ERC Advanced Investigator Grant MOBOCO Research Process Management Market-like mechanisms for the coordination of coupled units Real-time monitoring and optimization of resource efficiency Simulation environment for the distributed management of systems of systems emand-side management Control of biotechnological production processes Modeling and control of yeast fermentations Modeling and model-based optimization of CHO cultures Process Automation Intuitive specification of logic control programs Tool integration and tool chains Production Scheduling Planning and scheduling under uncertainty Timed automata based scheduling Reactive scheduling Process esign. Model-based support for the early stages of process development Algorithms for design problems with many local optima Batch-to-conti transfer of copolymerizations 9

10 Why Logic Control and Automation? World market: Automation (2005) Total volume: 214 bn (~ 232 bn US) Annual growth prediction 2005 : ~5-7% Annual growth prediction 2017 : > 8% Company s name SIEMES ABB okogawa Emerson Phoenix Contact Moeller Schneider electric Turnover [bn]* US 24.4 US 3.7 US 20.1 US 1.12 US 1.23 US 4.73 US * in

11 Why Process Control and Automation? Manager s answer: Higher productivity, lower labor cost higher profit and competitiveness Plant worker s answer: Improved safety, easier job increased standard of living Consumer s answer: Cheaper price, improved environmental protection increased wealth Chemist s answer: ecessary for increased sophistication of products more complex, better products Automation is an interdisciplinary field present or emerging in all areas of business and life 11

12 Syllabus of the Lecture (1) I. I.1 Automation of Technical Processes I.2 Process Instrumentation I.3 Characteristics of Logic Controllers II. Basic Mathematics for Logic Control II.1 Boolean Algebra II.2 Boolean Functions II.3 Minimization of Boolean Functions (KV-iagrams) III. Realization of and Hardware for Logic Controllers III.1 Hierarchy of Automation III.2 Hardwired Logic III.3 Programmable Logic Controllers 12

13 Syllabus of the Lecture (2) IV. Programming Languages for Logic Controllers IV.1 The IEC Standard IV.2 Function Block iagrams (FB) IV.3 Ladder iagrams (L) IV.4 Instruction List (IL) IV.5 Structured Text (ST) IV.6 Sequential Function Charts (SFC) 13

14 Syllabus of the Lecture (3) V. Modeling of Plant and Controller for Controller esign V.1 Finite-state Automata V.2 Timed Automata V.3 Controller and Plant Modeling with Automata V.4 Composition and Synchronization VI. esign of Logic Controllers VI.1 Overview VI.2 Controllability, Reachability, and Reducibility VI.3 esign Procedures 14

15 Syllabus of the Lecture (4) VII. Analysis of Logic Controllers VII.1 Introduction VII.2 Testing by Simulation VII.2 Requirement formulation by Temporal Logic VII.3 Algorithmic (Formal) Verification VIII. Systematic Procedures for Logic Control Projects VIII.1 An Industrial Approach to Logic Control VIII.2 Industrial Classifications of Safety 15

16 Chapter I: I.1 Automation of technical processes A general scheme of automated processes Examples General objectives of automation I.2 Instrumentation - Choice of sensors and actuators - Process and Instrumentation iagram (P&I) I.3 Characteristics of logic controllers Functions realized by logic controllers iscrete variables 16

17 I.1: A General Scheme of Automated Processes 7 Operator Control Goals 6 isturbances 8 measurements y Automation evice(s) 4 control actions u isturbances 8 Sensors Actuators 2 3 isturbances 8 Exchange of material, energy, information Technical Process: Plant 1 Environment 5 isturbances 8 17

1 Technical Process Example: Batch Plant of the Process Control Lab Relevant issues to be discussed in this course: How to consider plant behavior in controller design?

18 1 Technical Process Example: Batch Plant of the Process Control Lab Relevant issues to be discussed in this course: How to consider plant behavior in controller design? Storage Mixing Evaporation Condensation Cooling Pumping Other aspects here: 5 7 Environment: cooling water inlet Operator Console 8 isturbances: e.g. room temperature 18

Sensors: 2 + 3 Which quantities are required? Where and how to measure? How to cope with malfunctions?

19 Sensors: Which quantities are required? Where and how to measure? How to cope with malfunctions? Sensors and Actuators temperature sensor Actuators: Which variables are to be manipulated? What type of actions? How to cope with malfunctions? magnetic valves actuator wire 0/24V signal sensor wire 4-20mA signal electronic transducer 19

4 Automation evice Which hardware and which programming

Bus Power Pack Automation evice Analog Output igital Output

20 4 Automation evice Which hardware and which programming language is suitable? How to design a control program and to ensure safety? How to model and analyze a control program in an abstract way? Bus Power Pack Automation evice Analog Output igital Output Analog Input igital Input CPU RAM Sensors Actuators user actions (& programs) plant data operator console (and programming) 20

21 6 Control Goals Issues of control goals: How to specify requirements and performance measures? How to transform control goals into program logic? process steps actions Control program running on the automation device (View on the programming console) 21

22 Try to Assign the umbers to this Batch Reactor 23

23 Goals: esired Operation of a Batch Reactor over Time 24

24 The Same for a Mars Robot 26

25 Control Goals for the Mars Robot Motion Control Go to a target point: push forward, push backwards, rotate, Circumvent obstacles (avoid deadlock situations safe operation) Collect material from ground: Move gripper (up, down, close, open) Initiate material analysis 27

26 General Objectives of Automation Enable (semi-)autonomous operation of the plant! 1) Supervision Measure, pre-process, predict, record and display process information y otify operator of malfunctions 2) Control Apply actions u (for some manipulated variable) such that the plant behavior satisfies the goals even for disturbances and malfunctions Sometimes, it is only specified how the plant should behave. In this case, the designer has to deduce how the controller has to behave much more difficult (and unsafe) than with a plant model. 28

27 General Scheme for esigning Automated Systems 1) Analysis of the plant etermine relevant behavior/dynamics for the given goals Implement a suitable model 2) Investigation of the plant behavior on the model What can be achieved with the plant inputs? Advantages: not dangerous, less expensive 3) esign of the control function Choose suitable inputs for all possible outputs 4) Test of the controller at the model Modify if control goals are not met 5) Implementation at the plant Choose hardware, test at plant, productive operation 29

28 I.2: Instrumentation Control Goals choice of inputs y Which plant quantities have to be observed (at acceptable costs) and where (e.g. not near tank inlet)? choice of outputs u Which plant variables have to be influenced? Which actions are needed? (e.g., only on / off?) irect / indirect manipulation? How does u effect y? Functional aspects (what?) specified in the P&I appropriate sensors - Measuring principle, accuracy - Redundancy, Reliability - Accessibility, Maintenance appropriate actuators - Robustness - Redundancy, Reliability - Accessibility, Maintenance Technical aspects (how?) detail engineering 30

29 Process and Instrumentation iagram (P&I) ISO 3511 and I Standard for graphical representation of measuring, actuating, and controlling devices. Typical applications: processing systems, chemical plants, power plants, air-conditioning and refrigeration, etc. Crossing with connection: Crossing without connection: 31

30 Identification of Sensors, Actuators, and Controllers in P&Is Quantity Symbols: Processing Symbols: (first letter) (supplementary second) (following letters) - density - difference A - alarm E - electric F - ratio C - continuous control F - flow Q - integral E - sensing H - hand I - indication K - time O - display L - level R - recording P - pressure S - switching / logic control Q - quantity T - transmitting S - speed X - unclassified T - temperature - computing relay U - multivariable Z - emergency action W - weight + - upper limit X - unclassified - - lower limit (selection of important symbols only) 32

31 P&I: Typical Examples 33

32 P&I iagram for a Batch Reactor 34

33 I.3: Characteristics of Logic Control Types of controllers: distinction by signals / variables and by time (1) Continuous signals, continuous time Continuous feedback controllers (Regelung) Continuous feedforward controllers (Steuerung) (2) Continuous signals, discrete time Sampled-data systems, sampled signals (e.g. in a PCS) Control strategy: u t ) f ( u( t ), u( t ),..., y( t ), y( t ),...) ( k = k 1 k 2 k 1 k 2 (3) iscrete signals, continuous time Event-driven controller: event evokes a (usually delayed) reaction Input and output signals are discrete (from a finite set) Logic controller 35

34 Continuous Variables - iscrete Variables tank level sensor output (LIS±) controller state controller output 36

35 Examples and Objectives Examples and Objectives of Logic Controllers (1) Safety Trip: initiate an emergency routine when the process approaches a state that is critical for safety (2) Interlocks: block operator actions that could lead to process states that are potentially critical for safety (3) Sequential Controller: realize a sequence of steps (two steps are separated by a condition; actions are executed in a step) Objectives in general ( Specification ): drive the process into a desired final state establish a certain sequence of process states always exclude process states that are critical for safety (safety-related functions usually have highest priority) 37

36 Example of a Sequential Controller Control Steps: (1) when operator starts production: open V 1 (2) when medium level is reached (LIS+ 1): close V 1, switch on M, open V 2 (3) when upper level reached (LIS+ 2): close V 2, open V 4 [heating] (4) when TIS+ reached: close V 4, start timer (t:=0) [reaction] (5) when t = t limit : open V 5 [cooling] (6) when TIS- : close V 5, switch off M, open V 3 (7) when LIS- : close V 3 38

Brief Summary of Last Lecture. Model checking of timed automata: general approach

Brief Summary of Last Lecture. Model checking of timed automata: general approach Brief Summary of Last Lecture Formal verification Types: deductive (theorem proving) and algorithmic (model checking) ields proof that a (formal) specification is fulfilled Formalization of specs e.g.