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Add-on Harmonic Disturbance Cancellation control in Continuous Hot-Dip Galvanizing Lines

IFAC-PapersOnLine 2023年第2期56卷 6181-6186页

作者： L. Marko A. Kugi A. Steinboeck Christian Doppler Laboratory for Intelligent Process Control for High-Quality Steel Products Automation and Control Institute TU Wien Austria Automation and Control Institute TU Wien Austria

In continuous hot-dip galvanizing of steel strips, unwanted vibrations of the processed strip can significantly degrade the coating uniformity and quality. Thus, an increasing number of hot-dip galvanizing lines are equipped with electromagnetic strip stabilization devices to enable active strip-shape and vibration control. Typically, commercial strip stabilizers achieve adequate broad-band vibration attenuation. However, their disturbance rejection capabilities are usually insufficient in case of persistently exciting harmonic disturbances. This work proposes a new multivariable harmonic disturbance cancellation control strategy which can be used as add-on to the position control loop of an existing strip stabilization device. The unknown amplitude, phase angle, and disturbance frequency are estimated during online operation. The systematic consideration of controller-output and estimator constraints in the design guarantees a reliable and safe operation in the challenging industrial environment. The devised control system works well even in the case of non-persistently exciting harmonic disturbances. The effectiveness of the proposed control scheme is demonstrated by short- and long-term measurement results from an industrial hot-dip galvanizing line.

关键词： Steel industry advanced process control Vibration control Disturbance rejection Constrained control

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Barriers to Integrated Flotation control Solutions: Lessons from an Industrial Implementation

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IFAC-PapersOnLine 2023年第2期56卷 2335-2340页

作者： Daniël J. Oosthuizen Bradley A. Williams Daniël D.V. van der Spuy *Process IQ Perth Australia

Different aspects of froth flotation have received varying levels of interest from the automation community over the past 30 years. Model-based level stabilisation and mass-pull based grade control strategies continue to deliver significant benefit to industry. However, industry seems slow to adopt the use of image processing applications and more comprehensive flotation models in industrial advanced process control (APC) applications - despite the benefits reported in the literature. In this paper an industrial flotation control system that includes basic visual froth imaging functionality is presented as a case study, to highlight some of the challenges experienced, and to identify reasons why integrated industrial APC implementations including advanced models and machine learning components remain scarce.

关键词： System identification and modelling advanced process control Machine learning methods and applications

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Overcoming challenges raised by wafer load grid overlay fingerprints and correction per exposure management

Overcoming challenges raised by wafer load grid overlay fing...

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SPIE advanced Lithography + Patterning

作者： Benjamin Duclaux Allwyn Boustheen Anne Pastol Othman El Hassani Maxime Gatefait Blandine Minghetti Bin Chen Auguste Lam Laurent Lecarpentier STMicroelectronics S.A. (France) ASML Netherlands B.V. (Netherlands) ASML France S.a.r.l. (France)

ISBN: (纸本)9781510686380

Fab productivity is often constrained by photolithography cluster capacity. To maximize the use of scanners, layers are often run in both DCO (Dedicated Chuck Overlay) and MMO (Matched Machine Overlay) modes if desired specs can be achieved. For MMO overlay, delta scanner fingerprint is a significant contribution and is minimized by Baseliner product from ASML. For scanners, wafer back side and the wafer table interactions results in Wafer Load grid fingerprint (WLG) (figure 1). WLG is influenced by the roughness of the wafer back side and the wafer table status. Baseliner corrections generated from wafers with smooth backside adds WLG fingerprint to product wafers with rough back side. Corrections Per Exposure (CPE) can compensate WLG fingerprint differences between product and baseliner wafers and has been extensively investigated at ST. CPE implementation has been studied for several layers on two scanner combinations (Top and Bottom scanner). These correction sub-recipes are needed per product layout and per scanner couple to handle all sources of variability resulting in high metrology cost. In the light of this WLG fingerprint, different dynamic CPE application scenarios have been tested, from lot specific feed-forward to complete feedback strategy to find the optimum solution for production wafers. Additionally, these corrections need to be reset at each wafer table swap which leads to a lot of engineering management and productivity loss with reworks, because each CPE baseline per context needs the measurement of at least one lot to be re-learned. To optimize this, the team has worked on a global model to generate layout independent CPE corrections and enable faster processability recoveries post wafer table swap. Studied solutions are applied at ST on automotive grade products with nodes from 40nm to 18nm.

关键词： Semiconducting wafers Scanners advanced process control Engineering Mathematical optimization Metrology Optical lithography

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APC Air Conditioning Energy Conservation control System

APC Air Conditioning Energy Conservation Control System

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第三十一届中国汽车工程学会年会暨展览会（SAECCE 2024）

作者： Hu Congmei Jia Haoxin Zhao Rui MMI Planning & Engineering Institute Ⅸ Co.Ltd.

For the process air conditioning and workstation air conditioning systems in automotive factory painting workshops,we developed a complete set of algorithm control models,utilizing advanced process control technology with artificial intelligence (AI) as the *** includes rolling optimization,feedback correction,object prediction,parameter controllers,HVAC (heating,ventilation,and air conditioning) process simulation,dynamic tuning,*** models enable the construction of an intelligent system for the precise control of temperature and humidity in paint spray rooms through model *** system significantly reduces energy consumption (natural gas,hot and cold water,pure water,electricity,etc.) and improves product quality by enhancing process ***,the system has strong versatility and can be applied to any large-scale industrial air conditioning system.

关键词： artificial intelligence simulation optimization advanced process control model predictive control HVAC engineering energy conservation

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Combining Feature Extraction-Based and Full Trace Analysis Capabilities in Fault Detection: Methods and Comparative Analysis 32

Combining Feature Extraction-Based and Full Trace Analysis C...

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32nd Annual SEMI advanced Semiconductor Manufacturing Conference (ASMC)

作者： Li, Fei Cai, Haoshu Moyne, James Iskandar, Jimmy Armacost, Michael Lee, Jay Appl Global Serv Appl Mat Santa Clara CA 95054 USA Univ Cincinnati Coll Engn & Appl Sci Cincinnati OH USA

ISBN: (纸本)9781728186450

As semiconductor manufacturing processes become more complex and sophisticated, manufacturers demand high quality, efficient process monitoring and fault detection (FD). Segmentation feature extraction (SFE) has been shown to be successful in FD when the anomaly patterns are well described by feature extraction, but not in cases of complex anomaly patterns. This paper proposes a novel approach that combines feature extraction-based and full trace analysis (FTA) capabilities in FD. First, a novel multivariate trace segmentation is applied to segment trace data based on defined patterns across key sensors, and then the pattern features and parameters are extracted within each segment. Second, full trace analysis generates adaptive guardbands on key sensors. These guardbands detect "anomaly" throughout the whole trace with a certain confidence interval Third, a multivariate fault detection model is developed that combines SFE and FTA capabilities. Furthermore, multivariate data generation is developed to exhaustively validate combination and isolation of the proposed capabilities. Experimental results indicate that FTA can better capture the anomaly features with complex/atypical patterns, and the combined capability of SFE + FTA exhibits better performance than each method applied individually.

关键词： Fault Detection advanced process control Segmentation Feature Extraction Full Trace Analysis

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Optimized model-based control of main mine ventilation air flows with minimized energy consumption

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International Journal of Mining Science and Technology 2020年第4期30卷 533-539页

作者： S.Sjostrom E.Klintenas P.Johansson J.Nyqvist Department IAPI–Mining Automation ABB ABUmeå140090124Sweden

In early 2018,the Boliden Garpenberg operation implemented an optimized control strategy as an addition to the existing ventilation on demand *** purpose of the strategy is to further minimize energy use for main and booster fans,whilst also fulfilling airflow setpoints without violating constraints such as min/max differential pressure over fans and interaction of air between areas in *** air flow measurements and a dynamical model of the ventilation system,a mine-wide coordination control of fans can be carried *** numerical model is data driven and derived from historical operational data or step changes *** makes both initial deployment and lifetime model maintenance,as the mine evolves,a comparably easy *** control has been proven to operate in a stable manner over long periods without having to re-calibrate the *** prove a 40%decrease in energy use for the fans involved and a greater controllability of air ***,a 15%decrease of the total air flow into the mine will give additional proportional heating savings during winter *** in all,the multivariable controller shows a correlation between production in the mine and the ventilation system performance superior to all of its predecessors.

关键词： Mine ventilation Ventilation on demand Optimized model-based control Minimized energy consumption advanced process control

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Model Predictive control of a Pusher Type Reheating Furnace 14th

Model Predictive Control of a Pusher Type Reheating Furnace

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14th APCA International Conference on Automatic control and Soft Computing (controlO)

作者： Zanoli, Silvia Maria Cocchioni, Francesco Valzecchi, Chiara Pepe, Crescenzo Univ Politecn Marche Via Brecce Bianche 12 I-60131 Ancona AN Italy Alperia Bartucci SpA Corso Vittorio Emanuele II I-37038 Soave VR Italy

ISBN: (纸本)9783030586553;9783030586539;9783030586522

This paper focuses on the design of an advanced process control system for the control and the optimization of a pusher type billets reheating furnace. The controller formulation is based on a two-layer Model Predictive control strategy. The formulated linear model of the furnace variables and the billets temperature behavior is constituted by a combination of Linear Time Invariant and Linear Parameter Varying models. The basic control mode is based on an adaptive approach. Simulation and field results on a plant located in an Italian steel industry have shown the reliability of the proposed control system and its optimality with respect to the previous control system, based on local PID controllers managed by operators. Significant improvements on process control have been obtained, together with a major and safer approach to process operating limits.

关键词： Model Predictive control advanced process control Billets reheating furnace Energy efficiency

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Optimization of the Clinker Production Phase in a Cement Plant 14th

Optimization of the Clinker Production Phase in a Cement Pla...

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14th APCA International Conference on Automatic control and Soft Computing (controlO)

作者： Zanoli, Silvia Maria Orlietti, Lorenzo Cocchioni, Francesco Astolfi, Giacomo Pepe, Crescenzo Univ Politecn Marche Via Brecce Bianche 12 I-60131 Ancona Italy Alperia Bartucci SpA Corso Vittorio Emanuele II I-37038 Soave VR Italy

ISBN: (纸本)9783030586553;9783030586539;9783030586522

In this paper, the control and the optimization of the clinker production phase of an Italian dry cement industry is described. A tailored advanced process control architecture has been proposed, based on a two-layer Model Predictive control strategy. The critical process variables have been included in the controller setup through linear models with delays. The controllermoves are computed through two subsequent constrained optimization problems with cooperation and consistency assumptions. The developed controller replaced a previous control system based on operators' conduction. Thanks to the predictive approach, more profitable operating points have been guaranteed, significantly improving the process control performances. Energy consumption and environmental emissions have been reduced, taking into account quality and production requirements.

关键词： advanced process control Model Predictive control Clinker production Cement rotary kiln Energy efficiency

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Artificial Intelligence Approaches For The Ladle Predictive Maintenance In Electric Steel Plant

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IFAC-PapersOnLine 2022年第2期55卷 331-336页

作者： Marco Vannucci Valentina Colla Matteo Chini Daniele Gaspardo Birgit Palm TeCIP Institute Scuola Superiore Sant’Anna Pisa Italy Ferriere Nord Pittini group Osoppo (Udine) Italy VDEh-Betriebsforschungsinstitut GmbH Dusseldorf Germany

This paper presents an Artificial Intelligence based tool for real-time estimation of ageing status of all the ladles operating within an electric steelworks. The developed system exploits real data collected and operators’ experience for tuning its core models and formulates the problem as a multi-class classification problem on a highly imbalanced dataset. Two classifiers are applied, based on the Decision Tree and Random Forest approaches. Both approaches provide satisfactory results, especially in the identification of the most critical situations, namely when the ladle is close to its end of life or needs an immediate maintenance intervention, but the Decision Tree shows slightly better performance. The system, therefore, effectively supports predictive maintenance approaches.

关键词： Steel industry Artificial intelligence advanced process control Maintenance scheduling production planning Ladle operations Data mining multivariate statistics Reliability

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A Virtual Plant for Integrated Continuous Manufacturing of a Carfilzomib Drug Substance Intermediate, Part 3: Manganese-Catalyzed Asymmetric Epoxidation, Crystallization, and Filtration

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ORGANIC process RESEARCH & DEVELOPMENT 2020年第10期24卷 1891-1908页

作者： Maloney, Andrew J. Icten, Elcin Capellades, Gerard Beaver, Matthew G. Zhu, Xiaoxiang Graham, Lauren R. Brown, Derek B. Griffin, Daniel J. Sangodkar, Rahul Allian, Ayman Huggins, Seth Hart, Roger Rolandi, Pablo Walker, Shawn D. Braatz, Richard D. MIT Dept Chem Engn Cambridge MA 02139 USA Amgen Inc Proc Dev Cambridge MA 02142 USA Amgen Inc Proc Dev Thousand Oaks CA 91320 USA

This article describes the process characterization and development of models to inform a process control strategy to prepare (R,R)-epoxy ketone 2, an intermediate in the manufacture of carfilzomib. Model calibration for relevant unit operations and the development of a dynamic integrated flowsheet-level model in gPROMS FormulatedProducts software enabled investigation of the impact of process disturbances and model uncertainties on the critical quality attributes (CQAs) and identification of critical process disturbances and failure modes to guide a process control strategy. The model development was similar to that described in the previous parts of this series, but with the added complexity of comparing two distinct kinetic formulations for the epoxidation reaction. The main CQAs for this process were (1) the conversion of enone 1 (target >= 99.0 mol % conversion) and (2) the purity target for solids prior to cake wash (target >= 97.5% purity by weight). Conversion of enone was not always achieved with the expected disturbances: whereas 99.5% conversion was expected for normal operating conditions, 97.2% conversion was predicted for the worst-case combination of disturbances. The chiral purity of crystalline (R,R)-epoxy ketone 2 was not always achieved with the expected disturbances: 98.2% purity was expected for normal operating conditions, and 96.7% purity was expected for the worst-case combination of disturbances. These analyses allowed for rank ordering of critical process parameters that impact conversion and suitable manipulated variables to develop a robust process control strategy for the manufacturing scheme.

关键词： continuous pharmaceutical manufacturing process modeling flow chemistry continuous crystallization continuous filtration advanced process control

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