SIMULATION OPTIMIZATION IN DOSING PROCESS CONTROL SYSTEM IN REAL TIME IN A FREE AND OPEN-SOURCE SOFTWARE

Fraga, Gustavo Rodrigues; Peixoto, Túlio Almeida; Rangel, João José de Assis

doi:10.1590/0101-7438.2018.038.02.0273

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Articles • Pesqui. Oper. 38 (2) • May-Aug 2018 • https://doi.org/10.1590/0101-7438.2018.038.02.0273 copy

SIMULATION OPTIMIZATION IN DOSING PROCESS CONTROL SYSTEM IN REAL TIME IN A FREE AND OPEN-SOURCE SOFTWARE

Authorship SCIMAGO INSTITUTIONS RANKINGS

ABSTRACT

The purpose of this work is to implement an on-line control system able to adjust the production in real time applying a simulation model with algorithmic optimization and data transfer for a programmable logic controller. The Solver tool of the Excel software was integrated into a simulation software used to find the optimal dosing of input aggregates in a Hot Mix Asphalt process. Tests were carried out in different scenarios; the results demonstrated that the proposed control was effective, leading to a possible improvement in the quality of the product, enabling it to be kept within the specifications desired for most of the time. Besides, the proposed solution appeared to be simple and accessible for small companies as it applies the Excel software and a free and open-source discrete event simulation software.

Keywords:
Real time optimization; Simulation; PLC; Excel; Industry 4.0

Aggregate criteria	Bins	Sieves
Aggregate criteria	Bins	3/8”	Number 8	Number 30	Number 200
Mean of gradation	1	52	14	7.9	3.7
	2	100	96	51	14
	3	100	86	41	1.4
	4	100	7	1	0.1
	5	100	52	9	0.7
Standard deviation of gradation	1	3.00	2.00	1.00	1.00
	2	0.00	1.00	4.00	2.00
	3	0.00	2.00	3.00	0.50
	4	0.00	1.00	0.50	0.50
	5	0.00	3.00	2.00	0.01
JMF sieves target percentage		82.20	33.00	14.30	3.50
Specification limit tolerance		8.00	5.00	4.00	2.00
Product limit tolerance		5.00	4.00	3.00	2.00

Bin	Initial proportion	Bin capacity range percentage
Bin	Initial proportion	Minimum	Maximum
1	37	17	57
2	14	5	23
3	7	2	12
4	30	10	50
5	12	5	23

		Control Strategy		% Reduction
Control Limit	Aggregate Variation	No Control	Solver Control	Time Out of Control	Total Cumulative Deviation
SL	Low	31 (0)	25 (25)	19.35	28.93
SL	Low	804.86	572.05	19.35	28.93
SL	High	70 (0)	63 (67)	10.00	22.06
SL	High	944.22	735.95	10.00	22.06
PL	Low	544 (0)	40 (39)	92.65	38.55
PL	Low	1156.73	710.81	92.65	38.55
PL	High	502 (0)	139(140)	72.31	28.83
PL	High	1313.23	934.62	72.31	28.83

Name	Function	Parameters
E1	Create	Constant (1)min
L1	Hold	if Release == 0
CT1	OR	(TNOW <=120) i ((TNOW>240) && (TNOW<=360)) i (TNOW>480)
A1	Assign (Variable)	Release == 1
A2	Assign (Variable)	Function1 == 1.33
A3	Assign (Variable)	Function2 == 0.67
A4	Assign (Variable)	Function1 == 0.67
A5	Assign (Variable)	Function2 == 1.33
CT2	OR	100% (Union)
A6	Assign (Variable)	Var1Sieve38 == Function2*NORM(52,3)
A7	Assign (Variable)	Var1Sieve8 == Function2*NORM(14,2)
A8	Assign (Variable)	Var2Sieve8 == Function1*NORM(96,1)
A9	Assign (Variable)	Var3Sieve8 == Function2*NORM(86,2)
A10	Assign (Variable)	Var4Sieve8 == Function1*NORM(7,1)
Name	Function	Parameters
A11	Assign (Variable)	Var5Sieve8 == Function2*NORM(52,3)
A12	Assign (Variable)	Var1Sieve30 == Function2*NORM(7.9,1)
A13	Assign (Variable)	Var2Sieve30 == Function1*NORM(51,4)
A14	Assign (Variable)	Var3Sieve30 == Function2*NORM(41,3)
A15	Assign (Variable)	Var4Sieve30 == Function1*NORM(1,0.5)
A16	Assign (Variable)	Var5Sieve30 == Function2*NORM(9,2)
A17	Assign (Variable)	Var1Sieve200 == Function2*NORM(3.7,1)
A18	Assign (Variable)	Var2Sieve200 == Function1*NORM(14,2)
A19	Assign (Variable)	Var3Sieve200 == Function2*NORM(1.4,0.5)
A20	Assign (Variable)	Var4Sieve200 == Function1*NORM(0.1,0.05)
A21	Assign (Variable)	Var5Sieve200 == Function2*NORM(0.7,0.01)
RW1	Read/Write in Excel	Write all sieves functions in Excel
RM1	Run Macro in Excel	VBA “Application.CalculateFull”
RW2	Read/Write in Excel	Read Sieves Gradation, Deviations, # Sieve Out Specifications, % Bin Openings
A22	Assign (Variable)	AcumDeviation == AcumDeviation + TotalDeviation
C1	Communication (Real Tag)	BinOpen1
C2	Communication (Real Tag)	BinOpen2
C3	Communication (Real Tag)	BinOpen3
C4	Communication (Real Tag)	BinOpen4
C5	Communication (Real Tag)	BinOpen5
C6	Communication (Real Tag)	AcumDeviation
C7	Communication (Real Tag)	Bin1Sieve38
C8	Communication (Real Tag)	Bin2Sieve38
C9	Communication (Real Tag)	Bin3Sieve38
C10	Communication (Real Tag)	Bin4Sieve38
C11	Communication (Real Tag)	Bin5Sieve38
C12	Communication (Real Tag)	GradationSieve38
C13	Communication (Real Tag)	DeviationSieve38
C14	Communication (Real Tag)	Bin1Sieve8
C15	Communication (Real Tag)	Bin2Sieve8
C16	Communication (Real Tag)	Bin3Sieve8
C17	Communication (Real Tag)	Bin4Sieve8
C18	Communication (Real Tag)	Bin5Sieve8
C19	Communication (Real Tag)	GradationSieve8
C20	Communication (Real Tag)	DeviationSieve8
Name	Function	Parameters
C21	Communication (Real Tag)	Bin1Sieve30
C22	Communication (Real Tag)	Bin2Sieve30
C23	Communication (Real Tag)	Bin3Sieve30
C24	Communication (Real Tag)	Bin4Sieve30
C25	Communication (Real Tag)	Bin5Sieve30
C26	Communication (Real Tag)	GradationSieve30
C27	Communication (Real Tag)	DeviationSieve30
C28	Communication (Real Tag)	Bin1Sieve200
C29	Communication (Real Tag)	Bin2Sieve200
C30	Communication (Real Tag)	Bin3Sieve200
C31	Communication (Real Tag)	Bin4Sieve200
C32	Communication (Real Tag)	Bin5Sieve200
C33	Communication (Real Tag)	GradationSieve200
C34	Communication (Real Tag)	DeviationSieve200
C35	Communication (Real Tag)	TotalDeviation
OR2	OR	# Sieve Out Specifications >= 1
RM2	Run Macro in Excel	VBA “SolverSolve(True)”
RW3	Read/Write in Excel	Read Sieves Gradation, Deviations, # Sieve Out Specifications, % Bin Openings
R1	Counter	CounterSolver == CounterSolver + 1
R2	Counter	CounterOK == CounterOK + 1
A23	Assign (Variable)	Release == 0

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[1] *Corresponding author.