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Control Performance Improvement PID/CPM/APC

By implementing control performance improvement solutions, it is possible to optimize the stability and efficiency of enterprise production and reduce finished product defects and equipment losses caused by unexpected problems. Solutions include: PID control parameter tuning optimization, CPM full-loop real-time monitoring, APC advanced process control, etc.

PID Control Parameter Tuning Optimization

System Overview

The control loop PID parameter automatic tuning system refers to adjusting the PID controller parameters (proportional coefficient KP, integral time TI, differential time TD) when the controller law has been determined to be in the form of PID, so that the controlled object, control The dynamic characteristics of the control loop composed of the controller, etc. It can meet the expected index requirements and achieve the ideal control effect. A good PID controller parameter tuning method can not only reduce the operator's burden, but also make the control system in the best operating state.

In the field of industrial process control, a simple PID problem can solve 90% of the control problems. However, in the actual implementation process, the working efficiency of the control parameters will not be corrected in real time. Parameter values have to be readjusted only if there is a problem with the control system. Therefore, many industrial field control systems are in a "non-optimal" working state, or even improperly set, which seriously affects the control quality of the control system.

Functional Effect

By implementing PID parameter tuning, it can effectively help users improve the control level of industrial loops, and even improve the efficiency by more than 80%. In addition, many controlled processes have the characteristics of high nonlinearity, slow time variation, pure lag, etc., so that the tuning of PID parameters cannot be completed by ordinary engineers. Based on this demand background, the company launched the PID parameter automatic tuning software PIDGuRu, which uses the internal model control tuning method to automatically tune the control loop, which has high robustness. Through the monitoring and automatic calculation of the performance indicators of the control system, the improvement direction is found and the reasonable control parameters are determined, so as to achieve the purpose of greatly improving, optimizing and improving the control performance of the system.

The Main Function

  • Online Model
    Online open-loop and closed-loop models available
  • Identification and Simulation Simulation Functions
    Automatically collecting loop data, obtaining a state space model, and converting it into a transfer function model
  • Automatic Capture and Modeling
    Automatically capturing step change information, automatically modeling and calculating PID parameters.
  • Simulation Environment
    Providing a simulation environment to compare the PID parameters before the actual implementation, understanding and comparing the tuning effect
  • Logging
    Loop tuning history report and PID logging

APC Advanced Process Control

System Overview

On the basis of the parameter setting of the PID control loop, all control loops can be switched back to the "automatic" mode, so that the production line is in a stable control state. However, for complex control systems, it is impossible to obtain satisfactory performance output only by PID parameter arrangement. At this time, in order to further improve the automation level of the factory, it is recommended that users continue to implement the APC advanced process control system.

On the premise of fully understanding the current situation and control objectives of the production plant, the company's technical experts can provide a targeted integrated advanced control solution (Omni APC), and propose the rectification of the basic control system and equipment required for the implementation of the solution. necessary advice. The main goal of the whole system is to realize advanced control of the device, optimize and monitor the control loop in the DCS system, and improve the performance of the loop on this basis, so as to ensure the investment of the enterprise in the control system, It enables the device continue to function throughout its life cycle, making a greater contribution to the increased economic benefits of the device.

It is very difficult fot the application of predictive control technology, and the model identification part is the most difficult and time-consuming task. In the newly put into operation predictive control project, the model identification workload accounts for more than 50%. The APC scheme adopts a multi-variable closed-loop identification method, which can reduce the identification time by 70% and achieve fully automatic online identification. Based on the online identifier, a new generation of adaptive predictive control controller is developed. The technology integrates an online identifier and a predictive control controller, uses closed-loop/open-loop identification, and automatically generates a model during the identification experiment. When the accuracy of a certain model reaches the standard, it is automatically used by the APC controller. The adaptive predictive control can increase the efficiency of predictive control projects by 200% and greatly reduce engineering difficulty.

Functional Effect

The APC advanced process control system uses advanced control strategies to improve the overall operation efficiency and quality of equipment, and realize large-scale and complex multi-variable control. Use the world's leading predictive control technology software to integrate identification testing, model identification, control simulation and online control into one software, using one project file. Based on years of accumulated experience, the original multi-variable closed-loop identification technology, linear/non-linear predictive control technology, adaptive interference prediction technology, dynamic model soft measurement technology, and research and development of industrial adaptive advanced control system solutions, in order to achieve high control Under the condition of quality, the project time can be reduced by 70%, and the control system maintenance time can be reduced by 80%.

From the perspective of actual production effect, the implementation of APC project can solve the production performance optimization problem of complex control system, so that the system with long lag and strong correlation can be effectively controlled; it can make the actual operation more stable and respond faster; it can effectively save the energy consumption of the system. APC advanced process control system has been widely used in the actual production process of petrochemical industry, (coal) chemical industry, iron and steel industry, non-ferrous metal industry, electric power industry, cement industry and other enterprises.

Real-time monitoring of CPM full loop

System Overview

The CPM full-loop real-time monitoring system is designed to help enterprises perform online performance monitoring, analysis and modification of various types of DCS control loops and advanced control systems in multiple sites, so as to solve the problems of low control performance and insufficient benefits for users.

The CPM system can help plant operators monitor and optimize multi-brand control systems to ensure reliable and efficient operation of process control equipment and systems. Automated monitoring, fault identification, performance analysis and maintenance of control systems at all levels throughout the plant. The CPM system adopts the same platform and unified data interface, and integrates functions such as monitoring, optimization and adjustment, and model establishment.

The CPM system adopts a condition-based maintenance mode,  pre-alarm based on fault diagnosis, when performance declines instead of failure, maintenance is taken in advance to prevent failures from expanding; avoiding more failures; smoother maintenance workflow, Improve work efficiency.

The system is widely used in chemical, petrochemical, oil refining, oil and gas production and processing, power, pulp and paper and other process industries.It can perform online performance monitoring, analysis and modification of various types of DCS control loops, advanced control systems in multiple sites, to solve the problem of low user control performance and insufficient benefit.

Functional Effect

  • Improve Business Efficiency
    Improve control performance of all control systems
    Can be applied to all different brands and types of control systems, reducing management costs
    Reduced degradation of control system performance
    Improve efficiency and profitability
  • Optimize Operation and Maintenance
    Find and determine the root cause of the problem in a timely manner
    Proactively identify underperforming control systems
    Advanced control monitoring and modeling tools
    Automatic Control System Model Identification
  • Cost Reduction and Efficiency Increase
    Improve process performance and output
    Reduce process variability
    improve product quality
    Increase yield and conversion rates
    Reduce costs and energy consumption
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Contact | Hangzhou Apogee Technology Co., Ltd.